Battery post welding

Abstract

An apparatus arranged for establishing an electrical connection to a battery cell is described. The apparatus includes a bushing, a post, and a weld. The bushing has a bushing first portion and a bushing second portion. The post is in physical contact with the bushing. The weld is laser welded and includes a bushing material and a post material. A weld first portion extends outwardly from at least the bushing. A weld second portion is contiguous with the weld first portion, within the bushing, and above the post. A weld third portion is contiguous with the weld second portion, within the bushing, and around the post. The weld has a first depth measured from the bushing first portion and / or a second depth measured from the bushing second portion. The first depth and / or the second depth reaches or exceeds a depth minimum threshold.

Description

Technical Field

[0001] This disclosure relates to a manufacturing method and an apparatus including a battery cell connection portion (e.g., a welding portion). Background Technology

[0002] With the development of battery technology, the demand for improved power sources (such as energy storage modules for vehicles) continues to grow. Existing battery systems, such as lead-acid battery systems, typically offer limited performance and fault monitoring. More specifically, existing lead-acid battery systems may not provide one or more battery parameters (e.g., parameters that can be used to determine performance and / or predict / monitor faults) for one or more individual 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 faults or the onset of faults.

[0003] In addition, some batteries may have individual cells with cell-cell connections. These cell-cell connections, often referred to as welds, provide electrical connections to the cell cells for measuring battery parameters such as cell voltage. These welds are typically formed and sealed to the battery cover using tungsten inert gas (TIG) welding. TIG welding can also be called gas tungsten arc welding (GTAW) and can use a tungsten electrode that generates the welding arc. The inert gas is used to cool the tungsten electrode and the weld. However, in some cases, TIG welding does not provide consistent results. For example, using TIG welding to form the weld may result in poor sealing between the weld and the battery cover, poor weld characteristics, and damage to other battery components such as the cover. Summary of the Invention

[0004] Some embodiments advantageously provide a battery cell connection (and / or a method of manufacturing a battery cell connection) for sensing parameters associated with the battery cell and / or battery. In some embodiments, the connection is a weld formed between two or more battery components using a welding process such as laser welding.

[0005] According to one aspect, an apparatus arranged for establishing an electrical connection to a battery cell is described. The apparatus includes a bushing, a terminal post, and a weld portion. The bushing includes a bushing material and has a first bushing portion and a second bushing portion. The terminal post is in physical contact with the bushing and includes a terminal post material. The weld portion is formed using laser welding and includes both the bushing material and the terminal post material. The weld portion includes a first weld portion, a second weld portion, and a third weld portion. The first weld portion extends at least outward from the bushing. The second weld portion is connected to the first weld portion, located within the bushing, and above the terminal post. The third weld portion is connected to the second weld portion, located within the bushing, and surrounding the terminal post. The weld portion has one or both of a first depth measured from the first bushing portion and a second depth measured from the second bushing portion. One or both of the first depth and the second depth reaches or exceeds a minimum depth threshold.

[0006] According to another aspect, a battery includes a cover, a housing, a bushing, terminals, and a welded portion. The housing is coupled to the cover, and the bushing is coupled to the cover. The bushing includes a bushing material and has a first bushing portion and a second bushing portion. The terminals are in physical contact with the bushing and include terminal material. The welded portion is formed using laser welding. The welded portion is coupled to the cover and includes the bushing material and the terminal material. Furthermore, the welded portion includes a first welded portion, a second welded portion, and a third welded portion. The first welded portion extends outward from the cover. The second welded portion is connected to the first welded portion, located within the bushing, and above the terminal. The third welded portion is connected to the second welded portion, located within the bushing, and surrounding the terminal. The welded portion has one or both of a first depth measured from the first bushing portion and a second depth measured from the second bushing portion, wherein one or both of the first depth and the second depth reaches or exceeds a minimum depth threshold.

[0007] According to one aspect, a method for manufacturing a welded portion for establishing an electrical connection to a battery cell of a battery is described. The battery has terminals, bushings, a housing, and a cover sealing the housing. The terminals are inserted through the bushings, and at least a portion of the bushings is in physical contact with the cover and the terminals. The bushings comprise bushing material and have a first bushing portion and a second bushing portion. The terminals comprise terminal material. The method includes: directing a laser beam to one or more regions and one or more depths of one or more of the terminals and the bushings; and using the laser beam to form a welded portion. The formed welded portion includes a first welded portion, a second welded portion, and a third welded portion. The first welded portion extends at least outward from the bushing. The second welded portion is connected to the first welded portion, located within the bushing, and above the terminals. The third welded portion is connected to the second welded portion, located within the bushing, and surrounding the terminals. The welded portion has a first depth measured from the first portion of the bushing and / or a second depth measured from the second portion of the bushing. The first depth and / or the second depth reaches or exceeds a minimum depth threshold. Attached Figure Description

[0008] The embodiments described herein, along with their associated advantages and features, will be more readily understood when considered in conjunction with the accompanying drawings, in which: Figure 1 An example battery according to the principles of this disclosure and one or more components of the example battery are shown; Figure 2 An example battery (e.g., an exploded view) and one or more components of the example battery are shown in accordance with the principles of this disclosure; Figure 3 An example housing and a cover including a bushing are shown according to the principles of this disclosure; Figure 4 An example first cover body is shown, which is connected to the housing according to the principles of this disclosure; Figure 5 Example poles and bushings are shown in accordance with the principles of this disclosure; Figure 6 Another example pole and bushing according to the principles of this disclosure is shown; Figure 7 Example steps of a laser welding process based on the principles of this disclosure are shown; Figure 8 An example battery is shown after a laser welding process according to the principles of this disclosure has been completed; Figure 9 The principles of this disclosure are shown. Figure 8 A view of an example welded section; Figure 10 The principles of this disclosure are shown. Figure 9 A cross-sectional view of an example welded section; Figure 11 The principles of this disclosure are shown. Figure 8 A view of an example weld shown; Figure 12 The principles of this disclosure are shown. Figure 11 A cross-sectional view of an example welded section; Figure 13 A cross-sectional view of an example welded portion according to the principles of this disclosure is shown; Figure 14 It shows Figure 13 A section of a sectional view; Figure 15 It shows Figure 13 Another section of the sectional view; Figure 16 A flowchart illustrating an example method for manufacturing a battery cell connection (welding part) according to the principles of this disclosure is shown; and Figure 17 A flowchart is shown as another example method for manufacturing a battery cell connection (welding part) according to the principles of this disclosure. Detailed Implementation

[0009] Before describing the exemplary embodiments in detail, it should be noted that these embodiments primarily exist in a combination of apparatus components and processing steps related to providing a connection (and / or a method of manufacturing the connection) for sensing parameters associated with a battery cell and / or battery. Therefore, system and method components have been indicated in the drawings with conventional symbols where appropriate, showing only those specific details relevant to understanding embodiments of this disclosure, so as not to obscure the disclosure with details that would be obvious to those skilled in the art who benefit from the description herein.

[0010] As used herein, relational terms such as “first” and “second,” “top” and “bottom” are used only to distinguish one entity or element from another, and do not necessarily require or imply any physical or logical relationship or order between these entities or elements. The terminology used herein is for describing particular embodiments only and is not intended to limit the concepts described herein. As used herein, unless the context clearly indicates otherwise, the singular forms “a,” “an,” and “the” are also intended to include the plural forms. It should also be understood that when the terms “comprising” and / or “including” are used herein, it indicates the presence of the stated feature, integer, step, operation, element, and / or component, but does not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or combinations thereof.

[0011] Unless otherwise defined, all terms used herein (including technical and scientific terms) shall have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains. It should also be understood that the terms used herein shall be interpreted as having the same meaning as in the context of this specification and related art, and shall not be interpreted in an idealized or overly formalized sense unless expressly defined herein.

[0012] In the embodiments described herein, the connection term "communicating with" and the like can be used to refer to electrical or data communication, which can be achieved, for example, through physical contact, induction, electromagnetic radiation, radio signals, infrared signals, or optical signals. Those skilled in the art will understand that multiple components can work together, and that electrical and data communication can be achieved through modification and variation.

[0013] In some embodiments, the term "connection" is used, which can refer to two or more components of a battery that are connected to each other. A connection may also include two or more components joined by welding or using any other connecting mechanism or process. In some other embodiments, a connection may be referred to as a welded portion, such as a shaped component resulting from welding two or more components together. A welded portion may include at least a first portion and a second portion continuous with the first portion. The first portion may be a top, and the second portion may be a side. The first and / or second portions may be referred to as weld bosses and may extend beyond another component (e.g., a battery cover) and may be accessible and / or exposed, for example, to receive other components to which the weld boss may also be connected (welded). A welded portion may be referred to as a connection or a battery cell connection.

[0014] Figure 1 and Figure 2 An example battery (e.g., a lead-acid battery with an Adsorbent Glass Fiber (AGM) battery assembly) and one or more components of the example battery are shown. Battery 10 may include at least one of the following components: a housing 12 (which may be made of resin or any other suitable material), one or more cell cells 14, a terminal assembly 15 (e.g., a Coated Steel Strap (COS) terminal assembly), one or more strips 16, one or more terminals 18 (e.g., terminal terminals, micro-terminal 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 circuit 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.

[0015] 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 (such as...) Figure 2 (As shown) has been inserted into the housing 12. The battery cell 14 is connected to the terminal post 18 (via...) Figure 2 The first cover 20 includes one or more bushings 22, such as bushing 22a (e.g., a micro bushing) and bushing 22b, and one or more terminal structures 23 that can be coupled to the first cover 20 and include corresponding bushings 22, such as bushing 22a. The terminal structures 23 can be electrically connected to their corresponding terminal posts 25, which are arranged to connect to and provide electrical power to an electrical load (e.g., a vehicle system). Bushing 22a is aligned with post 18a, and bushing 22b is aligned with post 18b. Other bushings 22 can be aligned with other posts 18. The first cover 20 is then coupled (and / or sealed) to the housing 12.

[0016] Figure 4 An example first cover 20 is shown attached to housing 12. More specifically, the first cover 20 is shown attached to housing 12, wherein the pole post 18 can contact its respective bushing 22, and at least a portion of the pole post 18 protrudes from the respective bushing 22, as shown. Figure 5 and Figure 6 As shown. In Figure 5 In this configuration, the electrode post 18a has been inserted through the bushing 22a, wherein the electrode post 18a can directly contact the bushing 22a, and a portion of the electrode post 18a protrudes from the bushing 22a. Figure 6 In the middle, the pole post 18b has been inserted through the bushing 22b, wherein the pole post 18b can directly contact the bushing 22b, and a part of the pole post 18b protrudes from the bushing 22b.

[0017] Figure 7Example steps of a laser welding process are shown. This laser welding process can be used to join two or more components together. More specifically, a head 40 is arranged to emit a laser beam 42 and guide the laser beam 42 along the direction of the electrode 18 and the bushing 22. The laser beam 42 is guided to join the electrode 18 to the bushing 22, that is, to weld the electrode 18 and the bushing 22 together. The laser beam 42 provides a concentrated energy source, thereby allowing control over which area and / or depth of the electrode 18 and / or bushing 22 receives energy. The position of the head 40 can be changed to change the angle of the laser beam 42, thereby allowing the laser beam 42 to deliver a concentrated energy source to different areas and depths in a controlled manner. That is, the laser beam 42 of the laser welding process can be used to perform precision welding along one or more axes and achieve a predetermined “depth of penetration” (DOB) without damaging battery components (e.g., battery cover) and / or weakening the connection between the weld and the cover. Furthermore, the laser beam 42 of the laser welding process provides a welding rate higher than conventional TIG welding and other conventional welding techniques. This laser welding process may be referred to as laser deep penetration welding.

[0018] Conventional welding methods rely on heat conduction, which may limit the ability to achieve a predetermined DOB. A reliable, leak-free weld seal (e.g., a joint) may require a predetermined DOB. If heat is applied to achieve a sufficient DOB, the material embedded in the bushing 22 (e.g., plastic) will absorb some of the heat and may change its properties (e.g., it may exhibit plasticity, plasticize, become plastic, or become malleable), causing the bushing 22 to shift out of position, create a leak path, or migrate into the weld area.

[0019] In some embodiments, by using a laser welding process, sufficient heat can be applied deep into the interior of the lead material without relying on heat conduction (e.g., other conventional methods). Because the energy density of the laser welding process is higher than other conventional methods, shorter cycle times can be achieved. Furthermore, energy can be directly transferred to the welded area / region without affecting surrounding temperature-sensitive components, such as the first cover 20, which may be made of plastic material. That is, the laser welding process described herein provides a consistent weld between the terminal post 18 and the bushing 22 while maintaining the bushing 22 (and the terminal post 18) sealed to the first cover 20, for example, without heating the terminal post 18 and / or bushing 22 to the point of melting the battery casing. In some embodiments, the terminal post 18 and / or bushing 22 may be made of lead material. In some embodiments, at least a portion of the cover 20 is joined to the weld produced by the laser welding process, and at least that portion of the cover meets or exceeds quality requirements. Quality requirements may include: the shape and / or morphology of the cover 20 does not change during and / or after welding, the material parameters of the cover material do not change beyond a predetermined threshold, etc.

[0020] although Figure 7 The laser welding process is shown as welding the electrode post to the bushing, but the embodiments of this disclosure are not limited thereto, and the laser welding process can also be used to weld any other components, such as welding parts 46, 48 (e.g. Figure 8 Any solder joint shown is soldered to any component of the lead assembly 24, etc.

[0021] Figure 8 An example battery after the laser welding process is shown. More specifically, it can be used... Figure 7 The laser welding process shown welds the electrode post 18 and the bushing 22 to form welded portions 46 and 48. More specifically, it will... Figure 5 The pole post 18a and bushing 22a shown are welded to form a welded portion 46. Similarly, the pole post 18a and bushing 22a are welded to form a welded portion 46. Figure 6 The terminal post 18b and bushing 22b shown are welded to form a weld portion 48. In some embodiments, weld portion 46 is associated with the battery cell 14, and weld portion 48 is associated with the terminal of the battery 10. Once weld portions 46 and 48 are completed, the terminal post 18 and bushing 22 are welded to each other. Additionally, after welding is completed, at least a portion of the terminal post 18 is integrated with the bushing 22. In some embodiments, once weld portions 46 and 48 are completed, weld portions 46 and 48 are sealed to the first cover 20, for example, such that the internal space (e.g., including the battery cell 14) defined by the first cover 20 and the housing 12 is sealed. In some other embodiments, the weld portions 46 and 48 formed by welding the terminal post 18 and bushing 22 into a single integral structure are sealed to the first cover 20. Either weld portion 46 or 48 may be a first weld portion or a weld boss.

[0022] Figure 9 It shows Figure 8 The diagram shows a view of an example welded portion 46. The welded portion 46 extends from the first cover 20. That is, a portion of the welded portion 46 extends from the first cover 20 and is accessible and / or exposed, for example, to receive other components to which the welded portion 46 may also be joined (welded). Figure 10 It shows Figure 9 A cross-sectional view of an example welded portion 46. The welded portion 46 is in physical contact with and / or coupled to the first cover 20. Furthermore, the welded portion 46 includes at least a portion (e.g., a previously melted portion) of the pole post 18a and / or the bushing 22a. For example, when the welded portion 46 is formed using the laser welding process described herein, the welded portion 46 includes at least some material from the pole post 18a and / or some material from the bushing 22a. A gap 19 may be arranged between the pole post 18a and the bushing 22a.

[0023] Furthermore, the weld portion 46 is not limited to having the shape or size shown, and may have any other shape or size. For example, the weld portion 46 may also include additional material for the terminal post 18a and the bushing 22a, which may fill at least a portion of the gap 19 between the terminal post 18a and the bushing 22a. That is, the gap 19 may be arranged to form a flow space, such that molten material from the weld portion 46 flows into and / or fills at least a portion of the gap 19. In addition, the terminal post 18a may be electrically connected to one or more battery cells 14, such that an electrical connection can be established between the weld portion 46 and the battery cell 14.

[0024] Figure 11 It shows Figure 8 The diagram shows a view of an example welded portion 48. The welded portion 48 extends from the first cover 20 and is connected to and / or welded to a terminal structure 33, which can be connected to the first cover 20. That is, a portion of the welded portion 48 extends from the first cover 20 and is accessible to and / or exposed to other components (such as the terminal structure 33), with which the welded portion 48 can also be connected (welded). Figure 12 It shows Figure 11 A cross-sectional view of an example welded portion 48. The welded portion 48 may be in physical contact with and / or coupled to the first cover 20. Furthermore, the welded portion 48 includes at least a portion (e.g., a previously melted portion) of the pole 18b and / or the bushing 22b. For example, when the welded portion 48 is formed using the laser welding process described herein, the welded portion 48 includes at least some material from the pole 18b and / or some material from the bushing 22b. A gap 21 may be arranged between the pole 18b and the bushing 22b.

[0025] It should be noted that the weld portion 48 is not limited to having the shape or size shown, and may have any other shape or size. For example, the weld portion 48 may also include additional material for the terminal 18b and the bushing 22b, such as material in the area where the terminal 18b and the bushing 22b contact each other, and the welding material may fill at least a portion of the gap 21. That is, the gap 21 may be arranged to form a flow space, such that molten material from the weld portion 48 flows into and / or fills at least a portion of the gap 21. Furthermore, the terminal 18b may be electrically connected to one or more battery cells 14, such that an electrical connection can be established between the weld portion 48 and the battery cell 14.

[0026] Figure 13 A cross-sectional view of example weld 46 or weld 48 is shown (e.g., in relation to...). Figure 7(After the described process is completed). Welded portions 46, 48 may include welding materials, such as materials that have been melted as part of the welding process, and / or materials that have solidified after a predetermined time and / or after the welded portions 46, 48 have cooled to below a predetermined temperature threshold. The melted material may include material from the bushing 22 and / or the pole 18 (e.g., material that does not melt or is damaged from the cover 20). Since laser welding provides a concentrated energy source, this allows control over which area and / or depth of the pole 18 and / or bushing 22 receives energy, thus enabling several depths and diameters of the welded portions. In this non-limiting example, when welded portions 46, 48 are formed, several portions of the welded portions 46, 48 may have different diameters at different depths of the welded portions 46, 48, such as a first diameter d1, a second diameter d2, a third diameter d3, a fourth diameter d4, a fifth diameter d5, a sixth diameter or distance d6, a seventh diameter or distance d7, etc. Different depths of welded portions 46, 48 are shown, and these depths can be measured relative to different points of welded portions 46, 48 and / or bushing 22 and / or cover 20. For example, welded portions 46, 48 may have a depth "a" measured from bushing portion 50 to welded portion 52, and a depth "b" measured from bushing portion 54 to welded portion 56. However, the depths are not limited to this and can be measured from / to any other portion, such as bushing portion 58 or bushing portion 60, and may be more or less than two depths.

[0027] In this non-limiting example, the completed welded portions 46, 48 have three parts 62, 64, 66, where part 62 may be a top (or crown) having a height h1 extending from the cover 20 (e.g., above the pole post 18 and bushing 22). Part 64 is connected to part 62, may be located within a portion of the bushing 22, may include material from the pole post 18 and / or bushing 22, and may be located above a portion of the pole post 18. The height of part 64 may be h2. Furthermore, the pole post 18 may be cylindrical, have a truncated conical shape, have a radial shape, or have any other shape. Part 66 may be a bottom (or root) having a height h3 and may surround at least a portion of the pole post 18. Part 66 may have a top diameter (e.g., given by d5+d6) and be spaced from the bushing 22 by a distance or diameter d7 at parts 52, 56, respectively. At least some material of part 88 may flow into and fill at least a portion of the gaps 19, 21. Another portion of gaps 19 and 21 may be left unfilled and may have a height h4. Therefore, laser welding of the pole piece 18 and bushing 22 can produce weld portions 46 and 48 extending to predetermined depths (depths "a", "b", or other depths), and / or leave a portion of height h4 that may not contain welding material, or in which welding material does not reach the pole piece 18 and / or bushing 22. In other words, laser welding of the pole piece 18 and bushing 22 can produce a controlled process in which the depth of the weld portion can reach one or more predetermined thresholds without burning or damaging the cover 20.

[0028] Figure 14 It shows Figure 13 The section A of the welded portions 46 and 48, and another example depth “c” measured from bushing portion 50 to bushing portion 70, wherein the diameter of the bottom 66 (e.g., the root) of the welded portions 46 and 48 is d6. That is, the laser welding process can be arranged such that at a predetermined depth “c” from a predetermined portion (i.e., portion 50) of the bushing 22, the diameter of portion 66 is less than and / or equal to, or greater than and / or equal to, the predetermined diameter d6.

[0029] Similarly, Figure 15 It shows Figure 13 The section B of the welded portions 46 and 48, and another example depth “d” measured from bushing portion 54 to bushing portion 72, wherein the diameter of the bottom 66 (e.g., the root) of the welded portions 46 and 48 is d7. That is, the laser welding process can be arranged such that at a predetermined depth “d” from a predetermined portion (i.e., portion 54) of the bushing 22, the diameter of portion 64 is less than and / or equal to, or greater than and / or equal to, the predetermined diameter d7.

[0030] Furthermore, the configuration of welded portions 46 and 48 provides a connection mechanism that allows the terminal post 18 and bushing 22 to be fixed to each other and to the cover 20 without damaging the cover 20, while providing an electrical path to the battery cell and the battery management system for measuring cell parameters. Additionally, the laser welding forming welded portions 46 and 48 allows for a predetermined DOB (Dependency On Board), which provides a reliable and leak-free seal for welded portions 46 and 48.

[0031] In some embodiments, the battery 10 includes a lead assembly 24 connected to a plurality of solder joints, including solder joints 46 and 48. The lead assembly is electrically connected to the BMS 26, such that an electrical connection is established between the BMS 26 and the battery cell 14 via the lead assembly 24 and the corresponding solder joints 46, 48. In some other embodiments, the solder joints 46, 48 are formed using a predetermined solder pattern and a predetermined soldering time. The predetermined solder pattern and / or predetermined soldering time are based on whether the terminal post 18 is connected to the battery cell 14 or to the battery terminal structure 23 or terminal post 25 (i.e., battery terminal).

[0032] Figure 16 A flowchart illustrating an example method for manufacturing battery cell connectors (e.g., weld portions 46, 48) is shown. The method includes: inserting a terminal post 18 through a bushing 22 (box S100), wherein at least a portion of the bushing 22 is in physical contact with a cover 20; guiding a laser beam 42 to one or more regions and one or more depths of one or more of one or more regions of either the terminal post 18 or the bushing 22 (box S102); and using the guided laser beam to form weld portions 46, 48 comprising the bushing 22 and the terminal post 18 coupled to the bushing 22 (box S104). At least the bushing 22 of the weld portions 46, 48 is sealed to the cover 20.

[0033] Figure 17A flowchart of another example method for manufacturing a battery cell connection (e.g., welded portions 46, 48) for establishing an electrical connection to a battery cell 14 of a battery 10 is shown. The battery 10 has a terminal post 18, a bushing 22, a housing 12, and a cover 20 sealing to the housing 12. The terminal post 18 is inserted through the bushing 22, and at least a portion of the bushing 22 is in physical contact with the cover 20 and the terminal post 18. The bushing 22 includes bushing material and has a first bushing portion 50 and a second bushing portion 54. The terminal post 18 includes terminal post material. The method includes: directing a laser beam 42 to one or more regions and one or more depths of one or more of one or more regions of one or both of the terminal post 18 and the bushing 22 (box S200); and forming welded portions 46, 48 using the laser beam 42 (box S202). The formed welded portions 46, 48 include a first welded portion 62, a second welded portion 64, and a third welded portion 66. The first portion 62 of the weld extends outward from at least the bushing 22. The second portion 64 of the weld is connected to the first portion 62, located within the bushing 22 and above the pole post 18. The third portion 66 of the weld is connected to the second portion 64, located within the bushing 22 and surrounding the pole post 18. The weld portions 46 and 48 have one or both of a first depth "a" measured from the first portion 50 of the bushing and a second depth "b" measured from the second portion 54 of the bushing. One or both of the first depth "a" and the second depth "b" reach or exceed a minimum depth threshold.

[0034] In some embodiments, bushing 22 further includes bushing third portion 52 and bushing fourth portion 56, and the method further includes guiding a laser beam 42 to melt one or both of the bushing material and the pole piece material to achieve a first depth “a” measured from bushing first portion 50 to bushing third portion 52 and a second depth “b” measured from bushing second portion 54 to bushing fourth portion 56.

[0035] In some other embodiments, bushing 22 further includes a fifth bushing portion 70 and a sixth bushing portion 72. The method also includes guiding a laser beam 42 to melt one or both of the bushing material and the pole piece material. The guided laser beam causes weld portions 46, 48 to have a third depth “c” measured from the first bushing portion 50 to the fifth bushing portion 70, and a fourth depth “d” measured from the second bushing portion 54 to the sixth bushing portion 72. A first depth “a” is greater than the third depth “c”, and a second depth “b” is greater than the fourth depth “d”.

[0036] In some embodiments, the laser beam 42 guides the third portion 66 of the weld to have a width that extends from the fifth portion 70 of the bushing to the pole post 18 and reaches or exceeds a width threshold.

[0037] In some other embodiments, one or more of the following: (A) the pole piece 18 and the weld portions 46, 48 define gaps 19, 21; (B) the guide laser beam 42 causes a portion of one or both of the bushing material and the pole piece material to fill at least a portion of the gaps 19, 21; (C) the weld portions 46, 48 are formed using a predetermined weld pattern and a predetermined weld time; and (D) one or both of the predetermined weld pattern and the predetermined weld time are based on whether the pole piece 18 is connected to a battery cell 14 or battery terminals 23, 25.

[0038] Although the battery 10 is described as having terminals 18, bushings 22, a housing 12, and a cover 20, the embodiments are not limited thereto, and the battery 10 may include one or more of each of the terminals 18, bushings 22, housing 12, cover 20, and any other components described herein. In a non-limiting example, the battery 10 has a plurality of terminals 18 and a plurality of corresponding bushings 22 and / or welds 46, 48. One or more embodiments described herein are advantageous, at least because the BMS 26 can be electrically connected to the battery cell 14 via the welds 46, 48, terminals 18, and bushings 22, for example, to determine battery cell parameters such as voltage, state of charge, and state of health, while controlling the DOB of the welds 46, 48, and protecting other battery components, such as the cover 20 (e.g., to prevent melting due to excessive heat from conventional welding techniques).

[0039] Those skilled in the art will understand that the embodiments described herein are not limited to those specifically shown and described above. Furthermore, unless otherwise stated above, it should be noted that all figures are not drawn to scale. Various modifications and variations can be made based on the foregoing teachings without departing from the scope of the following claims.

Claims

1. A means for being arranged to establish an electrical connection to a battery cell (14) of a battery (10), the means comprising: Bushing (22), the bushing includes bushing material and has a first bushing portion (50) and a second bushing portion (54); The pole (18) is in physical contact with the bushing (22) and includes pole material; as well as Welded portions (46, 48), formed by laser welding and comprising the bushing material and the pole material, the welded portions (46, 48) include: The first part of the welding section (62) extends outward from the bushing (22) at least; The second part of the welding section (64), which is connected to the first part of the welding section (62), is located inside the bushing (22) and above the pole post (18); and The third welding portion (66), which is connected to the second welding portion (64), is located inside the bushing (22) and surrounds the pole post (18). The welding portion (46, 48) has one or both of a first depth (a) measured from the first bushing portion (50) and a second depth (b) measured from the second bushing portion (54), one or both of the first depth (a) and the second depth (b) reaching or exceeding a minimum depth threshold.

2. The apparatus according to claim 1, wherein, The bushing (22) further includes a third bushing portion (52) and a fourth bushing portion (56), wherein the first depth (a) is measured from the first bushing portion (50) to the third bushing portion (52), and the second depth (b) is measured from the second bushing portion (54) to the fourth bushing portion (56).

3. The apparatus according to any one of claims 1 and 2, wherein, The bushing (22) further includes a fifth bushing portion (70) and a sixth bushing portion, the welded portions (46, 48) having a third depth (c) measured from the first bushing portion (50) to the fifth bushing portion (70), and the welded portions (46, 48) having a fourth depth (d) measured from the second bushing portion (54) to the sixth bushing portion (72), the first depth (a) being greater than the third depth (c), and the second depth (b) being greater than the fourth depth (d).

4. The apparatus according to claim 3, wherein, The third part (66) of the welded portion has a width that extends from the fifth part (70) of the bushing to the pole post (18) and reaches or exceeds a width threshold.

5. The apparatus according to any one of claims 1 to 4, wherein, The pole (18) and the weld (46, 48) define a gap (19, 21) that is arranged to receive at least a portion of one or both of the bushing material and the pole material.

6. A battery (10), comprising: Cover (20) and housing (12) connected to the cover (20); A bushing (22), which is connected to the cover (20), includes bushing material and has a first bushing portion (50) and a second bushing portion (54). The electrode post (18), which is in physical contact with the bushing (22) and comprises electrode post material; and Welded portions (46, 48), formed by laser welding, are connected to the cover and include the bushing material and the pole material. The welded portions (46, 48) include: The first part of the welding section (62) extends outward from the cover body; The second part of the welding section (64), which is connected to the first part of the welding section (62), is located inside the bushing (22) and above the pole post (18); and The third welding portion (66), which is connected to the second welding portion (64), is located inside the bushing (22) and surrounds the pole post (18). The welding portion (46, 48) has one or both of a first depth (a) measured from the first bushing portion (50) and a second depth (b) measured from the second bushing portion (54), one or both of the first depth (a) and the second depth (b) reaching or exceeding a minimum depth threshold.

7. The battery (10) according to claim 6, wherein, The bushing (22) further includes a third bushing portion (52) and a fourth bushing portion (56), wherein the first depth (a) is measured from the first bushing portion (50) to the third bushing portion (52), and the second depth (b) is measured from the second bushing portion (54) to the fourth bushing portion (56).

8. The battery (10) according to any one of claims 6 and 7, wherein, The bushing (22) further includes a fifth bushing portion (70) and a sixth bushing portion (72), the welded portions (46, 48) having a third depth (c) measured from the first bushing portion (50) to the fifth bushing portion (70), and the welded portions (46, 48) having a fourth depth (d) measured from the second bushing portion (54) to the sixth bushing portion (72), the first depth (a) being greater than the third depth (c), and the second depth (b) being greater than the fourth depth (d).

9. The battery (10) according to claim 8, wherein, The third part (66) of the welded portion has a width that extends from the fifth part (70) of the bushing to the pole post (18) and reaches or exceeds a width threshold.

10. The battery (10) according to any one of claims 6 to 9, wherein, The pole (18) and the weld (46, 48) define a gap (19, 21) that is arranged to receive at least a portion of one or both of the bushing material and the pole material.

11. The battery (10) according to any one of claims 6 to 10, wherein, At least a portion of the cover connected to the welded portion (46, 48) meets or exceeds the quality requirements.

12. The battery (10) according to any one of claims 6 to 11, wherein, The battery (10) also includes a lead assembly (24) connected to the welded portion (46, 48).

13. The battery (10) according to claim 12, wherein, The battery (10) also includes a battery management system (BMS) (26) which is electrically connected to the lead assembly (24).

14. The battery (10) according to claim 13, wherein, The battery (10) further includes at least one battery cell (14), and the BMS (26) is electrically connected to the at least one battery cell (14) via the lead assembly (24) and the solder joints (46, 48).

15. The battery (10) according to claim 14, wherein, The welded portion (46, 48) is at least one of a plurality of welded portions (46, 48), and the at least one welded portion (46, 48) corresponds to the battery terminal structure (23) or at least one battery cell (14).

16. A method of manufacturing a welded portion (46, 48) for establishing an electrical connection to a battery cell (14) of a battery (10), the battery (10) having a terminal (18), a bushing (22), a housing, and a cover sealed to the housing, the terminal (18) being inserted through the bushing (22), at least a portion of the bushing (22) being in physical contact with the cover (20) and the terminal (18), the bushing (22) comprising bushing material and having a first bushing portion (50) and a second bushing portion (54), the terminal (18) comprising terminal material, the method comprising: The laser beam (42) is directed to one or more regions of one or both of the pole post (18) and the bushing (22) and to one or more depths of a plurality of depths (S200). as well as The welded portions (46, 48) are formed using the laser beam (S202), and the formed welded portions (46, 48) include: The first part of the welding section (62) extends outward from the bushing (22) at least; The second part of the welding section (64), which is connected to the first part of the welding section (62), is located inside the bushing (22) and above the pole post (18); and The third welding portion (66), which is connected to the second welding portion (64), is located inside the bushing (22) and surrounds the pole post (18). The welding portion (46, 48) has one or both of a first depth (a) measured from the first bushing portion (50) and a second depth (b) measured from the second bushing portion (54), one or both of the first depth (a) and the second depth (b) reaching or exceeding a minimum depth threshold.

17. The method according to claim 16, wherein, The bushing (22) further includes a third bushing portion (52) and a fourth bushing portion (56), and the method further includes: guiding the laser beam (42) to melt one or both of the bushing material and the pole piece material to achieve a first depth (a) measured from the first bushing portion (50) to the third bushing portion (52) and a second depth (b) measured from the second bushing portion (54) to the fourth bushing portion (56).

18. The method according to any one of claims 16 and 17, wherein, The bushing (22) further includes a fifth part (70) and a sixth part (72) of the bushing, and the method further includes: The laser beam (42) is directed to melt one or both of the bushing material and the pole piece material, the directed laser beam causing the weld (46, 48) to have a third depth (c) measured from the first part (50) of the bushing to the fifth part (70) of the bushing, and to have a fourth depth (d) measured from the second part (54) of the bushing to the sixth part (72) of the bushing, the first depth (a) being greater than the third depth (c), and the second depth (b) being greater than the fourth depth (d).

19. The method according to claim 18, wherein, The laser beam (42) is guided so that the third part (66) of the weld has a width that extends from the fifth part (70) of the bushing to the pole post (18) and reaches or exceeds a width threshold.

20. The method according to any one of claims 16 to 19, wherein, One or more of the following: The pole post (18) and the welded part (46, 48) define a gap (19, 21). The laser beam (42) is guided to fill at least a portion of the gap (19, 21) with a portion of one or both of the bushing material and the pole piece material; The welded portions (46, 48) are formed using a predetermined welding pattern and a predetermined welding time; and One or both of the predetermined welding pattern and the predetermined welding time are based on whether the pole (18) is connected to the battery cell (14) or the battery terminal (23, 25).

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