Battery cover

Abstract

A second cover couplable to a first cover is described. The second cover includes a shell that includes a first cover space and a second cover space. The first cover space is a common space arranged to receive a gas from the battery and is physically separated from the second cover space and the gas from the battery. The second cover also includes at least one vent port and at least one valve in the first cover space. The at last one valve has an inlet side and an outlet side. The inlet side is in fluid communication with the first cover space. The outlet side is in fluid communication with the at least on vent port. The at least one valve is arranged to open and release the gas to the at least one vent port when a gas pressure exceeds a predetermined threshold.

Description

[0001] BATTERY COVER

[0002] TECHNICAL FIELD

[0003] This disclosure relates to batteries and in particular to a cover for a battery.

[0004] BACKGROUND

[0005] As battery technology evolves, the demand for improved power sources such as energy storage modules for vehicles continues to grow. Lead acid batteries can be found all around us and are used to power a variety of different applications including cars, trucks, boats, vehicles, wheelchairs, and uninterruptable power supply (UPS) backups. Existing battery systems, for example lead acid battery systems, typically offer limited or no performance and failure monitoring functions, and have complex venting arrangements. These complex venting arrangements are relied on to provide gas venting from individual battery cells.

[0006] Lead-acid batteries release gasses, including oxygen and hydrogen, which are both flammable and can potentially be explosive. These gasses must be allowed to vent from the battery. Accordingly, batteries must have adequate ventilation to avoid the build-up of these gasses. During the operation of a battery, gasses must be removed. There are various complex venting arrangements to prevent the build-up of pressure inside the battery, but the complex venting arrangements can be difficult and expensive to manufacture and can have failure points which can cause issues in the venting of the batteries. These venting arrangements may also be complex to manufacture.

[0007] SUMMARY

[0008] Some embodiments advantageously provide a battery with a cover. In some embodiments, the cover may include a first portion and a second portion, each of the first portion and the second portion having a first end and a second end opposite the first end. The cover may further include a connecting portion contiguous with the first end of the first portion and the first end of the second portion, and a cover space contiguous with the second end of the first portion and the second end of the second portion. The cover space has a plurality of channels and a plurality of vent ports. The cover space is arranged such that, when the cover is secured to the battery, a volume is created in the cover space whose only fluid path from cells of the battery to the external atmosphere is via the vent ports. In some other embodiments, a battery may comprise a case, a plurality of battery cells within the case and a battery management system (BMS). The battery may also include a first cover that is sized to retain the BMS. The first cover may affixed to the case, and the first cover may have at least one cover opening to allow fluid communication with the plurality of battery cells through the first cover. The battery may further have a second cover that is affixed to the first cover. The second cover may include a first portion and a second portion, each of the first portion and the second portion having a first end and a second end opposite the first end. The cover may further include a connecting portion contiguous with the first end of the first portion and the first end of the second portion, and a cover space contiguous with the second end of the first portion and the second end of the second portion. The cover space has a plurality of channels and a plurality of vent ports. The cover space is arranged such that, when the cover is secured to the battery, a volume is created in the cover space whose only fluid path from cells of the battery to the external atmosphere is via the vent ports.

[0009] According to one aspect, a second cover couplable to a first cover of a battery is described. The second cover includes a shell. The shell includes a first cover space and a second cover space. The first cover space is a common space arranged to receive a gas from the battery. The first cover space is physically separated from the second cover space and the gas from the battery. The second cover space is arranged to house a battery management system. The second cover also includes at least one vent port and at least one valve in the first cover space. The at last one valve has an inlet side and an outlet side. The inlet side is in fluid communication with the first cover space. The outlet side is in fluid communication with the at least on vent port. The at least one valve is arranged to open and release the gas to the at least one vent port when a gas pressure exceeds a predetermined threshold.

[0010] In some embodiments, the at least one vent port includes a plug in fluid communication with the outlet side of the at least one valve.

[0011] In some other embodiments, the plug is arranged to control release of the gas.

[0012] In some embodiments, the at least one vent port further includes a flame arrestor positioned between the outlet side of the valve and the plug. The flame arrestor is arranged to prevent a flame from forming as the gas is released to the at least one vent port.

[0013] In some other embodiments, the first cover space and the second cover space formed by the shell are physically separated by a cover wall.

[0014] In some embodiments, the second cover further includes a chamber arranged to receive the at least one valve to couple the at least one valve to the second cover. In some other embodiments, the at least one valve includes a valve head, where the valve head includes valve head nub and a release portion contiguous to the valve head nub.

[0015] In some embodiments, the second cover comprises a second cover nub in physical contact with the valve head nub, and the release portion is in physical contact with a portion of the chamber when the at least one valve is closed or not in physical contact at least with the portion of the chamber when the at least one valve is open.

[0016] In some other embodiments, the predetermined threshold is based on a size of the second cover nub.

[0017] In some embodiments, the second cover further includes a receiving portion and a vehicle connector. The receiving portion is arranged to receive the vehicle connector and is physically separated from the first cover space.

[0018] In some other embodiments, the shell further includes at least one housing in the second cover space. The at least one housing is arranged to receive and house a terminal post assembly of the battery.

[0019] In some embodiments, the second cover further includes an aperture arranged as an access port to leak test the second cover.

[0020] In some other embodiments, the second cover may further include an electronic access opening in fluid communication with the second cover space.

[0021] In some embodiments, the electronic access opening is arranged to house the battery management system and couple to a third cover.

[0022] According to another aspect, a battery is described. The battery includes a plurality of battery cells, a case, a first cover, a battery management system, and a second cover. The case has an internal space and houses the plurality of battery cells in the internal space. The first cover is coupled to the case and includes a plurality of cover openings in fluid communication with the internal space and the plurality of battery cells. The battery management system is physically coupled to the first cover and electrically coupled to at least one battery cell of the plurality of battery cells. The second cover is coupled to the first cover. The second cover includes a shell, at least one vent port, and at least one valve. The shell includes a first cover space and a second cover space. The first cover space is in fluid communication with the cover openings and defines at least in part a first common space arranged to receive a gas from the internal space. The first common space is physically separated from the second cover space. The second cover space is arranged to house the battery management system. The at least one valve is in the first cover space and has an inlet side and an outlet side. The inlet side is in fluid communication with the first cover space. The outlet side is in fluid communication with the at least on vent port. The at least one valve is arranged to open and release the gas to the at least one vent port when a gas pressure exceeds a predetermined threshold.

[0023] In some embodiments, the first cover further includes a third cover space and a fourth cover space. The third cover space includes the plurality of cover openings. The second cover space and the fourth cover space house the battery management system.

[0024] In some other embodiments, the first cover space and the third cover space define the first common space. The second cover space and the fourth cover space define a second common space physically separated from the first common space. The second common space houses at least the battery management system.

[0025] According to one aspect, a method of assembling a battery is described. The battery includes a case, a first cover, and a second cover. The method includes sealing the first cover to the case and forming the second cover. The formed second cover includes a shell. The shell includes a first cover space and a second cover space. The first cover space is a common space arranged to receive a gas from the battery and is physically separated from the second cover space. The shell also includes at least one vent port. The method also includes coupling at least one valve to the second cover in the first cover space. The at least one valve has an inlet side and an outlet side. The inlet side is in fluid communication with the first cover space. The outlet side is in fluid communication with the at least on vent port. The at least one valve is arranged to open and release the gas to the at least one vent port when a gas pressure exceeds a predetermined threshold.

[0026] In some embodiments, the method further includes coupling a plug to the at least one vent port, where the plug is in fluid communication with the outlet side of the at least one valve.

[0027] In some other embodiments, the method further includes coupling a flame arrestor to the at least one vent port. The flame arrestor is positioned between the outlet side of the valve and the plug. The flame arrestor is arranged to prevent a flame from forming as gas is released to the at least one vent port.

[0028] In some embodiments, the forming further includes forming a cover wall comprised in the shell and physically separating the first cover space and the second cover space formed by the shell.

[0029] In some other embodiments, the forming further includes forming a chamber in the first cover space. The chamber is arranged to receive the at least one valve to couple the at least one valve to the second cover. In some embodiments, the forming further includes forming at least one housing comprised in the shell. The at least one housing further defines the second cover space. The at least one housing is arranged to receive and house a terminal post assembly of the battery.

[0030] In some other embodiments, the forming further includes forming an aperture in the second cover. The aperture is arranged as an access port to leak test the second cover.

[0031] In some embodiments, the forming further includes forming an electronic access opening on the shell of the second cover. The electronic access opening is in fluid communication with the second cover space.

[0032] In some other embodiments, the battery further includes a battery management system, the case houses a plurality of battery cells, and the method further includes physically coupling the battery management system to the first cover and electrically coupling the battery management system to at least one battery cell of the plurality of battery cells. The electronic access opening is arranged to house the battery management system and couple to a third cover.

[0033] In some embodiments, the method further includes coupling the second cover to the first cover. The battery management system is housed in the second cover space and is accessible via the electronic access opening.

[0034] In some other embodiments, the battery further includes a third cover, and the method further includes coupling the third cover to the second cover. The third cover defines at least a portion of the second cover space and covers the electronic access opening.

[0035] BRIEF DESCRIPTION OF THE DRAWINGS

[0036] A more complete understanding of embodiments described herein, and the attendant advantages and features thereof, will be more readily understood by reference to the following detailed description when considered in conjunction with the accompanying drawings wherein:

[0037] FIG. 1 shows an example battery and one or more components of the example battery according to the principles of the present disclosure;

[0038] FIG. 2 shows an overhead perspective view of an example second cover according to the principles of the present disclosure;

[0039] FIG. 3 shows an exploded view of an example second cover according to the principles of the present disclosure; FIG. 4 shows an overhead perspective view of an example second cover according to the principles of the present disclosure;

[0040] FIG. 5 shows a bottom perspective view of an example second cover according to the principles of the present disclosure;

[0041] FIG. 6 shows the bottom perspective view of the second cover including a plug according to the principles of the present disclosure;

[0042] FIG. 7 shows a bottom view of an example second cover according to the principles of the present disclosure;

[0043] FIG. 8 shows a side view of the second cover according to the principles of the present disclosure;

[0044] FIG. 9 shows a closeup view of a portion of the second cover according to the principles of the present disclosure;

[0045] FIG. 10 shows a top view of a first cover according to the principles of the present disclosure;

[0046] FIG. 11 shows an example second cover and a corresponding step of an assembly process according to the principles of the present disclosure;

[0047] FIG. 12 shows an example second cover assembled on the battery according to the principles of the present disclosure;

[0048] FIG. 13 shows an example of an overhead view of the second cover assembled on the battery according to the principles of the present disclosure;

[0049] FIG. 14 shows an overhead perspective view of an example third cover according to the principles of the present disclosure;

[0050] FIG. 15 shows a bottom perspective view of the example third cover according to the principles of the present disclosure;

[0051] FIG. 16 shows an example second cover and a corresponding step of an assembly process of the third cover according to the principles of the present disclosure; and

[0052] FIG. 17 shows a flowchart of an example method of assembling a battery according to the principles of the present disclosure.

[0053] DETAILED DESCRIPTION

[0054] As battery technology evolves, there is a need to provide improved power sources, and more efficient and effective methods for manufacturing such power sources as compared to conventional systems and methods. Accordingly, embodiments described and shown herein provide a multi-functional top cover with an integrated venting arrangement that is less complex than those currently used and that is suitable for use in batteries that have integrated electronics such as an integrated BMS. In some embodiments, at least one lead to a corresponding battery cell may be connected to the BMS, e.g., to determine / measure at least one parameter, such as cell voltage, cell current, cell temperature, etc. In some other embodiments, the battery includes a valve, e.g., a pressure release valve, arranged to release a pressure from the case where battery cells are housed.

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

[0056] As used herein, relational terms, such as “first” and “second,” “top” and “bottom,” and the like, may be used solely to distinguish one entity or element from another entity or element without necessarily requiring or implying any physical or logical relationship or order between such entities or elements. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the concepts described herein. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises,” “comprising,” “includes” and / or “including” when used herein, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0057] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. It will be further understood that terms used herein should be interpreted as having a meaning that is consistent with their meaning in the context of this specification and the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

[0058] In embodiments described herein, the joining term, “in communication with” and the like, may be used to indicate electrical or data communication, which may be accomplished by physical contact, induction, electromagnetic radiation, radio signaling, infrared signaling or optical signaling, for example. One having ordinary skill in the art will appreciate that multiple components may interoperate and modifications and variations are possible of achieving the electrical and data communication.

[0059] Referring now to the drawing figures where like reference designators refer to like elements, FIG. 1 shows an example battery 10 and one or more components of the example battery 10. Battery 10 may include various components including at least one of the following: a case 12 (which may be made of from a resin or any other suitable material), one or more battery cells disposed in the case 12 (not shown), battery terminals 14, one or more posts (e.g., a terminal post, a mini-post) (not shown), a first cover 16, a BMS 80 (as shown in FIG. 11), a second cover 18 (also referred to herein as a top cover), and a third cover 20

[0060] FIG. 2 shows an example of a first side 24 of the second cover 18. The second cover 18 includes a shell 19, which may define one or more spaces (e.g., internal spaces) and / or comprise one or more cover components. Further, second cover 18 includes a receiving portion 26 contiguous with vehicle connector 22. The vehicle connector 22 provides a location for an electrical connector to be housed in a way that seals the internal portions of the battery, e.g., the BMS, from the external environment but still allow electronic communications from the BMS to locations external to the battery. Thus the electrical connector may be inserted and / or coupled to the second cover 18 through a receiving portion 26. The vehicle connector 22 may be arranged within the receiving portion 26 to receive at least one wire, for example a wire harness, so that a connection from BMS to a component of a vehicle via the wire harness can be made. At least a portion of the vehicle connector 22 may be accessible from the first side 24 of the second cover 18 and the vehicle connector 22 may extend through an interior portion of the second cover 18 to the receiving portion 26. Although first side 24 is referred to as first side 24 of the second cover 18, the first side 24 may be referred to as first side 24 of shell 19.

[0061] The second cover 18 can be made of the same material(s) as first cover 16 or any other material. For example, for lead acid batteries, second cover 18 may be made of resin, acid resistant polymers such as polypropylene (PP), etc. For non-lead acid batteries, second cover 18 may be made of any thermoplastic and / or thermoset. The second cover 18 may have one or more vent ports 28, which may be arranged to receive a plug (i.e., any member arranged to seal / plug an opening such as vent port 28). The second cover 18 also may include an aperture 30 which is created during the manufacturing process of the second cover 18. Aperture 30 may be arranged as an access port to leak test the seal of the second cover 18. Further, aperture 30 which may be sealed once the battery 10 is assembled with the second cover 18. The shell 19 of second cover 18 may also include at least one housing 32 and as shown in FIG. 2 there are two housings 32 on the second cover 18. Each housing 32 may he sized and shaped to accommodate the various components of the battery 10 when the second cover 18 is affixed to the first cover 16. For example, each housing 32 may be sized and shaped to cover a terminal post assembly and each housing 32 may be removable so that when the second cover 18 is placed over the first cover 16 on the battery, the terminal post assembly may be accessible by removing the housing 32. The second cover 18 may also include an opening 34 which may provide easy access to the BMS when the second cover 18 is placed over the first cover 16 on the battery 10.

[0062] FIG. 3 shows an example of an exploded view of the second cover 18 including a plug 36, a flame arrestor 38, and at least one valve 40 in a flow path from the first cover 16 before the plug 36, the flame arrestor 38, and the at least one valve 40 are inserted into the second cover 18. The flame arrestor 38 may be arranged to receive fluids such as gases emitted by the battery 10 which may include flammable elements and discharge the gases while preventing the gas from igniting. In some embodiments, flame arrestor 38 permits a predetermined flow of gas to travel through the flame arrestor 38. In some other embodiments, flame arrestor 38 prevent flames from traveling into the second cover 18 or toward the source of the gasses. Valve 40 may be include an inlet side and an outlet side. The inlet side may be in fluid communication with a cover space and / or gasses contained by the cover space. The outlet side may be in fluid communication with vent port 28.

[0063] FIG. 4 shows the first side 24 of the second cover 18 with the flame arrestor 38 and the plug 36 secured in the vent ports 28. The second cover 18 may have one or more vent ports 28, which may be arranged to receive the plug 36. Plug 36 may be arranged seal / plug an opening such as vent port 28 and / or provide a controlled released of gas. Control release of gas may refer to releasing gas in a predetermined manner such as not to exceed a flow threshold. Plug 36 may comprise an orifice arranged to facilitate the control release. Further, the second cover 18 may be arranged to receive one or more valves 40 within second cover 18. The steps of assembly may then include coupling at least one plug 36 and at least one flame arrestor 38 to a corresponding vent port 28 and / or one or more valves 40 to the second cover 18. That is, once the valve 40 is installed and / or received by second cover 18, valve 40 (i.e., an internal portion of the valve) is in fluid communication with first cover space 44 (see FIG. 5) (which may be in fluid communication with case 12 and / or the internal space in the case). The valve 40 (i.e., an external portion of the valve) may also be in fluid communication with the flame arrestor plug and / or the environment exterior to second cover 18 and / or battery 10.

[0064] FIG. 5 shows a second side 42 of the second cover 18. The second side 42 of the second cover 18 may include shell 19 which may define or comprise a first cover space 44 and a second cover space 46, each of which are within a different portion of the second side 42 of the second cover 18, e.g., separated by a cover wall. The second cover 18 may be arranged to receive one or more valves 40 within first cover space 44. The first cover space 44 may include at least one chamber 48 and at least one chamber 48. At least one chamber 48 may be sized and shaped to receive the valve 40. The chamber 48 may be in fluid communication with the vent port 28. For example, the chamber 48 may be situated perpendicular to the vent port 28 such that the chamber 48 and the vent port 28 are readily connected to one another. Also, valve 40 is installed and / or received in the chamber 48 by second cover 18, the valve 40 (i.e., an internal portion of the valve) is in fluid communication with first cover space 44 (which may be in fluid communication with another portion of the battery 10). Furthermore, when the valve 40 is installed and / or received in the chamber 48, the valve 40 (i.e., an external portion of the valve) may also be in fluid communication with the plug 36 and the flame arrestor 38 when the plug 36 and the flame arrestor 38 are installed and / or received within the vent port 28 of the second cover 18. Alternatively, if nothing is secured and / or received within the vent port 28 while the valve 40 is installed and / or received in the chamber 48, the valve 40 may be in communication with the environment exterior to second cover 18 and / or the battery 10 through the vent port 28. Although second side 42 is referred to as second side 42 of the second cover 18, the second side 42 may be referred to as second side 42 of shell 19.

[0065] Continuing to refer to FIG. 5, the first cover space 44 may be sized and shaped to cover a portion of the first cover 16. The first cover 16 may be arranged to include one or more cover openings 74 (as shown in FIG. 10). The one or more cover openings 74 may be disposed in a location on the first cover 16 so that the first cover space 44 corresponds with the one or more cover openings 74. Accordingly, when the second cover 18 is secured onto the first cover 16, the cover openings 74 on the first cover 16 will be disposed within the first cover space 44 of the second cover 18. This configuration places the cover openings 74 on the first cover 16 in communication with the at least one chamber 48 and any valves 40 within the at least one chamber 48 in communication with the cover openings 74. Furthermore, if the vent ports 28 are in communication with the at least one chamber 48, the cover openings are also in communication with the vent ports 28 as well as the plug 36 and the flame arrestor 38 if the plug 36 and the flame arrestor 38 are disposed within the vent ports 28.

[0066] FIG. 6 shows another view of the second side 42 of the second cover 18 with the flame arrestor plugs 36 and the flame arrestor 38 secured in the vent ports 28 and the valve 40 secured within the chamber 48. When positioned on the first cover 16, the second side 42 faces the side of the first cover 16 that is external to the case 12, i.e., the top of the first cover 16.

[0067] FIG. 7 is an overhead view of the second side 42 of the second cover 18. In this overhead view, the vehicle connector 22 is shown protruding from the main body of the second cover 18. The vehicle connector 22 may extend from an exterior portion 50 of the second cover 18 through the second cover 18 and into the opening 34. The vehicle connector may be installed by insertion into the vehicle connector 22 which forms a contiguous channel with receiving portion 26 and is segregated from the first cover space 44 of shell 19.

[0068] Continuing to refer to FIG. 7, the second side 42 of the second cover 18 has the two housings 32 disposed on opposite sides of the opening 34. On one side of the opening 34 is the housing 32 which is disposed on a first portion 52 and on the other side of the opening 34, the housing 32 is disposed on a second portion 54. Each of the first portion 52 and the second portion 54 has a first end and a second end opposite the first end. The first portion 52 and the second portion 54 are formed together with a connecting portion 56 such that the connecting portion 56 is contiguous with the first end of the first portion 52 and the first end of the second portion 54. The first cover space 44 is contiguous with, i.e., can be formed with, the second end of the first portion 52 and the second end of the second portion 54. As shown in FIG. 7, the first portion 52 and the second portion 54 may have a rectangular shape and the connecting portion 56 may have an elongated shape to securely connect the first portion 52 to the second portion 54. Further, shell 19 may also define or comprise the second cover space 46. It will be understood that different sizes and shapes for the first portion 52, the second portion 54, and the connecting portion 56 may be used so that the second cover 18 may fit with the battery 10. It is also understood that the second cover 18 can be formed / manufactured as a single piece (other than the flame arrestor and vent components). FIG. 8 shows a cross section view second cover 18. FIG. 9 shows a cross section of a portion of second cover 18. Valve 40 is inserted into the chamber 48. The flame arrestor 38 and the plug 36 are inserted into the vent port 28. Also, the chamber 48 is shown with a connector 58 connecting the chamber 48 with the vent port 28 such that an air, liquid, or gas could flow through the chamber 48 to the vent port 28 or from the vent port 28 to the chamber 48. The second cover 18 may be arranged to receive one or more valves 40 within first cover space 44. It will be noted that the valve 40 may be arranged to have one or more valve states, e.g., closed, open, throttling (e.g., to maintain a parameter), partially open, partially closed, etc. In a nonlimiting example, the valve 40 may be closed. When the valve 40 is closed, a pressure (e.g., of a gas) throughout several portions of battery 10 may be kept (e.g., by valve 40 and / or a heat seal 59) the same and / or within a predetermined pressure difference. For example, the pressure around battery cells and / or first cover space 44 and / or case 12 may be kept within the predetermined pressure difference. In another nonlimiting example, valve 40 may be arranged to open when a pressure (e.g., a pressure of a gas) within the first cover space 44 (and / or case 12) exceeds a predetermined threshold. Opening valve 40 may allow a gas (and / or any other matter) within the first cover space 44 (and / or case 12) to exit the battery 10 through the valve 40, the flame arrestor 38, and the plug 36. In other words, the arrangement of the case 12 and / or first cover 16 and / or second cover 18 and / or valve 40 and / or any other component of the battery 10 allows the battery 10 to keep a uniform pressure around the various components of the battery 10 and / or release pressure based on a predetermined threshold. In some embodiments, valve 40 can be a one-way valve that simply allows fluid, e.g., gas, to flow in one direction from the case 12 to the external atmosphere without allowing the external air to flow into the first cover space 44.

[0069] Valve 40 may comprise valve head 60. Valve head 60 may comprise a valve head nub 62 and release portion 64 contiguous to valve head nub 62. Valve head nub 62 may be in physical contact with second cover nub 66. In the closed position, release portion 64 is in physical contact with a portion of chamber 48 and / or second cover 18, thereby preventing gas from being released to connector 58. In some embodiments, to open valve 60, the gas may push release portion 64 and terminate the physical contact with the portion of chamber 48 and / or second cover 18, thereby allowing the gas from being released to connector 58. After the pressure is lower than the predetermined threshold, the release portion 64 reestablishes physical contact with the portion of chamber 48 and / or second cover 18, again preventing gas from being released to connector 58. The predetermined threshold may be determined by the size of second cover nub 66. For example, to increase the predetermined threshold the heigh to second cover nub 66 may be increased, i.e., pushing valve head nub 62 further and exerting additional force on release portion 64.

[0070] FIG. 10 shows an example first cover 16. First cover 16 includes battery terminals 14, a first cover section 69 that comprises or defines third cover space 70 and fourth cover space 72. First cover section 69 may comprise one or more walls and a one or more surfaces that define third cover space 70 and fourth cover space 72. Third cover space 70 comprises one or more cover openings 74 (e.g., on a first surface of first cover section 69). Fourth cover space 72 comprises terminal post assemblies 76 and one or more cell post assemblies 78 (e.g., on a second surface of first cover section 69). Third cover space 70 of the first cover section of the first cover 16 may be arranged to conform to the size and shape of first cover space 44 of shell 19 of second cover 18. Fourth cover space 72 of first cover 16 may be arranged to conform to the size and shape of second cover space 46 of shell 19 of second cover 18. The first cover space 44 and the third cover space 70 may define a first common space arranged to receive battery gasses. The second cover space 46 and the third cover space 72 may define a second common space arranged at least to house the BMS.

[0071] FIGS. 11 and 12 show the second cover 18 being secured and / or coupled with the first cover 16 on the battery 10. After the second cover 18 is coupled to first cover 16 of the battery 10, which may be performed using a heating process such as infrared welding, heat sealing, etc. the second cover 18 may have the opening 34, e.g., defining a space for other components such as BMS 80 to be accessed / installed / maintained after second cover 18 has been coupled to first cover 16. The second cover 18 can be secured to the first cover 16 via any suitable process, e.g., glue, epoxy, heat welding, etc. When secured, the lip on the second side (bottom) that forms the first cover space 44 is sealed to the corresponding portion of the first cover 16 (i.e., first cover space 70) to create a volume in the first cover space 44 whose only fluid path from the battery cells to the external atmosphere is via vent port 28 and valve 40. This arrangement allows the first cover 16 to provide area to support electronics such as the BMS 80 and electrical post connectors (and provide access to the BMS 80, if needed, while also sealing off the cells from the electronics and electrical elements and providing a venting arrangement for the cells. As shown in FIG. 12, the plug 36 is retained within the vent port 28 and the vehicle connector 22 is retained within the receiving portion 26.

[0072] FIG. 13 is an overhead view of the second cover 18 secured to the first cover 16 with the BMS 80 visible. For example, the vehicle connector 22 is coupled to the second cover 18 and a wiring harness 82 may be connected to BMS 80 and the vehicle connector 22. The wiring harness 82 may be connected to BMS 80, e.g., using a pig-tail of the wiring harness 82 and / or vehicle connector 22. Sealing of the battery 10 may be performed which may include sealing the second cover 18. Sealing the second cover 18 may include sealing vent port 28 by coupling the flame arrestor 38 and the plug 36 to the second cover 18 (e.g., to the vent port 28) and / or integrate (i.e., couple) valve(s) 40 (i.e., pressure relief valves) and / or flame arrestor(s) 38 to the second cover 18. Data may be analyzed, e.g., to access the state of heath of battery 10 and / or its components. The BMS 80 may be connected to external connectors, e.g., Controller Area Network (CAN) connectors, Local Interconnect Network (LIN) connectors, vehicle connectors.

[0073] FIG. 14 is a third cover 20 that is couplable (e.g., mated) with at least a portion of the second cover 18. The third cover 20 has a top side 90, and the top side 90 may have a smooth surface. Alternatively, the top side 90 may have a textured surface, for example, so that it can be easily grasped by an object or hand. In some embodiments, third cover 20 may be part of second cover 18. FIG. 15 is a second view of the third cover 20 showing a bottom side 92, and the bottom side 92 may have various textures and / or protrusions so that when the bottom side 92 of the third cover 20 is mated with the second cover 18, the third cover 20 seals with the second cover 18 so that the BMS 80 is not exposed to the external environment. The bottom side 92 may include a raised portion 94 that is arranged to correspond with and / or conform to the aperture 30 on the second cover 18 such that the aperture 30 is completely sealed when the third cover 20 is secured with the second cover 18. The bottom side 92 may also have a raised perimeter 96 that is sized and shaped to correspond with and / or conform to the various components that are being covered by the third cover 20 when it is secured with the second cover 18. The bottom side 92 also includes a raised interior portion 98 that is sized and shaped to correspond with the opening 34 on the second cover 18. When the third cover 20 is secured with the second cover 18, the raised interior portion 98 will generally be the size and shape of the opening 34. The raised interior portion 98 may also have at least one protrusion 100, and each protrusion 100 may be sized and shaped to go around the perimeter of the opening 34 when the third cover 20 is secured to the second cover 18. When the third cover 20 is placed over the second cover 18 the protrusions 100 may help to further seal the third cover 20 to the second cover 18, e.g., may couple to the second cover 18, snap into a receiving portion of the second cover 18, etc. The third cover 20 may also have at least one recessed portion 102 which could be in a variety of different sizes and shapes. The at least one recessed portion 102 may be sized and shaped to correspond with and / or conform to various components on the battery 10. For example, if the first cover 16 has a component that extends outwardly from the battery 10, the recessed portion 102 may be sized and shaped to accommodate the component that extends outwardly.

[0074] FIG. 16 shows an example of the first cover 16 coupled to the second cover 18, and a third cover 20 in the process of being coupled to the second cover 18, e.g., to isolate (e.g., seal) electronics (e.g., BMS 80) from the outside environment. The assembly of the first cover 16 with the second cover 18 and the third cover 20 may include isolating electronics such as the BMS 80 from the environment and / or connecting to a vehicle CAN / LIN and / or connecting another device that may be associated with a customer, e.g., using a protocol such as Bluetooth. The third cover 20 (and / or any component of battery 10) may include one or more interfaces such as a laser welding interface and / or third cover 20 may be coupled to the second cover 18 using a heating process such as laser welding. In nonlimiting example, laser welding refers to combining (i.e., welding) one or more parts such as combining the second cover 18 with third cover 20. Other components may also be coupled (i.e., welded) using laser welding as well. The third cover 20 may be made of any material, e.g., including materials of the first cover 16 and / or second cover 18. For example, for lead acid batteries, the third cover 20 may be made of resin, acid resistant polymers such as polypropylene (PP), etc. For non-lead acid batteries, third cover 20 may, without being limited to, be made of any thermoplastic and / or thermoset.

[0075] FIG. 17 shows a flowchart of an example method of assembling a battery 10. The battery 10 includes a case 12, a first cover 16, and a second cover 18. The method includes sealing the first cover 16 to the case 12 and forming the second cover 18. The formed second cover 18 includes a shell 19. The shell 19 includes a first cover space 44 and a second cover space 46. The first cover space 44 is a common space arranged to receive a gas from the battery 10 and is physically separated from the second cover space 46. The shell 19 also includes at least one vent port 28. The method also includes coupling at least one valve 40 to the second cover 18 in the first cover space 44. The at least one valve 40 has an inlet side and an outlet side. The inlet side is in fluid communication with the first cover space 44. The outlet side is in fluid communication with the at least on vent port 28. The at least one valve 40 is arranged to open and release the gas to the at least one vent port 28 when a gas pressure exceeds a predetermined threshold.

[0076] In some embodiments, the method further includes coupling a plug 36 to the at least one vent port 28, where the plug 36 is in fluid communication with the outlet side of the at least one valve 40. In some other embodiments, the method further includes coupling a flame arrestor 38 to the at least one vent port 28. The flame arrestor 38 is positioned between the outlet side of the valve 40 and the plug 36. The flame arrestor 38 is arranged to prevent a flame from forming as gas is released to the at least one vent port 28.

[0077] In some embodiments, the forming further includes forming a cover wall comprised in the shell 19 and physically separating the first cover space 44 and the second cover space 46 formed by the shell 19.

[0078] In some other embodiments, the forming further includes forming a chamber 48 in the first cover space 44. The chamber 48 is arranged to receive the at least one valve 40 to couple the at least one valve 40 to the second cover 18.

[0079] In some embodiments, the forming further includes forming at least one housing 32 comprised in the shell 19. The at least one housing 32 further defines the second cover space 46. The at least one housing 32 is arranged to receive and house a terminal post assembly 76 of the battery 10.

[0080] In some other embodiments, the forming further includes forming an aperture 30 in the second cover 18. The aperture 30 is arranged as an access port to leak test the second cover 18.

[0081] In some embodiments, the forming further includes forming an electronic access opening 34 on the shell 19 of the second cover 18. The electronic access opening 34 is in fluid communication with the second cover space 46.

[0082] In some other embodiments, the battery 10 further includes a battery management system 80, the case 12 houses a plurality of battery cells, and the method further includes physically coupling the battery management system 80 to the first cover 16 and electrically coupling the battery management system 80 to at least one battery cell of the plurality of battery cells. The electronic access opening 34 is arranged to house the battery management system 80 and couple to a third cover 20.

[0083] In some embodiments, the method further includes coupling the second cover 18 to the first cover 16. The battery management system 80 is housed in the second cover space 46 and is accessible via the electronic access opening 34.

[0084] In some other embodiments, the battery 10 further includes a third cover 20, and the method further includes coupling the third cover 20 to the second cover 18. The third cover 20 defines at least a portion of the second cover space 46 and covers the electronic access opening 34. It will be appreciated by persons skilled in the art that the present embodiments are not limited to what has been particularly shown and described herein above. In addition, unless mention was made above to the contrary, it should be noted that all of the accompanying drawings are not to scale. A variety of modifications and variations are possible in light of the above teachings without departing from the scope of the following claims.

Claims

What is claimed is:

1. A second cover (18) couplablc to a first cover (16) of a battery (10), the second cover (18) comprising: a shell (19) comprising: a first cover space (44), the first cover space (44) being a common space arranged to receive a gas from the battery (10); and a second cover space (46), the first cover space (44) being physically separated from the second cover space (46) and the gas from the battery (10), the second cover space (46) being arranged to house a battery management system (80); at least one vent port (28); and at least one valve (40) being in the first cover space (44) and having an inlet side and an outlet side, the inlet side being in fluid communication with the first cover space (44), the outlet side being in fluid communication with the at least on vent port (28), the at least one valve (40) being arranged to open and release the gas to the at least one vent port (28) when a gas pressure exceeds a predetermined threshold.

2. The second cover (18) of Claim 1, wherein the at least one vent port (28) comprises a plug (36) in fluid communication with the outlet side of the at least one valve (40).

3. The second cover (18) of Claim 2, wherein the plug (36) is arranged to control release of the gas.

4. The second cover (18) of Claim 3, wherein the at least one vent port (28) further includes a flame arrestor (38) positioned between the outlet side of the valve (40) and the plug (36), the flame arrestor (38) being arranged to prevent a flame from forming as the gas is released to the at least one vent port (28).

5. The second cover (18) of any one of Claims 1-4, wherein the first cover space (44) and the second cover space (46) formed by the shell (19) are physically separated by a cover wall.

6. The second cover (18) of any one of Claims 1-5, wherein the second cover (18) further includes a chamber (48) arranged to receive the at least one valve (40) to couple the at least one valve (40) to the second cover (18).

7. The second cover (18) of Claim 6, wherein the at least one valve (40) includes a valve head (60), the valve head (60) includes valve head nub (62) and a release portion (64) contiguous to the valve head nub (62).

8. The second cover (18) of Claim 7, wherein the second cover (18) comprises a second cover nub (66) in physical contact with the valve head nub (62), and the release portion (64) is in physical contact with a portion of the chamber (48) when the at least one valve (40) is closed or not in physical contact at least with the portion of the chamber (48) when the at least one valve (40) is open.

9. The second cover (18) of Claim 8, wherein the predetermined threshold is based on a size of the second cover nub (66).

10. The second cover (18) of any one of Claims 1-9, wherein the second cover (18) further includes a receiving portion (26) and a vehicle connector (22), the receiving portion (26) being arranged to receive the vehicle connector (22) and being physically separated from the first cover space (44).

11. The second cover (18) of any one of Claims 1-10, wherein the shell (19) further comprises at least one housing (32) in the second cover space (46), the at least one housing (32) being arranged to receive and house a terminal post assembly (76) of the battery (10).

12. The second cover (18) of any one of Claims 1-11, wherein the second cover (18) further includes an aperture (30) arranged as an access port to leak test the second cover (18).

13. The second cover (18) of any one of Claims 1-12, wherein the second cover (18) may further include an electronic access opening (34) in fluid communication with the second cover space (46).

14. The second cover (18) of Claim 13, wherein the electronic access opening (34) is arranged to house the battery management system (80) and couple to a third cover.

15. A battery (10) comprising : a plurality of battery cells; a case having an internal space and housing the plurality of battery cells in the internal space; a first cover (16) coupled to the case and comprising a plurality of cover openings in fluid communication with the internal space and the plurality of battery cells; a battery management system (80) physically coupled to the first cover (16) and electrically coupled to at least one battery cell of the plurality of battery cells; a second cover (18) coupled to the first cover (16), the second cover (18) comprising; a shell (19) comprising: a first cover space (44), the first cover space (44) in fluid communication with the cover openings and defining at least in part a first common space arranged to receive a gas from the internal space; and a second cover space (46), the first common space being physically separated from the second cover space (46), the second cover space (46) being arranged to house the battery management system (80); at least one vent port (28); and at least one valve (40) being in the first cover space (44) and having an inlet side and an outlet side, the inlet side being in fluid communication with the first cover space (44), the outlet side being in fluid communication with the at least on vent port (28), the at least one valve (40) being arranged to open and release the gas to the at least one vent port (28) when a gas pressure exceeds a predetermined threshold.

16. The battery (10) of Claim 15, wherein the first cover (16) further includes a third cover space (70) and a fourth cover space (72), the third cover space (70) including the plurality of cover openings, the second cover space (46) and the fourth cover space (72) housing the battery management system (80).

17. The battery (10) of Claim 16, wherein the first cover space (44) and the third cover space (70) define the first common space, the second cover space (46) and the fourth cover space (72) define a second common space physically separated from the first common space, the second common space housing at least the battery management system (80).

18. A method of assembling a battery (10), the battery (10) comprising a case, a first cover (16), and a second cover (18), the method comprising: sealing (S100) the first cover (16) to the case; forming (S102) the second cover (18), the formed second cover (18) comprising: a shell (19) comprising: a first cover space (44), the first cover space (44) being a common space arranged to receive a gas from the battery (10); and a second cover space (46), the first cover space (44) being physically separated from the second cover space (46); at least one vent port (28); and coupling (S104) at least one valve (40) to the second cover (18) in the first cover space (44), the at least one valve (40) having an inlet side and an outlet side, the inlet side being in fluid communication with the first cover space (44), the outlet side being in fluid communication with the at least on vent port (28), the at least one valve (40) being arranged to open and release the gas to the at least one vent port (28) when a gas pressure exceeds a predetermined threshold.

19. The method of Claim 18, wherein the method further includes: coupling a plug (36) to the at least one vent port (28), the plug (36) being in fluid communication with the outlet side of the at least one valve (40).

20. The method of Claim 19, wherein the method further includes:coupling a flame arrestor (38) to the at least one vent port (28), the flame arrestor (38) being positioned between the outlet side of the valve (40) and the plug (36), the flame arrestor (38) being arranged to prevent a flame from forming as gas is released to the at least one vent port (28).

21. The method of any one of Claims 18-20, wherein the forming further includes: forming a cover wall comprised in the shell (19) and physically separating the first cover space (44) and the second cover space (46) formed by the shell (19).

22. The method of any one of Claims 18-21, wherein the forming further includes: forming a chamber (48) in the first cover space (44), the chamber (48) being arranged to receive the at least one valve (40) to couple the at least one valve (40) to the second cover (18).

23. The method of any one of Claims 18-22, wherein the forming further includes: forming at least one housing (32) comprised in the shell (19), the at least one housing(32) further defining the second cover space (46), the at least one housing (32) being arranged to receive and house a terminal post assembly (76) of the battery (10).

24. The method of any one of Claims 18-23, wherein the forming further includes: forming an aperture (30) in the second cover (18), the aperture (30) being arranged as an access port to leak test the second cover (18).

25. The method of any one of Claims 18-24, wherein the forming further includes: forming an electronic access opening (34) on the shell (19) of the second cover (18), the electronic access opening (34) being in fluid communication with the second cover space (46).

26. The method of Claim 25, wherein the battery (10) further includes a battery management system (80), the case houses a plurality of battery cells, and the method further includes: physically coupling the battery management system (80) to the first cover (16) and electrically coupling the battery management system (80) to at least one battery cell of theplurality of battery cells, the electronic access opening (34) being arranged to house the battery management system (80) and couple to a third cover (30).

27. The method of Claim 26, wherein the method further includes: coupling the second cover (18) to the first cover (16), the battery management system(80) being housed in the second cover space (46) and being accessible via the electronic access opening (34).

28. The method of Claim 27, wherein the battery (10) further includes a third cover (30), and the method further includes: coupling the third cover (30) to the second cover (18), the third cover (30) defining at least a portion of the second cover space (46) and covering the electronic access opening (34).

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