Battery system, components for a battery system, and methods of manufacturing a battery system and components for a battery system

Abstract

Disclosed is a lead assembly for a battery system and a battery or battery system having the lead assembly. The battery system includes a shunt bridge to electrically couple adjacent battery cells. The shunt bridge can be electrically coupled to a printed circuit board (PCB). The battery system can be a lead-acid battery system having multiple compartments. A first compartment can be a battery cells compartment, a second compartment can be a battery monitoring system (BMS) compartment, and a third compartment can be a venting compartment. In an embodiment, multiple posts extend through bushings from the first compartment to the second compartment. A lead assembly couples the posts to the BMS.

Description

BATTERY SYSTEM. COMPONENTS FOR A BATTERY SYSTEM, AND METHODS OF MANUFACTURING A BATTERY SYSTEM AND COMPONENTS FOR A BATTERY SYSTEMCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and the benefit of United States Provisional Patent Application No. 63 / 655,748, filed June 4, 2024, entitled “BATTERY SYSTEM, COMPONENTS FOR A BATTERY SYSTEM. AND METHODS OF MANUFACTURING A BATTERY SYSTEM AND COMPONENTS FOR A BATTERY SYSTEM,” the entire content of which is incorporated by reference herein in its entirety.FIELD OF THE DISCLOSURE

[0002] This disclosure relates to lead-acid batteries. An example lead-acid battery is an absorbent glass mat (AGM) battery.

[0003] The disclosure relates to a lead assembly for a battery system, such as a lead-acid battery system. The disclosure relates to a lead assembly having one or more lead frames. The disclosure also relates to a battery system having the lead assembly.

[0004] The disclosure relates to a lead-acid battery system having a shunt bridge. The disclosure also relates to a removeable circuit board assembly for a lead-acid battery system having the shunt bridge.

[0005] The disclosure relates to a lead-acid battery system having a multi-compartment housing. The disclosure also relates to a lead-acid battery system having a multi-compartment cover.BACKGROUND

[0006] One example environment for a lead-acid battery is a vehicle. A conventional vehicle with a conventional internal combustion engine (ICE) might include, for example, a traditional flooded lead-acid battery. A vehicle with a conventional ICE or a start-stop system or a mild- hybrid engine might include a traditional AGM lead-acid battery. Some vehicles, such as some mild-hybrid engine vehicles, may also include non-lead-acid batteries. Other vehicle types andbattery arrangements are known. However, as vehicles become more automated or autonomous, and as vehicles become more electric, battery intelligence, reliability, and performance need to increase.

[0007] For some environments, detecting individual cell health and / or deterioration of a lead- acid battery can enable a user to detect a potential battery failure more quickly. This would allow the user more time to replace the lead-acid battery before failure. Thus, in embodiments, an intelligent (or “smart”) lead-acid battery can monitor a parameter associated with a cell of a lead- acid battery. Also, an intelligent lead-acid battery can monitor other parameters, e.g., battery temperature, cell temperature, compartment temperature, etc., that traditional lead-acid batteries do not monitor. Inasmuch, current intelligent lead-acid batteries can be complex to assemble. Once assembled, components may not be easily accessible, serviced, or replaced.

[0008] A new and useful battery system and components for a battery system are desired.SUMMARY

[0009] Disclosed herein are intelligent (or “smart”) lead-acid battery systems and improvements thereto. An example intelligent lead-acid battery is an intelligent or “smart” absorbent glass mat (AGM) battery system. An intelligent AGM battery system includes sensor technology not normally associated with traditional lead-acid batteries. Without limitation, the additional sensed parameters can improve predictions of the battery’s state of health, state of charge, state of function, life expectancy, charging and discharging capability, etc. An intelligent battery system can understand the battery’s status, which can allow for modification of the charging / discharging of the battery system and / or operation of the vehicle or environment that the battery system is placed. In some embodiments, cell voltage monitoring allows better charging management to ensure battery is neither undercharged nor overcharged. Example parameters sensed by the intelligent battery system can include one or more of the following: battery voltage, battery current, cell voltage, cell current, partial battery voltage, partial battery current, battery temperature, cell temperature, ambient or environment temperature, compartment temperature, battery pressure, cell pressure, cell state of charge, battery state of charge, etc.

[0010] In at least one example lead-acid battery system described herein, the battery system includes a housing defining at least in part multiple compartments. A first compartment may be referred to as a “cells” compartment, a second compartment may be referred to as a “battery monitoring system” (BMS) compartment, and a third compartment may be referred to as a “venting” compartment. The housing can include a wall disposed between the cells compartment and the BMS compartment. The wall can be a cover for the cells compartment and a base for the BMS compartment. A plurality of battery cells is housed in the cells compartment. The plurality of battery cell has a plurality of posts. A first post and a second post protrude through the wall from the cells compartment to the BMS compartment. The BMS is housed by the BMS compartment. The BMS compartment can be accessed from an external environment, for example, to sendee the BMS or components of the BMS. The BMS includes a voltage sensor electrically coupled to the first post and the second post and can sense a voltage less than the battery voltage. An example of a voltage less than the battery voltage is a cell voltage. Another example of a voltage less than the battery voltage is a voltage for a plurality of cells (e.g., 2 cells) but not the total voltage for the plurality of cells (e.g., 6 cells if the battery system consists of 6 cells).

[0011] In one or more embodiments, multiple smaller (“shunt” or “mini”) posts, as compared to conventional terminal posts, are positioned on straps of the battery cells. The strap posts may be operable to help measure a voltage, such as a voltage for an individual battery cell. The strap posts can extend through a battery housing cover and into the BMS compartment. To reduce assembly complexity, the strap posts can electrically couple adjacent battery cells using a shunt bar. The shunt bar bridges the electrical connection between adjacent cells. This removes the need for bus bar connectors or a traditional intercell weld. Additionally, by removing these components, the overall system resistance is reduced. The shunt bar can be electrically coupled to a printed circuit board (PCB) which is mounted in the BMS compartment. In embodiments, the shunt bar can be used to measure current. Fasteners can couple the shunt bar and the PCB to the battery system. The shunt bar can be welded to the PCB. The shunt bar and PCB can be removeable from the battery system.

[0012] In embodiments, the disclosure provides a lead assembly for a battery comprising a plurality of battery cells and a battery monitoring system. The lead assembly includes a pluralityof leads, and a plurality of support connectors. Each lead of the plurality of leads has a conductive path with a first end and a second end opposite to the first end. Each first end comprises a first connector, and each second end comprises a second connector. The first connector is couplable to a battery cell and the second connector is couplable to the battery monitoring system. The first connector is couplable to a respective strap post. Each support connector of the plurality of support connectors couples one lead of the plurality of leads with an adjacent lead of the plurality of leads.

[0013] In other embodiments, the disclosure provides a batery including the lead assembly and a method of assembling a battery. In at least one example lead-acid battery system described herein, the battery system is split into two batery cell groups, for example, cells 1-3 defining a first battery cell group and cells 4-6 defining a second battery cell group (e.g., if the battery system has 6 cells). The method includes providing the lead assembly as a first lead frame and a second lead frame, each of the respective first and second lead frames having a plurality of leads, enclosing a portion of each of the first and second lead frames with a lead body , flexing the plurality of leads to couple to a post and a bushing, welding the plurality of leads to the post and the bushing, and electrically coupling the plurality of leads to a battery monitoring system. The first lead frame electrically couples cells 1-3 and the second lead frame electrically couples cells 4-6. The method additionally includes providing a shunt bar, electrically coupling the shunt bar to a post and a bushing of the first battery cell group, electrically coupling the shunt bar to a pos t and a bushing of the second battery cell group, electrically coupling the shunt bar to the battery monitoring system, and coupling the battery monitoring system to the battery monitoring system compartment.

[0014] Other aspects of the invention can be identified by the below representative claims.

[0015] These and other features, advantages, and embodiments of apparatus and methods according to this invention are described in, or are apparent from, the following detailed descriptions of various examples of embodiments.BRIEF DESCRIPTION OF THE DRAWINGS

[0016] FIG. 1 is an isometric view of a prior-art traditional lead-acid battery.

[0017] FIG. 2 is an isometric view of the lead-acid battery of FIG. 1 with the cover removed.

[0018] FIG. 3 is a partially exploded isometric view of the lead-acid battery of FIG. 1.

[0019] FIG. 4 is an isometric view of a prior-art vehicle having a battery system contributing all or a portion of the power for the vehicle.

[0020] FIG. 5 is an isometric view of a lead-acid battery system incorporating aspects of the invention.

[0021] FIG. 6 is an isometric view of the battery system of FIG. 5 with the battery monitoring system (BMS) cover removed and the vent cover removed.

[0022] FIG. 7 is an isometric vi ew of the battery system of FIG. 5 with the cells cover removed, the venting cover in place, and a printed circuit board (PCB) shown in a transparent manner.

[0023] FIG. 8 is a perspective view of the battery system of FIG. 5 with the cells compartment cover removed.

[0024] FIG. 9 is a top elevation view of the main current path and a lead assembly for the battery system of FIG. 5.

[0025] FIG. 10 is an isometric view of the main current path for the battery system of FIG. 5 with the PCB shown in a transparent manner.

[0026] FIG. 11 is an enlarged side elevation view of a portion of one of the leads shown in FIG. 13.

[0027] FIG. 12 is a block diagram of the battery system of FIG. 5 having a BMS.

[0028] It should be understood that the drawings are not necessarily to scale. In certain instances, details that are not necessary to the understanding to the invention or render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the apparatus or processes illustrated herein.

[0029] Within the scope of this application, it is expressly intended that the various aspects, embodiments, examples, and alternatives set out in the preceding paragraphs, the following description, the claims, and / or the drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and all features of any embodiment can be combined in any way and / or combination, unless such features are incompatible. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and / or incorporate any feature of any other claim although not originally claimed in that manner.DETAILED DESCRIPTION

[0030] FIGS. 1-3 show a prior art absorbent glass mat (AGM) lead-acid battery 100 having a housing 105. The lead-acid battery 100 of FIGs. 1-3 is used for showing some of the underlying elements of a lead-acid battery and for providing background to the battery (or battery systems) and processes (or methods) described herein. It should be understood by one skilled in the art, however, that other styles of AGM lead-acid batteries (e.g., a cylindrical cell-type AGM lead- acid battery, bi-polar AGM battery, AGM batteries with differing cell numbers) and other types of lead-acid batteries (e.g., a non- AGM lead-acid battery, flooded and extended lead-acid batteries, gel-type battery) can be used with aspects of the invention. However, for ease of description, the disclosure herein will generally focus on the style of AGM lead-acid battery 100 shown in FIGS 1-3. This includes variations of the AGM lead-acid battery systems described after FIG. 3.

[0031] With reference to FIG. 1, the housing 105 includes a base 110 and a cover 115. The cover 115 is secured to the base 110. An example means of securing is by heat sealing the cover 115 to the base 110. The battery 100 further includes terminals 120, 125 and a vent aperture 130 for venting gas from a venting system. The terminals protrude through or on the housing 105 (e.g., the cover 115 as shown). The terminals 120, 125 are provided on the cover 1 15 for connecting or coupling the battery 100 to electrical loads. Example electrical loads could include loads of a vehicle electrical system (discussed below).

[0032] FIG. 2 shows the cover 115 removed. The battery housing 105 supports a plurality of battery cell chambers (one chamber, 135, is labeled). The battery cell chambers can be formed bythe housing 105 and a plurality of cell walls or partitions (one partition, 140, is labeled) that define the plurality of cell chambers. The partitions may be formed as being unitary with the housing 105. While the construction discussed herein has six cell chambers, a different number of chambers may be provided. Further, while the shown chambers are generally rectangular in shape, other shapes may be used for the chambers. The cell chambers (and related battery cells) may conventionally be referred to by number. For example, a six-cell batteiy would have cells 1, 2, 3, 4, 5, and 6. According to an example construction in which a battery is provided as having six cells, five partitions are provided.

[0033] FIG. 3 shows one of a plurality of battery cells in a partially exploded view. The battery cell 145 includes a plurality of positive frames or plates, a plurality of separators partially surrounding the positive plates, and a plurality of negative frames or plates. FIG. 3 has one positive frame or plate 150, one separator 155, and one negative frame or plate 160 labeled.

[0034] In some types of lead-acid batteries, the positive and negative plates each comprise a lead or lead-alloy grid that serves as a substrate and supports an electrochemically active material deposited or otherwise provided thereon during manufacture to form the battery plates. The grids provide an electrical contact between the positive and negative active materials or paste which serves to conduct current.

[0035] Separators are provided between the plates to prevent shorting and / or undesirable electron flow produced during the reaction occurring in the battery 100. Positive and negative electrode plates can be classified into various types according to the method of manufacturing. In one or more examples, each frame has a generally rectangular shape and includes a lug which is electrically coupled to the battery terminals 120, 125. The frame also may include side walls, a bottom edge, and opposing faces.

[0036] The one or more battery separators are used to insulate and separate the positive and negative electrodes. A separator material for an AGM lead-acid battery has sufficient porosity and retention to contain at least substantially all of the electrolyte necessary to support the electrochemical reactions. In various examples, the separator material is compressible so that upon stacking of the elements, the separator material substantially conforms to the contour of the surface of the plates to help it perform its wicking or capillary action.

[0037] FIG. 4 is a perspective view of a prior art vehicle 175 having a battery system (represented by block 180). A vehicle (e.g., a petrol or gasoline vehicle, an electric vehicle, a hybrid vehicle) uses one or more batteries or battery systems. As will be appreciated by those skilled in the art, hybrid electric vehicles (HEVs) combine an internal combustion engine (ICE) propulsion system and a battery-powered electric propulsion system, such as 48 Volt (V) or 130V systems. Electric vehicles (EVs ) are vehicles with no ICE. Each of these hybrid or full electric vehicles can be classified using the acronym xEV. Generally, the battery system 180 may capture / store electrical energy generated in or by the vehicle 175 and output electrical energy to power electrical devices in the vehicle 175. The battery system 180 may supply power to components of the vehicle’s electrical system (e.g., a vehicle console, an ignition system, and an electric motor / generator).

[0038] The battery systems described herein may be used to provide power to various types of vehicles. The battery systems described herein may also be used to provide power to other energy storage / expending applications. Other example applications or environments include: starting, cycling, and powemet support applications; deep cycle primary power and motive power applications; and high rate and long duration reserve power applications. Example starting, cycling, and powemet support applications include: automotive; van and light duty commercial; heavy duty truck; bus and utility; agriculture; construction; marine; residential vehicle (RV); power sports including motorcycle, all-terrain vehicle (ATV), snowmobile, electric bicycle; genset; lawn and garden; rail; military, aerospace, and defense; etc. Example deep cycle primary power and motive power applications include: heavy duty load and lift gates; marine cycling; golf vehicles; motive such as forklift and guided vehicles; industrial such as scissor lift, scrubber, and pallet jack; wheelchairs; etc. Example high rate and long duration reserve power applications include: uninterruptible power source such as for a data center, critical power system, and emergency lighting; telecommunications such as wireline, wireless, broadband, and microwave; power generation and distribution, renewable energy; grid support including smart and distributed; safety, security, and traffic; etc. Such battery systems may include one or more batteries, each battery having a housing and a number of battery cells arranged within the housing, to provide particular voltages, currents, and / or power to the associated application.

[0039] Battery system 100 can be used with vehicles or other non-vehicle applications. As previously discussed with FIGS. 1-3, above, it should be understood by one skilled in the art, that other sizes and styles of AGM lead-acid batteries (e.g., a cylindrical cell-type AGM lead-acid battery, bi-polar AGM battery, AGM batteries with differing cell numbers) and other types of lead-acid batteries (e.g., a non-AGM lead-acid battery, flooded and extended lead-acid batteries, gel-type battery) may be used with the aspects of the invention discussed and / or shown herein.

[0040] Figures 5-13 show an example battery system according to the invention. With reference to FIG. 5, the housing 105 includes a battery cells base 110 and a battery cells cover 115. The cells cover (or cells compartment cover) 1 15 is secured to the cells base 110, for example, by heat sealing the cells cover 115 to the cells base 110. A handle 117 can be coupled to cells cover 115. Housing 105 further includes a battery management system (BMS) base 11 1 and a BMS compartment cover 116. The BMS base 111 can be integral with the cells compartment cover 115. In some examples, the BMS compartment cover 116 can be coupled to the BMS base 111 by heat sealing. However, in the illustration, the BMS compartment cover 116 is connected to the BMS base 111 using a number of fasteners (e.g., screws, bolts, chemical fasteners). Fasteners coupling the BMS compartment cover 116 can, in various constructions, also couple a printed circuit board (PCB) to the BMS base 111, which will be discussed later. The fasteners allow BMS compartment cover 1 16 to be removeable to access the BMS and other components of battery system 100. This is particularly useful for seivicing the battery or swapping components of the PCB assembly 290, such as the PCB itself. The BMS compartment cover can facilitate connection via a communication connector 126. In the construction shown, a communication connecter 126 (e.g., for coupling to a vehicle connector) protrudes through a side surface of BMS cover 116. The housing 105 further includes a venting compartment cover 118. Collectively, the cells cover 115, the BMS cover 116, and the venting cover 118 form a multicompartment system for battery 100. In the illustrated example, a portion of the BMS compartment cover 116 is configured to overlap with the venting compartment cover 118. Fasteners can couple both the BMS compartment cover 1 16 and the venting compartment cover 118 to the battery cells cover 115.

[0041] FIG. 6 shows battery 100 with the BMS compartment cover 116 and the venting compartment cover 118 removed. A plurality of vent openings 245 are provided in cellscompartment cover 1 15. In FIG. 7, battery 100 is shown with the venting compartment cover 1 18 in place. Venting compartment cover 118 may be heat sealed to the cells cover 115. Venting compartment cover 1 18 functions to receive, contain, and exhaust gases vented through vent openings 245. More specifically, the venting compartment cover 1 18 forms a sealed compartment with the cells compartment cover 115 above vent openings 245 which are disposed above at least a portion of the battery cells 145. The venting compartment cover 118 defines an open headspace to divert vented gas from battery cells 145. In this way, vented gas is directed away from the BMS and other sensitive components of battery 100. The open headspace includes a common space spanning a width and a height of venting compartment cover 118 and a length of battery system 100. The venting compartment cover 118 includes exhaust ports 119 at either end of battery 100. A first region of the venting compartment cover 118 can extend along a first plane and a second region of the venting compartment cover 118 can extend along a second plane. The first plane can be parallel to and a distance from the second plane. Respective first and second regions of venting compartment cover 118 can have a varying heights relative to cells cover 115. For example, venting compartment cover 118 can be sloped. The second region can include exhaust ports 119. Gases venting from battery cells 145 may vent from the first region to the second region and through exhaust ports 1 19 to an exterior environment.

[0042] The battery system 100 further includes terminals 120, 125 protruding through the housing (e.g., the cells cover 1 15 as shown). Terminals 120, 125 can protrude through standard bushings 230, which will be discussed later. Terminals 120, 125 are provided on the cells cover 115 for connecting or coupling the battery system 100 to electrical loads (e.g., a vehicle electrical system).

[0043] Referring again to FIG. 6, the BMS cover 116 is removed to show inner details of battery 100. The cells cover 1 15 includes a platform 131 integrally formed with the cells cover 115. Platform 131 includes a shelf surface 132 and a shelf wall 133. The BMS cover 116 includes an edge and an inner wall. When coupled, the edge is directly connected to the shelf surface 132, and the inner wall is near the shelf wall 133. More specifically, the BMS cover 116 can use the shelf wall 133 to help align the edge of the BMS cover 116 onto the shelf surface 132 when coupling the BMS cover 116 to battery 100. In the example shown, the edge is continuous on a perimeter of the BMS cover 116 and the edge is in continuous contact with the shelf surface132 (best shown in FIG. 5). The BMS cover 1 16 can be coupled with the shelf surface 132 and or shelf wall 133 using a fastener. Platform 131 may also be configured to support components of the PCB assembly 290. In the construction shown, mini bushings 235 and L-shaped bushings 240 protrude through platform 131 into the BMS compartment 143, thus facilitating electrical connection from each cell to the PCB assembly 290. Platform 131 can also support a plurality of leads 300 to electrically couple strap posts 225, 250 via bushings 235, 240 with the PCB, which will be discussed later.

[0044] FIGS. 7 and 8 show battery 100 without cells compartment cover 115. The cells base 110 supports a plurality of battery cell chambers (one chamber 135 is labeled). The cell chambers can be formed by cells base 110 and a plurality of cell walls or partitions (one wall 140 is labeled) that define the plurality of cell chambers. The partitions may be formed as being unitary with the cells base 110. While the constructions discussed herein have six cell chambers, a different number of cells chambers may be provided. Further, while the shown chambers are a generally rectangular shape, other shapes may be used for the chambers. The cell chambers (and related battery cells 145) may conventionally be referred to by number (e.g., 1, 2, 3, 4, 5, 6).

[0045] The battery cells 145 include a plurality of positive frames or plates, a plurality of separators partially surrounding the positive plates, and a plurality of negative frames or plates. The design and implementation of the battery cells 145 can be similar to what was discussed above with the battery of FIGS. 1-3, which is incorporated here.

[0046] The housing 105, including the cells base 110, the cells cover 115, the BMS base 111, the BMS cover 116, and the venting cover 118 may be made of any polymeric (e.g., polyethylene, polypropylene, a polypropylene containing material, etc.), acryl butyl stearate (ABS), polycarbonate, or composite (e.g., glass-reinforced polymer) material. For example, the housing 105 may be made of polypropylene-containing material (e.g., pure polypropylene, copolymers comprising polypropylene, polypropylene with additives, etc.). Such polymeric material is relatively resistant to degradation caused by acid (e.g., sulfuric acid) provided within cells of the container. Further, and as will be discussed in more detail, a wall 141, which is part of the housing 105, between the cells compartment 142 and the BMS compartment 143, is also resistant to degradation caused by acid provided within the cells chamber 135. The cells cover1 15 and the BMS base I I I in the BMS compartment 143 can be the unitary wall 141 and is shown in the examples herein as the unitary wall 141.

[0047] The cells compartment 142 includes cast-on battery straps 205 coupling one cell to the next or one cell to a terminal. The combination of the cast-on battery straps 205 and battery cells 145 create the battery voltage. Example battery straps 205 include the battery straps, as shown herein.

[0048] The battery straps 205, according to various constructions, connect a number of battery cells 145, for example six battery cells, in series. The battery cells 145 may be comprised of flat-plates, similar to plates 150, 160 above, stacked together. Each plate can have a respective lug extending out of the top of the grid. The batteiy straps 205 may be understood to connect the lugs of the grids in the battery cells 145 together. It is envisioned that the battery straps 205, as is known in the art, may be of a different design and / or connected to the lugs by different means.

[0049] Figure 9 shows an example post assembly 206 for the battery system of FIG. 5. In the illustration, battery straps 205 comprise connecting straps 210 and further comprise end straps 215. Four connecting straps 210 and a shunt bar 255 are shown, which couple six battery cells in series. Connecting straps 210 can include an intercell weld 21 1. The positive terminal 120 and the negative terminal 125 are electrically coupled to terminal posts 220 and end straps 215. The positive and negative terminals 120, 125 are shown on opposite sides of the battery system 100 in the illustrated examples. A connecting strap 210 connects the lugs of a first polarity of battery plates of a battery cell to the lugs of the battery plates of an opposite polarity of a second battery cell. A terminal post 220 connected to an end strap 215 having a polarity (e.g., a positive terminal post corresponding to the positive terminal 120) connects the lugs of plates of the same polarity (e.g., positive) of one end battery cell. Similarly, another terminal post 220 connected to an end strap 215 having an opposite polarity (e.g., a negative terminal post corresponding to the negative terminal 125 ) connects the lugs of plates of the same polarity (e.g., negative) of the other end battery cell. This provides all six cells being connected in electrical series to result in the battery voltage for the battery system 100. Other series and parallel battery cell arrangements are possible for the battery system as is knowm in the art to provide different and / or multiple voltages.

[0050] In various constructions, the battery straps 205 comprise a lead or lead alloy. The lead alloy may be a substantially pure lead and may, in various constructions, include lead, tin, antimony, calcium, and combinations thereof. The alloy, as a non-limiting example, may be a lead-tin alloy with a tin composition range of 1-4%, 1-2.25%, 1-1.5%, and the like. The lead may be virgin lead or high purity lead or highly purified secondary lead, in numerous examples of constructions. In some implementations, one or more of the battery straps 205 may be made of any material and / or coated (i.e., at least a portion) using one or more materials such as coated using an insulator material.

[0051] Various battery straps 205 include strap posts (e.g., terminal posts 220, mini posts 225, shunt post 250) that are coupled with the battery strap 205. For example, the strap posts can be integrated (including directly cast) on the battery strap 205, welded onto the battery strap 205, or connected by other means. The strap posts 225, 250 protrude from the cells compartment 142 through the cells cover 115 and BMS base 111 (i.e., the compartment wall 141 ) into the BMS compartment 143 (see FIG. 6). For example, each strap post 225, 250 may be in communication with a measurement device to measure a voltage of each battery cell and / or set of battery cells.

[0052] The strap posts 220, 225, 250 protrude through bushings (e.g., standard bushings 230, mini bushings 235, L-shaped bushings 240, shown in FIGS. 5 and 6). The cells cover 115 can include one or more bushings such as mini bushings 235, L-shaped bushings 240, and standard bushings 230. A standard bushing 230 may refer to a bushing arranged to conform to the specifications of one or more parts of a standard type of battery. For example, a standard bushing 230 may be arranged to conform to the shape / size of a standard post (e.g., a post meeting the specifications of a standard battery such as a terminal post). A mini-bushing 235 may refer to a bushing arranged to conform to the specifications of one or more mini-posts. An L-shaped bushing 240 can refer to a bushing arranged to the specifications of one or more shunt posts 250. A standard post (e.g., terminal post 220) is designed with a diameter to allow the post to cany the full-rated current of the battery system 100. A mini post 225 is designed with a diameter to allow the post to make voltage measurements and is designed to allow a minimal current (i.e., much less than full-rated current) to the BMS 395 (shown and described w'ith FIG. 12).However, because the mini post 225 consists essentially of a lead or lead alloy, the mini post 225 requires a minimum diameter to work the post. An example diameter for the terminal post at itssmallest diameter is 7mm with a range of 5mm to 10mm or more. An example diameter for the mini post at its smallest diameter is 3mm with a range of 1.5mm to 5mm. A shunt post 250 is designed with a diameter to allow the post to carry the full-rated current of the battery system 100. The diameter of the shunt post 250 can be smaller than the diameter of the standard post 220.

[0053] A first terminal post 220 is electrically connected to the positive electrodes of a battery cell 145 and electrically connected to the positive terminal 120 of the battery system 100. A second terminal post 220 is electrically connected to the negative electrodes of a battery cell 145 and electrically connected to the negative terminal 125 of the battery system 100. Each one of the six mini posts 225 are electrically connected to a positive portion of one battery cell 145 and a negative portion of an adjacent battery cell 145. Of course, one skilled in the art can arrange the straps, posts, and sense arrangements differently from what is shown. The strap posts 225, 250 are arranged to protrude through a respective bushing 235, 240 (shown in FIG. 6) of the cells cover 115, via platform 131, and can be coupled to a lead assembly (discussed below) for the BMS. For example, each strap post 225, 250 may be in communication with the BMS to measure one or more parameters disclosed earlier. Specifically, the bushing posts 250 are arranged to electrically couple to a shunt bar 255, which can include leads 260 (discussed below).

[0054] With reference again to FIGS. 5 and 6, the cells cover 1 15 includes standard bushings 230, mini bushings 235, and L-shaped bushings 240. The cells cover 115 is arranged to include one or more cover openings to be arranged to receive terminal posts 220, mini posts 225, and shunt posts 250. The bushings 230, 235, 240 provide sealing features, where coupling the bushings 230, 235, 240 to the cells cover 115 and to the strap posts 220, 225, 250 seals the BMS compartment 143 from the cells compartment 142. Further, the cells cover 115 may comprise one or more cover openings which may be arranged as vent openings (one vent opening is labeled 245) The vent openings 245 allow fluid (e.g., gas) communication with the internal space of the cells compartment 142.

[0055] A main electrical path from the negative battery terminal 125 to the positive battery terminal 120 is shown in FIG. 9. In the illustration, the electrical path from the negative batteryterminal 125 to the positive battery terminal 120 is split between a first battery cell group and second battery cell group. The first battery cell group includes respective cells 1, 2, and 3. The second battery cell group includes respective cells 4, 5, and 6. The electrical path includes negative terminal 125, end strap 215, schematically represented battery cells 145 connecting straps 210, and intercell welds 211 (one of each is labeled in FIG. 9), shunt posts 250, shunt bar 255, end strap 215, and positive terminal 120. In the example, cells 1, 2, and 3 are electrically coupled by shunt posts 250 and shunt 255 to cells 4, 5, and 6. By using the shunt bar instead of, for example, bus bar connectors or intercell welds, the number of components and connections are reduced, which in turn, reduces assembly complexity. This configuration additionally reduces overall system resistance. In the example, shunt bar 255 is a manganin shunt; however, other low-resistance shunts are possible. Shunt 255 may facilita te measurement of current and voltage drop, e.g., between cells 3 and 4. In at least one example, shunt bar 255 can be removable. Shunt 255 may include, in various constructions, one or more hole cutouts for fasteners for coupling to the PCB. Alternatively, shunt 255 may be welded directly to the PCB as shown in FIG. 8.

[0056] According to one or more examples, shunt bar 255 may additionally includes leads 260. Leads 260 are electrically coupled to the PCB assembly 290, described below. In the illustration, leads 260 extend from shunt bar 255 in a first direction and bend in a second direction which may be orthogonal to the first direction. Leads 260 can include more than one bend or may be straight. A current sense path is provided by connecting a current sensor of the BMS 395 (best shown in FIG. 12) to the shunt bar 255 via lead 260. The current sense path can also provide a voltage sense point 270 corresponding to the negative terminal 125 and the first cell voltage. A second voltage sense point 275 corresponds to the positive terminal 120 and the last cell voltage. The first and second voltage sense points 270, 275 can be coupled to a respective mini post 225. Other series and parallel battery cell arrangements are possible for the battery system 100 as is known in the art to provide different and / or multiple voltages.

[0057] Figure 9 shows strap posts (e.g., terminal posts 220, mini posts 225, shunt posts 250) protruding through bushings (e.g., standard bushings 230, mini bushings 235, L-shaped bushings 240). A lead assembly 280 is coupled (e.g., welded) to the strap posts 220, 225 with ring connectors (one ring connector 285 is labeled in FIG. 10). Battery system 100 may have more than one lead assembly 280. In the example, a lead assembly 280 is provided for each of batterygroups 1 and 2. The lead assembly 280 further includes a BMS connector 286 to electrically couple to the PCB assembly 290. As shown in FIG. 6, platform 131 supports each lead assembly 280 within the BMS compartment 143.

[0058] Figure 10 shows a circuit board assembly, which is a printed circuit board (PCB) assembly 290, coupled to the BMS connector 286. The PCB assembly 290 provides the BMS 395, discussed below. Also connected to the PCB assembly 290 is the shunt bar 255 for measuring current and acquiring a voltage. The PCB assembly 290 can also include additional connectors for temperature measurements (discussed below) or other parameters. In the illustrated example, the PCB assembly 290 is removably fastened within the BMS compartment. Thus, when necessary', PCB assembly 290 may be removed from the battery system 100. This may allow a user to easily swap electrical components on the PCB assembly 290 or access internal components within the battery' housing. The removeable PCB assembly 290 also reduces assembly / complexity. For example, the removeable PCB assembly 290 can allow for different components to be swapped at the request of various business to business customers. In various examples, the PCB assembly is fastened to shunt bar 255. Shunt bar 255 can be removed or swapped. As discussed earlier, the shunt bar 255 can alternatively be welded directly to the PCB assembly 290.

[0059] A plurality of leads 300 (e.g., six leads) can include a first lead skeleton 305 and a second lead skeleton 310. Each lead 300 includes one or more of each of the following (only one of which is labeled in FIG. 10): a post connector 285, a BMS connector 465, and a conductive path 470 connecting the post connector 285 to the BMS connector 465. In the illustrated example, the respective first and second lead skeletons 305, 310 may be stamped in the shape of a frame and configured to electrically couple various posts 225 to voltage sensors. The lead skeletons 305, 310 may be made of lead or a lead alloy. Similar to the discussion above, it should be contemplated within the present disclosure that a “smart” lead-acid battery system constructed with the lead skeletons 305, 310 can be communicatively coupled to a processor 430 and memory 435.

[0060] Lead skeletons 305, 310 are coated with a protective and / or electrically insulating over molding, referred to herein as a lead body 320. The over molding provides structuralsupport to the lead skeletons 305, 310 and improve ease of manufacturing. The lead body 320 can be an overmolding polymer (e.g., to make lead assembly 280) over the leads 300 to thereby provide structure for the leads 300. Lead assembly 280 can be rigid or flexible or a combination thereof depending on the intended design.

[0061] The lead skeletons, as shown in FIG. 10, can further include support connectors (one connector 468 is labeled). Each support connector 468 couples one lead (e.g., lead 300A) of the plurality of leads 300 with an adjacent lead (e.g., lead 300B) of the plurality of leads 300. The support connectors 468 provide structural support to the lead skeletons 305, 310 and improve ease of manufacturing prior to the addition of the lead body 320.

[0062] The post connectors 285 are shown as ring connectors. The ring connectors 285 are arranged to physically and / or electrically connect a lead 300 to a respective post, for example the mini posts 225. Other shapes, and additional conductors (e.g., spikes) are possible for the post connectors 285.

[0063] The BMS connectors 465 of the lead 300 are arranged to extend from the conductive paths 470 to a corresponding connector of the PCB assembly 290. The BMS connectors 465 can bend to a predetermined angle and / or physically and / or electrically connect to the BMS 395 and / or any of its components.

[0064] The leads 300 may be made of any material including conductive materials, e.g., to conduct and / or propagate signals. In a nonlimiting example, the lead skeletons 305, 310 are a stamped frame and be made of at least one of copper, brass, steel, aluminum, titanium, platinum, etc. Further, leads 300 may include a coating and / or a finish such as a finish using copper, nickel, tin, palladium, silver, gold, zinc, etc. The leads 300 may be used by the BMS 395 to measure / determine one or more parameters associated with a strap post 220 / 225 and / or corresponding battery cells 145.

[0065] The lead skeletons 305, 310 may be comprised in a lead assembly 280 further comprising the lead body 320. The lead body 320 can be an over molded assembly as shown in FIG. 13. Further, the lead body 320 includes one or more apertures 330 for exposing at least a portion of the support connectors 468. The apertures 330 allow the breaking of the structuresupport connectors 468 after the lead body 320 forms. The breaking of the structures 468 electrically isolates each lead 300 from the adjacent lead 300, for example 300A from 300B.

[0066] Figure 10 shows a portion of the conducting path 470 and a ring connector 285. As shown, one or more bends may be a part of an intermediate path 350 in the conductive path 470. For some leads, the bends of the intermediate path 470 are nearer to the ring connector 285 than the BMS connector 286 and are external to the lead body. This allows flexing or movement of the ring connector 285 as part of the assembly process to connect the ring connector 285 to the mini post 225. In some examples, bends of the intermediate path 350 can also allow the conductive path 470 to change from a first plane to a second plane. This allows the lead assembly 280 to sit lower within the BMS compartment 143 than as compared to the ring connector 285 sitting in the first plane. Further, the top surface of the ring connector 285 can be in the same plane as the top surface of the lead body. In other implementations, the bends of the intermediate path 350 can be more complex. For example, the hinged bends in FIG. 14 include a “U-shaped” bend for each lead.

[0067] With reference to FIG. 11 a single lead 300 is shown. The lead 300 has a conductive path 470 from the BMS connector 286 to the ring connector 285. The ring connector 285 couples to a mini post 225. The conductive path 470 extends in a first direction 492 in a first plane 495. The conductive path 470 includes an intermediate path 350. The conductive path 470 from the BMS connector to the ring connector 285 includes a path in a first direction 492 in a first plane 495. At the U-Shaped Bend, a first bend 505 has an obtuse angle changing the direction of the conductive path to a second direction 510. Next, a second bend 515 has an acute angle changing the direction of the conductive path 470 from the second direction 510 to a third direction 520. Last, a third bend 525 has an obtuse angle changing the direction of the conductive path 470 from the third direction 520 to the first direction 492. Further, the conductive path 470 after the third bend 525 is in a second plane 530, which is different than the first plane 495. Additional bends from the shown bends 505, 515, and 525 are envisioned. Accordingly, the majority of the lead skeleton 455 sits in a lower plane; i.e., the first plane 495, than the ring connectors 285.Moreover, the inclusion of the bends 505, 515, and 525 allow the ring connectors 285 to be more flexible during the assembly process.

[0068] It should also be noted that the cross-sectional area of the leads 300 can be smaller within the lead body 320 than outside of the lead body 320. The larger cross-section area allows for additional rigidity. Further, the larger cross-sectional area is rectangular allowing for more flexing in one direction over the other. Lastly, the lead 300 associated with arm 470 has a larger cross-sectional area within the body 320 than the other leads to allow for a greater current to travel the conductive path since it connected to the terminal lead 220.

[0069] The battery system 100 is a “smart” battery system. Figure 12 is a block diagram for an implementation of the smart lead-acid battery systems 100 of FIG. 5. The lead-acid battery system 100 of FIG. 15 has an integrated battery monitoring system (BMS) 395 disposed within the BMS compartment 143, thereby resulting in a battery system. In one or more alternative implementations, the BMS 395 may be partially located remote from the battery system 100.

[0070] As shown in FIG. 12, the battery system 100 includes an array of battery cells (which are schematically represented as 145) electrically connected to the BMS 395. The BMS 395 includes a communication module 410 configured to receive and / or transmit signals from external devices (e.g., a vehicle). For example, certain constructions of the BMS 395 include a communication module 410 that includes a transmitter capable of communicating through radio frequency signals, such as via a Bluetooth connection, a wireless local area network connection, a cell phone data connection (e.g., code division multiple access), or other suitable connection. The communication module 410 can alternatively or additionally use a wired-communication scheme. Example wired communication standards include controller area network (CAN), local interconnect network (LIN), on-board diagnostic (e.g., OBD-II), recommended standard (e.g., RS-340), etc.

[0071] In the illustration, the BMS 395 includes a battery measurement device / circuit 415. The battery measurement device / circuit 415 includes one or more sensors configured to monitor the battery cells 145 and is configured to output a signal indicative of parameters (e.g., cell voltages) to the BMS 395. As illustrated, leads are coupled to various terminals (or lugs). Depending on the attached leads, the measurement device 415 can acquire individual cell voltages, group cell voltages, and / or battery voltages for the battery system 100. For the shown example, the measurement circuit 415 is located in the BMS compartment 143.

[0072] For the battery system 100, the measurement circuit 415 can include voltage sensors (e.g., voltmeters) electrically coupled to the various leads provided to the measurement circuit 415, Because the first lead is electrically connected to a mini post 225 adjacent the positive post 120 and the second lead is electrically connected to a mini post 225 adjacent the negative post 125, the voltage sensor senses the voltage across the battery cell 145. The voltage sensor is coupled to a processor 430 and a memory 435. The processor 430 receives a signal from the voltage sensor indicative of the cell voltage, and to determine the cell voltage based on the signal. For example, in certain implementations, the voltage sensor outputs an analog signal proportional to the sensed voltage. In such implementations, the processor 430 may be configured to convert the analog signal into a digital signal, and to determine the voltage based on the digital signal. The memory 435 may be configured to store battery cell identification information, operational parameter history' information, battery cell type information, and / or usage information. For example, a unique identification number may be associated with each battery cell 145 and stored within the memory 435.

[0073] It should be appreciated that the battery system 100 includes additional sensors configured to monitor other operational parameters of the battery cells 145 and or the battery system 100. The measurement circuit 415 can include a temperature sensor 440. The temperature sensor 440 outputs a signal indicative of the battery cell temperature. For example, the temperature sensor 440 may output an analog signal proportional to a measured temperature. It should also be appreciated that alternative constructions may include additional sensors configured to monitor other operational parameters of the battery cell 145. For example, the measurement circuit 415 may include a sensor configured to measure the state of charge within the battery cell 145, a current sensor 445 configured to determine a current being provided by the battery cell 145, a pressure sensor configured to detect an excessive pressure within the battery cell 145, an acid density measurement to measure acid density in a battery cell 145, and / or other sensors configured to monitor an electrical, physical, or chemical parameter of the battery cell 145.

[0074] The processor 430 can include a component or group of components that are configured to execute, implement, and / or perform any of the processes or functions described herein for the BMS 395 or a form of instructions to carry out such processes or cause suchprocesses to be performed. Examples of suitable processors include a microprocessor, a microcontroller, and other circuitry that can execute software. Further examples of suitable processors include, but are not limited to, a core processor, a central processing unit (CPU), an array processor, a vector processor, a digital signal processor (DSP), a Held-programmable gate array (FPGA), a programmable logic array (PLA), an application specific integrated circuit (ASIC), math co-processors, and programmable logic circuitry. The processor 430 can include a hardware circuit (e.g., an integrated circuit) configured to carry out instructions. In arrangements in which there are a plurality of processors, such processors can work independently from each other, or one or more processors can w'ork in combination with each other.

[0075] The memory 435 includes memory for storing one or more types of instructions and / or data. The memory 435 can include volatile and / or non-volatile memory. Examples of suitable memory include RAM (Random Access Memory), flash memory, ROM (Read Only Memory), PROM (Programmable Read-Only Memory), EPROM (Erasable Programmable Read- Only Memory), EEPROM (Electrically Erasable Programmable Read-Only Memory), registers, disks, drives, or any other suitable storage medium, or any combination thereof. The memory 435 can be a component of the processor 430, can be operatively connected to the processor 430 for use thereby, or a combination of both.

[0076] In one or more arrangements, the memory 435 can include various instructions stored thereon. For example, the memory 435 can store one or more instruction (e.g., software or firmware) modules. The instruction modules can be or include computer-readable instructions that, when executed by the processor 430, cause the processor 430 to perform the various functions disclosed for the battery system 100. While functions may be described herein for purposes of brevity, it is noted that the functions for the battery system 100 are performed by the processor 430 using the instructions stored on or included in the various modules. Some modules may be stored remotely and accessible by the processor 430 using, for instance, various communication devices and protocols.

[0077] The memory 435 may also be configured to store battery identification information, battery operational parameter history information, battery type information, and / or battery usage information. The memory 435 may be further configured to store, for each battery cell 145,battery cell identification information, battery cell operational parameter history information, battery cell type information, and / or battery cell usage information. For example, a unique identification number may be associated with each battery cell 145 and stored within the memory 435. In such a configuration, the battery monitoring unit may identify a particular battery cell 145 based on the unique identification number, thereby providing more context to the measured parameters. The memory 435 may also be configured to store historical values of measured operational parameters of the battery system 100 and the battery cells 145. For example, the memory 435 may store the maximum and / or minimum voltage measured by a voltage sensor. Such information may be useful for diagnosing faults within a battery cell, as will be discussed in some of the further constructions below. Furthermore, the memory 435 may be configured to store usage information, such as a verage load, maximum load, duration of operation, or other parameters that may be usefid for monitoring the operational status of the battery system 100 and / or battery cells 145. Similar information may be stored in the BMS 395 for combinations of battery cells 145 (e.g., cells 1-3 and cells 4-6).

[0078] The battery system 100 also includes a communication (or connector) port 448 for connecting a communication cable to the housing 105. The communication port 448 can promote communication between the battery system 100 and an external apparatus, such as a vehicle control module if the battery system 100 is used in a vehicle.

[0079] Before moving to other components, it should be understood by somebody skilled in the art that the battery monitoring unit may include additional conventional elements typically found in a battery system or a monitoring unit. Further discussion regarding these components is not provided herein since the components are conventional and their operation are conventional.

[0080] During one operation of the battery system 100, each measurement circuit 415 monitors a cell voltage of each respective battery cell 145 the measurement circuit 415 is associated with. The measurement circuit 415 can sense other parameters associated with the battery system 100, such as a total battery voltage, various combinations of battery cell voltages, a total battery current, a total battery charge, etc. Analog value or processed value can be provided to the BMS 395 by the measurement circuit 415. Based on the acquired parameters and related values, the BMS 395 can determine a state of health of the lead-acid battery system 100,particularly the battery system 100 and the battery cells 145. Further based on the acquired parameters and related values, the BMS 395 can determine a state of function of the lead-acid battery system (e.g., readiness in terms of usable energy by observing state-of-charge in relation to the available capacity), particularly the battery and battery cells. By monitoring cell voltage, the BMS 395 can identify a potentially faulty cell, thereby identifying a possible issue for the lead-acid battery system 100 sooner than an external (e.g., vehicle) control unit can identify a possible issue through the total battery voltage. The lead-acid battery system 100 herein can also provide better prediction capabi lities using the additional voltage information related to the individual battery cells 145. By extension, this applies to the other possible cell parameters (discussed above) sensed by the measurement devices 415 and the BMS 395.

[0081] The information related to the lead-acid battery system 100 and the state of the lead- acid battery can also be communicated through a wire connection and / or through wireless communication. For example, information may be communicated to the vehicle control module, which can provide information to the driver via the indicator panel. Alternatively, an analysis tool can be coupled (either wireless or direct connection) to the lead-acid battery system 100 for communicating with the BMS 395, and more specifically obtain information from the memory 435.

[0082] Accordingly, this disclosure provides new and useful intelligent battery systems, new and useful components for intelligent battery systems, and new and useful methods of manufacturing and operating intelligent battery systems and components of the same.

[0083] Some of the systems, components, and / or processes described above can be realized in hardware or a combination of hardware and software and can be realized in a centralized fashion in one processing system or in a distributed fashion where different elements are spread across several interconnected processing systems. Any kind of processing system or another apparatus adapted for carrying out the methods described herein is suited. A typical combination of hardware and software can be a processing system with computer-usable program code that, when being loaded and executed, controls the processing system such that it carries out the methods described herein. Some of the systems, components, and / or processes also can be embedded in a computer-readable storage, such as a computer program product or other dataprograms storage device, readable by a machine, tangibly embodying a program of instructions executable by the machine to perform methods and processes described herein. These elements also can be embedded in an application product which comprises all the maintenance conditions enabling the implementation of the methods described herein and which, when loaded in a processing system, is able to carry out these methods.

[0084] Furthermore, some arrangements described herein may take the form of a computer program product embodied in one or more computer-readable media having computer-readable program code embodied, e.g., stored, thereon. Any combination of one or more computer- readable media may be utilized. The computer-readable medium may be a computer-readable signal medium or a computer-readable storage medium. The phrase “computer-readable storage medium” means a non-transitory storage medium. A computer-readable storage medium may be, for example, but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or a suitable combination of the foregoing. More specific examples (a non-exhaustive list) of the computer-readable storage medium would include the following: a portable computer diskette, a hard disk drive (HDD), a solid-state drive (SSD), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), a portable compact disc read-only memory (CD-ROM), a digital versatile disc (DVD), an optical storage device, a magnetic storage device, or any suitable combination of the foregoing. In the context of this document, a computer-readable storage medium may be any tangible medium that can contain or store a program for use by or in connection with an instruction execution system, apparatus, or device.

[0085] Program code embodied on a computer-readable medium may be transmitted using an appropriate medium, including but not limited to wireless, wireline, optical fiber, cable, RF, etc., or any suitable combination of the foregoing. Computer program code for carrying out operations for aspects of the present arrangements may be written in any combination of one or more programming languages. Instructions of the program code may be executed entirely at one location, or processor, or across multiple locations, or processors, as discussed herein.

[0086] The terms “a” and “an,” as used herein, are defined as one or more than one. The term “plurality,” as used herein, is defined as two or more than two. The term “another,” as usedherein, is defined as at least a second or more. The terms “including” and / or “having,” as used herein, are defined as comprising (i.e., open language). The phrase “at least one of . .. and . . as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. As an example, the phrase “at least one of A, B, and C” includes A only , B only, C only, or any combination thereof (e.g., AB. AC, BC, or ABC),

[0087] It should also be noted that, in some alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved.

[0088] For the purpose of this disclosure, the term “coupled” means the joining of two members directly or indirectly to one another unless limited otherwise. Such joining may be stationary in nature or moveable in nature. Such joining may be achieved with the two members, or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another. Such joining may be permanent in nature or may be removable or releasable in nature.

[0089] The terms fixedly, non-fixedly, and removably, and variations thereof, may be used herein. The term fix, and variations thereof, refer to making firm, stable, or stationary. It should be understood, though, that fixed does not necessarily mean permanent — rather, only that a significant or abnormal amount of work needs to be used to make unfixed. The term removably, and variations thereof, refer to readily changing the location, position, station. Removably is meant to be the antonym of fixedly herein. Alternatively, the term non-fixedly can be used to be the antonym of fixedly.

[0090] Preferences and options for a given aspect, feature or parameter of the disclosure should, unless the context indicates otherwise, be regarded as having been disclosed in combination with any and all preferences and options for all other aspects, features, and parameters of the disclosure.

[0091] Aspects herein can be embodied in other forms without departing from the spirit or essential attributes thereof. Accordingly, reference should be made to the following claims, rather than to the foregoing specification, as indicating the scope hereof.

Claims

CLAIMSWhat is claimed is:

1. A battery comprising: a housing; a cover; a plurality of battery cells provided in the housing, the plurality of battery cells divided between a first battery cell group and a second battery cell group; a shunt bar electrically coupling the first battery cell group to the second battery cell group; and a printed circuit board assembly electrically coupled with the shunt bar.

2. The battery of claim 1, wherein the cover includes a cells cover, a first cover portion provided on the cells cover, and a second cover portion provided on the cells cover and the first cover portion encloses the printed circuit board assembly.

3. The batery of claim 2, further comprising a fastener removably coupling the printed circuit board assembly to the cover, wherein the fastener removably couples the first cover portion to the cells cover.

4. The battery of claim 2 or 3, wherein the cells cover includes a plurality of vent openings to vent gas exhaust from the plurality of battery ceils.

5. The battery of claim 4, wherein the second cover portion includes a common headspace provided above the plurality of vent openings.

6. The battery of any of claims 2-5, wherein the second cover portion includes a vent port to vent gas exhaust from the plurality of battery cells.

7. The battery of any of claims 2-6, wherein the second cover portion of the cover is heat sealed to the cells cover.

8. The battery of any of claims 2-7, wherein the cells cover is heat sealed to the housing.

9. The batery of' any of claims 1 -S, further comprising a battery monitoring system; and a lead assembly coupling each respective first and second battery cell group to the batery monitoring system.

10. A battery cover system comprising: a cells compartment cover; a venting compartment cover; a battery monitoring system cover; and a fastener removably coupling the battery monitoring system cover to the cells compartment cover.

11. The battery cover system of claim 10, wherein the battery monitoring system cover is provided on the cells compartment cover and together, the batery monitoring system cover and the cells compartment cover define a battery monitoring system compartment.

12. The battery cover system of claim 11, further comprising a battery monitoring system provided in the battery monitoring system compartment, the batery monitoring system having a printed circuit board.

13. The battery cover system of claim 12, wherein the fastener couples the printed circuit board to the cells compartment cover.

14. The battery cover system of any of claims 10-13, wherein the cells compartment cover includes a plurality of vent openings.

15. The battery cover system of any of claims 10-14, wherein the venting compartment cover provided on the cells compartment cover and together, the venting compartment cover and the cells compartment cover define a venting compartment.

16. The batery cover system of any of claims 10-15, wherein the venting compartment cover is heat sealed to the cells compartment cover.

17. The battery cover system of claim 15 or 16, wherein the venting compartment includes a common headspace.

18. The battery cover system of any of claims 10- 17, further including a vent port provided on the venting compartment cover.

19. A battery having: a housing having cells; a plurality of battery elements provided within the cells; a battery strap cast onto the plurality of battery elements, the battery strap having a plurality of posts.

20. The battery of claim 19, wherein the plurality of posts includes a first post and a second post, the first post being configured as terminal post and the second post being configured to support a battery monitoring system.

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