Patent Description:
The present disclosure relates to batteries. The present disclosure more specifically relates to batteries and internal electrical connections in batteries.

It is known to provide for a battery having one or more battery cell elements in a flat-plate format that may be used for deep cycle, SLI (Starting, Lighting, Ignition) or other applications. Such known batteries typically include a variety of shapes and configurations. In batteries with multiple cell elements, the cells are connected in series by conductive straps. These conductive straps comprise conductive material, which typically requires substantial additional material costs and weight. However, such known batteries do not realize certain advantageous features and/or combinations of features.

Therefore, the disclosed battery straps connect a number of battery elements in series. The disclosed straps may advantageously allow for the connection of multiple battery cells with a reduction in material, and therefore material costs and weight, relative to known batteries. In addition, the disclosed straps may allow for improved conductivity relative to known batteries. Also, the disclosed straps may allow for improved circulation of gasses in a battery.

The present invention which is disclosed in the claims, relates to a battery comprising six battery cells wherein the cells are electrically coupled in series by five straps which pass through recesses in a cell divider.

The present disclosure relates to a battery according to various embodiments having a housing having at least two cells and a cell wall provided between the two cells, a plurality of elements provided within the cells, a battery strap cast onto two of the elements and directly connecting two of the elements in series through the cell walls, a common headspace defined by the cell wall, wherein the battery strap has a top surface with a front edge, a first side edge, a second side edge, and a back edge, the first side edge and the second side edge being parallel to each other and perpendicular to the front edge and the back edge. The present disclosure further relates to a battery wherein the cell wall features a cutout and the battery strap connects two elements through the cutout. The present disclosure further relates to a battery wherein the battery straps comprise a first, second, third, fourth, and fifth connecting strap. The present disclosure further relates to a battery wherein the first, second, and third connecting strap are provided in a first row and the fourth and fifth connecting straps are provided in a second row opposite the first row. The present disclosure further relates to a battery wherein the second row further comprises two end straps. The present disclosure further relates to a battery wherein the cutout has a cutout width and the straps have a strap width and the cutout width is larger than the strap width. The present disclosure further relates to a battery wherein the cutout has a cutout height and the straps have a strap height and the cutout height is larger than the strap height.

The present disclosure according to various embodiments further relates to a battery having: a housing having cells and cell walls, the cell walls each having a cutout; a plurality of battery elements provided within the cells; a plurality of battery straps connecting the plurality of battery elements in series, each battery strap extending through a cell wall through a cutout; a common headspace defined by the cutout; wherein the battery strap has a top surface with a front edge, a first side edge, a second side edge, and a back edge, the first side edge and the second side edge being parallel to each other and perpendicular to the front edge and the back edge. The present disclosure further relates to a battery wherein the cutout has a cutout width and the straps have a strap width and the cutout width is larger than the strap width. The present disclosure further relates to a battery wherein the cutout has a cutout height and the straps have a strap height and the cutout height is larger than the strap height. The present disclosure further relates to a battery wherein the battery straps comprise five connecting straps and two end straps. The present disclosure further relates to a battery, wherein the battery straps comprise a first row having three connecting straps and a second row comprising two connecting straps and two end straps.

The present disclosure relates to a battery according to various embodiments comprising: six cells, each cell being divided by a cell wall; seven straps, the straps being arranged in two rows, a first row having a first connecting strap, a second connecting strap, and a third connecting strap; a second row having a fourth connecting strap and a fifth connecting strap; the second row further comprising a first end strap and a second end strap; the first, second, third, fourth, and fifth connecting straps directly connecting the six cells in series through the cell wall.

The present disclosure further relates to a battery wherein the cells are separated by five cell walls, each cell wall having a cutout. The present disclosure further relates to a battery, wherein each connecting strap passes through the cutout to connect adjacent battery elements. The present disclosure further relates to a battery, wherein each cutout has a cutout height which is larger than a connecting strap height. The present disclosure further relates to a battery wherein each cutout has a cutout width which is larger than a connecting strap width.

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.

In certain instances, details that are not necessary to the understanding to the invention or render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein.

The battery straps <NUM>, according to various embodiments, connect a number of battery cells <NUM>, for example, six battery cells, in series. The battery straps <NUM> may be, according to various examples of embodiments, direct path cast-on straps. The battery cells <NUM> may be comprised of flat-plate grids stacked together. The grids may have a lug extending out of the top of the grid. The straps <NUM> may be understood to connect the lugs of the grids in the cell <NUM> together.

<FIG> shows an isometric view of a battery <NUM> having the battery straps <NUM> or conductive straps, according to various examples of embodiments. The battery straps <NUM> may comprise connecting straps <NUM> and end straps <NUM>. The battery <NUM> may be seen to comprise a number of flat-plate grids stacked together and provided within a number of cells <NUM>.

The battery <NUM> includes a battery housing <NUM>. The battery straps <NUM> disclosed herein according to various embodiments may be "cast-on straps. " The straps may be "cast on" in that they are cast onto the lugs of the battery element lugs. Five connecting straps <NUM> are shown in <FIG> as coupling six battery elements in series. A positive terminal and a negative terminal (first terminal <NUM>, second terminal <NUM>) integrated into end straps <NUM> are shown on one side of the battery in the illustrated example. The connecting straps <NUM> are shown in <FIG> in parallel planes passing through cutouts <NUM> provided in the battery cell walls <NUM> to connect adjacent cell elements in series. The connecting straps <NUM> can be seen, in various embodiments, as having a thickness such that the cell wall <NUM> is taller than the connecting strap <NUM>. In particular, the connecting straps <NUM> may have a height <NUM> that is shorter than a height <NUM> of a cutout <NUM>. In addition, the connecting straps <NUM> may have a width <NUM> that is smaller than a cutout width <NUM>.

The connecting straps <NUM> can be seen, in various embodiments, connecting the lugs of a first polarity of battery plates of a battery element <NUM> to the lugs of the battery plates of an opposite polarity of a second battery element <NUM>. A terminal <NUM> connected to an end strap <NUM> having a polarity (e.g. a positive terminal) which connects the lugs of plates of the same polarity (e.g. positive) of a battery element <NUM> can be seen in <FIG> as provided in a lower right-hand corner of the battery <NUM>, according to various examples of embodiments. Similarly, another terminal <NUM> (e.g. a negative terminal) connected to an end strap <NUM> which connects the lugs of plates (e.g. negative plates) of a battery element <NUM> can be seen in <FIG> as provided in a lower left-hand corner of the battery <NUM>, according to various examples of embodiments.

<FIG> shows a top side view of a battery <NUM> having straps <NUM> (e.g. cast-on straps), according to various examples of embodiments. A first row <NUM> and second row <NUM> of battery straps <NUM> are shown. The first row <NUM> may be seen relative to the top of <FIG>, while the second row 121may be seen below the first row <NUM> in <FIG>. The first row <NUM> comprises, in various embodiments, three connecting straps <NUM>. The second row <NUM>, which has a first battery terminal <NUM> and end strap <NUM> as well as a second battery terminal <NUM> and end strap <NUM>, has two connecting straps <NUM> positioned parallel to the three connecting straps <NUM> in the first row <NUM>. While a specific configuration is illustrated and described, variations thereon may also be acceptable. For example, the positive and negative terminals may be on the first row or second row or both (e.g., one on each). The straps can be understood to be cast onto the positive or negative lugs provided within each battery element which is offset from the other elements by a separating cell wall <NUM>.

As can be seen in <FIG>, a cutout <NUM> or recess may be provided for the connecting strap <NUM> which can be found in a single location along each battery cell wall <NUM>. The cutout <NUM> may be seen, in various embodiments, as suitably positioned relative to the location of the lugs of the elements <NUM> and connecting straps <NUM> attached thereto. The positioning of the connecting straps <NUM> and cutouts <NUM> can be seen in <FIG> as forming an alternating pattern. While a single cutout or recess is specifically disclosed, more than one cutout is also contemplated. In various embodiments, it should be understood the connecting straps <NUM> are cast through the cutout <NUM> or hole in the wall. The battery straps <NUM> may be sized to be smaller than the cutout <NUM> or recess in the cell wall. This may advantageously allow for further open space (i.e. common headspace <NUM>) in the battery <NUM> cavity.

<FIG> shows battery straps <NUM>, according to various embodiments, outside of the battery or battery housing. Five of the connecting straps <NUM> can be seen to be approximately equal in shape. Similarly, the end straps with the terminals may be approximately equally shaped. The connecting straps <NUM>, in various embodiments, may be substantially rectangular shaped when viewed from above. The connecting straps <NUM> may be, in various embodiments, substantially a rectangular prism shape. The battery straps <NUM> may widen from a top surface towards a bottom surface. In various embodiments, the connecting straps <NUM> may have two projections <NUM> on the side of the cast-on strap.

It should be understood the battery <NUM> may also include a battery cover <NUM> provided on the housing <NUM>. <FIG> shows a battery cover <NUM> positioned relative to the battery straps <NUM>, according to various examples of embodiments. The cover <NUM>, in various embodiments, may be sized to accept the straps <NUM> and terminals <NUM>, <NUM>. The cover <NUM> may likewise include element separators, sized to accommodate the straps <NUM> disclosed herein. In addition, the cover <NUM> may be sized to accept the terminals <NUM>, <NUM> provided on opposite ends of the battery straps, in various embodiments, on one side. In various exemplary embodiments, a first terminal post (positive) and second terminal post (negative) may be positioned in areas substantially near the intersections of either the front edge or back edge (both of the terminals may be near the same edge) with the first end and second end.

<FIG> shows a side view of the straps <NUM> (e.g. cast on straps) with cell walls <NUM> having a cutout <NUM>, according to various examples of embodiments. A space can be seen on either side of the connecting strap <NUM> in the cutout (i.e. the strap width <NUM> may be smaller than a cutout width <NUM>), according to various examples of embodiments. In addition, the strap may be sized to allow a space (or headspace <NUM>) above the strap, that is, the height <NUM> of a cutout, in various embodiments, may be smaller than a height <NUM> of a connecting strap <NUM>.

<FIG> shows a side cut-away view of a battery having the cast-on straps (straps <NUM>), according to various examples of embodiments. A connecting strap <NUM> may be seen on the lug of a plate on a left-hand side of the cut-away battery <NUM> of <FIG>. In various embodiments, a terminal post and end strap <NUM> may be seen, the terminal post protruding through the battery cover <NUM>. A common headspace <NUM> may be seen created between the sides of the connecting strap <NUM> in the cutout <NUM> and the battery cover <NUM>, according to various examples of embodiments. <FIG>, according to various embodiments of the invention, shows one cell wall <NUM> having a recess with a connecting strap, or cast-on strap, provided through the recess to connect adjacent cell elements, creating an open space or headspace <NUM> between the strap <NUM> and the cover <NUM>. The headspace <NUM> shown in <FIG> should be understood to lead to a common headspace <NUM> within the battery <NUM>, according to various embodiments.

The common headspace may be created, according to various examples of embodiments, by sizing the connecting <NUM> (cast-on) straps smaller than a recessed portion or cutout <NUM> of the cell dividing wall <NUM>. Therefore, in various embodiments, a path of open headspace <NUM> is created between the cells and creates a common space between the housing <NUM> and cover <NUM>.

The common headspace <NUM> may allow for certain advantages to the function and longevity of the battery. For example, common headspace <NUM> may allow for gasses to more easily be vented from the battery. While common headspace <NUM> is shown on one cell as an example, it should be understood to, in various embodiments, occur at each cell wall <NUM>. The common headspace <NUM> may be defined by the cutout <NUM>, as well as the cover <NUM>. The connecting strap <NUM> may be smaller in strap width <NUM> and connecting strap height <NUM> than a cutout width <NUM> or cutout height <NUM>. This allows for a space around the strap <NUM>.

<FIG> likewise shows an isometric view of a battery <NUM> having the battery straps <NUM> or conductive straps, according to various examples of embodiments. The battery includes a battery housing <NUM>. The straps may be "cast on" in that they are cast onto the lugs of the battery element lugs. Five connecting straps <NUM> are shown in <FIG> as coupling six battery elements <NUM> in series. A positive terminal and a negative terminal integrated into end straps <NUM> are shown on one side of the battery <NUM> in the illustrated example. The connecting straps <NUM> are shown in <FIG> in parallel planes passing through recesses (cutouts <NUM>) provided in the battery cell walls <NUM> to connect adjacent cell elements in series. Again, the straps can be seen, in various embodiments, as having a thickness or strap height <NUM> such that the cell wall <NUM> and cutout <NUM> is taller than the strap and the cutout height <NUM> is larger than the strap height <NUM>. In addition, the cutout <NUM> can be seen as having a larger cutout width <NUM> than the strap width <NUM>. The straps <NUM> can be seen, in various embodiments, connecting the lugs of the negative battery plates of a first battery element to the lugs of the positive battery plates of a second battery element.

As can be seen in <FIG>, a cutout <NUM> or recess may be provided for the battery strap <NUM> which can be found in a single location along each battery cell wall <NUM>. The cutout position may be seen, in various embodiments, as suitably positioned relative to the location of the lugs and connecting straps <NUM>. The positioning of the straps and cutouts can be seen as forming an alternating pattern. While a single cutout or recess is specifically disclosed, more than one cutout is also contemplated. In various embodiments, it should be understood the straps are cast through the cutout or hole in the wall. The battery straps may be sized to be smaller than the cutout or recess in the cell wall (i.e. connecting strap width <NUM> may be smaller than cutout width <NUM>). This may advantageously allow for further open space in the battery cavity.

<FIG> shows a side view of the connecting straps <NUM> provided in a battery <NUM>, according to various examples of embodiments. Again, the cutout <NUM> can be seen to be sized larger in various dimensions than the connecting strap <NUM>, according to various examples of embodiments.

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). Likewise, the strap members and end straps may be made of one or more conductive materials (e.g., lead or a material containing lead).

The strap members may be comprised, in various embodiments, of a lead alloy. In various embodiments, this alloy may be a substantially pure lead and may, in various embodiments, include lead, tin, antimony, calcium, and combinations thereof. The alloy may, as a non-limiting example, be a lead tin alloy with a tin composition range of <NUM>-<NUM>%, <NUM>-<NUM>%, <NUM>-<NUM>%, and the like. The lead may be virgin lead or high purity lead or highly purified secondary lead, in various examples of embodiments.

The battery straps may be cast directly onto the cell elements. The battery straps may therefore couple together lugs of battery plates, the collection of battery plates coupled together forming a cell element, which is comprised of positive plates and negative plates. Separators may be provided between the positive plates and negative plates. The straps may connect the positive plates together or the negative plates together, as described above. The straps may have an elongate body form to suitably couple adjacent cell elements together through the recesses provided in the cell walls.

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 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.

It is also important to note that the construction and arrangement of the system, methods, and devices as shown in the various examples of embodiments is illustrative only. Although only a few embodiments 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 show as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied (e.g. by variations in the number of engagement slots or size of the engagement slots or type of engagement). The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments.

While this invention has been described in conjunction with the examples of embodiments outlined above, various alternatives, modifications, variations, improvements and/or substantial equivalents, whether known or that are or may be presently foreseen, may become apparent to those having at least ordinary skill in the art. Accordingly, the examples of embodiments of the invention, as set forth above, are intended to be illustrative, not limiting. Therefore, the invention is intended to embrace all known or earlier developed alternatives, modifications, variations, improvements and/or substantial equivalents.

Claim 1:
A battery (<NUM>) having:
- a housing (<NUM>) having at least two cells and a cell wall (<NUM>) provided between the two cells;
- at least two battery elements (<NUM>) provided within the cells;
- at least one battery strap (<NUM>) cast onto two of the battery elements (<NUM>) and directly connecting two of the battery elements (<NUM>) in series through the cell wall (<NUM>);
- a common headspace (<NUM>) defined by the cell wall (<NUM>);
wherein each battery strap (<NUM>) has a top surface with a front edge, a first side edge, a second side edge, and a back edge, the first side edge and the second side edge being parallel to each other and perpendicular to the front edge and the back edge.