Abstract: Disclosed is a lead assembly for a battery system, a battery or battery system having the lead assembly, and a method of manufacturing or assembling the lead assembly, the battery, or battery system. The battery system can be a lead-acid battery system having multiple compartments. A first compartment can be a battery cells compartment and a second compartment can be a battery monitoring system (BMS) compartment. In an embodiment, multiple posts extend through bushings from the first compartment to the second compartment. A lead assembly couples the posts to the BMS. Also disclosed are various bushing designs, and various programmable circuit designs and arrangements.

Abstract: A battery system having a housing configured to receive a battery cell that is configured to generate thermal energy. The housing includes a first wall and a second wall, both of which are positioned proximate to the battery cell. The first wall and the second wall form in part a cell compartment. The battery system further includes a unitary heat sink having a first portion embedded into the first wall and a second portion embedded into the second wall.

Abstract: A lead assembly of a battery comprising a plurality of battery cells is described. The lead assembly includes a plurality of leads. Each lead has a first end and a second end opposite to the first end. The first end includes a first connector, and the second end includes a second connector. The second connector of one or more leads is couplable to a corresponding battery cell of the plurality of battery cells. Further, the lead assembly includes a lead frame enclosing at least a portion of each of the leads of the plurality of leads.

Abstract: A thermal exchanger for a battery is described. The battery includes one or both of a first stack and a second stack of battery cells. The thermal exchanger includes a thermal exchanger leg portion and a thermal exchanger foot portion. The thermal exchanger leg portion is positionable to thermally couple to one or both of the first stack and the second stack of battery cells. Further, the thermal exchanger leg portion is arranged to transfer thermal energy from one or both of the first stack and second stack to the thermal exchanger foot portion.

Abstract: Intelligent lead-acid battery system capable of monitoring a parameter (e.g., voltage, temperature) of one or more battery cells of a lead-acid battery. In one implementation, the battery system includes a housing having a cells compartment, a battery monitoring system (BMS) compartment, and a wall disposed between the cells compartment and the BMS compartment. A first post and a second post are associated with a battery cell. The first post and the second post protrude through the wall between the cells compartment to the BMS compartment. A voltage sensor electrically couples to the first post and the second post to monitor the voltage of the battery cell. A temperature sensor can couple to the first or second or both posts. The intelligent AGM battery system can predict the battery module's state of health, state of charge, module status, power capability, life expectancy, etc.

Abstract: Intelligent lead-acid battery system capable of monitoring a parameter (e.g., voltage, temperature) of one or more battery cells of a lead-acid battery. In one implementation, the battery system includes a housing having a cells compartment, a battery monitoring system (BMS) compartment, and a wall disposed between the cells compartment and the BMS compartment. A first post and a second post are associated with a battery cell. The first post and the second post protrude through the wall between the cells compartment to the BMS compartment. A voltage sensor electrically couples to the first post and the second post to monitor the voltage of the battery cell. A temperature sensor can couple to the first or second or both posts. The intelligent AGM battery system can predict the battery module's state of health, state of charge, module status, power capability, life expectancy, etc.

Abstract: Intelligent lead-acid battery system capable of monitoring a parameter (e.g., voltage, temperature) of one or more battery cells of a lead-acid battery. In one implementation, the battery system includes a housing having a cells compartment, a battery monitoring system (BMS) compartment, and a wall disposed between the cells compartment and the BMS compartment. A first post and a second post are associated with a battery cell. The first post and the second post protrude through the wall between the cells compartment to the BMS compartment. A voltage sensor electrically couples to the first post and the second post to monitor the voltage of the battery cell. A temperature sensor can couple to the first or second or both posts. The intelligent AGM battery system can predict the battery module's state of health, state of charge, module status, power capability, life expectancy, etc.

Abstract: Intelligent lead-acid battery system capable of monitoring a parameter (e.g., voltage, temperature) of one or more battery cells of a lead-acid battery. In one implementation, the battery system includes a housing having a cells compartment, a battery monitoring system (BMS) compartment, and a wall disposed between the cells compartment and the BMS compartment. A first post and a second post are associated with a battery cell. The first post and the second post protrude through the wall between the cells compartment to the BMS compartment. A voltage sensor electrically couples to the first post and the second post to monitor the voltage of the battery cell. A temperature sensor can couple to the first or second or both posts. The intelligent AGM battery system can predict the battery module's state of health, state of charge, module status, power capability, life expectancy, etc.

Abstract: Disclosed is a non-lead conductive cap for a battery terminal and battery. The battery may comprise a battery housing and a positive and negative terminal, the positive and negative terminal being accessible through the battery housing; wherein the positive and negative terminal further comprise an electrically conductive cap mounted on both the positive and negative terminal, wherein the electrically conductive cap does not comprise lead.

Abstract: An overcharge protection device cover assembly for use with a battery cell housing. The battery cell housing has a first terminal and a second terminal, the overcharge protection device cover assembly including a first terminal pad having a first length. The first terminal pad is contactable with the first terminal of the battery cell housing. The assembly also includes a second terminal pad having a second length that is greater than the first length. The second terminal pad is contactable with the second terminal of the battery cell housing. A reversal device of the assembly is deflectable toward the first and second terminal pads. A conductive element of the assembly is positioned between the reversal device and the first and second terminal pads.

Abstract: A method for bonding components of a lithium ion battery module includes positioning an energy absorbing insert adjacent to a first thermoplastic layer of the lithium ion battery module and to a second thermoplastic layer of the lithium ion battery module. Energy is applied to the energy absorbing insert to melt the energy absorbing insert and thereby fuse the first thermoplastic layer to the second thermoplastic layer. The first thermoplastic layer is a transmissive or semi-transmissive layer configured to allow the energy the pass through the first thermoplastic layer for absorption by the energy absorbing insert.

Abstract: Female-style terminals for an electrical power storage device is described herein. The terminals include one or more features that provide a more secure connection between a vehicle connector and the terminal compared to traditional clamp-style connectors. The terminals can include an annular ring or groove. The terminals can additionally or alternatively include a threaded portion and one or more protrusions. The electrical power storage device includes a cover, a portion of the cover adjacent to the terminal includes a keyed section to secure the connector. The disclosed terminals reduce or eliminate movement of the connector relative to the terminal, thereby reducing wear and increasing the performance of the connection.

Abstract: Example terminals on a battery cover and example battery covers are described herein. The example terminals provide a more secure connection between a terminal and a connector. Additionally, the example terminals may be shaped such that only specific batteries or battery types can be used with certain vehicles or connectors. The example battery covers may include terminal covers and handles that are integrated into the design of the cover such that a top surface of the cover is planar.

Abstract: A battery system includes an electrochemical cell. The electrochemical cell includes a cover having an opening. The electrochemical cell also includes an aluminum terminal pad disposed proximate an outer surface of the cover. The pad opening includes a tapered surface such that the pad opening has a larger cross-sectional width proximate an upper surface of the aluminum terminal pad than proximate a lower surface of the aluminum terminal pad opposite the upper surface and facing the outer surface of the cover. The electrochemical cell also includes a rivet having a body portion extending through the opening in the cover, a head portion disposed in the pad opening of the aluminum terminal pad, and a shoulder extending between the body portion and the head portion. The head portion includes an inverted cone shape corresponding with the tapered surface of the pad opening.

Abstract: A battery system includes a housing configured to receive a battery cell, where the battery cell is configured to output thermal energy as a byproduct of electrical energy generation and/or consumption, a wall of the housing positioned proximate to the battery cell, and a plurality of fins extending from the wall, where the plurality of fins is configured to absorb thermal energy from the battery cell and dissipate the thermal energy to air, or a heat sink, or both, and where a fin of the plurality of fins comprises a channel configured to facilitate a flow of the air between the fin of the plurality of fins and an adjacent fin of the plurality of fins.

Abstract: A battery terminal bushing is disclosed. The battery terminal bushing comprises a body having an insertion end and an exterior end opposite the insertion end. One or more sealing rings surround the body between the insertion end and the exterior end. A terminal post connector segment is provided on the insertion end of the body. An anti-torque pattern is provided on one or more surfaces of the body configured to engage and be contained within the battery housing material. A lead acid battery comprising the battery terminal bushing is also disclosed.