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CN-120500766-B - Sensing connection method

CN120500766BCN 120500766 BCN120500766 BCN 120500766BCN-120500766-B

Abstract

A lead connection for coupling a first end of a lead (50) to a post (18) and bushing (22) of a battery is described. The lead connection includes a first weld (40, 42) including a bushing and a post welded to the bushing. The wire bond also includes a second weld (70, 72). The second weld includes a first weld and a first end of the lead. At least a portion of the first weld is distributed around and over the first end of the lead to electrically couple the first end of the lead to the bushing and the post.

Inventors

  • JEFFREY L. TROXEL
  • Branislav Blankov
  • Luke William Fulbringer

Assignees

  • CPS科技控股有限公司

Dates

Publication Date
20260508
Application Date
20231228
Priority Date
20221228

Claims (20)

  1. 1. A lead connection for coupling a first end (52) of a lead (50) to a post (18) and bushing (22) of a battery (10), the lead connection comprising: A first weld (40, 42) comprising the bushing (22) and the post (18) welded to the bushing (22), and A second weld (70, 72) comprising the first weld (40, 42) and the first end (52) of the lead (50), at least a portion of the first weld (40, 42) being distributed around and over the first end (52) of the lead (50) to electrically couple the first end (52) of the lead (50) to the bushing (22) and the post (18).
  2. 2. The lead connection of claim 1, wherein the first weld (40, 42) is a button extending from the post (18).
  3. 3. The wire bond of claim 2 wherein the solder button comprises a first portion and a second portion adjacent the first portion, the second portion being of a curved configuration.
  4. 4. The lead connection of claim 3, wherein a first end (52) of the lead (50) is positioned between the first portion and the second portion and is physically coupled to the post (18).
  5. 5. The lead connection of any of claims 1 to 4, wherein the first weld (40, 42) has a third portion that covers the post (18) and is in physical contact with the post (18).
  6. 6. The wire connection of any of claims 1 to 5, wherein the first weld (40, 42) and the second weld (70, 72) are integrated into a unitary construction.
  7. 7. The lead connection of any of claims 1 to 6, wherein the first end (52) of the lead (50) is a loop and is coupled to a post connector (54).
  8. 8. The lead connection of any of claims 1 to 7, wherein the first and second weld beads (40, 42, 70, 72) are electrically connectable to a battery cell (14) via the post (18), and the lead (50) is connectable to a battery management system, BMS, (26), which is configurable to measure battery parameters via the lead connection.
  9. 9. A battery (10), the battery (10) comprising: A housing (12) housing a plurality of battery cells (14); a plurality of posts (18), each post (18) of the plurality of posts (18) being electrically coupled to at least one battery cell (14) of the plurality of battery cells (14); A cap (20) sealed to the housing (12) and including a plurality of bushings (22) coupled to the cap (20), each of the plurality of posts (18) being inserted through a corresponding bushing (22), and A plurality of leads (50), the plurality of leads comprising a plurality of lead connections, each lead (50) comprising a first end (52) and a second end opposite the first end (52), each lead connection of the plurality of lead connections comprising: A first weld (40, 42) comprising one bushing (22) of the plurality of bushings (22) and one post (18) of the plurality of posts (18), the one post (18) being welded to the one bushing (22), and A second weld (70, 72) comprising the first weld (40, 42) and the first end (52) of the lead (50), at least a portion of the first weld (40, 42) being distributed around and over the first end (52) of the lead (50) to electrically couple the first end (52) of the lead (50) to the bushing (22) and the post (18).
  10. 10. The battery (10) of claim 9, wherein the cover (20) sealed to the housing (12) defines a housing interior space that houses the plurality of battery cells (14), each lead being connected outside of the housing interior space.
  11. 11. The battery (10) according to any one of claims 9 and 10, wherein the battery (10) further comprises: A battery management system, BMS, (26) configured to measure battery parameters via each of the plurality of lead connections, the BMS (26) being electrically coupled to a second end of each lead (50).
  12. 12. The battery (10) of any of claims 9 to 11, wherein the first weld (40, 42) is a weld button extending away from the cover (20).
  13. 13. The battery (10) of claim 12, wherein the weld button includes a first portion and a second portion adjacent to the first portion, the first portion being adjacent to the cover (20), the second portion being of a curved configuration.
  14. 14. The battery (10) of any of claims 9 to 13, wherein the first weld (40, 42) has a third portion that covers the one terminal post (18) and is in physical contact with the one terminal post (18).
  15. 15. The battery (10) of any of claims 9 to 14, wherein the first weld (40, 42) and the second weld (70, 72) are integrated into a single unitary construction.
  16. 16. The battery (10) of any of claims 9 to 15, wherein the first end (52) of the lead (50) is a loop and is coupled to a post connector (54).
  17. 17. A method for coupling a first end (52) of a lead (50) to a post (18) and a bushing (22) of a battery (10), the battery (10) including a cover (20), the bushing (22) coupled to the cover (20), the method comprising: -inserting (S106) the binding post (18) through the bushing (22), at least a portion of the binding post (18) protruding from the bushing (22) and the cover (20); -performing (S108) a first weld (40, 42) by welding (S108) the terminal (18) to the bushing (22), said welding being applied to at least the portion of the terminal (18) protruding from the bushing (22), and -Performing (S110) a second weld (70, 72) by welding the first weld (40, 42) to the first end (52) of the lead (50), at least another portion of the first weld (40, 42) being distributed around and over the first end (52) of the lead (50).
  18. 18. The method of claim 17, wherein performing the first weld (40, 42) comprises: Forming a weld button extending away from the cover (20).
  19. 19. The method of claim 18, wherein the weld button includes a first portion and a second portion adjacent to the first portion, the second portion being a curved structure.
  20. 20. The method of claim 19, wherein the method further comprises: positioning a first end (52) of the lead (50) between the first portion and the second portion, and -Coupling the first end (52) to the post (18) and the bushing (22).

Description

Sensing connection method Technical Field The present disclosure relates to batteries, and in particular to the manufacture and/or assembly of intelligent batteries that facilitate battery performance/fault monitoring. Background As battery technology evolves, there is a continuing need for improved power sources (such as energy storage modules for vehicles). Existing battery systems, such as lead acid battery systems, typically provide limited performance and fault monitoring approaches and have complex venting arrangements. More specifically, existing lead-acid battery systems may not be able to provide one or more battery parameters of one or more battery cells of the lead-acid battery system (e.g., may be used to determine performance and/or predict/monitor faults). In other words, existing lead acid battery systems have difficulty providing information about important components, such as the state of health of the individual battery cells. Therefore, the state of health of the battery cells cannot be monitored and/or determined, thereby impeding the ability to predict an upcoming battery failure or the onset of a failure. Disclosure of Invention Some embodiments advantageously provide a connection (and/or method of making a connection) for sensing parameters associated with a battery cell and/or battery. In some embodiments, the method of making the connection is a sense connection method. According to one aspect, a lead assembly connection for a post connector for coupling a lead assembly is described. The lead assembly connection includes a first weld including a bushing and a post welded to the bushing. The lead assembly connection further includes a second weld including the first weld and the post connector. At least a portion of the first weld is distributed around and over the post connector to electrically couple the post connector to the bushing and the post. According to another aspect, a battery is described. The battery includes a housing that houses a battery cell, wherein the battery cell includes a terminal post electrically coupled to the battery cell. Further, the battery includes a cover sealed to the housing and including a bushing coupled to the cover. A cover sealed to the housing defines a housing interior space. The post is inserted through the bushing. At least a portion of the post protrudes from the bushing and is external to the housing interior space. The battery further includes a first weld, a lead assembly, and a second weld. The first weld includes a bushing and a post welded to the bushing. The lead assembly includes a post connector. The second weld includes a first weld welded to the post connector. At least a portion of the first weld is distributed around and over the terminal connector to electrically couple the terminal connector to the bushing, the terminal, and the battery cell. One or more of the first weld and the second weld seal the post and the bushing to the cap. The second weld is external to the housing interior space. According to one aspect, a lead connection for coupling a first end of a lead to a post and bushing of a battery is described. The lead connection includes a first weld including a bushing and a post welded to the bushing. The wire bond also includes a second weld. The second weld includes a first weld and a first end of the lead. At least a portion of the first weld is distributed around and over the first end of the lead to electrically couple the first end of the lead to the bushing and the post. In some embodiments, the first weld is a button (weld button) extending from the post. In some other embodiments, the weld button includes a first portion and a second portion adjacent to the first portion, the second portion being a curved structure. In some embodiments, the first end of the lead is positioned between the first portion and the second portion and is physically coupled to the post. In some other embodiments, the first weld has a third portion that covers and is in physical contact with the lug. In some embodiments, the first weld and the second weld are integrated into a unitary construction. In some other embodiments, the first end of the lead is one of a loop and a post connector. In some embodiments, the first weld and the second weld may be electrically connected to the battery cells via the studs, and the leads may be connected to a Battery Management System (BMS) that may be configured to measure battery parameters via the lead connections. According to another aspect, a battery is described. The battery includes a housing, a cover, a plurality of terminals, and a plurality of leads. The shell accommodates a plurality of battery cells. Each of the plurality of terminals is electrically coupled to at least one of the plurality of battery cells. The cover is sealed to the housing and includes a plurality of bushings coupled to the cover. Each of the plurality of studs is inserted through a corresponding bushing. The pluralit