Abstract:
The present disclosure relates to a battery for use in various applications including starting, lighting, and ignition and other purposes in vehicles such as automobiles and boats. The disclosed battery design includes a number of battery cell elements connected in series by a number of straps. The present disclosure describes a system of connecting the cells that minimizes the size and weight of the straps and increases the operating efficiency of the battery.

Description:
PRIORITY 
     This application claims priority to U.S. Provisional Application 61/076,948 filed Jun. 30, 2008 and International Application PCT/US2009/049231 filed Jun. 30, 2009, which are incorporated herein by reference in their entirety. 
    
    
     BACKGROUND 
     1. Field 
     The present disclosure relates to batteries (e.g., lead-acid batteries for use as automotive, commercial, industrial, and marine batteries in starting, lighting, and ignition (“SLI”) and other applications). The present disclosure more specifically relates to batteries and internal electrical connections in batteries. 
     2. Related Art 
     It is known to provide for a battery having one or more battery cell elements in a wound configuration (e.g., spiral wound or jelly roll) that may be used for SLI and other applications. Such known batteries typically include a variety of shapes and configurations. In batteries with multiple coiled cell elements, the cells are connected in series by conductive straps requiring substantial additional material costs and weight. However, such known batteries do not realize certain advantageous features and/or combinations of features. 
     SUMMARY 
     The present invention relates to a battery comprising six battery cells in a two by three pattern with three cells located on either side of a dividing line wherein the cells are electrically coupled in series by five straps and wherein no more than two of the straps cross the dividing line. 
     The present invention also relates to a battery comprising a first row of three battery cells and a second row of three battery cells wherein the cells of the first row are electrically coupled in series by two battery straps and wherein the first and second cells in the second row are electrically coupled by a battery strap and wherein a strap couples one of the first or second cells in the second row is electrically coupled to a cell in the first row and wherein a strap electrically couples the third cell of the second row to a cell of the first row and wherein the battery cells are electrically coupled in series by the straps. 
     These and other features and advantages of various embodiments of systems and methods according to this invention are described in, or are apparent from, the following detailed description of various exemplary embodiments of various devices, structures, and/or methods according to this invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Various exemplary embodiments of the systems and methods according to the present disclosure will be described in detail, with reference to the following figures, wherein: 
         FIG. 1  is an isometric view of a vehicle including a battery according to an exemplary embodiment; 
         FIG. 2  is an exploded isometric view of a portion of a battery according to an exemplary embodiment; 
         FIG. 3  is an isometric view of a battery according to an exemplary embodiment with cover removed; 
         FIG. 4  is a top view of a battery of the prior art with cover removed; 
         FIG. 5  is a top view of the cast-on strap shown in  FIG. 4 ; 
         FIG. 6  is a top view of a battery according to an exemplary embodiment with cover removed; and 
         FIG. 7  is a top view of the cast-on strap shown in  FIG. 6 . 
     
    
    
     It should be understood that the drawings are not necessarily to scale. In certain instances, details that are not necessary to the understanding of the invention or render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein. 
     DETAILED DESCRIPTION 
     The present disclosure improves battery performance and/or reduces weight and cost. The present disclosure relates to a method and apparatus for connecting battery cells in series using straps with reduced overall size and electrical resistance compared to conventional battery straps. The straps and configuration thereof according to various exemplary embodiments provide a more efficient electrical path and/or use less material than conventional battery straps. 
     Referring to  FIG. 1 , a vehicle  130  is shown that includes a battery  100  according to an exemplary embodiment. While vehicle  130  is shown as an automobile, according to various alternative embodiments, the vehicle may comprise any variety of types of vehicles including, among others, motorcycles, buses, recreational vehicles, boats, and the like. According to an exemplary embodiment, vehicle  130  uses an internal combustion engine for locomotive purposes. 
     Battery  100  shown in  FIG. 1  is configured to provide at least a portion of the power required to start or operate vehicle  100  and/or various vehicle systems (e.g., SLI). Further, it should be understood that battery  100  may be utilized in a variety of applications not involving vehicle  130 , and all such applications are intended to be within the scope of the present disclosure. 
     The battery may include any type of secondary battery (e.g., rechargeable battery). According to an exemplary embodiment, battery  100  includes a lead-acid storage battery. Various other embodiments of lead-acid storage batteries may be either sealed (e.g., non-maintenance) or unsealed (e.g., wet). 
     Battery  100 , according to an exemplary embodiment, is illustrated in  FIG. 2 . In various exemplary embodiments, battery  100  includes a cover  102  and a housing or container  101 , one or more battery elements  110 , straps  106 , and battery terminals  103 - 104 . In various exemplary embodiments, each battery element  110  includes a negative electrode, a positive electrode, and a separator in a wound configuration (e.g., spiral wound or jelly roll). The battery cells or elements are electrically coupled in series by straps  106  and battery terminals  103 - 104  are electrically coupled to the cells at each end of the series. 
     Battery  100 , according to an exemplary embodiment, with the cover removed, is illustrated in  FIG. 3 . In various embodiments, battery  100  includes several cell elements  111 - 116  provided in compartments defined by a container or housing  101 . The illustrations provided herein relate to automotive applications, wherein six spiral wound cells are used for producing a standard automotive 12-volt battery. It will be apparent to those skilled in the art after reading this specification that the size and number of the cells used to construct a battery may vary widely, depending upon the desired end use. 
     In various embodiments, container  101  includes a plurality of housings or cell containers defined by one or more walls. While the figures generally illustrate a container having six cell containers or compartments, a different number of cell containers or compartments may be provided according to other exemplary embodiments. While the figures generally illustrate the cell containers arranged in a symmetrical fashion, it should be appreciated that the cell containers may be arranged in other patterns (e.g., an off-set or staggered pattern). 
     In various embodiments, each cell container is configured to substantially contain therein a cell element of battery  100 . The cell element may be a wound cell element that includes a positive electrode, a negative electrode, and a separator such as an absorbent glass mat (“AGM”) separator provided between the positive and negative electrode. In various embodiments, the electrodes and the separator are wound or wrapped in a spiral, and acid (e.g., sulfuric acid) may be provided in the cell container. 
     According to an exemplary embodiment, the each container or compartment has a generally cylindrical configuration. However, one or more cell containers may have other configurations (e.g., a “tapered” shape having a different diameter at one of the bottom or top of the cell container, an “hourglass” shape, etc.). One or more of the cell containers or compartments may also have features formed on the bottoms thereof (i.e. the closed ends). 
     In various embodiments, container  101  also includes a base. According to one exemplary embodiment, the base is integrally formed with container  101 . According to another exemplary embodiment, the base is produced separately and coupled to the container. 
       FIG. 3  also shows cast-on-straps  121 - 125  which includes an elongated body portion of a length sufficient to electrically couple each turn in a coil (e.g., via lugs (not shown) extending upwardly from the coil).  FIG. 2  also illustrates a cast-on-strap coupling lugs to a negative terminal. In the casting process, molten lead is poured into a mold containing a portion of the battery cell coils (e.g., the lugs) to which the lead adheres as it cools and hardens. 
     In various embodiments, a plurality of individual electrochemical cells or elements  111 - 116  are disposed within the cell containers of battery  100 . In various embodiments, the elements  111 - 116  are preferably generally cylindrical in form. In various embodiments, elements  111 - 116  and the cell containers or compartments are arranged in two substantially parallel rows of three. Cell elements  111 - 116  are electrically coupled in series by electrically conducting straps or strap members  121 - 125 . The terminals are electrically coupled to cell elements  111 - 116  by end straps  126 - 127 . Certain channels are positioned between the cell containers or compartments to allow strap members  121 - 125  to be nested below the top of the container. 
       FIG. 4  illustrates an embodiment of a portion of prior art six-cell battery  200 .  FIG. 5  shows straps  221 - 225  from the battery of  FIG. 4 . The size, shape, and configuration of straps  221 - 225  each affects the cost/or and performance of battery  200 . The cost of materials, including straps  221 - 225 , is a significant portion of the battery&#39;s cost. Straps  221 - 225  also contribute to the weight of battery  200 . Straps  221 - 225  form part of the path for internal current flow. The total path length affects total resistance and, thus, the performance of battery  200 . Therefore, it would be advantageous to reduce the size and weight of straps  221 - 225 . 
       FIG. 6  illustrates one exemplary configuration of strap members  121 - 125 , end straps  126 - 127 , cell containers, and cell elements  111 - 116 .  FIG. 7  shows the straps  121 - 125  from the battery of  FIG. 6 . As shown in  FIG. 6 , a first strap  121  electrically couples a first element  111  to a second element  112 , a second strap member  122  electrically couples second element  112  to a third element  113 , a third strap member  123  electrically couples third element  113  to a fourth element  114 , a fourth strap member  124  electrically couples fourth element  114  to a fifth element  115 , and a fifth strap member  125  electrically couples fifth element  115  to a sixth element  116 . In various embodiments, a first end strap  126  electrically couples the first terminal post to first element  111  and a second end strap  127  electrically couples the second terminal post to sixth element  116 . 
     Strap members  121 - 125  and end straps  126 - 127  may be utilized in any number of configurations. For example, strap members  121 - 125  may electrically couple sixth element  116  to second element  112 , second element  112  to fifth element  115 , fifth element  115  to fourth element  114 , fourth element  114  to third element  113 , and third element  113  to first element  111 . 
     Alternatively, strap members  121 - 125  may connect third element  113  to fourth element  114 , fourth element  114  to first element  111 , first element  111  to second element  112 , second element  112  to sixth element  116 , and sixth element  116  to fifth element  115 . 
     In yet another alternative embodiment, strap members  121 - 125  may electrically couple fifth element  115  to fourth element  114 , fourth element  114  to sixth element  116 , sixth element  116  to second element  112 , second element  112  to first element  111 , and first element  111  to third element  113 . 
     By electrically coupling cells  111 - 116  in series in these or similar patterns, the overall efficiency of the battery  100  is improved and the material needed to electrically couple cells  111 - 116  is reduced. More specifically, the battery (e.g. configuration of strap members) illustrated in  FIGS. 6-7 , uses at least about 13 percent less material than the battery (e.g. configuration of strap members) illustrated in  FIGS. 4-5 . Furthermore, the battery (e.g. configuration of strap members) illustrated in  FIGS. 6-7 , performs at least about 25 percent better than the battery (e.g. configuration of strap members) illustrated in  FIGS. 4-5  (performance measured in cold crank amps). 
     In various exemplary embodiments, as illustrated in  FIG. 6 , the battery  100  including six battery cells symmetrically arranged in a 2×3 pattern. In such embodiments, the battery may be seen as comprising two sections, each containing three full battery cell elements (illustrated in  FIG. 6  by dividing line  105 ). In various exemplary embodiments, no more than two of five strap members  121 - 125  cross dividing line  105 . For example, in the embodiment of  FIG. 6 , dividing line  105  is crossed by second strap member  122  and fifth strap member  125 , but not by first strap member  121 , third strap member  123 , or fourth strap member  124 . In other exemplary embodiments, such as those described above, the straps that do or do not cross dividing line  105  may differ, but no more than two straps cross dividing line  105  according to various exemplary embodiments. 
     In various exemplary embodiments with six cells in a 2×3 pattern, such as the embodiment of  FIG. 6 , each battery cell element is directly adjacent to two or three other cell elements and diagonally adjacent to one or two other cell elements (e.g., first cell element  111  is directly adjacent to second cell element  112  and third cell element  113  and diagonally adjacent to fourth cell element  114 ; second cell element  112  is directly adjacent to first cell element  111 , fourth cell element  114 , and sixth cell element  116  and diagonally adjacent to third cell element  113  and fifth cell element  115 ; etc.). In various exemplary embodiments, there are five battery straps with four of the battery straps electrically coupling directly adjacent cell elements and one battery strap electrically coupling diagonally adjacent cell elements. For example, in the embodiment of  FIG. 6 , second strap member  122  electrically couples diagonally adjacent second cell element  112  and third cell element  113  while first strap member  111  electrically couples first cell element  111  to second cell element  112 , third strap member  113  electrically couples third cell element  113  to fourth cell element  114 , fourth strap member  114  electrically couples fourth cell element  114  to fifth cell element  115 , and fifth strap member  115  electrically couples fifth cell element  115  to sixth cell element  116 . In various other exemplary embodiments, strap members other than the second strap member  112  may be used to electrically couple diagonally adjacent cell members. 
     In various exemplary embodiments, a first terminal post  103  and a second terminal post  104  extend from the top surface of the cover  102 . In various exemplary embodiments, the first terminal post  103  and the second terminal post  104  extend from the top surface of the cover  102  and are positioned substantially near margins of the cover  102 . In one exemplary embodiment, the first terminal post  103  and second terminal post  104  are positioned in areas substantially near the intersections of either the front edge or back edge (both of the terminals  103  and  104  are near the same edge) with the first end and second end. 
     The various elements of the battery, the battery housing, the battery cover, and the cell containers may be made of a wide variety of materials as is well known in the art. For example, the cover, container, and/or various components may be made of any polymeric (e.g., polyethylene, polypropylene, a polypropylene containing material, etc.) or composite (e.g., glass-reinforced polymer) material. For example, the container may be made of polypropylene-containing material (e.g., pure polypropylene, co-polymers comprising polypropylene, polypropylene with additives, etc.). Such polymeric material is relatively resistant to degradation caused by acid (e.g., sulfuric acid) provided within cells of the container. The terminal posts, side terminals and connection members may be made of one or more conductive materials (e.g., lead or a material containing lead). 
     The strap members  121 - 125  and end straps  126 - 127  may be made of one or more conductive materials (e.g., lead or a material containing lead). 
     In various embodiments, the container  101  includes one or more lips and/or flanges configured for coupling (e.g., heat sealing) to the cover  102 . The cover  102  includes one or more terminals  103  and/or  104  that are electrically coupled or conductively coupled (e.g., post burned) to the end straps  126  and/or  127 . 
     For shipping and/or handling purposes, the container  101  may also include one or more flanges located on an upper portion of each end of the container. The battery  100  may be lifted and/or carried by the flanges rather than the cover  102  to prevent any damage to the seal between the cover  102  and the container  101 . 
     For purposes of fitment, the container may also include one or more footings located on the lower portion of one or both ends of the container. In addition, an adapter system may be provided to elevate the battery and improve fitment. 
     As utilized herein, the terms “approximately,” “about,” “substantially,” and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the invention, as recited in the appended claims. 
     It should be noted that references to relative positions (e.g., “top” and “bottom”) in this description are merely used to identify various elements, as they are oriented in the figures. It should be recognized that the orientation of particular components may vary greatly depending on the application in which they are used. 
     For the purpose of this disclosure, the term “coupled” means the joining of two members directly or indirectly to one another. Such joining may be stationary in nature or moveable in nature. Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another. Such joining may be permanent in nature or may be removable or releasable in nature. 
     For the purpose of this disclosure, the term “electrically coupled” means the joining or connecting or two members directly or indirectly to one another in such a manner that electrical current may flow between the members. Such electrical connection may be stationary or movable in nature. Such electrical connection may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another. Such electrical connection may be permanent in nature or may be removable or releasable in nature. 
     It is important to note that the construction and arrangement of the elements of the system, as shown and described in the preferred and other exemplary embodiments, is illustrative only. Although only a few embodiments of the present inventions have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements and/or elements shown as multiple parts may be integrally formed, the operation of interfaces may be reversed or otherwise varied, the length and/or width of the structures and/or members or connections or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. It should be noted that the elements and/or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be included within the scope of the present invention. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the preferred and other exemplary embodiments without departing from the scope of the present inventions.