U.S. patent application number 09/912048 was filed with the patent office on 2002-02-21 for modular battery.
This patent application is currently assigned to Johnson Controls Technology Company. Invention is credited to Andrew, Michael G., Bolstad, James J., Daley, James T., Pierson, John R., Segall, William P. JR..
Application Number | 20020022159 09/912048 |
Document ID | / |
Family ID | 25356098 |
Filed Date | 2002-02-21 |
United States Patent
Application |
20020022159 |
Kind Code |
A1 |
Pierson, John R. ; et
al. |
February 21, 2002 |
Modular battery
Abstract
A modular electric storage battery is adaptable to a variety of
applications, and for example, as a starting, lighting and ignition
(SLI) battery of a car, truck, motorcycle, lawn and garden
equipment or other internal combustion engine powered product. The
modular battery is constructed from a plurality of battery cells
assembled into a battery housing. The cells are sealed,
maintenance-free, rechargeable cells. The housing includes quick
connect termination, and the starting application is adapted with a
base unit having complementary termination. The modular battery and
base unit also include aligning features to ensure proper
interconnection of the battery terminals. The base unit may be
adapted to receive several sizes of modular battery. In addition, a
second modular battery, that may be configured as a flashlight or
other device, is provided and can inter-connected with the base
unit to provide a jump starting capability.
Inventors: |
Pierson, John R.;
(Brookfield, WI) ; Andrew, Michael G.; (Wauwatosa,
WI) ; Bolstad, James J.; (Shorewood, WI) ;
Daley, James T.; (Grafton, WI) ; Segall, William P.
JR.; (Grafton, WI) |
Correspondence
Address: |
Christopher M.Turoski
FOLEY & LARDNER
Firstar Center
777 East Wisconsin Avenue
Milwaukee
WI
53202-5367
US
|
Assignee: |
Johnson Controls Technology
Company
|
Family ID: |
25356098 |
Appl. No.: |
09/912048 |
Filed: |
July 24, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09912048 |
Jul 24, 2001 |
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08870803 |
Jun 6, 1997 |
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6265091 |
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Current U.S.
Class: |
429/1 ; 429/100;
429/159; 429/178; 429/94; 429/99; 439/500 |
Current CPC
Class: |
Y02E 60/10 20130101;
H01M 50/213 20210101; Y02P 70/50 20151101; H01M 6/40 20130101; H01M
50/296 20210101; H01M 50/227 20210101; H01M 50/543 20210101; H01M
50/528 20210101; H01M 50/278 20210101; H01M 10/125 20130101; H01M
50/20 20210101; H01M 10/06 20130101 |
Class at
Publication: |
429/1 ; 429/94;
429/99; 429/100; 429/159; 429/178; 439/500 |
International
Class: |
H01M 002/10; H01M
002/02 |
Claims
We claim:
1. A modular battery system for internal combustion engine starting
comprising: a base member, the base member having first and second
terminal receptors electrically coupled with first and second
connectors, the base member being adapted to receive a battery
module and the connectors being electrically coupled to a starting
and charging circuit of an internal combustion engine powered
application; and a battery module including at least one
electrochemical cell coupled to first and second terminals and
contained within a housing, wherein the battery module includes an
aligning formation formed in the housing, the aligning formation
adapted to engage a complementary formation formed in the base
member such that the first terminal is aligned and electrically
coupled with the first receptor and the second terminal is aligned
and electrically coupled with the second connector.
2. The modular battery system of claim 1 wherein the
electrochemical cell comprises a spiral wound thin metal film
cell.
3. The modular battery system of claim 1 wherein the battery module
comprises a plurality of electrochemical cells, the cells being
coupled to each other and to the terminals.
4. The modular battery system of claim 1 wherein the first and
second connectors comprise first and second battery cables adapted
for connection to the starting circuit.
5. The modular battery system of claim 1 wherein the aligning
formation comprises at least one ridge member formed in the housing
and a complementary channel member formed in the base member for
each ridge member.
6. The modular battery system of claim 1 wherein the battery module
is adapted to one of a plurality of capacities.
7. The modular battery system of claim 6 wherein the aligning
formation retains substantially identical physical attributes for
each of the plurality of capacities.
8. The modular battery system of claim 7 wherein the base member is
adapted to accept battery modules of each of the plurality of
capacities.
9. The modular battery system of claim 7 wherein the first and
second terminals are in spaced relationship to the aligning
formation for each of the plurality of capacities.
10. The modular battery system of claim 9 wherein the terminals are
aligned with the aligning formation for each of the plurality of
capacities.
11. The modular battery system of claim I wherein the terminals are
recessed within the housing.
12. The modular battery system of claim 1 further comprising: a
second base member, the second base member having first and second
terminal receptors electrically coupled with first and second
connectors, the base member being adapted to receive a battery
module and the connectors being electrically coupled to the
starting circuit of the internal combustion engine powered
application; and a second battery module including at least one
electrochemical cell coupled to first and second terminals and
contained within a housing, wherein the second battery module
includes an aligning formation formed in the housing, the aligning
formation adapted to engage a complementary formation formed in the
second base member such that the first terminal is aligned and
electrically coupled with the first receptor and the second
terminal is aligned and electrically coupled with the second
connector.
13. The modular battery system of claim 12 wherein the second
battery module is interchangeable with the battery module.
14. The modular battery system of claim 12 wherein base member is
adapted to receive the second battery module.
15. The modular battery system of claim 12 wherein the second
battery module is adapted for use as a flashlight.
16. The modular battery system of claim 15 wherein the second
battery module is adapted with a removable flashlight
attachment.
17. In a device requiring a source of electrical power, a system
for providing electrical power comprising: a base member, the base
member having first and second terminal receptors electrically
coupled with first and second connectors, the base member being
adapted to receive a battery module and the connectors being
electrically coupled to the device; and a battery module including
at least one electrochemical cell coupled to first and second
terminals and contained within a housing, wherein the battery
module includes an aligning formation formed in the housing, the
aligning formation adapted to engage a complementary formation
formed in the base member such that the first terminal is aligned
and electrically coupled with the first receptor and the second
terminal is aligned and electrically coupled with the second
connector.
18. The system of claim 17 wherein the device comprises a starting
circuit for an internal combustion engine of an internal combustion
engine powered device.
19. The system of claim 18 wherein the internal combustion engine
powered device comprises one of: a motor vehicle, a tractor, a
motorcycle, an all-terrain vehicle, a snowmobile, a marine craft, a
lawn and garden power tool, and an aircraft.
20. The system of claim 19 wherein the base portion is adapted to
be coupled to either of a top terminal type connector and a side
terminal type connector of the starting circuit.
21. The system of claim 19 wherein the base portion includes an
adapter, the adapter being configured to couple to one of a top
terminal and a side terminal type connector of the starting
circuit.
22. The system of claim 17 wherein the device comprises an
uninterrupted power supply system.
23. The system of claim 17 wherein the application comprises a
power system of a hybrid electric vehicle.
24. The system of claim 17 wherein the base member is formed
integral with the device.
25. The system of claim 17 wherein the electrochemical cell
comprises a spiral wound thin metal film cell.
26. The system of claim 17 wherein the battery module comprises a
plurality of electro-chemical cells, the cells being coupled to
each other and to the terminals.
27. The system of claim 17 wherein the aligning formation comprises
at least one ridge member formed in the housing and a complementary
channel member formed in the base member for each ridge member.
28. The system of claim 17 wherein the battery module is adapted to
one of a plurality of capacities.
29. The system of claim 28 wherein the aligning formation retains
substantially identical physical attributes for each of the
plurality of capacities.
30. The system of claim 29 wherein the first and second terminals
are in spaced relationship to the aligning formation for each of
the plurality of capacities.
31. The modular battery system of claim 30 wherein the terminals
are aligned with the aligning formation for each of the plurality
of capacities.
32. The system of claim 29 wherein the base member is adapted to
accept battery modules of each of the plurality of capacities.
33. The modular battery system of claim 17 wherein the terminals
are recessed within the housing.
34. The system of claim 17 further comprising: a second base
member, the second base member having first and second terminal
receptors electrically coupled with first and second connectors,
the base member being adapted to receive a battery module and the
connectors being electrically coupled to the device; and a second
battery module including at least one electrochemical cell coupled
to first and second terminals and contained within a housing,
wherein the second battery module includes an aligning formation
formed in the housing, the aligning formation adapted to engage a
complementary formation formed in the second base member such that
the first terminal is aligned and electrically coupled with the
first receptor and the second terminal is aligned and electrically
coupled with the second connector.
35. The system of claim 34 wherein the second battery module is
interchangeable with the battery module.
36. The system of claim 34 wherein base member is adapted to
receive the second battery module.
37. The system of claim 34 wherein the second battery module is
adapted for use as a flashlight.
38. The system of claim 37 wherein the second battery module is
adapted with one of a removable flashlight attachment, a removable
power tool and a removable electronic device.
Description
FIELD OF THE INVENTION
[0001] The present invention relates generally to electric storage
batteries, and more particularly, to a modular electric storage
battery adaptable for a variety of applications.
BACKGROUND OF THE INVENTION
[0002] Existing starting, lighting and ignition (SLI) batteries of
the type commonly used to start the internal combustion engines of
cars, trucks, motorcycles, lawn and garden equipment and the like
are large, heavy, flooded electrolyte type lead-acid batteries.
These batteries consist almost exclusively of a prismatic container
into which a number of partitions are formed in order to define
cells. Stacks of electrodes, made from interleaved positive and
negative plates and separator material, are inserted into the cells
and are electrically interconnected and connected with either top
or side terminal mounts. The plates are typically lead or lead
alloy grids covered with an active material such as lead dioxide.
The cells are flooded with electrolyte, usually a dilute sulfuric
acid solution, and a cover is heat sealed to the container. Vents
are provided in the cover to allow for the venting of gases
generated during the normal discharge and recharge cycles.
[0003] A typical SLI battery can weigh as much as twenty (20)
kilograms. The construction also requires careful top-up mounting
to avoid spillage of electrolyte. Because of its size, the use of
liquid electrolyte, venting and other concerns, the SLI battery has
typically been mounted within the engine compartment of cars and
trucks. However, it is known that battery life is adversely
affected by heat and vibration so the engine compartment is
actually an undesirable location. In addition, the size, weight,
liquid electrolyte and gassing makes replacing worn or discharged
batteries a task best left to a skilled mechanic. Jump starting a
vehicle when the battery is discharged poses certain problems, and
requires a second vehicle or energy source.
[0004] Thin metal film battery technology provides in a compact
design a high power battery cell. Cells of this type are well known
and their construction and manufacture have been described in, for
example, U.S. Pat. Nos. 3,494,800; 5,045,086; 5,047,300; 5,198,313
and 5,368,961 the disclosures of which are hereby expressly
incorporated herein by reference. A thin metal film battery cell
includes thin metal film plates sealed within a sealed cell
container which is valve regulated. The cells include absorptive
glass-mat (AGM) separator technology in an electrolyte starved
system. The thin metal film plates are made from very thin lead
foil approximately about 0.005 inches thick, pasted with an active
material forming a pasted plate approximately about 0.012 inches
thick. The plates are spiral wound with separator material, and
terminations are cast-on or soldered to the ends of the spiral
roll. The roll is encapsulated in a container which is filled with
electrolyte and then sealed except for the vent. The performance
characteristics of thin metal film cells include a high
power/weight ratio and rapid recharge capability.
[0005] In spite of the existence of alternate cell technology, the
typical SLI battery remains a large, heavy, flooded electrolyte
battery. Such SLI battery construction has left little flexibility
to the car, truck or other product designer in packaging and
protecting the SLI battery. Cars and trucks still find large, heavy
SLI batteries located in the harsh under-hood environment.
[0006] In certain instances which can not be totally avoided, the
SLI battery may become discharged such that it can not provide
sufficient energy to start the engine of the car, truck or other
product. The common response to this problem is to couple a second
energy source, such as the electrical system of a second vehicle or
a specially designed jump starting energy source, to the SLI
battery. When coupled, the second energy source provides the energy
to start the engine, and once running, the engine is capable of
providing energy through a suitable charging system for recharging
the discharged SLI battery. However, one must be careful to
properly couple the energy sources. Failing to do so can lead to
serious damage to the electrical system of the vehicle, the SLI
battery and the second energy source. In the discharged battery
situation, with a typical SLI battery it is highly impractical but
would be very desirable to simply remove the discharged battery and
replace it with another battery having sufficient charge to start
the engine. Unfortunately, however, the typical large, heavy SLI
battery is not readily removed or uncoupled from the vehicle. And,
without a second energy source, the vehicle operator will be
stranded.
SUMMARY OF THE INVENTION
[0007] A preferred embodiment of the present invention provides a
modular electric storage battery capable of functioning as an SLI
battery for a car or truck or adaptable to a number of other
applications. The modular battery is maintenance free and sealed
such that use and handling is greatly simplified. In some
applications, the modular battery provides up to a 75 percent
weight savings over traditional battery designs. The modular
battery includes quick coupling terminals and is adapted to couple
into a base unit adapted to a given application for supplying
electrical energy thereto.
[0008] In another embodiment of the present invention, base units
and modular batteries are designed to be interchangeable. That is,
the base units include terminal receptors and aligning features.
Likewise, the modular batteries include terminals and complementary
aligning features. The terminals are designed to couple without the
use of tools. The base units may be designed to accept one of
several sizes of modular batteries (for example the base unit would
be designed to accept 1.2, 2.4, 4.8, etc. amp hour capacity modular
batteries).
[0009] The base units may configured to be installed and coupled
into the electrical system of a motor vehicle such as a car, truck,
motorcycle or lawn and garden tractor. A modular battery is plugged
into the base unit for providing starting energy. This modular
design offers a number of potential advantages. First among these
is a very easy ability to replace a worn or discharged battery, or
to install a higher capacity battery if necessary. In the event of
battery discharge, as opposed to jumping, the discharged battery
may be easily removed and a fresh battery plugged in to start the
vehicle.
[0010] In still another preferred embodiment of the present
invention, the vehicle may be adapted with a second base unit and a
second modular battery. The second base unit is coupled into the
vehicle electrical system so that the second modular battery
plugged into the unit is maintained at a full state of charge. The
second modular battery can then be used in jump starting situations
by exchanging it for the starter modular battery. The second
modular battery unit is also adapted to function with a number of
accessory items. For example a lantern or flashlight attachment, a
power wrench attachment, television or other portable electronic
device and the like. The second modular battery unit may also be
specially configured as, for example, a flashlight or similar item
in which case an attachment is not necessary for providing the
additional function.
[0011] In still an additional embodiment of the present invention,
the base units form an integral part of the fuse block of an
automotive electrical system or are installed as part of interior
components. In this regard, the base unit may be made part of, for
example, the instrument panel, the door trim panels or the seat
structures of the vehicle. Thus it will be appreciated that the
modular battery greatly frees the vehicle designer from the design
constraints associated with the typical SLI battery.
[0012] These and other advantages and applications of the present
invention will be appreciated by one of ordinary skill in the art
from the following detailed description of the preferred
embodiments and the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a perspective view of a modular battery in
accordance with a preferred embodiment of the present invention
with the top cover removed for clarity;
[0014] FIG. 2 is a side view of the modular battery shown in FIG.
1;
[0015] FIG. 3 is a top view of the modular battery shown in FIG. 1
with the top cover removed for clarity;
[0016] FIG. 4 is a bottom perspective view of the modular battery
shown in FIG. 1 and illustrating the battery terminals;
[0017] FIG. 5 is a perspective view of a base unit in accordance
with a preferred embodiment of the present invention;
[0018] FIG. 6 is a top view of the base unit shown in FIG. 5;
[0019] FIG. 7 is a side view of the base unit shown in FIG. 5 with
the terminal receptors shown in phantom;
[0020] FIG. 8 is a perspective view of a modular battery in
accordance with another preferred embodiment of the present
invention with the top cover removed for clarity;
[0021] FIG. 9 is a top view of the modular battery shown in FIG. 8
with the top cover removed for clarity;
[0022] FIG. 10 is a top view of a modular battery in accordance
with another preferred embodiment of the present invention with the
top cover removed for clarity;
[0023] FIG. 11 is a side view of terminal support for use with the
modular battery shown in FIG. 10;
[0024] FIG. 12 is a side view of a flashlight/modular battery in
accordance with a preferred embodiment of the present
invention;
[0025] FIG. 13 is a bottom end view of the flashlight/modular
battery shown in FIG. 12;
[0026] FIG. 14 is a lens view of the flashlight/modular battery
shown in FIG. 12;
[0027] FIG. 15 is a side view of the flashlight/modular battery
shown in FIG. 12 partially broken away to reveal the battery
cells;
[0028] FIG. 16 is a cross-section view of the flashlight/modular
battery shown in FIG. 12 and taken along line 16-16 of FIG. 12;
[0029] FIG. 17 is a schematic illustration of an electrical system
adapted in accordance with a preferred embodiment of the invention
for starting the internal combustion engine of a motor vehicle;
[0030] FIG. 18 is a schematic illustration of an electrical system
adapted in accordance with a second preferred embodiment of the
invention for starting the internal combustion engine of a motor
vehicle;
[0031] FIG. 19 is a front view of a light attachment for a modular
battery in accordance with a preferred embodiment of the present
invention;
[0032] FIG. 20 is a rear view of the light attachment shown in FIG.
17; and
[0033] FIG. 21 is a side view of the light attachment shown in FIG.
17 and further illustrating a modular battery for clarity.
DETAIL DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0034] The present invention is described in terms of preferred
embodiments and particularly in an exemplary modular battery
adapted for use as a starting, lighting and ignition (SLI) battery
for starting the internal combustion engines of cars, trucks,
motorcycles, lawn and garden equipment or other internal combustion
engine powered products. The modular battery is constructed from a
plurality of battery cells assembled into a battery housing. The
cells are sealed, maintenance-free, rechargeable cells and
preferably thin metal film battery cells. The modular battery
includes quick connect termination, and the starting application is
adapted with a base unit having complementary termination. The
modular battery and base unit also include aligning features to
ensure proper interconnection of the battery terminals. The base
unit may be adapted to receive several sizes of modular battery. In
addition, a second modular battery, that may be configured as a
flashlight or other device, is provided and can inter-connected
with the base unit to provide a jump starting capability.
[0035] Throughout the following description like reference numerals
are used to described like elements. Referring then to FIGS. 1-4,
modular battery 10 includes a housing 12 into which a plurality of
battery cells 14 are inserted. A top member is not shown in the
figures, but it will be appreciated by one of ordinary skill in the
art that a top member may be secured to housing 12 by bonding, heat
sealing or any other suitable means for enclosing housing 12. The
top member was omitted from the figures to facilitate illustration
of the component members of modular battery 10. Housing 12 is
preferably formed from a thermoplastic material such as
polypropylene as would be the top member.
[0036] Battery cells 14 are preferably thin metal film lead-acid
battery cells of the type shown and described in the aforementioned
United States patents. It should be understood, however, that the
principals of the present invention may be employed with other
battery cell formats without departing from its fair scope. Battery
cells 14 include positive and negative terminations 16 and 18 at
opposing ends, respectively, which are interconnected in series via
straps 20. Battery cells 14 are further connected to positive and
negative terminals 22 and 24, respectively, to form a 12 volt, 1.2
amp hour capacity battery. Battery cell 14 interconnection is
further illustrated in FIG. 3 with additional straps 20 shown in
phantom. As will be described herein later, modular battery 14 is
readily adapted to other sizes and capacities.
[0037] With continued reference to FIGS. 1-4, housing 12 is formed
with a plurality of apertures 26. In the event of the venting of
gases by battery cells 14, apertures 26 allow for the escape of the
these gases from housing 12. Apertures 26 are shown formed in side
wall members 32 and 34 of housing 12, although it should be
understood that apertures may be formed in fewer or more wall
members as required to provide adequate venting for the battery
cells 14. As best seen in FIG. 4, apertures (partially shown as 36)
are formed in bottom 40 of housing 12 and provide access to
terminals 22 and 24. Terminals 22 and 24 are preferably recessed
with respect to bottom 40 and are contained entirely within housing
12 in order to reduce the potential for shorting terminals 22 and
24 during use, installation and/or storage of modular battery
10.
[0038] Referring now to FIGS. 5-7 base unit 50 includes housing 52
including wall members 54-60 and base member 62. Side wall members
58-60 are shown as double wall members, however, it may be
preferred to form housing 52 as a single molded plastic piece.
Mounted into base member 62 are positive and negative terminal
posts 64 and 66, respectively. Terminal posts 64 and 66 are formed
with a threaded end which is passed through apertures formed in
base member 62. Nuts 72-76 secure terminal posts 64 and 66 to base
member 62. It will be appreciated that suitable cabling is provided
and is coupled to terminal posts 64 and 66 for electrically
coupling them to the electrically powered device.
[0039] Terminal posts 64 and 66 are a pair of cylindrical members
of a suitable conductive material. Terminals 22 and 24 are a pair
of annular members of a suitable conductive material and having an
inside diameter sized to provide sliding, tool-less engagement with
terminal posts 64 and 66, respectively, thereby electrically
coupling modular battery 10 to base unit 50. In this manner,
modular battery 10 is simply and easily electrically coupled to the
powered device. It should be appreciated that terminals 22 and 24
and posts 64 and 66 need not be annular and cylindrical,
respectively, but be of any configuration which provides quick,
secure coupling of the battery module to the base unit without the
use of tools.
[0040] With further reference to FIGS. 5-7 wall members 58 and 60
are formed with channels 68 and 70, respectively. Housing 12 is
formed with first and second aligning members 28 and 30,
respectively. Aligning members 28 and 30 are a pair a raised
surfaces formed in side walls 32 and 34, respectively. Aligning
members 28 and 30 are sized to respectively engage channels 70 and
68. Channel 70 and aligning member 28 have a slightly larger width
than channel 68 and aligning member 30. This ensures that battery
module 10 is inserted into base unit 50 in the correct orientation
such that the terminals 64 and 66 align and engage with terminal
posts 72 and 74, respectively, and a reverse polarity situation is
avoided.
[0041] With reference now to FIGS. 8 and 9, a modular battery 10'
of higher capacity is shown. Prime reference numerals are utilized
to refer to elements which are similar to previously referenced
elements but modified in accordance with the alternate preferred
embodiment. As seen in FIGS. 8 and 9, modular battery 10' includes
a housing 12' which is enlarged to receive twelve (12) battery
cells 14. Battery cells 14 are interconnected and connected to
positive and negative terminals 22 and 24, respectively, via straps
20' to form a twelve (12) volt, 2.4 amp hour capacity battery. As
is noted from FIGS. 3 and 9, aligning members 28 and 30 are
substantially aligned with terminals 22 and 24 along line t-t.
Moreover, the width "w" of modular battery 10 and modular battery
10' is the same. The added capacity of modular battery 10' was
created by increasing the length "I" of housing 12' and inserting
additional battery cells 14. In this manner, terminals 22 and 24
are maintained in constant relationship with aligning members 28
and 30. More importantly, modular batteries 10 and 10' of different
sizes may be accommodated by base unit 50 simply by providing a
sufficient length "I" for base unit 50. It may be preferable to
remove wall 56 providing acceptance of modular batteries of various
capacities into base unit 50.
[0042] In operation, modular batteries of differing capacities can
easily be coupled into an application. For example, if the
application is starting the internal combustion engine of an
automobile and the modular battery becomes discharged, the modular
battery may be easily removed without the use of tools and a
battery from another car or truck, a motorcycle, a lawn and garden
tractor, and the like of suitable voltage and capacity may be
substituted for starting the car. Hence, modular batteries 10 and
10' share certain common dimensions which ensure
inter-changeability and simplified battery replacement. Moreover,
modular batteries 10 and 10' provide self aligning features to
virtually eliminate improper installation. It will be further
appreciated that modular batteries for different applications may
be made with differing aligning features such that batteries from
incompatible applications are not incorrectly substituted.
[0043] FIGS. 10 and 11 illustrate still another embodiment of the
modular battery 10". Modular batter 10" includes a housing 12" into
which numerous battery cells 14 are inserted. Included within
housing 12" is a terminal support member 80. In this arrangement a
very high capacity modular battery may be formed. As will be
appreciated strap members (not shown) are provided for
interconnecting battery cells 14 into the desired capacity battery.
Again, housing 12" is shown without a top it being understood that
a suitable top member will be provided and secured to housing
12".
[0044] Terminal support 80 is a non-conductive support member into
which positive and negative terminals may be secured in apertures
82 and 84 formed therein. Terminal support 80 may be adapted to
threadably receive annular terminals 86 or post-type terminals 88
commonly found on SLI battery products. For exemplary purposes one
each of an annular terminal 86 and a post terminal 88 are shown in
FIG. 11 it being understood that in most application similar
terminals will be adapted to support 80. Terminals 86 and 88 are
suitably electrically coupled to battery cells 14, such as by
straps (not shown). Hence, modular battery 12" may be configured as
a replacement battery product for a traditional SLI battery.
[0045] Referring now to FIGS. 12-16 an additional embodiment of the
modular battery of the present invention is shown. In FIGS. 12-16
the modular battery of the present invention is configured as a
flashlight 100. Flashlight 100 has a substantially cylindrical
housing 102 formed with a plurality of axial ribs 103 for enhancing
grip. At one end of flashlight 100 is a lamp assembly 106 including
a lens 108, lamp 110 and reflector (not shown). At the other end of
flashlight 100 is a pair of terminals 112 and 114. As seen in FIG.
15 contained within housing 102 are a plurality of battery cells 14
suitably coupled to receive and/or deliver electrical energy
through terminals 112 and 114. Battery cells 14 are also coupled
via switch 104 to provide electrical energy to lamp 110. Flashlight
100 is operated by selective activation of switch 104.
[0046] In a preferred embodiment, flashlight 100 is adapted to
engage a base unit for receiving charge from a vehicle electrical
system. In this regard, terminals 112 and 114 are sized and spaced
to engage terminal posts 64 and 66 of base unit 50. In addition,
aligning formations 116 and 118 are formed in the end of housing
102 for engaging channels 68 and 70 of base unit 50. In the
preferred embodiment, the vehicle is adapted with a second base
unit into which flashlight 100 is secured for most vehicle
operation. When a need arises for a light source flashlight 100 may
be removed from the base unit and used. In the event of discharge
of the starter battery, flashlight 100 may further be used as the
energy source for starting the car or truck. In this regard, the
starter battery is removed from base unit 50 and flashlight 100
inserted in its place. Since flashlight 100 is normally maintained
at a full state of charge, it possess sufficient energy to start
the vehicle. It may be preferable to configure flashlight 100 in a
voltage slightly greater than the standard starting battery
voltage. This configuration would provide an increased pulse for
starting applications without substantially increasing the overall
volume of flashlight 100.
[0047] Referring now to FIG. 17 an electrical circuit 110 for
starting the internal combustion engine of a typical motor vehicle
and charging the starting battery is shown. A modular battery
system 112, including a modular battery and base unit in accordance
with preferred embodiments of the present invention, is
electrically coupled via switch 114 to starting motor 116 and
directly to controller 118. Controller 118, as is well known in the
art, may embody dedicated circuitry or may be integrated into an
engine/powertrain control module associated with the internal
combustion engine driven application. Controller 118 functions to
regulate the voltage (V1) delivered from alternator 120 in response
to being driven by the internal combustion engine to other
electrical loads (represented as essential loads 122 and other
loads 124) of the application. Controller 118 further functions to
regulate current flow in response to the charge state of the
modular battery of modular battery system 112 for charging the
modular battery. For starting the internal combustion engine of the
application, switch 114 is closed allowing current to flow from
battery system 112 to motor 116 which is coupled to the internal
combustion engine as is very well known in the art.
[0048] In FIG. 18, an electrical circuit 110' similar to that of
FIG. 17 is shown but is adapted with a second modular battery
system 126, in accordance with another preferred embodiment of the
present invention. Second modular battery system 126 is coupled to
controller 118' which functions similar to controller 118 and
further regulates a flow of current in response to the charge state
of the modular battery of second modular battery system 126 for
maintaining the modular battery at a substantially full state of
charge. That is, during normal operation of the application, the
charge of the modular battery in system 126 is maintained. As
illustrated, system 126 may embody a flashlight configuration as
described above or may simply embody a second modular battery. The
second modular battery is available for additional functions such
as being adapted with a flashlight attachment or adapted to other
electrically powered devices.
[0049] Preferably the second modular battery is also adaptable to
first battery system 112. That is, in the event that the modular
battery of system 112 becomes discharged, it may be removed from
system 112 and the modular battery of system 126 substituted
therefore for providing electrical energy for starting the internal
combustion engine. With sufficient voltage protection designed into
controller 118, after the internal combustion engine is started,
the second modular battery may be removed from system 112 and the
first modular battery reinstalled to receive charge. Alternatively,
the discharged modular battery may be coupled to the system 126 and
allowed to charge during operation of the application and later
replaced into system 112.
[0050] Referring now to FIGS. 19-21 the modular battery of the
present invention may be adapted for numerous other applications
beyond the SLI function. In FIGS. 17-19a lamp attachment 200
includes a light housing member 202, a switch housing 204, switch
206, terminal posts 208 and 210. Mounted into light housing member
202 is lens 212 behind which is secured a lamp and reflector (not
shown) which is of standard flashlight construction. The lamp is
electrically coupled into switch housing 204 within which it is
switchably coupled via switch 206 to terminal posts 208 and 210. In
accordance with the present invention, terminal posts 208 and 210
are configured and spaced to engage the standard spacing of the
terminals 22 and 24 of modular battery 10. In this manner, lamp
attachment is easily secured to modular battery 10 for providing
electrical energy to switch housing 202. Selective activation of
switch 206 couples modular battery 10 to the lamp. Lamp attachment
200 may be carried within a car. Should a light source be required,
modular battery 10 may be easily removed from base unit 50 and
light attachment 200 secured thereto. In a preferred arrangement,
the car or truck is equipped with a second modular battery which
may be utilized for providing energy source.
[0051] The present invention has been disclosed and described in
terms of several preferred embodiments. One of ordinary skill in
the art will readily appreciate its many applications and its fair
scope as defined in the subjoined claims.
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