Surface mount element on lead frame

Abstract

A lead frame of a battery comprising one or more battery cells is described. The lead frame includes one or more circuit elements and one or more leads. Each lead includes a first end, a second end, and a circuit element receiver. The second end is opposite to the first end. The second end is electrically couplable to a corresponding battery cell. The circuit element receiver is between the first end and the second end. The circuit element receiver is electrically coupled to at least one circuit element of the one or more circuit elements. At least the circuit element receiver and the at least one circuit element establish an electrical path between the first end and the second end.

Description

[0001] SURFACE MOUNT EEEMENT ON LEAD FRAME

[0002] TECHNICAL FIELD

[0003] This disclosure relates to electronic circuits, and in particular to a method and system for a circuit that creates a signal path for a battery such as a circuit element that is mountable on a surface of a lead frame of the battery.

[0004] BACKGROUND

[0005] Motor-powered and / or electrically powered vehicles tend to rely on using one or more battery or battery systems for providing 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, batteries may include circuit elements that are mounted during assembly of the battery. However, the circuit elements may be separate from some battery components and electrically connected to the battery components, thereby requiring a conductive signal path occupying a predetermined volume within the battery. Furthermore, including circuit elements in the conductive signal path during battery assembly adds manufacturing complexity, manufacturing time and expense.

[0006] SUMMARY

[0007] Some embodiments advantageously provide a method and system for a lead frame having an integrated circuit element, e.g., a chip resistor or a thermistor, for use within a battery. Some embodiments provide a circuit element (e.g., resistor) that does not require separate wiring and occupies a volume that is lower than the volume occupied by typical circuit elements. In some embodiments, the circuit element is as surface mount resistor, e.g., a resistor mounted on the surface or other areas of a lead frame of a battery.

[0008] In accordance with one aspect, a lead frame of a battery comprising one or more battery cells is provided. The lead frame comprises one or more circuit elements and one or more leads. Each lead comprises a first end, a second end opposite the first end and being electrically couplable to a corresponding battery cell, and a circuit element receiver between the first end and the second end, the circuit element receiver being electrically coupled to at least one circuit element of the one or more circuit elements, at least the circuit element receiver and the at least one circuit element establishing an electrical path between the first end and the second end.

[0009] In accordance with an embodiment of this aspect, each lead is electrically decoupled from other leads of the one or more leads. In accordance with an embodiment of this aspect, each lead further includes a first lead portion electrically coupled to the first end and a second lead portion electrically coupled to the second end. Each circuit element includes a first element portion electrically coupled to the first lead portion, a second element portion electrically coupled to the second lead portion, and a third element portion electrically coupled to the first element portion and the second element portion.

[0010] In accordance with an embodiment of this aspect, the circuit element receiver includes a first receiver portion and a third receiver portion, the first element portion being electrically coupled to the first receiver portion, and the second element portion being electrically coupled to the third receiver portion. In accordance with an embodiment of this aspect, the circuit element receiver further includes a second receiver portion and a fourth receiver portion, both of the second receiver portion and the fourth receiver portion coupled to the first receiver portion and the third receiver portion, and both of the second receiver portion and the fourth receiver portion being insulators. In accordance with an embodiment of this aspect, the first receiver portion and the third receiver portion are discontiguous. In accordance with an embodiment of this aspect, each circuit element is a thermistor mounted on a surface of the corresponding lead.

[0011] In accordance with another aspect, a battery is provided. The battery includes one or more battery cells, a connector, and a lead frame coupled to the connector and in electrical communication with the one or more battery cells. The lead frame comprises one or more circuit elements and one or more leads. Each lead comprises a first end, a second end opposite the first end, the first end being electrically couplable to the connector, the second end being electrically couplable to a corresponding battery cell, and a circuit element receiver between the first end and the second end, the circuit element receiver being electrically coupled to at least one circuit element of the one or more circuit elements, at least the circuit element receiver and the at least one circuit element establishing an electrical path between the first end and the second end.

[0012] In accordance with an embodiment of this aspect, the battery further comprises one or more posts, each post being electrically coupled to at least one battery cell, the lead frame, the second end of the one or more leads being electrically couplable to a corresponding battery cell via a corresponding post of the one or more posts. In accordance with an embodiment of this aspect, each lead is electrically decoupled from other leads of the one or more leads. In accordance with an embodiment of this aspect, each lead further includes a first lead portion electrically coupled to the first end and a second lead portion electrically coupled to the second end. Each circuit element includes a first element portion electrically coupled to the first lead portion, a second element portion electrically coupled to the second lead portion, and a third element portion electrically coupled to the first element portion and the second element portion.

[0013] In accordance with an embodiment of this aspect, the circuit element receiver includes a first receiver portion and a third receiver portion, the first element portion being electrically coupled to the first receiver portion, and the second element portion being electrically coupled to the third receiver portion. In accordance with an embodiment of this aspect, the circuit element receiver further includes a second receiver portion and a fourth receiver portion, both of the second receiver portion and the fourth receiver portion coupled to the first receiver portion and the third receiver portion, and both of the second receiver portion and the fourth receiver portion being insulators.

[0014] In accordance with an embodiment of this aspect, the first receiver portion and the third receiver portion are discontiguous. In accordance with an embodiment of this aspect, each circuit element is a thermistor mounted on a surface of the corresponding lead.

[0015] In accordance with another aspect, a method for assembling a lead frame of a battery is provided. The lead frame comprises one or more circuit elements and one or more leads in which each lead comprises a circuit element receiver. The method comprises forming the lead frame using a die cutting process, the formed lead frame having one or more inter-lead couplers, each inter-lead coupler coupling at least two leads, electrically coupling the circuit element to the circuit element receiver, removing each inter-lead coupler from the lead frame, the removal including decoupling the at least two leads, and over-molding a portion of the one or more leads and, optionally, overmolding each circuit element.

[0016] In accordance with an embodiment of this aspect, the method further includes removing at least a portion of the circuit element receiver from the lead frame. In accordance with an embodiment of this aspect, each circuit element is a thermistor mounted on a surface of the corresponding lead. In accordance with an embodiment of this aspect, the overmolding includes one or more of: over-molding each circuit element and the portion of the one or more leads in a single step; over-molding the portion of each circuit element, and after the over-molding of each circuit element is completed, over-molding each one of the one or more leads; and over-molding the portion of the one or more leads, and after the over- molding of the portion of the one or more leads is completed, over-molding each circuit element.

[0017] In accordance with an embodiment of this aspect, each circuit element is a thermistor.

[0018] BRIEF DESCRIPTION OF THE DRAWINGS

[0019] 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:

[0020] FIG. 1 is a diagram of an example system according to principles disclosed herein;

[0021] FIG. 2 shows an example battery constructed in accordance with the principles of the present disclosure;

[0022] FIG. 3 shows another example battery constructed in accordance with the principles of the present disclosure;

[0023] FIG. 4 is a block diagram of a battery management system according to some embodiments of the present disclosure;

[0024] FIG. 5 shows an example lead coupled to a battery cell according to some embodiments of the present disclosure;

[0025] FIG. 6 shows an example lead frame according to some embodiments of the present disclosure;

[0026] FIG. 7 shows an example lead frame including circuit elements according to some embodiments of the present disclosure;

[0027] FIG. 8 shows a perspective view of the example lead frame including a circuit element according to some embodiments of the present disclosure;

[0028] FIG. 9 shows a cross section of a lead and circuit element according to some embodiments of the present disclosure;

[0029] FIG. 10 shows an example punched-out lead frame according to some embodiments of the present disclosure; and

[0030] FIG. 11 is a flowchart of an example process for assembling a lead frame in accordance with the principles of the present invention.

[0031] DETAILED DESCRIPTION

[0032] Before describing in detail exemplary embodiments, it is noted that the embodiments reside primarily in combinations of apparatus components and processing steps related to a surface mount circuit element on lead frame of a battery. 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.

[0033] 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.

[0034] 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.

[0035] 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. 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. Although an LFP battery is described herein, the teachings described herein are equally applicable to other battery types such as other lithium ion batteries, lead acid batteries, etc. 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] In some embodiments, battery 14 may include battery management system (BMS) 16 that is configured to perform one or more battery management functions described herein. In some embodiments, the BMS 16 may measure / determine certain battery parameters, e.g., temperature, resistance (e.g., battery resistance), voltage (e.g., cell voltage), current, state of charge (SoC), a time parameter, a frequency parameter, etc., and transmit / receive data (and / or signals such as control signals) to / from another system / device. BMS 16 may also determine failures of battery components and perform actions such notify other components of system 10 (e.g., a server or computing device, not shown). A BMS 16 is configured to include a BMS management unit 18 (or battery management unit) that may be configured to perform one or more functions as described herein. However, BMS 16 and battery management unit 18 are optional. That is, the embodiments are not limited to requiring a BMS 16 and / or BMS management unit 18, and the battery 14 may provide any of the functions and / or features described herein, without a BMS 16 and / or BMS management unit 18. For example, without a BMS 16 and / or BMS management unit 18, battery 14 can be arranged so that measurement signals from each cell 26 are provided at an output of battery 14 for processing external to battery 14.

[0038] 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 and battery 14 (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.

[0039] FIG. 2 shows an example battery 14 constructed in accordance with the principles of the present disclosure. Battery 14 includes a housing 24 into which one or more battery components may be positioned. 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.

[0040] Battery 14 includes a monitoring connector 27 that allows for a removable external connection any other component of system 10 (e.g., to the vehicle’s data bus, to some other communication device, etc.) and / or internal connection, e.g., any components of battery 14. Connector 27 may be comprised in any other component of system 10. In some embodiments, connector 27 may be configured to removably couple and / or connect (electrically, physically) to another connector. Battery 14 also includes terminals, such as a positive terminal 28a and a negative terminal 28b (collectively referred to as terminals 28) to provide the contact points for electrical connection of the battery 14 (e.g., to power devices and / or the vehicle 12). Battery 14 may also include cover 34 which may be arranged to couple to cover 30. Cover 30 may include one or more cover walls that may (e.g., along with cover 34) define cover space 32. Cover 30 may be arranged to receive battery components in cover space 32 during assembly.

[0041] In addition, terminals 28 may be arranged to protrude through housing 24, such as protruding through cover 30 and / or cover 34. Terminals 28 may be electrically connected to the bus bars inside housing 24 and / or directly connected to cells 26 (bus bars and direct connection not shown).

[0042] 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 75Ah. 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 75Ah capacity. Power capacity scaling can be accomplished, for example, by using higher or lower power capacity cells 26 in the housing 24, and / or by using fewer or more cells 26 in the housing 24. 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 26 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 26 characteristics, the use of heat sinks and / or thermal energy discharge plates, etc., within or external to the housing 24. Further, BMS 16 may be connected to at least one of the cells such as to determine / measure at least one parameter of battery 14 and / or cells 26.

[0043] Battery 14 may also include a plurality of electrically conductive leads 36, where each lead 36 is electrically connected to a cell 26 and / or connector 27. For example, connector 27 may provide connection to leads 36 such that other systems, e.g., systems external to battery 14 such as vehicle systems may determine one or more parameters of each cell 26 via leads 36 such as SoC, voltage, cell temperature, cell pressure, etc. Leads 36 may be integrated or formed into a lead frame 40 (or plurality of leads) to facilitate electrical connectivity between the electrical connection points for each cell 26 and the connector 27. Lead frame 40 can be formed as an unit prior to battery assembly such that the lead frame 40 can be installed as an integrated module during the actual battery assembly process.

[0044] Battery 14 may also have battery internal space 38, which may be defined by housing 24, cover 30, cover 34, etc. In some embodiments, battery internal space 38 may be determined to house a predetermined quantity of battery components such as cells 26, leads 36, etc. Battery internal space 38 may be also determined to minimize unused space and to maximize the quantity or type of components it contains. Battery internal space 38 may also be arranged to contain additional battery components and to meet or exceed a predetermined internal used volume / space threshold. In some embodiments, the plurality of leads 36 is part of or comprised in a lead frame 40. The leads 36 and / or lead frame 40 may include one or more circuit elements 42 (collectively referred to as circuit element 42) such as resistors, capacitors, inductors, diodes, transistors, ground connections, source elements, sink elements, thermistors, sensors, flexible printed circuit (FPC), etc. Circuit element 42 may be arranged in any configuration or connection such as series, parallel, combinations thereof, etc. In some embodiments, the circuit element 42 may be a resistor mounted on one or more leads 36. The circuit element may be couplable (e.g., electrically couplable) to systems or system components (e.g., external to battery 14, vehicle control units, etc.) such as via leads 36 and connector 27.

[0045] FIG. 3 shows another example battery 14 constructed in accordance with the principles of the present disclosure. Battery 14 includes a housing 24 into which one or more battery components may be positioned. 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.

[0046] In one embodiment, a battery management system (BMS) 16 may be included. It is noted, however, that a BMS 16 is not required in some embodiments and that, as discussed below in detail, battery 14 can be made without a BMS 16 while still including the lead frame and circuit elements. For embodiments that include BMS 16, BMS 16 may include or be coupled to a monitoring connector 27 that allows for a removable external connection any other component of system 10 (e.g., to the vehicle’s data bus, to some other communication device, etc.) and / or internal connection, e.g., any components of battery 14 and / or BMS 16. Connector 27 may be comprised in BMS 16 and / or any other component of system 10. In some embodiments, connector 27 may be configured to removably couple and / or connect (electrically, physically) to another connector. Battery 14 also includes terminals, such as a positive terminal 28a and a negative terminal 28b (collectively referred to as terminals 28) to provide the contact points for electrical connection of the battery 14 (e.g., to power devices and / or the vehicle 12 and / or BMS 16). Battery 14 may also include cover 34 which may be arranged to couple to cover 30. Cover 30 may include one or more cover walls that may (e.g., along with cover 34) define cover space 32. Cover 30 may be arranged to receive BMS 16 in cover space 32 during assembly, e.g., such that BMS 16 are coupled to cover 30 and / or any other components of battery 14.

[0047] In addition, terminals 28 may be arranged to protrude through housing 24, such as protruding through cover 30 and / or cover 34. Terminals 28 may be electrically connected to the bus bars inside housing 24 and / or directly connected to cells 26 (bus bars and direct connection not shown). 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 75Ah. 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 75Ah capacity. Power capacity scaling can be accomplished, for example, by using higher or lower power capacity cells 26 in the housing 24, and / or by using fewer or more cells 26 in the housing 24. 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 26 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 26 characteristics, the use of heat sinks and / or thermal energy discharge plates, etc., within or external to the housing 24. Further, BMS 16 may be connected to at least one of the cells such as to determine / measure at least one parameter of battery 14 and / or cells 26.

[0048] Battery 14 may also include a plurality of electrically conductive leads 36, where each lead 36 is electrically connected to a cell 26 and / or BMS 16. BMS 16 may be configured to determine one or more parameters of each cell 26 via leads 36 such as SoC, voltage, cell temperature, cell pressure, etc. Leads 36 may be integrated or formed into a lead frame to facilitate electrical connectivity between the electrical connection points for each cell 26 and the BMS 16. In some embodiments, the lead frame includes an integrated electronic circuit component such as a surface mounted chip resistor.

[0049] Battery 14 may also have battery internal space 38, which may be defined by housing 24, cover 30, cover 34, etc. In some embodiments, battery internal space 38 may be determined to house a predetermined quantity of battery components such as cells 26, BMS 16, leads 36, etc. Battery internal space 38 may be also determined to minimize unused space and to maximize the quantity or type of components it contains. Battery internal space 38 may also be arranged to contain additional battery components and to meet or exceed a predetermined internal used volume / space threshold. In some embodiments, the plurality of leads 36 is part of or comprised in a lead frame 40. The leads 36 and / or lead frame 40 may include one or more circuit elements 42 (only one shown in this figure for ease of understanding) such as resistors, capacitors, inductors, diodes, transistors, thermistors, ground connections, source elements, sink elements, sensors, flexible printed circuit (FPC), etc. Circuit element 42 may be arranged in any configuration or connection such as series, parallel, combinations thereof, etc. In some embodiments, the circuit element 42 may be a resistor mounted on one or more leads 36. The circuit element may be couplable (e.g., electrically couplable) to BMS 16 such as via leads 36. In some embodiments, the circuit element 42 is a thermistor. In some embodiments, the thermistor can be connected in an electrical series configuration with the lead frame (see FIG. 10) for various measurements and circuit operational considerations. In other embodiments, the thermistor can be affixed to the lead frame but not electrically coupled to a lead 36, and the electrical connections on the thermistor used to determine a temperature of the lead frame lead 36.

[0050] Example implementations, in accordance with an embodiment, of BMS 16 discussed in the preceding paragraphs will now be described with reference to FIG. 4. BMS 16 may have hardware 44 that may include a communication interface 46 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 44 includes processing circuitry 48. The processing circuitry 48 may include a processor 50 and memory 52. In particular, in addition to or instead of a processor, such as a central processing unit, and memory, the processing circuitry 48 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 50 may be configured to access (e.g., write to and / or read from) memory 52, 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).

[0052] Thus, the BMS 16 may further comprise software 54, which is stored in, for example, memory 52, or stored in external memory (e.g., database, etc.) accessible by the BMS 16. The software 54may be executable by the processing circuitry 48.

[0053] The processing circuitry 48 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 BMS 16. The processor 50 corresponds to one or more processors 50 for performing BMS 16 functions described herein. The BMS 16 includes memory 52 that is configured to store data, programmatic software code and / or other information described herein. In some embodiments, the software 54 may include instructions that, when executed by the processor 50 and / or processing circuitry 48, causes the processor 50 and / or processing circuitry 48 to perform the processes described herein with respect to BMS 16. For example, the processing circuitry 48 of the BMS 16 may include BMS management unit 18 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 such as enabling and disabling battery operation and / or selecting a battery operating mode. While BMS management unit 18 is illustrated as being part of BMS 16, BMS management unit 18 and associated functions described herein may be implemented in a device separate from BMS 16 such as in battery 14 or another device. Although, in this embodiment BMS 16 is shown as including circuit element 42, the embodiments are not limited as such, and circuit element 42 may be comprised in any other battery component, without being comprised in the BMS 16, or in proximity to the battery 14, etc.

[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 surface mount circuit element 42 on lead frame 40 of a battery 14. In some embodiments, leads 36 and / or lead frame 40 may be coupled to battery cells 26 and to connector 27 (i.e., without a BMS 16). That is, leads 36 and / or lead frame 40 may provide a direct connection to battery cells 26, without the use of BMS 16, such as where the battery 14 includes connector 27 that is coupled to a vehicle system, and the vehicle system may determine battery cells parameters via the connector 27 and / or leads 36 and / or lead frame 40.

[0055] FIG. 5 shows an example of a lead 36 coupled to a cell 26 (or portion thereof). The lead 36 has a first end 56 and a second end 58. The first end 56 is couplable to connector 27 (and / or BMS 16, in some embodiments), and the second end 58 is coupled to a post 60 and / or bushing 62 to form an electrically conductive path from the first end to a corresponding cell 26 via the post 60 and / or bushing 62. The post 60 and / or bushing 62 are couplable to (but electrically isolated from) cover 30 and are coupled to a portion of cell 26. In some embodiments, there are no posts 60 or bushings 62, and the second end 58 of lead 36 is electrically coupled to a corresponding cell 26 in some other fashion, e.g., directly. Thus, an electrical path is created between the first end (e.g., coupled to connector 27) and cell 26, via lead 36. The lead 36 of the present disclosure is not limited to features of the embodiment shown in FIG. 5.

[0056] The assembly and composition of lead frame 40 is described with reference to FIGS. 6-10. FIG. 6 shows an example lead frame 40 which includes leads 36a, 36b (collectively referred to as leads 36). The lead 36a coupled to post 60 and bushing 62 is also shown. Specifically, bushing 62 is shown with a solid line / circle and a broken line / circle (to illustrate the bushing features that are below second end 58a and not visible in this particular view). Although not shown for ease of understanding, any of the remaining leads 36 may also be coupled to a corresponding post 60 and / or bushing 62 in a similar fashion. The lead frame 40 may be formed using a die cutting process. Lead 36a may have a first end 56a and the second end 58a (already described) that is opposite to the first end 56a. Similarly, lead 36b may have a first end 56b and a second end 58b that is opposite to the first end 56b. Each one of the first ends 56 may be electrically coupled to a connector 27 (or BMS 16, in some embodiments) or other external component, and each one of the second ends 58 may be electrically coupled to cell 26 (e.g., via post and / or bushing), thereby establishing an electrical path between first ends 56 (and components to which the first ends 56 are coupled to) and cells 26, such that the external component (e.g., vehicle system) may measure and determine cell parameters such as voltage.

[0057] Lead 36a may be physically and / or electrically coupled to lead 36b via at least one inter-lead coupler 63. Although only one inter-lead coupler 63 is labeled in FIG. 6, it is readily that leads 36 are interconnected by numerous inter-lead couplers 63 at this stage of fabrication. In some embodiments, inter-lead coupler 63 is arranged to maintain a mechanical coupling between leads 36 such that the leads 36 are separated by a predetermined distance and all the leads 36 are interconnected. Further, lead 36a (or any other lead 36) includes a circuit element receiver 64 which is part of or integrated with lead 36a. In this nonlimiting example, circuit element receiver 64 is in an electrical path between the second end 58a and the first end 56a of lead 36a. Circuit element receiver 64 is arranged to receive and hold one or more circuit elements 42 (e.g., a resistor), such that the circuit element 42 is coupled to lead 36a. In some embodiments, when the circuit element 42 is coupled to lead 36a the electrical path is established. In some other embodiments, when the circuit element 42 is coupled to lead 36a, an additional branch of the electrical path is established, e.g., the electrical path may include a first branch and a second branch, where the second branch includes the circuit element 42.

[0058] Further, circuit element receiver 64 includes various portions. More specifically, circuit element receiver 64 may include a first receiver portion 66, a second receiver portion 68, a third receiver portion 70, and a fourth receiver portion 72. The first receiver portion 66 is contiguous to the second receiver portion 68, the fourth receiver portion 72, and a first lead portion 74 of lead 36a. The second receiver portion 68 is contiguous to the third receiver portion 70, which is also contiguous to a second lead portion 76 of lead 36a, and to the fourth receiver portion 72. The first receiver portion 66, second receiver portion 68, third receiver portion 70, and fourth receiver portion 72 define an opening 78. Further, the first receiver portion may include a lip 80, and the third receiver portion may include another lip 82. Thus, circuit element receiver 64 may receiver and / or hold and / or couple to circuit element 42 via lips 80, 82, first receiver portion 66, second receiver portion 68, etc., where at least a portion of circuit element 42 may be in or in proximity to opening 78.

[0059] In one or more embodiments, any of the receiver portions may be removed or punched out. In some other embodiments, the receiver portions are not removed or punched out. In some embodiments, when circuit element 42 is coupled to circuit element receiver 64, the first branch of the electrical path may include any of the portions of the circuit element receiver 64, and the second branch may be the circuit element 42 itself. For example, the first branch may comprise the second receiver portion 68 and the fourth receiver portion 72. The electrical current flowing through any of the branches may be based on a parameter of the receiver portions and / or circuit element 42. For example, the second receiver portion 68 and the fourth receiver portion 72 may be made of a material that is not a conductor or is a poor conductor of electricity, i.e., the second receiver portion 68 and the fourth receiver portion 72 may be insulators, such that no electrical current or current that is less than a predetermined threshold flows through the first branch. In another example, when the circuit element 42 is a resistor, the current flowing via the first branch may depend on the resistance of the resistor, where the greater the resistance (i.e., resistance of the second branch), the greater the current of the first branch. Similarly, decreasing the resistance of the resistor, increases the current of the first branch, and decreases the current of the second branch. Thus, the circuit element parameter may be selected to direct more or less current on the branches, which may be beneficial for dissipating heat in certain areas of the lead 36. Further, circuit element 42 may be arranged to provide a predetermined voltage drop from cell 26 to first end 56 (or BMS 16, external component, etc.) and / or to limit the current flow from cell 26 to first end 56. In one or more embodiments, circuit element 42 is arranged to attenuate and / or prevent delivery of excess energy (e.g., above a predetermined threshold) to battery components such as cells 26 and / or external components such as vehicle systems. For example, a circuit element 42 (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 26 when leads 36 come in contact with each other during manufacturing and the leads 36 are already electrically coupled to the cells 26. It is also contemplated that other circuit elements can be used, e.g., capacitors, to achieve other desirable conditioning characteristics in the signal from cell 26 to connector 27 (and / or other system components), e.g., to smooth the signal to reduce noise, transient voltage spikes, etc.

[0060] Although lead frame 40 is shown including five leads 36, with two leads 36a, 36b showing reference designators, the embodiments are not limited as such, and lead frame 40 may include any quantity of leads 36. That is, the embodiment shown is described with respect to leads 36a, 36b for ease of understanding, but the embodiments of the present disclosure are not limited to having two leads 36 (and / or their components), and the leads 36 may or may not have the features corresponding to leads 36a, 36b.

[0061] FIG. 7 shows the example lead frame 40 of FIG. 6 including circuit elements 42. circuit element receiver 64 of lead 36a is shown coupled to (or holding) circuit element 42. The coupling may include soldering the circuit element 42 to lead 36a. As shown, circuit element 42 is in physical and electrical contact with circuit element receiver 64 and / or first receiver portion 66 and / or third receiver portion 70 and / or first lead portion 74 and / or second lead portion 76 and / or lip 80 and / or lip 82. FIG. 8 shows a perspective view of the example lead frame 40 including circuit element 42. Examples of circuit elements 42 include resistors, thermistors, capacitors, etc. Also, although embodiments are shown and described herein as including only a single circuit element 42 in each lead 36 signal path, it is contemplated that more than one circuit element 42 can be included in each lead 36 signal path from a cell 26 to first end 56 where the multiple circuit elements 42 may be of the same type, e.g., all resistors, or of different types, e.g., resistors and capacitors.

[0062] FIG. 9 shows a cross section of a lead 36 (e.g., lead 36e shown in FIG. 7) and circuit element 42. Circuit element 42 may include a first element portion 84, a second element portion 86, and a third element portion 88. Circuit element 42 may include a protective layer, on any of its portions, which is arranged to provide electrical, mechanical, and climatic protection. The first and second portions 84, 86 may be arranged for soldering the circuit element 42 to lead 36, for example, without compromising the characteristics (e.g., resistor characteristics) of circuit element 42, and without compromising the characteristics of lead 36. In a nonlimiting example, circuit element 42 may be placed on lead 36 (e.g., mounted on the surface of lead 36, over circuit element receiver 64. The first element portion 84 may be coupled to (e.g., soldered to) the first receiver portion 66 and / or lip 80, and the second element portion 86 may be coupled to (e.g., soldered to) the third receiver portion 70 and / or lip 82, while the third element portion 88 is exposed to opening 78, e.g., for releasing heat, etc. Thus, an electrical path between first end 56 and cells 26 at least via circuit element 42 is created. In order to provide individual signal paths from each cell 26 to first end 56, the interlead couplers 63 are removed. In order to remove the electrical short circuit around circuit elements 42 that is in place when the circuit element 42 is placed on and soldered to lead 36, the receiver portions of circuit element receiver 64 are removed. FIG. 10 shows an example lead frame 40, where the inter-lead couplers 63 have been removed, such as by cutting or punching out. In this embodiment, the second receiver portion 68 and the fourth receiver portion 72 have been removed or punched out. That is, each lead 36 (and its circuit element 42) are electrically isolated from the other leads 36 (and their circuit elements 42) and the electrical path is provided via the circuit element 42. Once the inter-lead couplers 63 and appropriate receiver portions of circuit element receivers 64 are removed, a portion of the leads 36 and the circuit elements 42 are over-molded (not shown) to provide structure to and electrical insulation for lead frame 40.

[0063] According to an aspect, a lead frame 40 of a battery that includes one or more battery cells 26 is described. The lead frame 40 includes one or more circuit elements 42 and one or more leads 36, where each lead 36 includes a first end 56 and a second end 58 opposite to the first end 56. The second end is electrically couplable to a corresponding battery cell 26. The lead frame 40 also includes a circuit element receiver 64 between the first end 56 and the second end 58. The circuit element receiver 64 is electrically coupled to at least one circuit element 42 of the one or more circuit elements 42. At least the circuit element receiver 64 and the at least one circuit element 42 establish an electrical path between the first end 56 and the second end 58.

[0064] In some embodiments, each lead 36 is electrically decoupled from other leads 36 of the one or more leads 36.

[0065] In some other embodiments, each lead 36 further includes a first lead portion 74 electrically coupled to the first end 56 and a second lead portion 76 electrically coupled to the second end 58. Each circuit element 42 includes a first element portion 84 electrically coupled to the first lead portion 74, a second element portion 86 electrically coupled to the second lead portion 76, and a third element portion 88 electrically coupled to the first element portion 84 and the second element portion 86. In some embodiments, the first element portion 84 and the second element portion 86 are the leads / circuit interconnection points of circuit element 42, while the third element portion 88 is the body of the circuit element, e.g., the resistive portion, the body of the thermistor, etc.

[0066] In some embodiments, the circuit element receiver 64 includes one or more of a first receiver portion 66, a second receiver portion 68, a third receiver portion 70, and a fourth receiver portion 72. The first element portion 84 is electrically coupled to the first lead portion 74 via the first receiver portion 66, and the second element portion 86 is electrically coupled to the second lead portion 76 via the third receiver portion 70.

[0067] In some other embodiments, the first receiver portion 66 and the third receiver portion 70 are discontiguous.

[0068] In some embodiments, each circuit element 42 is a resistor mounted on a surface of the corresponding lead 36.

[0069] In some embodiments, the circuit element receiver 64 includes a first receiver portion 66 and a third receiver portion 70, the first element portion 84 being electrically coupled to the first lead receiver portion 66, and the second element portion 86 being electrically coupled to the third receiver portion 70.

[0070] In some embodiments, the circuit element receiver 64 further includes a second receiver portion 68 and a fourth receiver portion 72 in which both of the second receiver portion 68 and the fourth receiver portion 72 are coupled to the first receiver portion 66 and the third receiver portion 70. Both of the second receiver portion 68 and the fourth receiver portion 72 are insulators.

[0071] In some embodiments, each circuit element 42 is a thermistor mounted on a surface of the corresponding lead 36.

[0072] According to another aspect, a lead frame 40 of a battery that includes one or more battery cells 26 and a BMS 16 is described. The lead frame 40 includes one or more circuit elements 42 and one or more leads 36, where each lead 36 includes a first end 56 and a second end 58 opposite to the first end 56. The first end 56 is electrically couplable to the BMS 16. The second end is electrically couplable to a corresponding battery cell 26. The lead frame 40 also includes a circuit element receiver 64 between the first end 56 and the second end 58. The circuit element receiver 64 is electrically coupled to at least one circuit element 42 of the one or more circuit elements 42. At least the circuit element receiver 64 and the at least one circuit element 42 establish an electrical path between the first end 56 and the second end 58.

[0073] In some embodiments, each lead 36 is electrically decoupled from other leads 36 of the one or more leads 36.

[0074] In some other embodiments, each lead 36 further includes a first lead portion 74 electrically coupled to the first end 56 and a second lead portion 76 electrically coupled to the second end 58. Each circuit element 42 includes a first element portion 84 electrically coupled to the first lead portion 74, a second element portion 86 electrically coupled to the second lead portion 76, and a third element portion 88 electrically coupled to the first element portion 84 and the second element portion 86.

[0075] In some embodiments, the circuit element receiver 64 includes one or more of a first receiver portion 66, a second receiver portion 68, a third receiver portion 70, and a fourth receiver portion 72. The first element portion 84 is electrically coupled to the first lead portion 74 via the first receiver portion 66, and the second element portion 86 is electrically coupled to the second lead portion 76 via the third receiver portion 70.

[0076] In some other embodiments, the first receiver portion 66 and the third receiver portion 70 are discontiguous.

[0077] In some embodiments, each circuit element 42 is a resistor mounted on a surface of the corresponding lead 36.

[0078] According to one aspect, a battery 14 is described. The battery 14 includes one or more battery cells 26 and one or more posts 60, where each post 60 is electrically coupled to at least one battery cell 26. The battery 14 also includes a connector 27 and lead frame 40 coupled to the connector 27 and the one or more posts 60. The lead frame 40 includes one or more circuit elements 42 and one or more leads 36. Each lead 36 includes a first end 56, a second end 58 opposite to the first end 56, and a circuit element receiver 64. The first end 56 is electrically coupled to the connector 27, and the second end 58 is electrically coupled to a corresponding battery cell 26 via a corresponding post 60. The circuit element receiver 64 is positioned between the first end 56 and the second end 58. The circuit element receiver 64 is electrically coupled to at least one circuit element 42. At least the circuit element receiver 64 and the at least one circuit element 42 establish an electrical path between the first end 56 and the second end 58.

[0079] According to another aspect, a battery 14 is described. The battery 14 includes one or more battery cells 26 and one or more posts 60, where each post 60 is electrically coupled to at least one battery cell 26. The battery 14 also includes a BMS 16 configured to determine one or more battery cell parameters and lead frame 40 coupled to the BMS 16 and the one or more posts 60. The lead frame 40 includes one or more circuit elements 42 and one or more leads 36. Each lead 36 includes a first end 56, a second end 58 opposite to the first end 56, and a circuit element receiver 64. The first end 56 is electrically coupled to the BMS 16, and the second end 58 is electrically coupled to a corresponding battery cell 26 via a corresponding post 60. The circuit element receiver 64 is positioned between the first end 56 and the second end 58. The circuit element receiver 64 is electrically coupled to at least one circuit element 42. At least the circuit element receiver 64 and the at least one circuit element 42 establish an electrical path between the first end 56 and the second end 58.

[0080] According to another aspect, a battery 14 is described. Battery 14 comprises or more battery cells 26, a connector 27 and a lead frame 40 coupled to the connector and in electrical communication with the one or more battery cells 26. The lead frame 40 comprises one or more circuit elements 42 and one or more leads 36. Each lead 36 comprises a first end 56, a second end 58 opposite the first end 56, the first end 56 being electrically couplable to the connector 27, the second end 58 being electrically couplable to a corresponding battery cell 26, and a circuit element receiver 64 between the first end 56 and the second end 58, the circuit element receiver 64 being electrically coupled to at least one circuit element 42 of the one or more circuit elements 42, at least the circuit element receiver 64 and the at least one circuit element 42 establishing an electrical path between the first end 56 and the second end 58.

[0081] In some embodiments, the battery 14 further comprises one or more posts 60, each post 60 being electrically coupled to at least one battery cell 26, the lead frame 40, the second end 58 of the one or more leads 36 being electrically couplable to a corresponding battery cell 26 via a corresponding post of the one or more posts.

[0082] In some embodiments, each lead 36 is electrically decoupled from other leads 36 of the one or more leads 36.

[0083] In some embodiments, each lead 36 further includes a first lead portion 74 electrically coupled to the first end 56 and a second lead portion 76 electrically coupled to the second end 58, and each circuit element 42 includes a first element portion 84 electrically coupled to the first lead portion 74, a second element portion 86 electrically coupled to the second lead portion 76, and a third element portion 88 electrically coupled to the first element portion 84 and the second element portion 86.

[0084] In some embodiments, the circuit element receiver 64 includes a first receiver portion 66 and a third receiver portion 70, the first element portion 84 being electrically coupled to the first receiver portion 66, and the second element portion 86 being electrically coupled to the third receiver portion 70.

[0085] In some embodiments, the circuit element receiver 64 further includes a second receiver portion 68 and a fourth receiver portion 72, both of the second receiver portion 68 and the fourth receiver portion 72 coupled to the first receiver portion 66 and the third receiver portion 70, and both of the second receiver portion 68 and the fourth receiver portion 72 being insulators. In some embodiments, the first receiver portion 66 and the third receiver portion 70 are discontiguous.

[0086] In some embodiments, each circuit element is a thermistor mounted on a surface of the corresponding lead.

[0087] A example method for assembling a lead frame 40 of a battery 14 is described with reference to FIG. 1 1. The lead frame 40 includes one or more circuit elements 42 and one or more leads 36. Each lead 36 includes a circuit element receiver 64. The method includes forming (Block S 100) the lead frame 40, for example, using a die cutting process. The formed lead frame 42 has one or more inter-lead couplers 63. Each inter-lead coupler 63 couples at least two leads 36. The method also includes electrically coupling the circuit element 42 to the circuit element receiver 64 (Block S 102), removing each inter-lead coupler 63 from of the lead frame 40 (Block SI 04), where the removal includes decoupling the at least two leads 36, over-molding a portion of the one or more leads 36 (Block S 106) and, optionally over-molding each circuit element 42.

[0088] In some embodiments, the method further includes removing at least a portion 68, 72 of the circuit element receiver 64 from the lead frame 40.

[0089] In some other embodiments, each circuit element 42 is a resistor mounted on a surface of the corresponding lead 36.

[0090] In some embodiments, the circuit elements 42 are affixed to the corresponding circuit element receiver 64 and / or lead 36 and then the over-molding operation is performed. However, assembly is not limited only to this procedure. It is contemplated that a portion of the lead frame 40 can be over-molded, with unmolded spaces left to insert and electrically conductively affix the circuit elements 42 to their corresponding element receiver 64 and / or lead 36. Once the circuit elements 42 are electrically conductively affixed to their corresponding element receiver 64 and / or lead 36, the openings in the over-molded area can be left open, over-molded in a second over-molding operation to encapsulate the circuit elements 42, filled with a potting material to encapsulate the circuit elements 42 or sealed in some other fashion, e.g., using an adhesive product such as tape / label to cover the openings left the over-molded areas.

[0091] In some embodiments, the method further includes physically mounting each circuit element 42 on a corresponding lead 36. In some other embodiments, the mounting includes electrically conductively affixing each circuit element 42 to the corresponding lead 36. In some embodiments, the affixing includes using a solder paste to affix each circuit element 42 to the corresponding lead 36.

[0092] In some other embodiments, the method further includes enclosing the circuit element 42, the enclosing including adding a layer of material on the circuit element 42.

[0093] In some embodiments, the over-molding includes one or more of: (A) over-molding each circuit element 42 and the portion of the one or more leads 36 in a single step: over-molding the portion of each circuit element 42, and after the over-molding of each circuit element 42 is completed, over-molding the portion of each one of the one or more leads 36; and over-molding the portion of the one or more leads 36, and after the over-molding of the portion of the one or more leads 36 is completed, over-molding each circuit element 42.

[0094] However, as noted above, the order of over-molding is not limited as such and may include over-molding a lead 36 and then a circuit element 42, or vice versa, and then overmolding another lead 36 and / or circuit element, or in any other order.

[0095] In some other embodiments, each circuit element 42 is a thermistor mounted on a surface of the corresponding lead 36.

[0096] It will be appreciated by persons skilled in the art that the present embodiments are not limited to what has been particularly shown and described herein above. In addition, unless mention was made above to the contrary, it should be noted that all of the accompanying drawings are not to scale. A variety of modifications and variations are possible in light of the above teachings without departing from the scope of the following claims.

Claims

Claims:1 . A lead frame (40) of a battery (14) comprising one or more battery cells (26), the lead frame (40) comprising: one or more circuit elements (42); and one or more leads (36), each lead (36) comprising: a first end (56); a second end (58) opposite the first end (56) and being electrically couplable to a corresponding battery cell (26); and a circuit element receiver (64) between the first end (56) and the second end (58), the circuit element receiver (64) being electrically coupled to at least one circuit element (42) of the one or more circuit elements (42), at least the circuit element receiver (64) and the at least one circuit element (42) establishing an electrical path between the first end (56) and the second end (58).

2. The lead frame (40) of Claim 1, wherein each lead (36) is electrically decoupled from other leads (36) of the one or more leads (36).

3. The lead frame (40) of any one of Claims 1 and 2, wherein: each lead (36) further includes: a first lead portion (74) electrically coupled to the first end (56); and a second lead portion (76) electrically coupled to the second end (58); and each circuit element (42) includes: a first element portion (84) electrically coupled to the first lead portion (74); a second element portion (86) electrically coupled to the second lead portion (76); and a third element portion (88) electrically coupled to the first element portion (84) and the second element portion (86).

4. The lead frame (40) of Claim 3, wherein the circuit element receiver (64) includes a first receiver portion (66) and a third receiver portion (70), the first element portion (84) being electrically coupled to the first lead receiver portion (66), and the second element portion (86) being electrically coupled to the third receiver portion (70).

5. The lead frame (40) of Claim 4, wherein the circuit element receiver (64) further includes a second receiver portion (68) and a fourth receiver portion (72), both of the second receiver portion (68) and the fourth receiver portion (72) coupled to the first receiver portion (66) and the third receiver portion (70), and both of the second receiver portion (68) and the fourth receiver portion (72) being insulators.

6. The lead frame (40) of Claim 4, wherein the first receiver portion (66) and the third receiver portion (70) are discontiguous.

7. The lead frame (40) of any one of Claims 1-6, wherein each circuit element (42) is a thermistor mounted on a surface of the corresponding lead.

8. A battery (14) comprising: one or more battery cells (26); a connector (27); and a lead frame (40) coupled to the connector and in electrical communication with the one or more battery cells (26), the lead frame (40) comprising: one or more circuit elements (42); one or more leads (36), each lead (36) comprising: a first end (56); a second end (58) opposite the first end (56), the first end (56) being electrically couplable to the connector (27), the second end (58) being electrically couplable to a corresponding battery cell (26); and a circuit element receiver (64) between the first end (56) and the second end (58), the circuit element receiver (64) being electrically coupled to at least one circuit element (42) of the one or more circuit elements (42), at least the circuit element receiver (64) and the at least one circuit element (42) establishing an electrical path between the first end (56) and the second end (58).

9. The battery (14) of Claim 8, further comprising: one or more posts (60), each post (60) being electrically coupled to at least one battery cell (26), the lead frame (40), the second end (58) of the one or more leads (36) being electrically couplable to a corresponding battery cell (26) via a corresponding post of the one or more posts.

10. The battery (14) of any one of Claims 8 and 9, wherein each lead (36) is electrically decoupled from other leads (36) of the one or more leads (36).

11. The battery (14) of any one of Claims 8-10, wherein: each lead (36) further includes: a first lead portion (74) electrically coupled to the first end (56): and a second lead portion (76) electrically coupled to the second end (58); and each circuit element (42) includes: a first element portion (84) electrically coupled to the first lead portion (74); a second element portion (86) electrically coupled to the second lead portion (76); and a third element portion (88) electrically coupled to the first element portion (84) and the second element portion (86).

12. The battery (14) of Claim 11, wherein the circuit element receiver (64)includes a first receiver portion (66) and a third receiver portion (70), the first element portion (84) being electrically coupled to the first receiver portion (66), and the second element portion (86) being electrically coupled to the third receiver portion (70).

13. The battery (14) of Claim 12, wherein the circuit element receiver (64)further includes a second receiver portion (68) and a fourth receiver portion (72), both of the second receiver portion (68) and the fourth receiver portion (72) coupled to the first receiver portion (66) and the third receiver portion (70), and both of the second receiver portion (68) and the fourth receiver portion (72) being insulators.

14. The battery (14) of Claim 12, wherein the first receiver portion (66) and the third receiver portion (70) are discontiguous.

15. The battery (14) of any one of Claims 8-14, wherein each circuit element is a thermistor mounted on a surface of the corresponding lead.

16. A method for assembling a lead frame (40) of a battery (14), the lead frame (40) comprising one or more circuit elements (42) and one or more leads (36), each lead (36) comprising a circuit element receiver (64), the method comprising: forming the lead frame (40) using a die cutting process, the formed lead frame (40) having one or more inter-lead couplers (63), each inter-lead coupler (63) coupling at least two leads (36); electrically coupling the circuit element (42) to the circuit element receiver (64); removing each inter-lead coupler (63) from the lead frame (40), the removal including decoupling the at least two leads (36); and over-molding a portion of the one or more leads (36) and, optionally, overmolding each circuit element (42).

17. The method of Claim 16, wherein the method further includes: removing at least a portion of the circuit element receiver (64)from the lead frame (40).

18. The method of any one of Claims 16 and 17, wherein each circuit element (42) is a thermistor mounted on a surface of the corresponding lead (36).

19. The method of any one of Claims 16-18, wherein the over-molding includes one or more of: over-molding each circuit element (42) and the portion of the one or more leads (36) in a single step; over-molding the portion of each circuit element (42), and after the over-molding of each circuit element (42) is completed, over-molding each one of the one or more leads (36); and over-molding the portion of the one or more leads (36), and after the over-molding of the portion of the one or more leads (36) is completed, over-molding each circuit element (42).

20. The method of any one of Claims 16-19, wherein each circuit element (42) is a thermistor.

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