Method and apparatus for making internal connections within a battery pack
View Patent ↗A battery pack which provides for the making of internal connections within the battery pack includes a plurality of apertures ( 206 ) having battery pack contacts ( 204 ) in register with the apertures ( 206 ) and are located on top of corresponding metal tabs ( 104 ). The invention allows for a welding tip to be passed through the aperture ( 206 ) in order to weld the battery pack contacts ( 204 ) to their corresponding metal tabs ( 104 ). Once welded the apertures ( 206 ) can be sealed by preferably placing a battery label over the apertures ( 206 ).
1. A method for making internal connections within a battery pack, comprising the steps of:
providing an access port in the battery pack;
providing a battery contact in register with the access port;
providing a flat tab having a substantially rectangular cross section internal to the battery pack and in substantial alignment with the battery contact; and
welding the battery contact to the tab through the access port.
2. A method as defined in claim 1 , wherein the welding step comprises parallel resistance welding the battery to the contact tab.
3. A method as defined in claim 2 , further comprising the step of:
sealing the access port after the battery contact has been welded to the tab.
4. A method as defined in claim 3 , wherein the sealing step comprises attaching a label to the battery pack which covers the access port.
5. A method as defined in claim 2 , wherein the step of providing a battery pack in register with the access ports comprises the step of:
molding the battery contact to the battery back such that a portion of the battery contact is presented at the access port.
6. A method as defined in claim 2 , wherein the step of providing a tab comprises providing a tab which is electrically coupled to a battery cell which is located within the battery pack.
7. A battery pack, comprising:
a battery housing;
a battery cell located within the housing;
a flat tab having a substantially rectangular cross section electrically coupled by welding to the battery cell;
a battery pack cover attached to the battery housing such that the battery cell is enclosed within the battery housing and battery pack cover,
where the battery pack cover includes:
an access port; and
a battery pack contact attached to the cover and having a portion of the battery contact presented at the access port such that the battery contact and tab are aligned with each other and with the access port.
8. A battery pack as defined in claim 7 , wherein the access port is an aperture which is large enough to allow for attachment of the battery pack contact to the tab through the aperture.
9. A battery pack as defined in claim 7 , wherein the tab is attached to a flexible circuit which provides electrical interconnection between the tab and the battery cell.
10. A battery pack as defined in claim 7 , wherein the battery pack cover is ultrasonically welded to the battery housing.
11. A battery pack as defined in claim 7 , wherein a portion of the battery pack contact is partially molded into the battery cover.
12. A battery pack as defined in claim 7 , wherein the battery contact has a split end.
13. A battery pack as defined in claim 7 , wherein the battery contact is welded to the tab.
14. A battery pack as defined in claim 7 , wherein the tab is attached to the battery cell.
15. A battery pack as defined in claim 9 , wherein the cover includes an alignment guide and the flexible circuit includes an aperture for receiving the alignment guide.
16. A battery pack as defined in claim 12 , wherein the split end has a bumped out portion that mates with the tab.
17. The battery pack as defined in claim 11 , wherein the battery pack contact is cantilevered to either contact.