Sensing connection method

Abstract

A lead connection for coupling a first end of a lead (50) to a post (18) and a bushing (22) of a battery is described. The lead connection includes a first weld (40, 42) including the bushing and the post welded to the bushing. The lead connection also includes a second weld (70, 72). The second weld includes the first weld and the first end of the lead. At least a portion of the first weld is distributed around and over the first end of the lead to electrically couple the first end of the lead to the bushing and the post.

Description

Technical Field

[0001] This disclosure relates to batteries, and more specifically to the manufacture and / or assembly of smart batteries that facilitate battery performance / fault monitoring. Background Technology

[0002] With the development of battery technology, the demand for improved power sources (such as energy storage modules in vehicles) continues to grow. Existing battery systems, such as lead-acid battery systems, typically offer limited performance and fault monitoring pathways and have complex venting arrangements. More specifically, existing lead-acid battery systems may not provide one or more battery parameters (e.g., parameters that could be used to determine performance and / or predict / monitor faults) for one or more battery cells within the lead-acid battery system. In other words, existing lead-acid battery systems struggle to provide information about critical components, such as the health status of individual battery cells. Consequently, the inability to monitor and / or determine the health status of battery cells hinders the ability to predict impending battery failures or the onset of faults. Summary of the Invention

[0003] Some embodiments advantageously provide a connection (and / or a method for making a connection) for sensing parameters associated with battery cells and / or batteries. In some embodiments, the method for making a connection is a sensing connection method.

[0004] According to one aspect, a lead assembly connection for a terminal connector for connecting lead assemblies is described. The lead assembly connection includes a first weld seam including a bushing and a terminal welded to the bushing. The lead assembly connection further includes a second weld seam including the first weld seam and the terminal connector. At least a portion of the first weld seam is distributed around and above the terminal connector to electrically connect the terminal connector to the bushing and the terminal.

[0005] According to another aspect, a battery is described. The battery includes a housing housing a battery cell, wherein the battery cell includes a terminal electrically connected to the battery cell. Further, the battery includes a cover sealed to the housing and includes a bushing coupled to the cover. The cover sealed to the housing defines an internal space within the housing. A terminal is inserted through the bushing. At least a portion of the terminal protrudes from the bushing and is located outside the internal space of the housing. The battery further includes a first weld, a lead assembly, and a second weld. The first weld includes the bushing and a terminal welded to the bushing. The lead assembly includes a terminal connector. The second weld includes a first weld welded to the terminal connector. At least a portion of the first weld is distributed around and above the terminal connector to electrically connect the terminal connector to the bushing, the terminal, and the battery cell. One or more of the first and second welds seal the terminal and bushing to the cover. The second weld is located outside the internal space of the housing.

[0006] According to one aspect, a lead connection for connecting a first end of a lead to a terminal and a bushing of a battery is described. The lead connection includes a first weld seam comprising a bushing and a terminal welded to the bushing. The lead connection also includes a second weld seam comprising the first weld seam and the first end of the lead. At least a portion of the first weld seam is distributed around and above the first end of the lead to electrically connect the first end of the lead to the bushing and the terminal.

[0007] In some embodiments, the first weld is a weld button extending from the terminal post.

[0008] In some other embodiments, the solder button includes a first portion and a second portion adjacent to the first portion, the second portion being a curved structure.

[0009] In some embodiments, the first end of the lead is positioned between the first portion and the second portion and is physically connected to the terminal block.

[0010] In some other embodiments, the first weld has a third portion that covers and is in physical contact with the terminal.

[0011] In some embodiments, the first weld and the second weld are integrated into a single structure.

[0012] In some other embodiments, the first end of the lead is one of a loop and a terminal connector.

[0013] In some embodiments, the first weld and the second weld may be electrically connected to the battery cell via terminals, and the leads may be connected to the battery management system (BMS), which may be configured to measure battery parameters via the lead connections.

[0014] According to another aspect, a battery is described. The battery includes a housing, a cover, a plurality of terminals, and a plurality of leads. The housing houses a plurality of battery cells. Each of the plurality of terminals is electrically connected to at least one of the plurality of battery cells. The cover is sealed to the housing and includes a plurality of bushings coupled to the cover. Each of the plurality of terminals is inserted through a corresponding bushing. The plurality of leads includes a plurality of lead connections. Each lead includes a first end and a second end opposite the first end. Each of the plurality of lead connections includes a first weld and a second weld. The first weld includes one of the bushings and one of the terminals. The terminal is welded to the bushing. The second weld includes the first weld and a first end of the lead. At least a portion of the first weld is distributed around and above the first end of the lead to electrically connect the first end of the lead to the bushing and the terminal.

[0015] In some embodiments, a cover sealed to the housing defines an internal space within the housing that accommodates a plurality of battery cells, with leads connected to the outside of the internal space.

[0016] In some other embodiments, the battery further includes a battery management system (BMS) configured to measure battery parameters via each of a plurality of lead connections. The BMS is electrically connected to a second end of each lead.

[0017] In some embodiments, the first weld is a weld button that extends away from the cover.

[0018] In some other embodiments, the button includes a first portion and a second portion adjacent to the first portion. The first portion is adjacent to the cover, and the second portion is a curved structure.

[0019] In some embodiments, the first weld has a third portion that covers a terminal and is in physical contact with the terminal.

[0020] In some other embodiments, the first weld and the second weld are integrated into a single integral structure.

[0021] In some embodiments, the first end of each lead is one of a loop and a terminal connector.

[0022] According to one aspect, a method for connecting a first end of a lead to a terminal and a bushing of a battery is described. The battery includes a cap. The bushing is connected to the cap. The method includes: inserting a terminal through the bushing, wherein at least a portion of the terminal protrudes from the bushing and the cap; and performing a first weld by welding the terminal to the bushing. The weld is applied at least to the portion of the terminal protruding from the bushing. The method further includes performing a second weld by welding the first weld to the first end of the lead. At least another portion of the first weld is distributed around and above the first end of the lead.

[0023] In some embodiments, performing the first weld includes forming a weld button that extends away from the cover.

[0024] In some other embodiments, the solder button includes a first portion and a second portion adjacent to the first portion. The second portion is a curved structure.

[0025] In some embodiments, the method further includes positioning a first end of the lead between a first portion and a second portion, and connecting the first end to a terminal block and a bushing.

[0026] In some other embodiments, the first weld has a third portion covering the terminal block.

[0027] In some embodiments, the method further includes integrating the first weld and the second weld into a single integral structure.

[0028] In some other embodiments, the first end of the lead is one of a loop and a terminal connector.

[0029] In some embodiments, the battery further includes a battery management system (BMS) configured to measure battery parameters via a first end, a first weld, and a second weld of a lead. The lead further includes a second end opposite the first end, and the method further includes coupling the second end of the lead to the BMS. Attached Figure Description

[0030] A more complete understanding of the embodiments described herein, along with their accompanying advantages and features, will be readily achieved by referring to the following detailed description taken in conjunction with the accompanying drawings:

[0031] Figure 1 An example battery and one or more components of the example battery are shown in accordance with the principles of this disclosure;

[0032] Figure 2 An example battery (e.g., exploded view) and one or more components of the example battery are shown in accordance with the principles of this disclosure;

[0033] Figure 3 An example housing and cover including a bushing are shown in accordance with the principles of this disclosure;

[0034] Figure 4 An example first cover is shown attached to the housing in accordance with the principles of this disclosure;

[0035] Figure 5 Example terminals and bushings based on the principles of this disclosure are shown;

[0036] Figure 6 Another example of a terminal block and bushing based on the principles of this disclosure is shown;

[0037] Figure 7 An example weld is shown in accordance with the principles of this disclosure;

[0038] Figure 8 The principles based on this disclosure are shown. Figure 7 A view of an example weld;

[0039] Figure 9 The principles based on this disclosure are shown. Figure 8 A cross-sectional view of an example weld;

[0040] Figure 10 The principles based on this disclosure are shown. Figure 7 The example weld shown is a view;

[0041] Figure 11 The principles based on this disclosure are shown. Figure 10 A cross-sectional view of an example weld;

[0042] Figure 12 An example of multiple leads based on the principles of this disclosure is shown;

[0043] Figure 13 An example lead assembly based on the principles of this disclosure is shown;

[0044] Figure 14 Another example of multiple leads based on the principles of this disclosure is shown;

[0045] Figure 15 Another example of a lead assembly based on the principles of this disclosure is shown;

[0046] Figure 16 An example lead assembly and weld are shown in accordance with the principles of this disclosure;

[0047] Figure 17 An example weld is shown in accordance with the principles of this disclosure;

[0048] Figure 18 Another example weld is shown in accordance with the principles of this disclosure;

[0049] Figure 19 An example weld is shown in accordance with the principles of this disclosure;

[0050] Figure 20 Another example weld is shown in accordance with the principles of this disclosure;

[0051] Figure 21 A flowchart illustrating an example lead connection process based on the principles of this disclosure is shown; and

[0052] Figure 22 A flowchart illustrating an example lead connection process based on the principles of this disclosure is shown. Detailed Implementation

[0053] With the development of battery technology, there is a need for improved power sources and more efficient and cost-effective methods for manufacturing and / or assembling such power sources compared to conventional systems and methods.

[0054] Therefore, the embodiments described and illustrated herein provide a method for manufacturing and / or assembling a smart battery (e.g., a sensing connection method, a lead and / or lead assembly connection method, a method for connecting leads for bushings, terminals and lead frames).

[0055] In some embodiments, the term "smart battery" may be used and may refer to a battery having, for example, lead, lithium, or sodium chemicals that are enabled by electronic devices physically attached to the battery to monitor battery functional parameters, such as, but not limited to, state of charge, state of health, and / or trends thereof, or to transmit battery status from inside or outside the battery environment. The electronic devices may generally be referred to as connected electronic devices and may include a battery management system or any other electronic component. Further, the electronic devices may utilize wired or wireless transmission devices or communication interfaces configured to transmit data and / or information, such as applicable battery information and / or derivatives of battery information.

[0056] In some other embodiments, the term "connect" or "connection" may refer to a physical and / or electrical connection (e.g., coupling) of one or more components. In some embodiments, the term "connector" is used and may refer to two or more components of a battery that are connected to each other. A connector may also include two or more components welded or joined using any other connecting mechanism or process. In some other embodiments, a connector may be referred to as a weld, such as a shaped component created by welding two or more components together. A weld may include at least a first portion and a second portion adjacent to the first portion. The first portion may be a top portion, and the second portion may be a side portion. The first portion and / or the second portion may be referred to as a button and may extend from another component (e.g., a battery cover) and be accessible and / or exposed to receive other components to which the button may be additionally connected (welded).

[0057] Figure 1 and Figure 2 An example battery (e.g., a lead-acid battery with an intelligent absorbent glass pad (AGM) battery assembly) and one or more components of the example battery are shown. Battery 10 may include at least one of the following: a housing 12 (which may be made of resin or any other suitable material), one or more battery cells 14, a terminal assembly 15 (e.g., a cast-on-strap (COS) terminal assembly), one or more strips 16, one or more terminals 18 (e.g., terminal terminals, micro-terminals), a first cover 20, one or more bushings 22 (e.g., U1 bushings, micro-buffers), a lead assembly 24 (e.g., a lead frame), a battery management system (BMS) 26 (e.g., including a board), one or more fasteners 28, a second cover 30, a wiring harness 32, a vehicle connector 34, a third cover 36, and one or more terminal caps 38. The terminal assembly 15 may include one or more strips 16 coupled to one or more terminals 18. In some embodiments, the housing 12 may be referred to as a casing.

[0058] Figure 3 An example housing 12 and a first cover 20 including a bushing 22 are shown according to the principles of this disclosure. More specifically, the battery cell 14 ( Figure 2 (As shown) has been inserted into housing 12. Battery cell 14 (via Figure 2 The terminal assembly 15 shown is connected to the terminal 18. The first cover 20 includes one or more bushings 22, such as bushing 22a (e.g., a miniature bushing) and bushing 22b. Bushing 22a is aligned with terminal 18a, and bushing 22b is aligned with terminal 18b. Other bushings 22 may be aligned with other terminals 18. The first cover 20 is then coupled (and / or sealed) to the housing 12.

[0059] Figure 4 A first cover 20 is shown attached to the housing 12. More specifically, the first cover 20 is shown attached to the housing 12, wherein a terminal 18 can contact its corresponding bushing 22, and at least a portion of the terminal 18 protrudes from the corresponding bushing 22, as shown. Figure 5 and Figure 6 As shown. In Figure 5 In this configuration, terminal 18a is inserted through bushing 22a, wherein terminal 18a can directly contact bushing 22a, and a portion of terminal 18a protrudes from bushing 22a. Figure 6 In the middle, the terminal 18b has been inserted through the bushing 22b, wherein the terminal 18b can directly contact the bushing 22b, and a part of the terminal 18b protrudes from the bushing 22b. Figure 7 An example weld is shown based on the principles of this disclosure. The terminal 18 and bushing 22 can be welded to form welds 40 and 42. More specifically, the weld... Figure 5 The terminal 18a and bushing 22a are shown to form weld 40. Similarly, welding... Figure 6 The terminal 18b and bushing 22b are shown to form a weld 42. In some embodiments, weld 40 is associated with battery cell 14, and weld 42 is associated with terminals of battery 10. Once welds 40 and 42 are completed, terminal 18 and bushing 22 are welded together. Furthermore, after welding is completed, at least a portion of terminal 18 is integrated with bushing 22. In some embodiments, once weld 40 is completed, welds 40 and 42 are sealed to a first cover 20, for example, such that the internal space defined by the first cover 20 and housing 12 (e.g., including battery cell 14) is sealed. In some other embodiments, welding terminal 18 and bushing 22 forms a single integral weld 40 and 42 that seals to the first cover 20. Either weld 40 or 42 can be a first weld or a button.

[0060] Figure 8 It shows Figure 7 The diagram shows a view of an example weld 40. Weld 40 extends from the first cover 20. That is, a portion of weld 40 extends from the first cover 20 and is accessible and / or exposed to accommodate other components to which weld 40 may be additionally joined (welded). Figure 9 It shows Figure 8 A cross-sectional view of an example weld 40. Weld 40 is in physical contact with and / or connected to the first cover 20. Further, weld 40 includes at least a portion of a terminal 18a electrically connected to one or more battery cells 14.

[0061] Figure 10 It shows Figure 7 The diagram shows a view of an example weld 42. Weld 42 extends from the first cover 20. That is, a portion of weld 42 extends from the first cover 20 and is accessible and / or exposed to accommodate other components to which weld 42 may be additionally joined (welded). Figure 11 It shows Figure 10 A cross-sectional view of an example weld 42. Weld 42 is in physical contact with and / or connected to the first cover 20. Further, weld 42 includes at least a portion of a terminal 18b electrically connected to one or more battery cells 14 and / or terminals.

[0062] Figure 12 An example of multiple leads 50 (e.g., six leads) is shown. Figure 13 A lead assembly 24 is shown (e.g., including multiple leads 50). Reference Figure 12 and Figure 13Each lead 50 may include one or more of the following: a first end 52 and a second end 56 opposite to the first end 52. The first end 52 may be a lead loop and include a terminal connector 54 (e.g., a spoke) coupled to the first end 52. The second end 56 may be configured as a lead BMS connector (e.g., pins, pitch, etc.). The first end 52 (e.g., a loop that may include the terminal connector 54) may be arranged to physically and / or electrically connect the lead 50 to the terminal 18 and / or bushing 22. The second end 56 (e.g., a BMS connector) may be arranged to extend from another portion of the lead 50 and / or bend to a predetermined angle, and / or physically and / or electrically connect to the BMS 26 (and / or any component thereof). The lead 50 may be made of any material including conductive materials, for example, to conduct and / or propagate signals. In a non-limiting example, the lead 50 may refer to a stamped frame and / or be made of at least one of copper, brass, steel, aluminum, titanium, platinum, etc. Furthermore, lead 50 may include a coating and / or finish, such as a finish using copper, nickel, tin, palladium, silver, gold, zinc, etc. Lead 50 may be used by BMS 26 to measure / determine one or more parameters associated with terminal 18 and / or the corresponding battery cell 14. Parameters may include, but are not limited to, voltage, current, temperature, pressure, etc., and may be associated with any component of battery 10 (e.g., terminal 18, battery cell 14, etc.). Lead 50 (e.g., stamped lead) may be included in lead assembly 24 (e.g., overmolded assembly). Lead assembly 24 may include lead frame 25. Furthermore, lead assembly 24 may include one or more openings arranged for connecting lead assembly 24 to first cover 20.

[0063] Any portion of each lead 50 may be hinged and / or adapted to be flexible and / or adjustable, for example, to connect the lead 50 to a terminal 18, which may lie in a plane different from the plane corresponding to another portion of the lead assembly 24. The terminals of the battery 10 and / or their corresponding terminals 18 may lie in a plane different from the plane containing other terminals 18 (e.g., miniature terminals). In other words, it is conceivable that the terminals and terminals 18 need not be coplanar with respect to the top surface of the battery housing 12. In a non-limiting example, the lead assembly 24 includes an arm 58 that may be arranged to adjust the position of a portion of the lead assembly 24, for example, a portion corresponding to a predetermined terminal 18, such as a portion including a first end 52 (e.g., a loop) for the positive terminal terminal that is not coplanar with other first ends 52 (e.g., loops) in the lead assembly 24 and / or a portion of the terminal connector 54. In some embodiments, the arm 58 may be pivotable to allow adjustment. By making arm 58 adjustable, lead assembly 24 can be arranged to accommodate one or more terminals / pins in different positions. Further, the size of the first end 52 (which may include the pin connector 54) can be determined based on the pin type and / or any other parameters. In a non-limiting example, the first end 52 and / or the pin connector 54 can be made thicker and / or have a larger diameter than other first ends 52 and / or pin connectors 54 of lead assembly 24, for example, to accommodate the size and type of a positive terminal with a larger size and current rating. In a non-limiting example, the first end 52 and / or the pin connector 54 can be made thinner and / or have a smaller diameter than other first ends 52 and / or pin connectors 54 of lead assembly 24, for example, to accommodate the size and type of a miniature pin used for receiving / transmitting / measuring battery parameters. Lead assembly 24 can be fabricated by molding a polymer (e.g., to manufacture a lead frame 25) onto the lead 50, thereby providing a structure for the lead 50. The lead assembly 24 can be rigid, flexible, or a combination thereof, depending on the intended design.

[0064] Figure 14 Another example embodiment of multiple leads 50 (e.g., a first end 52 without a terminal connector 54) is shown. In this non-limiting example, the first end 52 is arranged to receive and contact a portion of any weld in welds 40, 42. Further, the first end 52 may be welded to any weld in welds 40, 42. Figure 15 Another example of a lead assembly 24 is shown, which includes a lead frame 25, a first end 52, leads 50, arms 58, and an opening 60. The opening 60 may be arranged to provide passage to a portion of the multiple leads 50 that interconnects the leads 50. The opening 60 may be used to disconnect the interconnections between the leads, thereby electrically isolating each lead 50 from the remaining leads 50.

[0065] Figure 16 An example lead assembly 24 and welds 70, 72 are shown according to the principles of this disclosure. The lead assembly 24 includes one or more leads 50, each lead having a first end 52 (e.g., ...). Figures 12 to 15 (as shown) and a second end 56 connected to the first end 52. Either the first end 52 (and / or the terminal connector 54) is arranged to be physically and / or electrically connected to one of the welds 40, 42 (including the terminal 18 and / or bushing 22), as shown. Figures 7 to 11 One or the other is shown. Second welds 70, 72 can be performed to weld the first end 52 of each lead 50 to the corresponding first weld 40, 42. Lead assembly 24 can be further coupled to first cover 20 via one or more fasteners. Lead assembly 24 can be connected to BMS 26 (e.g., via second end 56, such as BMS connector), wherein BMS 26 is configured to measure at least one parameter of battery 10, such as the voltage of battery cell 14, via terminal 18, bushing 22, lead assembly 24, welds 40, 42, 70, 72, first end 52, terminal connector 54, second end 56, etc. Either weld 70, 72 can be referred to as a second weld.

[0066] Figures 17 to 20 Examples of other welds (e.g., a second weld) based on the principles of this disclosure are shown. More specifically, Figure 17 A weld 40 is shown, comprising a terminal 18 and a bushing 22, wherein the terminal 18 is welded to the bushing 22. Any of the weld 40, the terminal 18, and the bushing 22 may be connected to a first cover 20. A first end 52 of the lead assembly 24 is positioned on the weld 40 (e.g., in preparation for forming a second weld 70). Figure 18 A weld 70 is shown, comprising a weld 40 (shown in dashed lines) and a first end 52 of a lead 50. At least a portion of the weld 40 is distributed around and above the first end 52 of the lead 50 to electrically connect the first end 52 of the lead 50 to the terminal 18 and the bushing 22. In some embodiments, the weld 70 is formed after the first end 52 is joined (e.g., welded) to the weld 40. Figure 19 A weld 42 is shown, comprising a terminal 18 and a bushing 22, wherein the terminal 18 is welded to the bushing 22. Any of the weld 42, the terminal 18, and the bushing 22 may be connected to a first cover 20. A first end 52 of the lead assembly 24 is positioned on the weld 42 (e.g., to prepare for forming a second weld 72). Figure 20A weld 72 is shown, comprising weld 42 (shown in dashed lines) and a first end 52 of another lead 50. At least a portion of weld 40 is distributed around and above the first end 52 of lead 50 to electrically connect the first end 52 of lead 50 to terminal 18 and bushing 22. In some embodiments, weld 72 is formed after the first end 52 is joined (e.g., welded) to weld 42.

[0067] In a non-limiting example, the first end 52 is first placed on top of weld 40 and brought into contact with the weld. Then, weld 70 is formed by redistributing (e.g., of weld 40) at least some material around and above the corresponding first end 52. Further, weld 72 is formed after the first end 52 is joined (e.g., welded) to weld 42. In another non-limiting example, the first end 52 is first placed on top of weld 42 and brought into contact with the weld. Then, weld 72 is formed by redistributing (e.g., of weld 42) at least some material around and above the first end 52. Welds 70, 72 can, for example, physically and / or electrically connect the first end 52 to the corresponding battery cell 14 via terminal 18 and bushing 22. In some embodiments, the connection of the first end 52 to welds 40, 42, 70, 72 can be referred to as a sensing connection or lead assembly connection or lead connection, any of which can be associated with sensing or measuring battery parameters.

[0068] Figure 21 A flowchart illustrating an example lead connection process (i.e., method) according to the principles of this disclosure is shown. The method is used to connect a lead assembly 24 to a terminal connector 54. The method includes: inserting (box S100) a terminal 18 through a bushing 22, wherein at least a portion of the terminal 18 protrudes from the bushing 22; and performing (box S102) a first weld by soldering the terminal 18 to the bushing 22. The weld is applied at least to the portion of the terminal 18 protruding from the bushing 22. Further, the method includes performing (box S104) a second weld by soldering the first weld to the terminal connector 54. The terminal connector 54 is on the first weld, and at least a portion of the first weld is distributed around and above the terminal connector 54. The second weld electrically connects the terminal connector 54 to the bushing 22 and the terminal 18.

[0069] In some embodiments, a method is provided for connecting leads (e.g., voltage sensing leads) of lead assembly 24 to a first weld. Each lead may include a terminal connector 54 that can be coupled to a terminal 18 and / or a bushing 22 and / or the first weld. In some embodiments, the first weld may be a lead (Pb) button burn produced using tungsten inert gas (TIG) welding. In some other embodiments, the first weld is formed with a diameter smaller than that of a second weld. In embodiments, the method includes performing a second weld, wherein the terminal connector 54 is added around the first weld. Performing the second weld may include redistributing lead (Pb) material around and over the terminal connector 54.

[0070] Figure 22 A flowchart of another example lead connection process (i.e., method) is shown. A method for connecting a first end 52 of a lead 50 to a terminal 18 and a bushing 22 of a battery 10 is described. The battery 10 includes a cover 20. The bushing 22 is attached to the cover 20. The method includes: inserting (box S106) the terminal 18 through the bushing 22, wherein at least a portion of the terminal 18 protrudes from the bushing 22 and the cover 20; and performing (box S108) first welds 40, 42 by welding the terminal 18 to the bushing 22. The weld is applied at least to the portion of the terminal 18 protruding from the bushing 22. The method also includes performing (box S110) a second weld 70 by welding (box S110) the first welds 40, 42 to the first end 52 of the lead 50. At least another portion of the first welds 40, 42 is distributed around and above the first end 52 of the lead 50.

[0071] In some embodiments, performing the first weld 40, 42 includes forming a weld button that extends away from the cover 20.

[0072] In some other embodiments, the solder button includes a first portion and a second portion adjacent to the first portion. The second portion is a curved structure.

[0073] In some embodiments, the method further includes positioning a first end 52 of the lead 50 between a first portion and a second portion, and connecting the first end 52 to a terminal 18 and a bushing 22.

[0074] In some other embodiments, the first welds 40, 42 have a third portion covering the terminal 18.

[0075] In some embodiments, the method further includes integrating the first welds 40, 42 and the second weld 70 into a single integral structure.

[0076] In some other embodiments, the first end 52 of the lead 50 is a loop and is connected to the terminal connector 54.

[0077] In some embodiments, the battery 10 further includes a battery management system (BMS) 26, which is configured to measure battery parameters via a first end of a lead 50, first welds 40, 42, and a second weld 70. The lead 50 further includes a second end opposite the first end, and the method further includes connecting the second end of the lead 50 to the BMS 26.

[0078] The disclosure provided herein advantageously offers an arrangement for providing individual terminals (e.g., terminals 18) to each individual battery cell 14 within the battery 10 to facilitate the ability to monitor each individual battery cell 14 of the battery 10, for example by connecting a lead frame to the terminals 18 to allow electrical connectivity from each battery cell 14 (via the corresponding terminal 18) to the battery management system (BMS) 26. Furthermore, embodiments of this disclosure are advantageous, at least because they avoid heat sinks or damage to the first weld caused by conventional welding.

[0079] Those skilled in the art will understand that this embodiment is not limited to what may have been specifically shown and described. Furthermore, unless the contrary is mentioned above, it should be noted that all figures may not be drawn to scale. Various modifications and variations may be possible in accordance with the foregoing teachings and the appended claims.

Claims

1. A lead connection for connecting a first end (52) of a lead (50) to a terminal (18) and a bushing (22) of a battery (10), the lead connection comprising: The first weld (40, 42) includes the bushing (22) and the terminal (18) welded to the bushing (22); as well as The second weld (70, 72) includes the first weld (40, 42) and the first end (52) of the lead (50), at least a portion of the first weld (40, 42) being distributed around and above the first end (52) of the lead (50) to electrically connect the first end (52) of the lead (50) to the bushing (22) and the terminal (18).

2. The lead connection as described in claim 1, wherein, The first weld (40, 42) is a weld button extending from the terminal (18).

3. The lead connection as described in claim 2, wherein, The welding button includes a first part and a second part adjacent to the first part, the second part being a curved structure.

4. The lead connection as described in claim 3, wherein, The first end (52) of the lead (50) is positioned between the first part and the second part and is physically connected to the terminal (18).

5. The lead connection as described in any one of claims 1 to 4, wherein, The first weld (40, 42) has a third portion that covers the terminal (18) and is in physical contact with the terminal (18).

6. The lead connection as described in any one of claims 1 to 5, wherein, The first weld (40, 42) and the second weld (70, 72) are integrated into a single structure.

7. The lead connection as described in any one of claims 1 to 6, wherein, The first end (52) of the lead (50) is a loop and is connected to the terminal connector (54).

8. The lead connection as described in any one of claims 1 to 7, wherein, The first weld (40, 42) and the second weld (70, 72) can be electrically connected to the battery cell (14) via the terminal (18), and the lead (50) can be connected to the battery management system (BMS) (26), which can be configured to measure battery parameters via the lead connection.

9. A battery (10), the battery (10) comprising: A housing (12) that houses a plurality of battery cells (14); Multiple terminals (18), each of the multiple terminals (18) being electrically connected to at least one of the multiple battery cells (14); A cover (20), said cover being sealed to the housing (12) and comprising a plurality of bushings (22) coupled to said cover (20), each of the plurality of terminals (18) being inserted through a corresponding bushing (22); and Multiple leads (50), the multiple leads including multiple lead connections, each lead (50) including a first end (52) and a second end opposite to the first end (52), each of the multiple lead connections including: A first weld (40, 42), the first weld comprising one of the plurality of bushings (22) and one of the plurality of terminals (18), the terminal (18) being welded to the bushing (22); and The second weld (70, 72) includes the first weld (40, 42) and the first end (52) of the lead (50), at least a portion of the first weld (40, 42) being distributed around and above the first end (52) of the lead (50) to electrically connect the first end (52) of the lead (50) to the bushing (22) and the terminal (18).

10. The battery (10) as claimed in claim 9, wherein, The cover (20) sealed to the housing (12) defines an internal space of the housing that accommodates the plurality of battery cells (14), with each lead connected to the outside of the internal space of the housing.

11. The battery (10) as claimed in any one of claims 9 and 10, wherein, The battery (10) further includes: A battery management system (BMS) (26) is configured to measure battery parameters via each of the plurality of lead connections, the BMS (26) being electrically connected to the second end of each lead (50).

12. The battery (10) according to any one of claims 9 to 11, wherein, The first weld (40, 42) is a weld button that extends away from the cover (20).

13. The battery (10) as claimed in claim 12, wherein, The welding button includes a first part and a second part adjacent to the first part, the first part being adjacent to the cover (20), and the second part being a curved structure.

14. The battery (10) according to any one of claims 9 to 13, wherein, The first weld (40, 42) has a third portion that covers and is in physical contact with one of the terminals (18).

15. The battery (10) according to any one of claims 9 to 14, wherein, The first weld (40, 42) and the second weld (70, 72) are integrated into a single integral structure.

16. The battery (10) according to any one of claims 9 to 15, wherein, The first end (52) of the lead (50) is a loop and is connected to the terminal connector (54).

17. A method for connecting a first end (52) of a lead (50) to a terminal (18) and a bushing (22) of a battery (10), the battery (10) including a cap (20), the bushing (22) being connected to the cap (20), the method comprising: The terminal (18) is inserted (S106) through the bushing (22), at least a portion of the terminal (18) protruding from the bushing (22) and the cover (20); The first weld (40, 42) is performed (S108) by welding the terminal (18) to the bushing (22), the weld being applied at least to the portion of the terminal (18) protruding from the bushing (22); as well as (S110) A second weld (70, 72) is performed by welding the first weld (40, 42) to the first end (52) of the lead (50), wherein at least another portion of the first weld (40, 42) is distributed around and above the first end (52) of the lead (50).

18. The method of claim 17, wherein, Performing the first weld (40, 42) includes: A weld button is formed that extends away from the cover (20).

19. The method of claim 18, wherein, The welding button includes a first part and a second part adjacent to the first part, the second part being a curved structure.

20. The method of claim 19, wherein, The method further includes: Position the first end (52) of the lead (50) between the first portion and the second portion; and Connect the first end (52) to the terminal (18) and the bushing (22).

21. The method according to any one of claims 17 to 20, wherein, The first weld (40, 42) has a third portion covering the terminal (18).

22. The method according to any one of claims 17 to 21, wherein, The method further includes: The first weld (40, 42) and the second weld (70, 72) are integrated into a single integral structure.

23. The method according to any one of claims 17 to 22, wherein, The first end (52) of the lead (50) is a loop and is connected to the terminal connector (54).

24. The method according to any one of claims 17 to 23, wherein, The battery (10) further includes a battery management system (BMS) (26) configured to measure battery parameters via a first end (52) of the lead (50), a first weld (40, 42) and a second weld (70, 72), the lead (50) further including a second end opposite to the first end (52), and the method further includes: Connect the second end of the lead (50) to the BMS (26).

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