AGM battery with individual voltage sense

Abstract

A battery comprising a housing, a plurality of battery cells within the housing, a plurality of posts, each post electrically coupled to one or more battery cells, a first cover coupled to the housing in which at least a portion of the plurality of posts extend away from the first cover, a plurality of leads, and a monitoring connector in electrical communication with plurality of leads, each lead being electrically coupled to one post and being coupled to the monitoring connector to provide an electrical parameter associated with a corresponding battery cell.

Description

[0001] A GM BATTERY WITH INDIVIDUAL VOLTAGE SENSE

[0002] TECHNICAL FIELD

[0003] This disclosure relates to a batteries, and in particular to batteries having a lead assembly and / or connector for monitoring battery cell parameters.

[0004] BACKGROUND

[0005] Motor-powered and / or electrically powered vehicles tend to rely on using one or more battery or battery systems to provide at least a portion of a motion power for the vehicle and, some cases, a starting power (e.g., power used to crank and start an engine). Such vehicles may include one or more of an air- or watercraft, a rail-guided vehicle, a street vehicle, etc., where a street vehicle may refer to, for example, cars, trucks, buses, recreational vehicles, etc. In some cases, vehicles can only receive power from the battery, but cannot receive, from the battery, additional information regarding battery components.

[0006] While arrangements for monitoring battery cell and battery parameters are known, these arrangements typically include sophisticated and complex microprocessor based battery management systems integrated within the battery. Batteries having integrated battery management systems are more complex and expensive to manufacture than batteries that do not include integrated battery management systems. Further, integrated battery management systems are prone to failure if the electrolyte in the battery leaks from the cells into the space occupied by the integrated battery management system.

[0007] On the other hand, batteries that do not have integrated battery management systems do not allow a way to monitor individual battery cell parameters.

[0008] SUMMARY

[0009] Some embodiments advantageously provide a method and system for a battery such as an absorbent glass mat (AGM) battery. The embodiments described herein may be applicable to batteries other than AGM batteries, e.g., lead acid, Li-Ion, etc. The battery may include a plurality of leads (or one or more leads) that may be coupled to battery cells and couplable to a vehicle (e.g., vehicle system) to provide battery cell parameters (e.g., battery cell voltage) to the vehicle. In some embodiments, the battery comprises a lead assembly comprising a lead frame and the plurality of leads, where at least a portion of the plurality of leads is within the lead frame. The leads may be arranged to provide the battery cell parameters. One or more leads may include a circuit element (such as a resistor) and be configured to provide circuit element functions. In some embodiments, the plurality of leads may be coupled to or comprise a first connector (e.g., vehicle connector receiver) arranged to couple to a second connector (e.g.,, vehicle connector). The second connector may be coupled to one or more vehicle systems (e.g., electronic control unit (ECU)) and accessory devices (On-board diagnostics (OBD) device and / or port). When the first connector and the second connector are coupled, the vehicle may receive battery cell parameters (e.g., battery cell voltage) via the plurality of leads and connectors. For example, a vehicle ECU and / or OBD device may be configured to receive and / or measure voltage of each individual battery cell and / or perform actions based on the received voltage and / or measured voltage. In some embodiments, one or more leads include a post connector end having one or more post connector end elements arranged to provide a plurality of connector functions.

[0010] In accordance with one aspect, a battery is provided. The battery comprises a housing, a plurality of battery cells within the housing, a plurality of posts in which each post is electrically coupled to one or more battery cells, a first cover coupled to the housing, at least a portion of the plurality of posts extending away from the first cover, a plurality of leads, and a monitoring connector in electrical communication with plurality of leads, each lead being electrically coupled to one post and being coupled to the monitoring connector to provide an electrical parameter associated with a corresponding battery cell.

[0011] In accordance with an embodiment of this aspect, each of the plurality of leads is an insulated wire. In accordance with an embodiment of this aspect, the battery further comprises a lead assembly, the lead assembly comprising the plurality of leads, a lead frame, and a lead assembly connector, at least one lead comprising a circuit element. In accordance with an embodiment of this aspect, the plurality of leads are over-molded with the lead frame. In accordance with an embodiment of this aspect, at least one lead comprises a circuit element. In accordance with an embodiment of this aspect, the at least one circuit element is a resistor. In accordance with an embodiment of this aspect, the at least one circuit element is placed in an electrically serial arrangement with the corresponding lead. In accordance with another embodiment of this aspect, the battery further includes a second cover coupled to the first cover, and the second cover and the monitoring connector are integrated into a single unitary construction. In accordance with an embodiment of this aspect, the battery is an absorbent glass mat, AGM, battery.

[0012] In another aspect a battery is provided that comprises a housing, a plurality of battery cells within the housing, a lead assembly comprising one or more leads electrically couplable to the one or more battery cells, at least one lead comprising a circuit element, the one or more leads being arranged to provide, to a device and / or a system external to the battery, an electrical parameter associated with the one or more cells, and a monitoring connector in electrical communication with plurality of leads, each lead being electrically coupled to one battery cell and being coupled to the monitoring connector to provide the electrical parameter associated with a corresponding battery cell to the device and / or the system external to the battery.

[0013] In accordance with an embodiment of this aspect, the lead assembly further includes a lead frame comprising at least a portion of the one or more leads and a lead assembly connector coupled to the lead frame. In accordance with an embodiment of this aspect, at least one lead comprises a circuit element. In accordance with an embodiment of this aspect, the at least one circuit element is a resistor. In accordance with an embodiment of this aspect, the at least one circuit element is placed in an electrically serial arrangement with the corresponding lead. In accordance with an embodiment of this aspect, the monitoring connector is coupled to the lead assembly connector. In accordance with an embodiment of this aspect, the battery further includes a first cover coupled to the housing and disposed over the plurality of battery cells and a second cover disposed over the first cover, the second cover including the monitoring connector, wherein the lead assembly is disposed between the first cover and the second cover. In accordance with an embodiment of this aspect, the battery is an absorbent glass mat, AGM, battery.

[0014] In another aspect, the disclosure provides a lead assembly associated with a battery in which the battery comprises one or more battery cells. The lead assembly comprises one or more leads electrically couplable to the one or more battery cells, at least one lead comprising a circuit element, the one or more leads being arranged to provide, to a device and / or a system external to the battery, an electrical parameter associated with the one or more cells.

[0015] In accordance with an embodiment of this aspect, the lead assembly further includes a lead frame comprising at least a portion of the one or more leads and a lead assembly connector coupled to the lead frame. In accordance with an embodiment of this aspect, the lead assembly further includes a monitoring connector coupled to the lead assembly connector, the monitoring connector being couplable to the device and / or the system, the system being a vehicle system, the device being an accessory device. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] 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:

[0017] FIG. 1 is a diagram of an example system according to principles disclosed herein;

[0018] FIG. 2 shows an example battery constructed in accordance with the principles of the present disclosure;

[0019] FIG. 3 is a block diagram of a vehicle system (VS) according to some embodiments of the present disclosure;

[0020] FIG. 4 is a block diagram of an accessory device (AD) according to some embodiments of the present disclosure;

[0021] FIG. 5 is an example battery according to some embodiments of the present disclosure;

[0022] FIG. 6 is an example post assembly according to some embodiments of the present disclosure;

[0023] FIG. 7 is an example cover according to some embodiments of the present disclosure;

[0024] FIG. 8 is an example post coupled to the cover according to some embodiments of the present disclosure;

[0025] FIG. 9 is an example lead assembly according to some embodiments of the present disclosure;

[0026] FIG. 10 is another view of the example lead assembly according to some embodiments of the present disclosure;

[0027] FIG. 11 is an example cover and connector according to some embodiments of the present disclosure;

[0028] FIG. 12 is an example assembly process according to some embodiments of the present disclosure;

[0029] FIG. 13 is an example battery with a first cover according to some embodiments of the present disclosure; and

[0030] FIG. 14 is an example battery with the first cover and a second cover according to some embodiments of the present disclosure. DETAILED DESCRIPTION

[0031] Before describing in detail example embodiments, it is noted that the embodiments reside primarily in combinations of apparatus components and processing steps related to lead assembly and / or connector for a battery system. Accordingly, the system and method components have been represented where appropriate by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.

[0032] 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.

[0033] 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.

[0034] 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. In some other embodiments, “in communication with” indicates the transmission and / or of signaling by the components that are in communication with each other. The signaling may cause one or more components to perform one or more actions based on the signaling. The term “in communication with” may also refer to being in fluid communication, such as where two spaces are in fluid communication with each other. 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.

[0035] In some embodiments, the general description elements in the form of “one of A and B” corresponds to A or B. In some embodiments, at least one of A and B corresponds to A, B or AB, or to one or more of A and B. In some embodiments, at least one of A, B and C corresponds to one or more of A, B and C, and / or A, B, C or a combination thereof.

[0036] Referring now to the drawing figures, in which like elements are referred to by like reference numerals, there is shown in FIG. 1 a diagram of a system 10, according to an embodiment, which comprises one or more vehicles 12, e.g., a car, motorcycle, scooter, golf cart, light utility vehicle, etc. The vehicle 12 comprises battery 14 for powering at least one function of vehicle 12. In some embodiments, battery 14 may include one or more energy storage modules / cells. Battery 14 may include one or more batteries such as a first battery 14a, second battery 14b, third battery 14c, fourth battery 14d, etc., e.g., electrically connected (e.g., in parallel, series, etc.) as part of a battery pack. Although battery 14 is shown in conjunction with a vehicle 12, battery 14 is not limited as such and may be used in conjunction with any other component (e.g.., such as to power any other system component).

[0037] Vehicle 12 may include vehicle system (VS) 16 that is configured to perform one or more vehicle management functions described herein. In some embodiments, the VS 16 may measure / determine certain battery parameters, e.g., resistance (e.g., battery resistance), voltage (e.g., cell voltage), current, state of charge (SoC), a time parameter, a frequency parameter, etc., and transmi t / receive data (and / or signals such as control signals) to / from another system / device. VS 16 may also determine the conditions of battery components and perform actions such notify other components of system 10.

[0038] System 10 may include an accessory device (AD) 18 that is configured to communicate with vehicle 12 (e.g., AD 18 couples to a port of vehicle 12 or wireless communicates with a communication interface of vehicle 12) and perform one or more management functions described herein. In some embodiments, the AD 18 may measure / determine certain battery parameters, e.g., resistance (e.g., battery resistance), voltage (e.g., cell voltage), current, state of charge (SoC), a time parameter, a frequency parameter, etc., and transmi t / receive data (and / or signals such as control signals) to / from another system / device. VS 16 may also determine the conditions of battery components and perform actions such notify other components of system 10. Although the device is described as an accessory device, AD 18 is not limited as such and may be any device, such as a wireless device, a server, a computing device, etc.

[0039] It is contemplated that one or more entities of system 10 are in communication with each other via one or more of wireless communication, power communication, wired communication, fluid communication, etc. For example, vehicle 12, battery 14, VS 16, and AD 18 (and / or any other device or server) may communicate with each other directly or indirectly using wireless communication, power communication, wired communication, etc. Further, while it may be assumed in one or more embodiments that there is no data or signal communication between battery 14 and vehicle 12, the embodiments described herein are equally applicable to vehicles 12 where there are at least some data / signal communications between battery 14 and vehicle 12. Further, although battery 14 is shown as part of vehicle 12 may be a standalone battery, removably couplable to any component of system 10 such as vehicle 12, etc.

[0040] FIG. 2 shows an example battery 14 constructed in accordance with the principles of the present disclosure. Battery 14 includes a housing 20 into which one or more battery components may be positioned such as battery cells 22. The components may be electrically interconnected (not shown in the FIGS), such as via an electrically conductive bus bar system which electrically interconnects the components in an electrically serial, electrically parallel or combination of electrically serial and parallel manner, depending on the intended voltage and current requirements.

[0041] Battery housing 20 may be coupled to a cover 24 which may be coupled to another cover 26. Cover 24 and housing 20 may define a space 28 where battery cells 22 and other components may be housed. Cover 24 and cover 26 may define another space 30. For example, cover 24 may include one or more cover walls that may (e.g., along with cover 26) define the space 30. Battery 14 also includes terminals, such as a positive terminal 32a and a negative terminal 32b (collectively referred to as terminals 32) to provide the contact points for electrical connection of the battery 14 (e.g., to power devices and / or the vehicle 12 and / or VS 16 and / or AD 18). In addition, terminals 32 may be arranged to protrude through housing 20, such as protruding through cover 24 and / or cover 26. Terminals 32 may be electrically connected to the bus bars inside housing 20 and / or directly connected to cells 22 (bus bars and direct connection not shown).

[0042] Battery 14 may also include one or more electrically conductive posts 34 and a lead assembly 38, which may include one or more electrically conductive leads 40 and a lead frame 42. At least a portion of the leads 40 may be within the lead frame 42, and each lead 40 may be electrically coupled to a battery cell 22 via a corresponding post 34. Battery 14 may also include connector 44 which may be coupled to the leads 40 of the lead assembly 38. In some embodiments, the connector 44 is coupled to the battery 14 (e.g., to cover 24, 26). The connector 44 can, in some embodiments, be integrated with the housing 20, such as in a cover 24 of the housing 20 or any other cover. In some other embodiments, connector 44 is part of lead assembly 38. Further, connector 44 may be arranged to allow for a removable external connection to any other component of system 10 (e.g., to the vehicle’s data bus, VS 16, AD 18, or to some other device, etc.) and / or internal connection, e.g., any components of battery 14. In some embodiments, connector 44 may be configured to removably couple and / or connect (electrically, physically) to another connector (e.g., a vehicle connector).

[0043] In some embodiments, cover 24 may be arranged to receive lead assembly 38 in cover space 30 during assembly, e.g., such that lead assembly 38 is coupled to cover 24 and / or any other components of battery 14 (e.g., posts 34). The leads 40 may be electrically connected to a corresponding cell 22 and / or connector 44. When connector 44 (and / or lead assembly 38) is coupled to vehicle 12 (e.g., VS 16) and / or AD 18, an electrical connection may be established, thereby allowing vehicle 12 (e.g., VS 16) and / or AD 18 to read, measure, or receive electrical parameters of battery cells 22 and perform one or more actions. The parameters may include voltage, state of charge (SoC), cell temperature, cell pressure, etc. As used herein, “electrical parameter” refers to parameters whose values may be electrically reported / provided to a measurement / monitoring device via an electrical connection, e.g., an actual electronic value such as current, voltage, etc., as well as an electronic representation of non-electronic values such as a temperature.

[0044] In some embodiments, lead assembly 38 may include one or more circuit elements 46 (collectively referred to as circuit element 46). For example, a lead 40 may include a circuit element 46 (only one shown in this figure for ease of understanding), rhe circuit element 46 may be configured to couple to one or more sections of lead 40 such that an electrical path is established at least between an end of lead 40 and the opposite end of lead 40, via circuit element 46. Circuit element 46 may be integrated into lead 40, mounted on a surface of lead 40, etc. In addition, circuit element 46 may include resistors, capacitors, inductors, diodes, transistors, ground connections, source elements, sink elements, sensors, etc. Circuit element 72 may be arranged in any configuration or connection such as series, parallel, combinations thereof, etc. In some embodiments, the circuit element 46 may be a resistor mounted on one or more leads 36. In one or more embodiments, circuit element 46 is arranged to attenuate and / or prevent delivery of excess energy (e.g., above a predetermined threshold) to battery components such as cells 22 and / or external components such as vehicle systems. For example, a circuit element 46 (e.g., resistor) may be arranged to inhibit current or prevent a portion of the current that might be based on an inrush current that otherwise would have been delivered to battery cells 22 when leads 40 come in contact with each other during manufacturing and the leads 40 are already electrically coupled to the cells 22.

[0045] Further, battery 14 may be arranged to provide many power capacities and physical sizes, and to operate under various parameters and parameter ranges. It is also noted that implementations of battery 14 some can be scaled to provide various capacities. For example, in some embodiments, the power capacity of battery 14 can range from 25 Ah to 75 Ah. It is noted, however, that this range is merely an example, and that it is contemplated that embodiments of battery 14 can be arranged to provide less than a 25 Ah capacity or more than a 75 Ah capacity. Power capacity scaling can be accomplished, for example, by using higher or lower power capacity cells 22 in the housing 20, and / or by using fewer or more cells 22 in the housing 20. In some embodiments, battery 14 may be incorporated as part of a vehicle where battery power is needed. Other electrical parameters of the battery 14 can be adjusted / accommodated by using cells 22 that may cumulatively have the desired operational characteristics, e.g., current, voltage, charge, charging capacity / rate, discharge rate, etc. Thermal properties can be managed based on cell 22 characteristics, the use of heat sinks and / or thermal energy discharge plates, etc., within or external to the housing 20.

[0046] Example implementations, in accordance with an embodiment, of VS 16 discussed in the preceding paragraphs will now be described with reference to FIG. 3. VS 16 may have hardware 60 that may include a communication interface 62 that is configured to communicate with one or more entities in system 10 via wired and / or wireless communication. The communication may be protocol based communications.

[0047] The hardware 60 includes processing circuitry 66. The processing circuitry 66 may include a processor 68 and memory 70. In particular, in addition to or instead of a processor, such as a central processing unit, and memory, the processing circuitry 66 may comprise integrated circuitry for processing and / or control, e.g., one or more processors and / or processor cores and / or FPGAs (Field Programmable Gate Array) and / or ASICs (Application Specific Integrated Circuitry) adapted to execute instructions. The processor 68 may be configured to access (e.g., write to and / or read from) memory 70, which may include any kind of volatile and / or nonvolatile memory, e.g., cache and / or buffer memory and / or RAM (Random Access Memory) and / or ROM (Read-Only Memory) and / or optical memory and / or EPROM (Erasable Programmable Read-Only Memory). Hardware 60 may also have one or more circuit elements 72 such as resistors, capacitors, inductors, diodes, transistors, ground connections, source elements, sink elements, sensors, etc. Circuit elements 72 may be arranged in any configuration or connection such as series, parallel, combinations thereof, etc.

[0048] Thus, the VS 16 may further comprise software 80, which is stored in, for example, memory 70, or stored in external memory (e.g., database, etc.) accessible by the VS 16. The software 52 may be executable by the processing circuitry 66.

[0049] The processing circuitry 66 may be configured to control any of the methods and / or processes described herein and / or to cause such methods, and / or processes to be performed, e.g., by VS 16. The processor 68 corresponds to one or more processors 68 for performing VS 16 functions described herein. The VS 16 includes memory 70 that is configured to store data, programmatic software code and / or other information described herein. In some embodiments, the software 80 may include instructions that, when executed by the processor 68 and / or processing circuitry 66, causes the processor 68 and / or processing circuitry 66 to perform the processes described herein with respect to VS 16. For example, the processing circuitry 66 of the VS 16 may include VS management unit 74 that is configured to perform any step and / or task and / or process and / or method and / or feature described in the present disclosure, e.g., determining one or more parameters, steps, and / or processes associated with battery 14. While VS management unit 74 is illustrated as being part of VS 16, VS management unit 74 and associated functions described herein may be implemented in a device separate from VS 16 such as in battery 14 or another device.

[0050] Example implementations, in accordance with an embodiment, of AD 18 discussed in the preceding paragraphs will now be described with reference to FIG. 4. AD 18 may have hardware 90 that may include a communication interface 92 that is configured to communicate with one or more entities in system 10 via wired and / or wireless communication. The communication may be protocol based communications.

[0051] The hardware 90 includes processing circuitry 96. The processing circuitry 96 may include a processor 98 and memory 100. In particular, in addition to or instead of a processor, such as a central processing unit, and memory, the processing circuitry 96 may comprise integrated circuitry for processing and / or control, e.g., one or more processors and / or processor cores and / or FPGAs (Field Programmable Gate Array) and / or ASICs (Application Specific Integrated Circuitry) adapted to execute instructions. The processor 98 may be configured to access (e.g., write to and / or read from) memory 100, which may include any kind of volatile and / or nonvolatile memory, e.g., cache and / or buffer memory and / or RAM (Random Access Memory) and / or ROM (Read-Only Memory) and / or optical memory and / or EPROM (Erasable Programmable Read-Only Memory). Hardware 90 may also have one or more circuit elements 102 such as resistors, capacitors, inductors, diodes, transistors, ground connections, source elements, sink elements, sensors, etc. Circuit elements 102 may be arranged in any configuration or connection such as series, parallel, combinations thereof, etc.

[0052] Thus, the AD 18 may further comprise software 110, which is stored in, for example, memory 100, or stored in external memory (e.g., database, etc.) accessible by the AD 18. The software 110 may be executable by the processing circuitry 96.

[0053] The processing circuitry 96 may be configured to control any of the methods and / or processes described herein and / or to cause such methods, and / or processes to be performed, e.g., by AD 18. The processor 98 corresponds to one or more processors 98 for performing AD 18 functions described herein. The AD 18 includes memory 100 that is configured to store data, programmatic software code and / or other information described herein. In some embodiments, the software 110 may include instractions that, when executed by the processor 98 and / or processing circuitry 96, causes the processor 98 and / or processing circuitry 96 to perform the processes described herein with respect to AD 18. For example, the processing circuitry 96 of the AD 18 may include AD management unit 104 that is configured to perform any step and / or task and / or process and / or method and / or feature described in the present disclosure, e.g., determining one or more parameters, steps, and / or processes associated with battery 14. While AD management unit 104 is illustrated as being part of AD 18, AD management unit 104 and associated functions described herein may be implemented in a device separate from AD 18 such as in battery 14 or another device.

[0054] Having described the general process flow of arrangements of the disclosure and having provided examples of hardware and software arrangements for implementing the processes and functions of the disclosure, the sections below provide details and examples of arrangements for a lead assembly and / or connector for a battery system.

[0055] Typical batteries may require an integrated battery management system to pass battery cell parameters to the connector (e.g., for the vehicle to use). Embodiments described herein provide a lead assembly 38 and / or connector 44 arranged to provide battery cell parameters without the use of a battery management system. For example, by connecting to lead assembly 38 and / or connector 44 the individual voltage sense may be directly accessed, e.g.., by connecting to the lead frame pins.

[0056] FIG. 5 shows an example battery 14 after being assembled, where housing 20 is coupled to cover 24, and cover 26 is coupled to cover 24.

[0057] FIG. 6 shows a post assembly 112 including multiple posts 34 and terminals 32. Post assembly 112 may include one or more straps 114 coupled to a corresponding post 34 or terminal 32. The straps 114 are coupled to one or more corresponding cells 22.

[0058] FIG. 7 shows an example cover 24 including one or more openings 1 16 which are arranged to receive posts 34 such that when the cover 24 is coupled to housing 20 at least a portion of post 34 extends away from the cover 24 and is exposed for coupling to a corresponding lead 40. FIG. 8 shows a cross section of cover 24 where post 38 has been inserted through opening 1 16 and is coupled to cover 24 via bushing 118.

[0059] FIG. 9 shows an example lead assembly 38. Lead assembly 38 has leads 40, where each lead has end 122 opposite to end 122. End 122 is couplable to a corresponding post 34 to establish an electrical connection to the cell 22 that post 34 is coupled to. Lead assembly 38 may also include lead frame 42 which may house at least a portion of leads 40 and couple to lead assembly connector 120. Lead assembly connector 120 may include one or more walls 126 that define space 128 where a corresponding end 122 of lead 40 is housed. Lead assembly connector 120 may be arranged to couple to connector 44. Connector 44 may be arranged to couple to vehicle 12 (or vehicle system 16) and / or AD 18. In some embodiments, lead assembly connector 120 may directly couple to vehicle 12 (or vehicle system 16) and / or AD 18. Lead 40 may also have post connector end 124 which may electrically couple to post 34 and bushing 118 and be in electrical communication with its corresponding end 122. That is, an electrical path may be established between post connector end 124 and end 122. Further, lead 40 may include circuit element 46, already described. When circuit element 46 is included, an electrical path may be established between post connector end 124 and end 122, via circuit element 46. Although a single circuit element 46 is shown in FIG. 9 for ease of understanding, the embodiments are not limited as such, and more than one lead 40 or all leads 40 may include one or more circuit elements 46 placed in an electrically serial connection along the corresponding lead 40. Further, although post connector end 124 is shown as a ring, post connector end 124 is not limited as such and may be any other type of post connector end (e.g., include inward or outward spokes, have a different shape / geometry, etc.). In some embodiments, there is no “ring” or other structural feature at the post connector end 124, and the end region, i.e., post connecter end 124, of the bare lead 40 can be affixed to the post, such as by welding.

[0060] FIG. 10 shows another view of lead assembly 38 with similar features to the features shown on FIG. 9, such as circuit element 46. Of note, although FIG. 10 shows a lead frame 42 with five leads 40, the depiction of five leads 40 is only for ease of understanding. It should be understood that implementations are not limited to arrangements with five leads 40. Lead frames 42 can be arranged with fewer or more than five leads 40. Also of note, although FIG. 10 shows a lead assembly connector 120 with five connection points, the depiction of connection points is only for ease of understanding. It should be understood that implementations are not limited to arrangements with five connections points. Lead assembly connector 120 can be arranged with fewer or more than five connection points and with a quantity of connection points generally corresponding to the quantity of leads 40.

[0061] FIG. 11 shows cover 26 which may include connector 44 and connector coupling elements 130 which are arranged to be coupled to the ends 122 of the leads 40. Although connector 44 is shown as being part of cover 26, the embodiments are not limited as such, and connector 44 may be coupled to any other battery component or standalone.

[0062] FIG. 12 shows various battery components being assembled. More specifically, post assembly 112 is coupled to cover 24, where posts 34 are inserted through openings 116. Lead assembly 38 is placed on cover 24 and coupled to posts 34. Cover 26 is coupled to cover 24, which couples connector 44 to lead assembly connector 120, thereby establishing an electrical connection between connector 44 and cells 22.

[0063] FIG. 13 shows an example battery 14. Posts 34 (being coupled to cells 22) are coupled to a corresponding lead 40 of lead assembly 38 (which is assembled on cover 24). In this nonlimiting example, lead assembly connector 120 is arranged to provide a connection to each cell 22 via leads 40.

[0064] FIG. 14 shows an example battery 14 where cover 26 is already coupled to cover 24. Cover 26 includes connector 44 which has been coupled to lead assembly connector 120. Connector coupling elements 130 of connector 44 are in physical contact with leads 40 of lead assembly 38, thereby establishing an electrical connection between the coupling elements 130 and the cells 22, via leads 40, posts 34, etc. Connector 44 may include pins 132 which are in electrical communication with coupling elements 130 and arranged to couple to one or more conductors to establish an electrical connection with VS 16, AD 18, and / or any other component of system 10. In one nonlimiting example, battery 14 (without a battery management system) is comprised / installed in a vehicle 12 and can be coupled to a VS 16 (e.g. an ECU of vehicle 12) or an AD 18 (e.g., an OBD device, or any other kind of device) via connector 44. VS 16 (e.g. the ECU) or AD 18 (e.g., an OBD device) may receive a signal such as cell voltage of via one or more of pins 132. One or more embodiments are beneficial at least because lead assembly 38 and / or connector 44 provide a direct access to cell information (e.g., cell voltage) without the need for a battery management system.

[0065] Although a number of the drawing figures and their corresponding descriptions provide embodiments in which the posts 34 are electrically coupled to monitoring connector 44 via a lead frame assembly 38, implementations are not limited to this arrangement. It is contemplated that posts 34 can be electrically connected to monitoring connector 44 and / or lead assembly connector 120 using individual insulated electrically conductive wires. In other words, in some embodiments, leads 40 are individual insulated wires that are not part of an “assembly” such as lead frame assembly 38 having a lead frame 42 where the leads 40 are over-molded with the lead frame 42 to form a connectorized assembly. Similarly, in some embodiments, the leads 40 that are comprised of individual wires can further comprise one or more electrically connected circuit elements 46 such as via an electrically serial and / or electrically parallel connection.

[0066] The following is a nonlimiting list of example embodiments.

[0067] According to an aspect, a lead assembly 38 associated with a battery 14 comprising one or more battery cells 22 is described. The lead assembly 38 includes one or more leads 40 electrically couplable to the one or more battery cells 22. The one or more leads 40 are arranged to provide, to a device and / or a system external to the battery 14, an electrical parameter associated with the one or more cells 22.

[0068] In some embodiments, the lead assembly 38 further includes: (A) a lead frame 42 comprising at least a portion of the one or more leads 40; and (B) a lead assembly connector 120 coupled to the lead frame 42.

[0069] In some other embodiments, the lead assembly 38 further includes a monitoring connector 44 coupled to the lead assembly connector 120. The monitoring connector 44 is couplable to the device and / or the system. The system is a vehicle system 16, and the device is an accessory device 18.

[0070] According to another aspect, a battery 14 is described. The battery 14 includes a housing 20, a plurality of battery cells 22 within the housing 20, a plurality of posts 34, a first cover 24, and a lead assembly 38. Each post 34 is electrically coupled to one or more battery cells 22. The first cover 24 is coupled to the housing 20, and at least a portion of the plurality of posts 34 extends away from the first cover 24. The lead assembly 38 includes a plurality of leads 40, a lead frame 42, and a lead assembly connector 120. At least a portion of the plurality of leads 40 is within the lead frame 42, and each lead 40 is electrically coupled to a corresponding post 34 and arranged to provide an electrical parameter associated with a corresponding battery cell 22.

[0071] In some embodiments, the battery 14 further includes a monitoring connector 44 electrically and, in some embodiments, physically coupled to the lead assembly connector 120.

[0072] In some other embodiments, the battery 14 includes a second cover 26, and the second cover 26 includes the monitoring connector 44.

[0073] In some embodiments, the monitoring connector 44 includes a plurality of pins 132, where each pin 132 is electrically coupled to a lead 40 to establish an electrical connection to a corresponding battery cell 22.

[0074] According to an aspect, a system 10 is described. The system 10 includes an accessory device 18 and a battery 14. The battery 14 is in communication with the accessory device 18, and the battery 14 includes a housing 20, a plurality of battery cells 22 within the housing 20, a plurality of posts 34, a first cover 24, a lead assembly 38, and a monitoring connector 44. Each post 34 is electrically coupled to one or more battery cells 22. The first cover 24 is coupled to the housing 20, and at least a portion of the plurality of posts 34 extend away from the first cover 24. The lead assembly 38 includes a plurality of leads 40, a lead frame 42, and a lead assembly connector 120. The monitoring connector 44 is coupled to the lead assembly connector 120. At least a portion of the plurality of leads 40 is within the lead frame 42, and each lead 40 is electrically coupled to one post 34 and coupled to the monitoring connector 44 to provide, to the accessory device 18, an electrical parameter associated with a corresponding battery cell 22.

[0075] In some embodiments, the accessory device 18 is an onboard diagnostics (OBD) device.

[0076] In some other embodiments, the battery 14 includes a second cover 26 coupled to the first cover 24. The second cover 26 and the monitoring connector 44 are integrated into a single unitary construction.

[0077] According to another aspect a system 10 is provided. The system 10 includes a battery 14. The battery 14 comprises a housing 20, a plurality of battery cells 22 within the housing 20, a plurality of posts 34, each post 34 electrically coupled to one or more battery cells 22, a first cover 24 coupled to the housing 20, at least a portion of the plurality of posts 34 extending away from the first cover 24, a plurality of leads 40, and a monitoring connector 44 in electrical communication with plurality of leads 40, each lead 40 being electrically coupled to one post 34 and being coupled to the monitoring connector 44 to provide an electrical parameter associated with a corresponding battery cell 22.

[0078] In some embodiments, each of the plurality of leads 40 is an insulated wire.

[0079] In some embodiments, at least one lead 40 comprises a circuit element.

[0080] In one aspect, a battery (14) comprises a housing (20), a plurality of battery cells (22) within the housing (20), a plurality of posts (34) in which each post (34) is electrically coupled to one or more battery cells (22), a first cover (24) coupled to the housing (20) in which at least a portion of the plurality of posts (34) extend away from the first cover (24), a plurality of leads (40), and a monitoring connector (44) in electrical communication with plurality of leads (40). Each lead (40) is electrically coupled to one post (34) and is coupled to the monitoring connector (44) to provide an electrical parameter associated with a corresponding battery cell (22).

[0081] In one embodiment of this aspect, each of the plurality of leads (40) is an insulated wire. In one embodiment of this aspect, the battery 14 further comprises a lead assembly (38). The lead assembly comprises the plurality of leads (40), a lead frame (42), and a lead assembly connector (120), in which at least one lead (40) comprises a circuit element (46). In one embodiment of this aspect, the plurality of leads (40) are over-molded with the lead frame (42). In one embodiment of this aspect, at least one lead (40) comprises a circuit element (46). In one embodiment of this aspect, the at least one circuit element (46) is a resistor. In one embodiment of this aspect, the at least one circuit element (46) is placed in an electrically serial arrangement with the corresponding lead (40). In one embodiment of this aspect, the battery (14) further includes a second cover (26) coupled to the first cover (24), and the second cover (26) and the monitoring connector (44) are integrated into a single unitary construction. In one embodiment of this aspect, the battery (14) is an absorbent glass mat, AGM, battery.

[0082] In accordance with another aspect, a battery (14), comprises a housing (20), a plurality of battery cells (22) within the housing (20) and a lead assembly (38). The lead assembly comprises one or more leads (40) electrically couplable to the one or more battery cells (22), at least one lead (40) comprising a circuit element (46), the one or more leads (40) being arranged to provide, to a device and / or a system external to the battery (14), an electrical parameter associated with the one or more cells (22). The battery 14 also comprises a monitoring connector (44) in electrical communication with plurality of leads (40), each lead (40) being electrically coupled to one battery cell (22) and being coupled to the monitoring connector (44) to provide the electrical parameter associated with a corresponding battery cell (22) to the device and / or the system external to the battery (14).

[0083] In one embodiment of this aspect, the lead assembly (38) further includes a lead frame (42) comprising at least a portion of the one or more leads (40) and a lead assembly connector (120) coupled to the lead frame (42). In one embodiment of this aspect, at least one lead (40) comprises a circuit element (46). In one embodiment of this aspect, the at least one circuit element (46) is a resistor. In one embodiment of this aspect, the at least one circuit element (46) is placed in an electrically serial arrangement with the corresponding lead. In one embodiment of this aspect, the monitoring connector (44) is coupled to the lead assembly connector (120). In one embodiment of this aspect, the battery (14) further includes a first cover (24) coupled to the housing (20) and disposed over the plurality of battery cells (22) and a second cover (26) disposed over the first cover (24), the second cover (26) including the monitoring connector (44), wherein the lead assembly (38) is disposed between the first cover (24) and the second cover (26). In one embodiment of this aspect, the battery (14) is an absorbent glass mat, AGM, battery.

[0084] In another aspect, a lead assembly (38) associated with a battery (14) is provided in which the battery (14) comprises one or more battery cells (22). The lead assembly (38) comprises one or more leads (40) electrically couplable to the one or more battery cells (22), at least one lead comprising a circuit element (46), the one or more leads (40) being arranged to provide, to a device and / or a system external to the battery (14), an electrical parameter associated with the one or more cells (22).

[0085] In one embodiment of this aspect, the lead assembly (38) further includes a lead frame (42) comprising at least a portion of the one or more leads (40) and a lead assembly connector (120) coupled to the lead frame (42). In one embodiment of this aspect, the lead assembly (38) further includes a monitoring connector (44) coupled to the lead assembly connector (120), the monitoring connector being couplable to the device and / or the system, the system being a vehicle system (16), the device being an accessory device (18).

[0086] It will be appreciated by persons skilled in the art that the embodiments described herein 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

Claims:

1. A battery (14), comprising: a housing (20); a plurality of battery cells (22) within the housing (20); a plurality of posts (34), each post (34) electrically coupled to one or more battery cells (22); a first cover (24) coupled to the housing (20), at least a portion of the plurality of posts (34) extending away from the first cover (24); a plurality of leads (40); and a monitoring connector (44) in electrical communication with plurality of leads (40), each lead (40) being electrically coupled to one post (34) and being coupled to the monitoring connector (44) to provide an electrical parameter associated with a corresponding battery cell (22).

2. The battery (14) of Claim 1, wherein each of the plurality of leads (40) is an insulated wire.

3. The battery (14) of Claim 1, further comprising a lead assembly (38), the lead assembly (38) comprising the plurality of leads (40), a lead frame (42), and a lead assembly connector (120), at least one lead (40) comprising a circuit element (46).

4. The battery (14) of Claim 3, wherein the plurality of leads (40) are overmolded with the lead frame (42).

5. The battery (14) of any one of Claims 1-4, wherein at least one lead (40) comprises a circuit element (46).

6. The battery (14) of Claim 5, wherein the at least one circuit element (46) is a resistor.

7. The battery (14) of any one of Claims 3-6, wherein the at least one circuit element (46) is placed in an electrically serial arrangement with the corresponding lead (40).

8. The battery (14) of any one of Claims 1-7, wherein the battery (14) further includes a second cover (26) coupled to the first cover (24), and the second cover (26) and the monitoring connector (44) are integrated into a single unitary construction.

9. The battery (14) of any one of Claims 1-8, wherein the battery (14) is an absorbent glass mat, AGM, battery.

10. A battery (14), comprising: a housing (20); a plurality of battery cells (22) within the housing (20); a lead assembly (38) comprising: one or more leads (40) electrically couplable to the one or more battery cells (22), at least one lead (40) comprising a circuit element (46), the one or more leads (40) being arranged to provide, to a device and / or a system external to the battery (14), an electrical parameter associated with the one or more cells (22); and a monitoring connector (44) in electrical communication with plurality of leads (40), each lead (40) being electrically coupled to one battery cell (22) and being coupled to the monitoring connector (44) to provide the electrical parameter associated with a corresponding battery cell (22) to the device and / or the system external to the battery (14).

11. The battery (14) of Claim 10, wherein the lead assembly (38) further includes: a lead frame (42) comprising at least a portion of the one or more leads (40); and a lead assembly connector (120) coupled to the lead frame (42).

12. The battery (14) of any one of Claims 10 and 11, wherein at least one lead (40) comprises a circuit element (46).

13. The battery (14) of Claim 12, wherein the at least one circuit element (46) is a resistor.

14. The battery (14) of any one of Claims 12 and 13, wherein the at least one circuit element (46) is placed in an electrically serial arrangement with the corresponding lead.

15. The battery (14) of any one of Claims 10-14, wherein the monitoring connector (44) is coupled to the lead assembly connector (120).

16. The battery (14) of any one of Claims 10-15, wherein the battery (14) further includes: a first cover (24) coupled to the housing (20) and disposed over the plurality of battery cells (22); and a second cover (26) disposed over the first cover (24), the second cover (26) including the monitoring connector (44), wherein the lead assembly (38) is disposed between the first cover (24) and the second cover (26).

17. The battery (14) of any one of Claims 10-16, wherein the battery (14) is an absorbent glass mat, AGM, battery.

18. A lead assembly (38) associated with a battery (14), the battery (14) comprising one or more battery cells (22), the lead assembly (38) comprising: one or more leads (40) electrically couplable to the one or more battery cells (22), at least one lead comprising a circuit element (46), the one or more leads (40) being arranged to provide, to a device and / or a system external to the battery (14), an electrical parameter associated with the one or more cells (22).

19. The lead assembly (38) of Claim 18, wherein the lead assembly (38) further includes: a lead frame (42) comprising at least a portion of the one or more leads (40); and a lead assembly connector (120) coupled to the lead frame (42).

20. The lead assembly (38) of Claim 19, wherein the lead assembly (38) further includes a monitoring connector (44) coupled to the lead assembly connector (120), the monitoring connector being couplable to the device and / or the system, the system being a vehicle system (16), the device being an accessory device (18).

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