# US 12,002,993 B2 · Battery pack with wire bonded bus bars

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- Number: US 12,002,993 B2
- Document ID: US12002993B2
- Status: Granted
- Kind: B2
- Application number: 17/941,179
- Filed: 2022-09-09
- Published: 2023-03-16
- Granted: 2024-06-04
- Earliest claimed: 2021-09-10
- Assignees: Milwaukee Electric Tool Corporation
- Applicants: Milwaukee Electric Tool Corporation
- Inventors: Kyle J. Radovich; Mark E. Brouwer; Michael A. Barrowclift; Max Karbin; Kyle R. Becker; Tao Zhao
- Web page: https://patentgrep.com/patent/US12002993B2

## CPC

- H01M 50/505: comprising a single busbar
- H01M 50/519: comprising printed circuit boards [PCB]
- H01M 10/425: {Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing (printed circuits H05K1/00)}
- H01M 10/48: Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte (constructional details of current conducting connections for detecting conditions inside cells or batteries, e.g. details of voltage sensing terminals, H01M50/569)
- H01M 50/213: adapted for cells having curved cross-section, e.g. round or elliptic (H01M50/209, H01M50/216 take precedence)
- H01M 50/218: characterised by the material
- H01M 50/247: specially adapted for portable devices, e.g. mobile phones, computers, hand tools or pacemakers
- H01M 2220/30: Batteries in portable systems, e.g. mobile phone, laptop
- Y02E 60/10: Energy storage using batteries
- H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION

## Abstract

A mobile power source that has a battery pack including at least two battery cell assemblies each having frame that has a first support member and a second support member, each of the first and second support members including a plurality of cylindrical recesses that receive the plurality of battery cells to support the battery cells. Bus bars are coupled to the first support member via injection molding and each is configured to electrically connect to at least two battery cells. The bus bars each include an elongated conductive body that has a base and fingers extending laterally away from the base. Each of the fingers extend within a first plane, and the base extends within a second plane that is parallel to the first plane and offset therefrom.

## Claims

### Claim 1

A mobile power source comprising:
a battery pack including at least two battery cell assemblies, each battery cell assembly including
a plurality of battery cells each having a first end, a second end opposite the first end, a positive terminal located at the first end and a negative terminal located at the first end,
a frame having a first support member and a second support member, each of the first and second support members including a plurality of cylindrical recesses arranged in vertical columns that receive the plurality of battery cells to support the battery cells and elongate recesses, each of the elongate recesses positioned adjacent to at least one column of the plurality of cylindrical recesses; and
a bus bar positioned within each of the plurality of elongate recesses of the first support member and configured to electrically connect to at least two battery cells, each of the bus bars including an elongated conductive body having a base and fingers extending laterally away from the base, the base defining a recess extending along a longitudinal length of the base between at least two of the fingers, the fingers extending within a first plane and the base extending within a second plane that is parallel to the first plane and offset therefrom;
a connection member filling the recess in each base and integrally formed with the first support member to couple the corresponding bus bar to the first support member; and
wires that connect the fingers of each the bus bars to either the positive terminal or the negative terminals.

### Claim 2 (depends on 1)

The mobile power source of claim 1, wherein each of the bus bars include a first portion that includes the base and the fingers and a second portion coupled between the first portion and a voltage sensing PCB.

### Claim 3 (depends on 2)

The mobile power source of claim 2, wherein the first portion is formed from a first material and the second portion is formed from a second material that is different than the first material.

### Claim 4 (depends on 2)

The mobile power source of claim 2, wherein the first portion is formed from a material formed from aluminum and the second portion is formed from a material that formed from copper.

### Claim 5 (depends on 1)

The mobile power source of claim 1, wherein the bus bar positioned in a first outer elongated recess is a first outer bus bar, the bus bar positioned in a second outer elongated recess is a second outer bus bar, and the bus bars positioned within middle recesses positioned between the first outer recess and the second outer recess are middle bus bars, and wherein
the fingers of the first outer bus bar extend from the base in a first direction,
the fingers of the second outer bus bar extend from the base in a second direction, and
the fingers of the middle bus bars include first fingers extending in the first direction from the base and second fingers extending in the second direction from the base.

### Claim 6 (depends on 5)

The mobile power source of claim 5, wherein the first fingers and the second fingers are aligned along the longitudinal length of the base.

### Claim 7 (depends on 5)

The mobile power source of claim 5, wherein the wires include
first wires that connect the fingers of one of the first outer bus bar or the second outer bus bar to the negative terminals of at least two battery cells and the first fingers of each of the middle bus bars to the negative terminals of at least two battery cells, and
second wires that connect the fingers of the other of the first outer bus bar or the second outer bus bar to the positive terminals of at least two battery cells and the second fingers of the middle bus bars to the positive terminals.

### Claim 8 (depends on 1)

The mobile power source of claim 1, wherein the bus bars are coupled to the first support member without fasteners.

### Claim 9 (depends on 1)

The mobile power source of claim 1, wherein the first support member and the connection member are both formed from a same material.

### Claim 10

A method of forming a mobile power supply, the method comprising:
forming a frame having a first support member and a second support member, each of the first and second support members being formed from a plastic material and including a plurality of cylindrical recesses arranged in vertical columns that receive the plurality of battery cells to support the battery cells and elongate recesses, each of the elongate recesses positioned adjacent to at least one column of the plurality of cylindrical recesses;
positioning a bus bar within one of the elongate recesses of the first support member, each bus bar including an elongated conductive body having a base and fingers extending laterally away from the base, the base defining a recess extending along a longitudinal length of the base between at least two of the fingers, the fingers extending within a first plane and the base extending within a second plane that is parallel to the first plane and offset therefrom;
injecting the recess of each of the bases with the plastic material such that the plastic material fills the recess and integrally forms with the first support member;
positioning a plurality of battery cells between the first support member and the second support member such that the plurality of cylindrical recesses of the first support member and the second support member support the plurality of battery cells, each of the battery cells having a first end, a second end opposite the first end, a positive terminal located at the first end, and a negative terminal located at the first end; and
wire bonding wires between the fingers each of the bus bars and either the positive terminal or the negative terminals.

### Claim 11 (depends on 10)

The method of claim 10, wherein injecting the recess of each of the bases with the plastic material such that the plastic material integrally forms with the first support member includes leaving the fingers exposed.

### Claim 12 (depends on 10)

The method of claim 10, wherein each of the bus bars include a first portion having the base and the fingers and a second portion coupled to and extending from the first portion, the first portion being formed of a first conductive material and the second portion being formed of a second conductive material that is different from the first conductive material.

### Claim 13 (depends on 12)

The method of claim 12, further comprising coupling the second portion to a voltage sensing PCB.