U.S. patent application number 12/708100 was filed with the patent office on 2010-06-10 for battery connector.
This patent application is currently assigned to Johnson Controls Technology Company. Invention is credited to Kenneth R. Davis, Daniel P. Heil, Edward N. Mrotek.
Application Number | 20100144192 12/708100 |
Document ID | / |
Family ID | 38174241 |
Filed Date | 2010-06-10 |
United States Patent
Application |
20100144192 |
Kind Code |
A1 |
Davis; Kenneth R. ; et
al. |
June 10, 2010 |
BATTERY CONNECTOR
Abstract
A device for electrically connecting a plurality of batteries
includes a member including a handle and two arms extending from
the handle. The handle includes a first portion, a second portion
spaced apart from the first portion, and a connector extending
between the first portion and the second portion. The member also
includes a contact coupled to a first of the two arms for
contacting at least a portion of a battery terminal when the device
is secured to a battery. The first of the two arms is configured
for securing the device to a first side of a battery and a second
of the two arms is configured for securing the device to a second
side of the battery.
Inventors: |
Davis; Kenneth R.; (Grafton,
WI) ; Mrotek; Edward N.; (Grafton, WI) ; Heil;
Daniel P.; (Savannah, MO) |
Correspondence
Address: |
LATHROP & CLARK LLP
740 REGENT STREET SUITE 400, P.O. BOX 1507
MADISON
WI
537011507
US
|
Assignee: |
Johnson Controls Technology
Company
|
Family ID: |
38174241 |
Appl. No.: |
12/708100 |
Filed: |
February 18, 2010 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
12248662 |
Oct 9, 2008 |
7690943 |
|
|
12708100 |
|
|
|
|
11703767 |
Feb 8, 2007 |
7452235 |
|
|
12248662 |
|
|
|
|
10900042 |
Jul 27, 2004 |
|
|
|
11703767 |
|
|
|
|
60490463 |
Jul 28, 2003 |
|
|
|
60497596 |
Aug 25, 2003 |
|
|
|
Current U.S.
Class: |
439/504 |
Current CPC
Class: |
H02J 7/0045 20130101;
H02J 7/0013 20130101; H01M 10/46 20130101; Y02E 60/10 20130101;
H01M 50/502 20210101 |
Class at
Publication: |
439/504 |
International
Class: |
H01R 11/00 20060101
H01R011/00 |
Claims
1. A device for electrically connecting a plurality of batteries
comprising: a member including a handle and two arms extending from
the handle, the handle including a first portion, a second portion
spaced apart from the first portion and generally parallel with the
first portion for at least a substantial length of the second
portion, and a connector extending between the first portion and
the second portion within a generally parallel section of the first
and second portions; and a contact coupled to a first of the two
arms for contacting at least a portion of a battery terminal when
the device is secured to a battery; wherein the first of the two
arms is configured for securing the device to a first side of a
battery and a second of the two arms is configured for securing the
device to a second side of the battery.
2. The device of claim 1 wherein at least a portion of the member
comprises a relatively flexible material so that the two arms may
be clamped to opposite sides of a battery.
3. The device of claim 1 wherein the arms and the handle portion
have a generally U-shaped configuration.
4. The device of claim 1 further comprising a wire coupled to the
contact.
5. The device of claim 4 further comprising a post coupled to the
member and electrically connected to the contact by the wire.
6. The device of claim 1 wherein the contact comprises a material
comprising lead.
7. The device of claim 1 wherein the first of the two arms
comprises a coupler and the contact includes a projection for
coupling the contact to the coupler.
8. The device of claim 1 further comprising a web of material
provided adjacent the connector and extending between the first
portion and the second portion for providing enhanced structural
rigidity for the device.
9. The device of claim 1 further comprising at least one projection
extending from the first portion.
Description
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
[0001] This application is a Continuation of U.S. application Ser.
No. 12/248,662, filed Oct. 9, 2008, which itself is a Continuation
of U.S. patent application Ser. No. 11/703,767 filed Feb. 8, 2007,
which is itself a Continuation of U.S. Patent application Ser. No.
10/900,042 filed Jul. 27, 2004, which claims the benefit under 35
U.S.C. .sctn.119(e) of U.S. Provisional Application No. 60/490,463,
filed Jul. 28, 2003, and U.S. Provisional Application No.
60/497,596, filed Aug. 25, 2003.
[0002] The following U.S. patent applications are expressly
incorporated herein by reference in their entirety: U.S. patent
application Ser. No. 12/248,662; U.S. patent application Ser. No.
11/703, 767; U.S. patent application Ser. No. 10/900,042; U.S.
Provisional Application No. 60/490,463, filed Jul. 28, 2003, and
U.S. Provisional Application No. 60/497,596, filed Aug. 25,
2003.
BACKGROUND
[0003] The present invention relates generally to the field of
batteries (e.g., lead-acid starting, lighting, and ignition
batteries such as those used as automotive batteries) and the
manufacturing of such batteries. More specifically, the present
inventions relate to connectors for use in battery charging or
formation operations with batteries having terminals provided on a
side surface of such batteries.
[0004] When batteries are initially charged in a manufacturing
facility (referred to as battery "formation"), it is generally more
efficient to simultaneously charge a number of batteries.
Accordingly, a number of batteries are typically electrically
connected together in series using wires that include contacts or
leads on each end of the wire. The wires and contacts connect a
positive terminal of a battery to a negative terminal of an
adjacent battery. This process is repeated until all batteries are
connected together. The first and last battery in the series have a
terminal that is not connected to another battery, but rather to a
charging or recharging device. For example, the negative terminal
of the first battery and the positive terminal of the last battery
in the series may be connected to the charging or recharging
device. When the charging or recharging device subsequently
provides a charge to the batteries, all connected batteries will be
charged simultaneously.
[0005] Certain batteries are manufactured such that they include
side terminals or bushings. Such bushings may be configured such
that the battery terminals may be connected to automobile battery
cables by threading a portion of the leads of the battery cables
into a threaded aperture provided in the terminals or bushings.
[0006] Initial charging of side terminal batteries in manufacturing
operations may be difficult in that conventional wires and contacts
used to connect a series of batteries together involve a threaded
contact that is screwed into the threaded battery terminals or
bushings. While such a configuration may provide for a relatively
secure connection between the contacts and the terminals, one
disadvantage of such a configuration is that the connection of a
number of batteries may be relatively inefficient in that time and
energy is expended to screw a contact into a threaded aperture and
to remove it after charging is complete.
[0007] Further, during manufacturing operations, several rows of
batteries may be placed adjacent to each other, with each row
representing one connected series of batteries. The spacing between
such adjacent rows may be such that it is difficult or awkward for
an operator to reach between the batteries to screw a contact into
the battery terminals.
[0008] It would therefore be advantageous to provide an improved
system for electrically connecting batteries together for a battery
charging operation (e.g., a battery formation operation). It would
also be advantageous to provide a system for electrically
connecting batteries together that is relatively efficient and that
provides a relatively secure coupling between contacts and battery
terminals in order to avoid undesirable shorting of batteries
during charging. It would also be advantageous to provide a system
and/or method for electrically connecting batteries that utilizes a
relatively simple device that is resistant to various conditions in
a manufacturing facility (e.g., exposure to acid, etc.). It would
be advantageous to provide a system and/or a method that may be
used to obtain one or more of these or other advantageous
features
SUMMARY
[0009] An exemplary embodiment relates to a device for electrically
connecting a plurality of batteries and includes a member including
a handle and two arms extending from the handle. The handle
includes a first portion, a second portion spaced apart from the
first portion, and a connector extending between the first portion
and the second portion. The member also includes a contact coupled
to a first of the two arms for contacting at least a portion of a
battery terminal when the device is secured to a battery. The first
of the two arms is configured for securing the device to a first
side of a battery and a second of the two arms is configured for
securing the device to a second side of the battery.
[0010] Another exemplary embodiment relates to a system for
electrically coupling a plurality of batteries together for a
battery charging operation. The system includes a first member
comprising a handle portion and two arms extending from the handle
portion. The handle portion includes a first portion, a second
portion spaced apart from the first portion, and a bridge
connecting the first portion to the second portion. The system also
includes a second member comprising a handle portion and two arms
extending from the handle portion. The handle portion includes a
first portion, a second portion spaced apart from the first
portion, and a bridge connecting the first portion to the second
portion. The system also includes a first contact provided on one
of the two arms of the first member and configured for engaging a
battery terminal and a second contact provided on one of the two
arms of the second member and configured for engaging a battery
terminal. A cable electrically connects the first contact to the
second contact.
[0011] Another exemplary embodiment relates to a battery charging
arrangement that includes a first battery comprising a positive
terminal and a negative terminal and a second battery comprising a
positive terminal and a negative terminal. A first member is
coupled to the first battery and comprises a handle portion and two
arms coupled to the handle portion, the handle portion including a
top portion, a bottom portion spaced apart from the top portion,
and a bridge connecting the top portion to the bottom portion. A
second member is coupled to the second battery and comprises a
handle portion and two arms coupled to the handle portion, the
handle portion including a top portion, a bottom portion spaced
apart from the top portion, and a bridge connecting the top portion
to the bottom portion. A first contact is provided on a first of
the two arms of the first member and in contact with the positive
terminal of the first battery, and a second contact is provided on
a first of the two arms of the second member and in contact with
the negative terminal of the second battery. A cable electrically
connects the first contact to the second contact such that the
positive terminal of the first battery is electrically connected to
the negative terminal of the second battery.
[0012] Another exemplary embodiment relates to a device for
electrically connecting a plurality of batteries that includes a
member comprising a first portion, a first arm extending from the
first portion, and a second arm extending from the first portion.
The member also includes a contact coupled to the first arm. The
member is configured for coupling to a battery such that the
contact engages a terminal provided on a first side of the battery
and the second arm engages a second side of the battery.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a perspective view of a connector (e.g., a battery
formation connector) according to an exemplary embodiment.
[0014] FIG. 2 is a partially exploded perspective view of the
connector shown in FIG. 1.
[0015] FIG. 3 is an exploded plan view of a portion of the
connector shown in FIG. 1.
[0016] FIG. 4 is a perspective view of a connector according to
another exemplary embodiment.
[0017] FIG. 5 is an exploded perspective view of a portion of the
connector shown in FIG. 4.
[0018] FIG. 6 is a perspective view showing batteries and
connectors coupled together in a battery formation operation.
[0019] FIG. 7A shows a connector prior to installation on a battery
according to an exemplary embodiment.
[0020] FIG. 7B shows the connector shown in FIG. 7A installed on a
battery according to an exemplary embodiment.
[0021] FIG. 8 is a perspective view of a connector according to
another exemplary embodiment.
[0022] FIG. 9 is another perspective view of the connector shown in
FIG. 8.
[0023] FIG. 10 is an exploded view of the connector shown in FIG.
8.
[0024] FIG. 11 is a perspective view of a connector according to
another exemplary embodiment.
[0025] FIG. 12 is an exploded perspective view of connector shown
in FIG. 11.
[0026] FIG. 13 is a perspective view of a connector according to
another exemplary embodiment.
[0027] FIG. 14 is a partially exploded perspective view of the
connector shown in FIG. 13 showing contacts or leads removed from
couplers provided on the connector.
[0028] FIG. 15 is a schematic plan view of a portion of the
connector shown in FIG. 13.
[0029] FIG. 16 is another schematic plan view of a portion of the
connector shown in FIG. 15.
[0030] FIG. 17 is a perspective view of a connector according to
another exemplary embodiment.
[0031] FIG. 18 is a partially exploded perspective view of the
connector shown in FIG. 17 showing a contact removed from a coupler
provided in the connector.
[0032] FIG. 19 is a schematic plan view of the connector shown in
FIG. 17.
[0033] FIG. 20 is a perspective view showing a plurality of
batteries electrically coupled together in a battery formation
operation utilizing a plurality of connectors (i.e., using
connectors similar to those shown in FIG. 13 in conjunction with
connectors similar to those shown in FIG. 17).
[0034] FIG. 21 is a schematic cutaway plan view of a coupler and a
lead or contact provided in a connector according to another
exemplary embodiment.
[0035] FIG. 22 is a schematic cutaway plan view of a coupler and a
lead or contact provided in a connector according to another
exemplary embodiment.
[0036] FIG. 23 is a perspective view of the coupler shown in FIG.
22.
[0037] FIG. 24 is a plan view of the coupler shown in FIG. 22.
[0038] FIG. 25 is a plan view of a contact for use with the coupler
shown in
[0039] FIG. 22.
[0040] FIG. 26 is a plan view of a connector according to another
exemplary embodiment.
[0041] FIG. 27 is a perspective view of a portion of the connector
shown in FIG. 26.
[0042] FIG. 28 is a plan view of a portion of the connector shown
in FIG. 26.
[0043] FIG. 29 is another plan view of a connector according to
another exemplary embodiment.
[0044] FIG. 30 is a plan view of a connector according to another
exemplary embodiment.
[0045] FIG. 31 is a perspective view of a portion of the connector
shown in FIG. 30 coupled to another similar connector.
DETAILED DESCRIPTION
[0046] FIG. 1 shows a system 10 in the form of a battery formation
connector that includes at least one member or clip for coupling to
a battery. As shown in FIG. 1, two members or clips 20, 60 are
shown, and are generally "U-shaped". Member 20 includes a top
portion 22 and two arms 24, 26 coupled to top portion 22.
Similarly, member 60 includes a top portion 62 and two arms 64, 66
coupled to top portion 62. According to an exemplary embodiment
(see e.g., FIG. 1), the arms are integrally formed with the top
portion. According to another exemplary embodiment, the arms may be
formed separately and coupled to the top portion (e.g., using
adhesive, screws, or other fasteners).
[0047] At least one of the top portion and the arms are made of a
relatively resilient and/or flexible material. According to an
exemplary embodiment, the arms and top portion comprise the same
material. According to another exemplary embodiment, at least one
of the arms and top portion comprise different materials (e.g., one
or both of the arms comprise a relatively flexible material and the
top portion comprise a relatively rigid and/or inflexible
material).
[0048] Arm 26 includes a contact or lead 40 (e.g., an electrical
contact) for coupling or attaching (e.g., abutting, interfacing,
etc.) to a terminal of a battery when the member is coupled
thereto. Arm 60 includes a contact or lead 80 similar to that
included with arm 26. According to an exemplary embodiment,
contacts 40, 80 comprise elements that have generally cylindrical
shapes (see, e.g., FIG. 2). For example, contact 40 includes a
first portion 42 having a generally cylindrical shape and a smaller
second portion 44 extending from first portion 42 having a
generally cylindrical shape, and contact 80 includes a first
portion 82 having a generally cylindrical shape and a smaller
second portion 84 extending from first portion 82 having a
generally cylindrical shape.
[0049] According to an exemplary embodiment (see e.g., FIG. 3), the
smaller generally cylindrical second portions 44, 84 have a
relatively smooth surface. According to another exemplary
embodiment, the smaller generally cylindrical second portions 44,
84 may include features such as ribs, threads, or other features
provided thereon.
[0050] When members 20, 60 are coupled to battery terminals or
bushings, the portions 44, 84 are inserted into openings or
apertures provided in the terminal of the battery (e.g., a bushing
type terminal). The face of the first portions 42, 82 abut the face
of the terminals to provide metal-to-metal contact between the
contacts and the terminals.
[0051] According to an exemplary embodiment (see e.g., FIGS. 2-3),
each of members 20, 60 includes a member 36, 76 for securing
contacts 40, 80 thereto. For example, contact 40 includes a
protrusion 46 having a geometry such that the protrusion may serve
as a ball in a ball-and-socket type joint (contact 80 includes a
similar protrusion, not shown). In such case, contact 40 is coupled
to member 36 by positioning the protrusion in a channel 37 (e.g., a
"T" shaped channel) that is provided in member 36. Member 36 is
secured to arm 26 with fasteners 38, 39, and according to other
exemplary embodiments, may be secured thereto using adhesives or
other fasteners or may be integrally formed therewith.
[0052] Channel 37 is provided with inserts 41, 42 to allow contact
40 a limited range of motion and to prevent contact 42 from sliding
out of channel 37 (see e.g., FIG. 2). This range of motion allows
for a good electrical connection between contact 40 and a terminal
of a battery while the member is in a variety of positions relative
to the battery. Also, the range of motion allows the same system to
be used with batteries of various size.
[0053] According to another exemplary embodiment, the contact may
lack a protrusion of the type described and may be coupled to
member 36 by fasteners (e.g., screws, rivets, or bolts).
[0054] To couple a member to a battery (e.g., a lead acid battery
having side terminals or bushings), the arm having a contact
provided thereon is provided on the battery such that the contact
abuts or is coupled to a battery terminal and the other arm is
secured or compressed against a surface of the battery. According
to another exemplary embodiment, one arm is provided adjacent a
first side of the battery and the other arm is provided adjacent a
second side of the battery (e.g., the opposite side of the battery
in relation to the side of the battery having a terminal provided
thereon).
[0055] While the member is coupled to a battery, the top portion of
the member extends over the top of the battery and is substantially
parallel to the top of the battery, while the arms of the member
are substantially parallel to the front and back of the battery
respectively (see e.g., FIG. 6).
[0056] In battery formation operations, one member is coupled to a
first battery, while the other member is coupled to a second
battery. For example, as shown in FIG. 6, member 20 is coupled to a
battery 90 and member 60 is coupled to a battery 92. Contact 40 of
member 20 is coupled to a negative terminal or bushing (not shown)
of battery 90, while contact 80 of member 60 is coupled to a
positive terminal or bushing (not shown) of battery 92. System 10
includes a wire or cable 50 (e.g., a rubber or plastic clad wire)
that electrically couples contact 40 to contact 80 (e.g., allows
current flow between contact 40 and contact 80, and hence, between
the battery terminals to which such contacts may be coupled by way
of the electrical connection provided therebetween).
[0057] Each of the members also includes a member in the form of a
brace or bracket for securing the member to the side of the battery
opposite the side of the battery having the terminals. For example,
member 20 includes a brace 30 having a base 32 and an extension 34
coupled to base 32. According to an exemplary embodiment, base 32
is coupled to arm 24 by fasteners 33, 35 (e.g., screws, rivets,
bolts, etc.). According to another exemplary embodiment, base 32
may be secured to arm 24 using other means (e.g., adhesive, etc.)
or may be integrally formed as part of arm 24 (e.g., arm 24 may be
injection molded as a single piece). Extension 34 is coupled or
secured to base 32 by a fastener 31 (e.g., a screw, a rivet, a
bolt, etc.). According to another exemplary embodiment, extension
34 may be secured to base 32 using other means (e.g., adhesive,
etc.) or may be integrally formed as part of base 32 or arm 24.
Member 60 also includes a brace or bracket 70 having a base 72 and
an extension 74. Base 72 and extension 74 may be secured to arm 64
similar to the ways described with respect to brace 30.
[0058] The extensions included in the braces act to contact a top
surface of a battery housing to prevent the members (e.g., members
20, 60) from moving downward with respect to the battery housing.
The base included in the braces act to contact or engage a feature
such as a lip or groove formed at the top of the battery housing to
prevent the members (e.g., members 20, 60) from moving upward with
respect to the battery housing.
[0059] According to other exemplary embodiments the extension,
base, or both may be omitted or a brace in the form of a block with
a flat or textured surface may be used. In either case, the force
exerted by the member creates enough friction or clamping force
(e.g., a compressive force) against the battery to prevent the
member from moving with respect to the battery housing.
[0060] The members and braces may comprise polymeric materials,
metals, or any other material that is relatively flexible,
sufficiently strong, and suitable for an acidic environment.
[0061] As described, system 10 is configured to couple a pair of
batteries together (and, in practice, multiple systems may be used
to couple more than two batteries in series). In such an
arrangement, all of the battery terminals are coupled to a contact,
such that the batteries are connected in series (e.g., the positive
terminal of one battery is coupled to the negative terminal of an
adjacent battery), except for the positive terminal of a battery at
one end of the group of batteries, and the negative terminal of a
battery at the other end of the group (see e.g., FIG. 6). According
to an exemplary embodiment, 15 to 20 batteries may be connected in
series during a battery charging operation. According to other
exemplary embodiments, a greater or lesser number of batteries are
connected to accommodate various charging and recharging
devices.
[0062] Connecting a group of batteries requires a number of
connectors (e.g., such as system 10) equal to the number of
batteries in the group less one (i.e., it would require 14
connectors to link 15 batteries). The system can be configured to
electrically couple a group of batteries where the group may
consist of any number of batteries.
[0063] While FIGS. 1-3 illustrate a system 10 for electrically
connecting terminals of adjacent batteries together during battery
charging and/or testing, FIGS. 4-5 illustrate a system 100 (e.g., a
connector) configured for connecting a series of batteries to a
charging or recharging device (e.g., a battery charging system or
charger) (see e.g., FIG. 6).
[0064] Connector 100 includes a member 120 having arms 124, 126 and
a top portion 122. A brace 130 having a base 132 and a top portion
134 is coupled to arm 124, and a member 136 having a channel 137
provided therein for receiving a protrusion 146 of a contact 140
(having a first portion 142 and a second portion 144, each of which
is generally cylindrical), which is held in place by a plug or
insert 141.
[0065] Connector 100 includes a post or terminal 180 for
electrically coupling the group of batteries to a charging or
recharging device via a wire or cable (see e.g., wires 96 and 98 in
FIG. 6). According to an exemplary embodiment (see e.g., FIG. 4),
post 180 is oriented vertically (e.g., parallel to arm 126) and
coupled to the outer surface of arm 126 which is parallel to the
front side of the battery housing by fasteners 181, 182, 183, 184
(e.g., a bolt, nut, and washers, etc.). Other means of coupling
post 180 may also be used according to various other exemplary
embodiments.
[0066] A wire or cable 150 is coupled to contact 140 at a first end
152 and to post 180 at a second end 154. Wire 150 may be inserted
into an aperture 185 provided in post 180 and secured therein using
a fastener 156. In this manner, contact 140 may be electrically
coupled to post 180, which may act to provide an electrical
connection between a terminal of a battery and a charging or
recharging device (see, e.g., FIG. 6). In the event that connector
100 comprises a conductive material (e.g., a metal) for arms 124
and 126 and/or top portion 122, an insulating material may be used
to separate connector 100 and post 180.
[0067] FIGS. 7A-7B illustrate the attachment of connector 100 to a
battery 92. As shown in FIG. 7A, prior to installation of connector
100 on battery 92, arms 124, 126 flex inward toward each other. Due
to the freedom of movement allowed contact 140 by virtue of the
provision of protrusion 146 within channel 137, connector 140 is
allowed to move relative to arm 126. Upon installation of connector
100 on battery 92, arms 124, 126 are flexed away from each other,
thus providing a clamping force on sides of the battery to secure
connector 100 in place relative to battery 92.
[0068] A system such as that described above (e.g., system 10) in
the form of a connector for battery formation may be used to
electrically connect a group of batteries in series to facilitate
charging and/or recharging of the batteries. After the batteries
are charged, the system is removed from the batteries.
[0069] According to an exemplary embodiment, between 15 and 20
batteries are connected in series for formation. In a production
facility, typically a large table is used to provide a water bath
(e.g. a pool of water for cooling the batteries during formation)
for the batteries during formation. A group of 15 to 20 batteries
are connected in series and the group of batteries is arranged in a
row. Three groups of batteries forming three rows occupy the table.
Each group is connected to a charging or recharging device (i.e.,
there are three charging and/or recharging devices), and all three
groups are charged simultaneously. The present system allows for
easier and faster connections to be made and broken, thus lowering
the time and labor required for the formation process. The present
system may also be used in different arrangements to accommodate a
variety of production environments. For example, the system may be
used without a water bath, and/or with a different number of
batteries in each group, and/or with a different number of battery
groups.
[0070] According to various other exemplary embodiments, the
connectors may have different configurations. As shown in FIGS.
8-10, a connector 200 (in the form of a connector configured to
couple a battery terminal to a charging or recharging device;
according to other exemplary embodiments, connectors such as
connector 200 may be coupled together, with a wire extending
between their contacts) may include an arm 226 and an arm 224, with
arm 224 having a generally curved shape extending away from arm
226. Arms 224 and 226 may be made of metal or another relatively
resilient and/or flexible material. Connector 200 may be configured
such that arm 226 is provided substantially parallel to a side of
the battery (e.g., the side having a terminal provided thereon),
and the rounded arm 224 defines a curve that ends in a portion that
is substantially parallel to a second side of the battery when
connector 200 is installed on a battery. Braces or brackets 230,
260 are provided to secure arm 224 to a side of a battery. Brace
230 includes a first portion 232 and a second portion 234 that act
to sandwich a portion of arm 224 therebetween, and are held in
place by fasteners 235, 236. Brace 260 may be secured to arm 224
using fasteners 261, 262, and 263. Other fasteners may be used to
couple braces 230 and 260 to arm 224, or braces 230, 260 may be
integrally formed with arm 224.
[0071] A post 280 is coupled or secured to arm 224 at a top portion
225 thereof, and is electrically connected to a contact 240
configured for coupling to a terminal or bushing of a battery. A
wire 250 is coupled to contact 240 at a first end 252 and to post
280 at a second end 254 (end 254 may be inserted into an aperture
282 of post 280 and secured in place by a fastener 256).
[0072] According to another embodiment (see e.g., FIGS. 11-12), a
system may have two or more members or segments 324, 326 that
contact either the front or back of two or more batteries, wherein
the rigid members are coupled together by a coupling component 360
(e.g., a spring or an elastic material such as rubber, with ends
coupled to the members and extending between the batteries, or by a
fastener such as a bolt extending through at least one member
whereby the two members can be tightened against the battery by
tightening a nut) (see e.g., FIG. 11). According to an exemplary
embodiment, the members or segments 324, 326 comprise a relatively
rigid (e.g., non-flexible) material. According to other exemplary
embodiments, the members or segments comprise a flexible
material.
[0073] Member 324 includes a base portion 328 having a brace or
extension 325 coupled thereto (e.g., using fasteners 327, 329, 331,
333 or other means). Member 326 includes a channel 337 formed
therein for receiving protrusions 346A and 346B of contacts 340A
and 340B. A wire or cable 350 connects contacts 340A and 340B, and
a separator or divider 362 is provided in channel 337 between
protrusions 346A and 346B of contacts 340A and 340B. An insert or
plug 341 is provided to contain connectors 340A and 340B and
separator 362 within channel 337. In use, contact 340A may be
coupled to a terminal of a first battery, with contact 340B coupled
to a terminal of a second battery. Coupling component 360 may be
stretched to allow arms 324, 326 to be positioned on adjacent
batteries to allow coupling between contacts 340A and 340B and the
battery terminals or bushings.
[0074] The systems as described above are intended to provide a
relatively efficient and convenient connector for use in a
manufacturing facility. The system includes members that may be
connected to and disconnected from batteries in a relatively quick
and easy manner, which is intended to provide increased
manufacturing efficiency.
[0075] With reference to FIGS. 1-7, for example, according to an
exemplary embodiment, a contact (e.g., contact 40) is aligned with
a negative bushing or terminal on a front side of a battery (e.g.,
battery 90). The contact includes a surface that abuts or is in
contact with at least a portion of the bushing or terminal. This
abutment is maintained during charging of the batteries to provide
an electrical connection by virtue of the contact between the metal
contact and bushing. A force is then be applied to the member
(e.g., member 20) whereby the member is flexed such that the member
is secured to the back side of the battery (see e.g., FIG. 6). The
process is then repeated such that the second contact (e.g.,
contact 80) is coupled to the positive bushing terminal of another
battery (e.g., battery 92), thus connecting the two batteries in
series (see e.g., FIG. 6). According to another exemplary
embodiment, the members are attached to the back of the batteries
(i.e., the side opposite the battery terminals) before the contact
is attached to the terminal.
[0076] When the connector is coupled to a pair of batteries (or
multiple systems are used to couple more than two batteries in
series), all the battery terminals are coupled to a contact, such
that the batteries are connected in series (e.g., the positive
terminal of one battery is coupled to the negative terminal of an
adjacent battery), except for the positive terminal of a battery at
one end of the group, and the negative terminal of a battery at the
other end of the group (see e.g., FIG. 6). According to an
exemplary embodiment, 15 to 20 batteries are so connected in the
formation process. According to alternative embodiments, a greater
or lesser number of batteries are so connected to accommodate
various charging and recharging devices.
[0077] A connector (e.g., connector 100) is coupled to the positive
terminal of a battery at one end of the group of batteries, and
another such connector is coupled to the negative terminal of a
battery at the other end of the group to couple the battery group
to a charging or recharging device. Such connectors include a post
(e.g., post 180) to electrically couple the group of batteries to a
charging or recharging device via one or more wires or cables (see
e.g., wires or cables 96, 98 in FIG. 6).
[0078] According to another exemplary embodiment, the system does
not have connectors for coupling to the charging or recharging
device. Rather, the charging or recharging device is coupled
directly to the two open terminals of the battery group (e.g., by a
wire).
[0079] The sequence in which the devices to secure the connector
and terminal connectors to the battery are attached to the battery
may be varied. The operation of attaching the connectors to the
batteries may be carried out by a human operator or by a machine.
One or both of the terminal connectors may be omitted, such that
the charging or recharging device is coupled to the battery
terminals that would have been coupled to the terminal
connectors.
[0080] The members comprise any polymeric material (e.g.,
polyethylene or poly propylene) or metal that is suitably strong,
flexible, returns to its original shape after flexing and is
suitable for use in an acidic environment. The braces, blocks, and
inserts comprise any polymeric material or metal that is suitably
strong. The contacts comprise any suitable conductive metal (e.g.,
lead) or other conductive material, and the wire or cable between
the contacts may be any suitable conductive metal (e.g., copper).
The members, braces, blocks and inserts may comprise the same
material or they may comprise different materials.
[0081] The members, braces, and blocks are formed independently and
connected by fasteners (see e.g., FIG. 2). The channel
(alternatively the groove, slot, or aperture) in the block (see
e.g., FIG. 2) or in the member (see e.g., FIG. 11) is made by use
of a mold or by removing material from a solid piece.
[0082] According to an exemplary embodiment (see e.g., FIG. 1), the
system is comprised of materials and/or has a construction that is
intended to suitably withstand the effects of a manufacturing
environment that may include acids, voltage and other elements that
may promote corrosion.
[0083] Another exemplary embodiment is shown in FIG. 13, in which a
system or connector 400 in the form of a battery formation
connector includes at least one member or clip (e.g., a generally
"U-shaped" member) for coupling to a battery. As shown in FIG. 13,
system 400 includes two members 420, 460, each of which includes a
handle or gripping portion (shown as handles 422 and 462). For
purposes of the following discussion, it should be noted that
features described with respect to one of members 422, 462 may also
be provided on the other of the members, and it is in no way
intended to limit the inclusion of such features on only one of the
two or more members.
[0084] According to an exemplary embodiment, handle portion 422,
462 includes a top or upper portion or member 423, 463. Handle
portion 422, 462 also includes a bottom or lower portion or member
425, 465 and a bridge or connector 427, 467 for connecting or
coupling top portion 423, 463 to bottom portion 425, 465.
[0085] A space or aperture 429, 469 is provided between top portion
423, 463 and bottom portion 425, 465 according to an exemplary
embodiment. Such space allows production of the member with less
material than if the handle portion 422, 462 were produced from a
solid piece of material. According to another exemplary embodiment,
the handle portion may be produced from a single piece of material
instead of having a top portion and a lower portion connected by a
bridge with an aperture provided between the top portion and the
bottom portion.
[0086] Members 420, 460 include one or more projections extending
from a top surface thereof (e.g., from top members 423, 463). For
example, member 420 includes projections 430 and 432, while member
460 includes projections 470 and 472. The projections may act as
stops to prevent the hand of a user or operator from slipping or
moving beyond a certain point when handle portions 422, 462 are
being gripped or held. According to other exemplary embodiments,
the members may include only one projection or another number of
projections.
[0087] One or more of the projections may have apertures, voids, or
channels formed therein. For example, projection 430 includes an
associated aperture or void 431, projection 432 includes an
associated channel 433, projection 470 includes an associated
aperture or void 471, and projection 472 includes an associated
channel 473. According to an exemplary embodiment, a channel
provided in a projection (e.g., channels 433, 473) may act as a
guide for a cable or wire 450 (see, e.g., FIGS. 13-14).
[0088] According to an exemplary embodiment, top portion 423, 463
is coupled to bottom portion 425, 465 by a connector in the form of
a bridge 427, 467 which is integrally formed with top portion 423,
463 and bottom portion 425, 465 between arms of the members (e.g.,
arms 424 and 426 of member 420 and arms 464 and 466 of member 460).
According to other exemplary embodiments, the top portion and
bottom portion may be coupled together by other structures (i.e.,
in place of the or in conjunction with the bridge) such as
fasteners (e.g., screws, bolts, adhesives, etc.), brackets, etc.
According to another alternative embodiment, the top portion and
the bottom portion may not be coupled together at any point between
the arms. One advantageous feature of providing members having
configurations such as members 420, 460 is that the handle portions
and arms may be more likely to withstand repeated usage as compared
to the embodiment shown, for example, in FIG. 1. For example, the
configuration shown in FIG. 13 may provide for enhanced rigidity
and more resilient flexibility of the members to allow the members
to return to their original shape once removed from a battery.
[0089] According to an exemplary embodiment, the arms (e.g., arms
424, 426) extend from the handle portion (e.g., handle portion 422)
in such a manner as to form a member having a generally "U-shaped"
configuration (see, e.g., FIG. 13). According to other exemplary
embodiments, other shapes and configurations for the arms may be
provided than those shown in the accompanying FIGURES.
[0090] Members 420, 460 include at least one element or member in
the form of a brace 434, 474 coupled to one of the arms (e.g., arm
424 for member 420 and arm 464 for member 460 as shown in FIG. 13)
for securing member 420, 460 to a side of a battery opposite the
side with a terminal.
[0091] According to an exemplary embodiment (see, e.g., FIG. 20),
the arm which is provided adjacent (e.g., substantially parallel)
to the back surface of the battery when the member is installed on
the battery is secured to the back of the battery (e.g., the side
of the battery opposite the side of the battery on which the
terminal is provided) by a device such as a brace (shown in the
form of a bracket).
[0092] Brace 434, 474 includes an extension 436, 476 that contacts
a top surface of a battery housing, fits in a groove in the battery
housing, or contacts some other surface of the battery housing to
prevent the member (or a portion thereof) from moving downward with
respect to the battery housing. Brace 434, 474 also has a base 438,
478 that contacts a feature such as a lip formed at the top of the
battery housing or that fits in a groove in the back surface of the
housing to prevent the flexible member from moving upward with
respect to the battery housing.
[0093] According to other exemplary embodiments, at least one of
the extension and base may be omitted or a brace in the form of a
block with a flat or textured surface may be used. In either case,
the force exerted by the member creates a sufficient amount of
friction or clamping force (e.g., a compressive force) to prevent
the member from moving with respect to the battery housing.
[0094] According to an exemplary embodiment (see, e.g., FIG. 13)
braces 434, 474 are integrally formed with arms 424, 464. According
to other exemplary embodiments, the brace may be formed separately
and secured to the arm by fasteners (e.g., screws, rivets, bolts,
adhesives, etc.).
[0095] According to an exemplary embodiment, the brace comprises
the same material as the arm to which it is coupled. According to
other exemplary embodiments, the brace and member may comprise
other polymeric materials, metals, or any other material that is
suitable for a battery production environment.
[0096] A contact or lead 440, 480 (e.g., an electrical contact) for
coupling or attaching (e.g., abutting) to a terminal of a battery
(e.g., a side terminal automotive battery) is provided (e.g.,
secured or fastened within) a coupler provided on one of the arms
of the member. According to an exemplary embodiment, the contact or
lead is made of lead (Pb) or a lead alloy. Conventionally, battery
terminals (e.g., side terminals or bushings) are also made of lead
or a lead alloy.
[0097] According to an exemplary embodiment (see, e.g., FIG. 14),
contact 440, 480 includes a base 442, 482 (shown as having a
generally cylindrical shape) from which a plurality of members in
the form of protrusions or extensions may extend. For example, base
442 has a protrusion 444 and a protrusion 446 extending therefrom,
while base 482 has a protrusion 484 and a protrusion 486 extending
therefrom.
[0098] According to an exemplary embodiment, a portion of the base
(e.g., a face) is provided to abut or contact a portion of a
terminal or bushing of a battery to provide an electrical
(metal-to-metal) contact between the contact and the terminal or
bushing. The face of the contact has a size and shape configured to
abut with the terminal or bushing (e.g., where the terminal has a
relatively flat portion, the portion of the contact configured to
abut the portion of the terminal also has a relatively flat
configuration).
[0099] According to an exemplary embodiment, the base (e.g., base
442) has a front or forward surface 443 that is generally concave
(e.g., extends inward from protrusion 444). According to another
exemplary embodiment, the front or forward surface may be
relatively planar or may be relatively convex.
[0100] According to an exemplary embodiment (see, e.g., FIGS.
21-22), the base has a rear or back surface 441 that is generally
convex. According to alternative embodiments, the rear surface may
be generally planar (see, e.g., FIG. 16) or concave.
[0101] According to an exemplary embodiment, the contact (e.g.,
contact 440) includes a member or element in the form of a
protrusion or extension (e.g., shown as a generally cylindrical
shaped member 444 having a rounded end portion) extending from
front or forward surface 443 of base 442 for coupling to a terminal
or bushing of a battery. Protrusion 444 has a size and shape
configured for insertion into an opening or aperture provided in a
terminal of a battery (e.g., a bushing type terminal). According to
an exemplary embodiment, protrusion 444 has a relatively smooth
surface. According to an other exemplary embodiments, the
protrusion may be provided with threads or other features
configured to mate or adapt to features provided in an aperture
provided in a battery terminal.
[0102] According to another exemplary embodiment, while the
protrusion is shown as having a generally cylindrical shape (e.g.,
having a generally circular transverse cross-sectional shape), the
protrusion may be provided as having alternative shapes (e.g., the
transverse cross-section may be relatively oblong or football
shaped, as with 1/4 or 1/2 turn fasteners, etc.). The protrusion
may be provided to have any shape suitable for mating or engaging a
battery terminal or bushing.
[0103] According to an exemplary embodiment, contact 440 includes a
member in the form of an extension or protrusion 446 (e.g., a
projection) extending from back or rear surface 441 of base 442 of
contact 440 and configured for coupling contact 440 to member 420
(e.g., by positioning the protrusion in a coupler). According to an
exemplary embodiment, protrusion 446 includes a shaft or elongated
member 447 and an enlarged portion 448 (e.g., shown in the form of
a knob or ball in FIG. 16).
[0104] Enlarged portion 448 may have a size and shape configured
for being retained within a structure or member (e.g., a coupler
452) provided on arm 426 of member 420 (e.g., it may have a larger
size (e.g., diameter) than the shaft such that the enlarged portion
may be secured within the coupler, etc.). According to an exemplary
embodiment, the enlarged portion includes an opening or depression
449 (see, e.g., FIGS. 21-22) provided in an end thereof (e.g., to
reduce the amount of material required to produce the knob or
ball). According to another exemplary embodiment, no opening or
depression is provided in the enlarged portion. According to
another exemplary embodiment, the contact may lack a protrusion of
the type described and may be coupled to the member by fasteners
(e.g., screws, rivets, bolts, adhesives) or by other means.
[0105] A device or element in the form of a coupler or coupling
device (see, e.g., coupler 452 in FIG. 14) is connected to or
provided on an arm (e.g., arm 426) for securing or coupling the
contact or lead (e.g., contact 440) to the member (e.g., member
420).
[0106] According to an exemplary embodiment, coupler 452 is
provided with prongs or "fingers" 454 (see, e.g., FIGS. 21-23) to
secure contact 440 to coupler 452. Fingers 454 may be made of a
relatively resilient and/or flexible material such that the they
bend or flex outward when enlarged portion 448 of protrusion 446
from contact 440 is inserted into coupler 452 (e.g., from the left
as viewed in FIG. 22).
[0107] Fingers 454 are configured to secure contact 440 to coupler
452 such that the centerline of contact 440 (e.g., of protrusion
446) is aligned properly. Such arrangement provides for relatively
constant electrical contact between the face of base 442 of contact
440 and the terminal or bushing of a battery.
[0108] The size, shape, and configuration of the prongs or fingers
may differ according to various exemplary embodiments. According to
an exemplary embodiment, seven prongs or fingers are provided
circumferentially about an opening formed in the coupler (see,
e.g., FIG. 24). According to other exemplary embodiments, a
different number of prongs or fingers may be provided.
[0109] According to one exemplary embodiment, the prongs or fingers
have a surface (labeled as reference numeral 453 in FIG. 16)
configured to secure the protrusion within the coupler by abutting
the enlarged portion or knob of the protrusion. Such abutment may
act to prevent the contact from sliding out of the coupler. Such
configuration may be used, for example, in situations where the
rear or back surface of the base of the contact has a relatively
planar or concave configuration.
[0110] According to another exemplary embodiment, the prongs or
fingers have a surface (labeled as reference numeral 455 in FIG.
21) configured to secure the protrusion within the coupler by
abutting the back or rear surface of base of the contact. For
example, the prong or finger may be angled such that it contacts
the rear surface of the base of the contact at a position such that
the knob or enlarged portion of the protrusion is secured within
the coupler (see, e.g., FIG. 21, in which the finger abuts or
contacts the rear surface of the base of the contact in such a
manner that the knob is larger and cannot easily be removed from
the coupler). Such a configuration may be desirable where the rear
or back surface of the base of the contact has a relatively convex
shape (e.g., extending into a concave aperture provided in the
coupler and defined in part by the angled surfaces of the fingers
or prongs).
[0111] According to yet another exemplary embodiment, the fingers
or prongs are provided such that lateral movement of the contact
(e.g., into and out of the coupler) are restricted. As shown in
FIG. 22, the fingers or prongs have a shape similar to the letter
"Y", with the base or bottom portion of the "Y" in abutment or
contact with the rear or back surface of the base of the contact,
one of the arms provided to restrict movement of the protrusion
(e.g., by abutting or contacting the knob if the protrusion moves
out of the coupler) and to abut with or contact a portion of the
shaft, and the other of the arms coupled to the remainder of the
coupler (e.g., integrally molded or secured thereto). By abutting
or contacting both the rear surface of the base of the contact and
the shaft, the fingers or prongs act to restrict the movement of
the contact and to keep the contact aligned along its centerline
(e.g., central longitudinal axis). Such a configuration may be
desirable where the rear or back surface of the base of the contact
has a relatively convex shape (e.g., extending into a concave
aperture provided in the coupler and defined in part by the angled
surfaces of the fingers or prongs).
[0112] According to various other exemplary embodiments, the size,
shape, and configuration of the prongs or fingers may differ from
those shown in the FIGURES without departing from the scope of the
inventions as described herein.
[0113] The coupler and protrusion are configured to allow the
contact to have a limited range of motion when coupled to the
coupler. This range of motion allows for a good electrical
connection between the contact and the terminal while the member is
in a variety of positions relative to the battery. Also, the range
of motion and the flexible nature of the member allows the same
system to be used with batteries of various sizes (see, e.g., FIG.
20 where the same system is used to couple three batteries 90, 92,
and 94, each battery being of a different size (i.e., the distance
between the side provided with a terminal and the side opposite
thereto is different for each of the three batteries)).
[0114] The components or features of the members may be integrally
formed or produced separately and coupled or connected together.
According to an exemplary embodiment, the handle portion (i.e., top
portion, bottom portion, and bridge), projections, arms, coupler,
and brace are integrally formed from a single material. According
to an exemplary embodiment, at least one of the handle portion
(i.e., top portion, bottom portion, and bridge), projections, arms,
coupler, and brace are formed from a different material than the
other components.
[0115] According to an exemplary embodiment, at least one of the
top portion, bottom portion, and one or both of the arms are made
of a relatively resilient and/or flexible material. The distance
between the brace (e.g., brace 434) and the contact (e.g., base 442
of contact 440) is intended to provide relatively secure fitment on
a variety of batteries having different sizes. Such distance is
sometimes referred to as the "harp opening." According to an
exemplary embodiment, the harp opening is between approximately
7.213 and 7.274 inches.
[0116] According to an exemplary embodiment, the top portion,
bottom portion, and arms comprise the same material. According to
an another exemplary embodiment, at least one of the top portion,
bottom portion, and arms comprise different materials (e.g., one or
both of the arms comprise a relatively flexible and/or resilient
material and the top portion and bottom portion comprise a
relatively rigid and/or inflexible material).
[0117] According to an exemplary embodiment, the top portion,
bottom portion, and arms are made of a material comprising
polypropylene and between approximately 10 and 30 percent glass
(e.g., glass fibers). According to another exemplary embodiment,
one or more of the top portion, bottom portion, and arms are made
of a different material (e.g., another polymeric, metal, or other
type of material suitable for use in a battery manufacturing
environment).
[0118] To couple the member (e.g., member 420) to a battery (e.g.,
a lead-acid battery having side terminals), the arm having a
contact provided thereon is provided on the battery such that the
contact abuts or is coupled or connected to a battery terminal and
the other arm is secured or compressed against another surface of
the battery (e.g., the opposite side of the battery as the
terminals). According to an exemplary embodiment, one arm is
provided adjacent a first side of the battery and the other arm is
provided adjacent a second side of the battery (e.g., the opposite
side of the battery in relation to the side of the battery having a
terminal provided thereon).
[0119] According to an exemplary embodiment, when the member is
coupled to a battery, the top portion and bottom portion of the
member extend over the top of the battery and are substantially
parallel to the top of the battery, while the arms of the member
are substantially parallel to the front and back of the battery,
respectively. According to alternative embodiments, the
configuration of the arms and top and bottom portions may differ
(e.g., at least one of the top portion and bottom portion may not
be parallel to the top surface of the battery, at least one of the
arms may not be parallel to a surface of the battery, etc.).
[0120] Members 420, 460 are coupled together by a wire or cable 450
that couples or connects the contacts provided on each of the
members together (e.g., to form an electrical connection between
the two contacts to allow current flow between the contacts). Wire
or cable 450 may have a cladding provided thereon in the form of a
rubber, plastic, or other electrically insulative material.
[0121] According to an exemplary embodiment, wire 450 extends
substantially perpendicular from the central longitudinal axes of
contacts 440, 480. According to alternative embodiments, wire 450
may be connected to the contacts in other ways (e.g., may be
coupled to the knob or ball provided within the coupler, etc.).
[0122] According to an exemplary embodiment (see, e.g., FIG. 13),
members 420, 460 may include features (e.g., shown as channels or
cutouts provided in projections or protrusions extending from the
top surface of the members) for routing wire 450 (e.g., channels
433, 473). According to other exemplary embodiments, no such
features are provided on the members for routing the wire.
[0123] While FIGS. 13-14 illustrate a system 400 for electrically
connecting terminals of adjacent batteries together during battery
charging and/or testing,
[0124] FIGS. 17-19 illustrate a system 500 (e.g., a connector such
as an end connector) configured for connecting a series of
batteries to a charging or recharging device (e.g., a battery
charging system or charger) (see e.g., FIG. 20).
[0125] Connectors 500 includes a member 520 (similar to the member
previously described) for securing connector 500 to a battery, and
includes a handle portion 522 having a top or upper portion 523, a
lower or bottom portion 525, and a bridge 527 connecting the upper
and lower portions. Member 520 also includes arms 524 and 526, a
contact or lead 540, and an element for attaching the contact to
the member (e.g., a coupler) (see, e.g., FIG. 7). A protrusion 530
having an aperture or void 531 provided therein extends from member
520 away from top portion 523, and a protrusion 532 having a
channel 533 extends from member 520 away from top portion 523 on
the opposite side of handle portion 522. A brace 534 including an
extension 436 and a base 438 is provided on arm 524.
[0126] Connector 500 includes a post 580 similar to post 180
described above for electrically coupling the group of batteries to
a charging or recharging device via a wire or cable 550 (see, e.g.,
FIG. 17). According to an exemplary embodiment, the post is made of
a material comprising lead or a lead alloy.
[0127] According to an exemplary embodiment, the post has a size
and shape configured for coupling to a connector of the charging or
recharging device (e.g., a "ring-type" connector configured to
receive at least of a portion of the post therein). Other
configurations for the post may be provided depending on the
particular type of connector used with the charging or recharging
device.
[0128] According to an exemplary embodiment, the post is oriented
substantially vertically (e.g., extending above the top portion of
the member) and is coupled to projection 532 on the arm which is
generally parallel to the terminal (front) side of the battery.
Post 580 is secured (e.g. clamped) to projection 532. A protrusion
or segment 582 extending from post 580 fits within channel 533
provided in projection 532 (see, e.g., FIG. 17). According to
another exemplary embodiment, the post may be coupled to the arm or
to another potion of the member. According to another exemplary
embodiment, the post may be coupled to the member by a fastener or
fasteners (e.g., a screw or a bolt, etc.).
[0129] According to an exemplary embodiment, wire 550 is provided
to electrically couple post 580 to contact 540 to allow current to
flow from the charging or recharging device to post 580 and to
contact 540 through wire 550.
[0130] According to an exemplary embodiment, while attaching a
member (e.g., member 420, 460, or 520, etc.) to or removing it from
a group of batteries, a human operator may grasp a member at the
handle portion (i.e., around the top portion and bottom portion
between the projections). The projections act as stops to prevent
the hand of the operator from sliding longitudinally along the
member beyond a certain point. The projections may have other
functions as well (e.g., routing cables, etc.).
[0131] The surfaces of the member where the operator grasps the
member (e.g., the lower surface of the bottom portion) may be
textured to improve the grip of the operator and further reduce any
slipping. According to another embodiment, one or both of the top
portion and the bottom portion may have a shape configured to
reduce the occurrence of slippage of the operator's hand (e.g., the
bottom portion may include a "grip" shape configured to receive the
operator's fingers). According to another exemplary embodiment, the
members may be attached to or removed from a group of batteries
utilizing a machine.
[0132] During charging and recharging operations, a plurality of
batteries are electrically connected to each other and to a
charging device such that each of the batteries is charged at the
same time (e.g., charge flows from the charging device through each
of the batteries) (see, e.g., FIG. 20). According to an exemplary
embodiment, 15 to 20 batteries are connected in series. According
to other exemplary embodiments, a greater or lesser number of
batteries are connected to accommodate various charging and
recharging devices.
[0133] The members (e.g., each having a top portion, bottom
portion, brace, bridge, coupler, and a pair of arms) comprise any
material (e.g., polymeric materials such as polyethylene or
polypropylene) that is suitable for use in a battery manufacturing
(e.g., acid-containing) environment. The polymeric material may
also be relatively flexible and/or resilient. According to an
exemplary embodiment, at least one of the components of the member
comprises a material including polypropylene and glass (e.g.,
between approximately 10 and 30 percent glass).
[0134] According to one exemplary embodiment, the top portion,
bottom portion, arms, bridge, and coupler of each member are
integrally formed from a single material. According to another
exemplary embodiment, one or more of these components is formed
from a different material and/or is produced separately and coupled
to the other components using a fastener or other means.
[0135] Channels, voids, and apertures provided or formed in the
member (e.g., in the form of a groove, slot, aperture, or other
structure) are made by use of a mold (e.g., injection molding
around a portion of a mold configured to provide an aperture or
other structure in a molded part) or by removing material from a
solid piece.
[0136] The contacts comprise any suitable conductive metal (e.g.,
lead or lead alloys), and the wire or cable between the contacts
may be copper, lead, or another conductive material.
[0137] According to a preferred embodiment (see, e.g., FIG. 1), the
system is comprised of materials and/or has a construction that is
intended to suitably withstand the effects of a manufacturing
environment that may include acids, voltage, and other elements
that may promote corrosion.
[0138] To couple the members of the connector to batteries, a
contact provided on one of the members is aligned with a bushing or
terminal on a first side of a battery. A force is then applied to
the member whereby at least a portion of the member is flexed such
that the opposite arm of the member is secured to the back side of
the battery. According to another exemplary embodiment, the members
are attached to the back of the batteries (e.g., the side opposite
the battery terminal) before the contact is attached to the
terminal. While attaching the connector to or removing the
connector from a group of batteries, a human operator may grasp the
connector by hand around the handle portion (i.e., top portion and
bottom portion) between the projections. The projections act as
stops to prevent the hand of the operator from sliding
longitudinally along the member. The surfaces of the member where
the operator would grasp the member may be textured or may include
other features to improve the grip of the operator and further
reduce any slipping.
[0139] The process is then repeated such that the second contact in
the second member of the connector is coupled to an
oppositely-charged bushing or terminal of another battery, thus
connecting the two batteries in series.
[0140] When the connector is coupled to a pair of batteries (or
multiple systems are used to couple more than two batteries in
series), all the battery terminals are coupled to a contact, such
that the batteries are connected in series (e.g., the positive
terminal of one battery is coupled to the negative terminal of an
adjacent battery), except for the positive terminal of a battery at
one end of the group, and the negative terminal of a battery at the
other end of the group. According to an exemplary embodiment, 15 to
20 batteries are so connected in the formation process. According
to alternative embodiments, a greater or lesser number of batteries
are so connected to accommodate various charging and recharging
devices.
[0141] An end connector is coupled to the positive terminal of a
battery at one end of the group of batteries, and another end
connector is coupled to the negative terminal of a battery at the
other end of the group. Such end connectors may be used to couple
the battery group to a charging or recharging device. Such
connectors include a member for securing the connector to a
battery, an electrical contact, and an element (e.g., a coupler)
for attaching the contact to the member similar to those disclosed
above. Such connectors also include a post to electrically couple
the group of batteries to a charging or recharging device via one
or more wires or cables.
[0142] According to an exemplary embodiment, the post is oriented
substantially vertically and coupled to a projection provided on
the member. The post is secured (e.g., clamped) to the projection.
A segment extending from the post fits within a channel provided in
the projection. According to another exemplary embodiment, the post
may be coupled to the member by a fastener or fasteners (e.g., a
screw, bolt, etc.). The post may be oriented horizontally or at
another angle to accommodate various production lines and
facilities. According to another exemplary embodiment where the
member is made of a conductive material, an insulating material is
used to separate the member and the post. The posts of the
connectors then provide points at which a charging or recharging
device may be electrically coupled to the group of batteries.
[0143] According to another exemplary embodiment, the system does
not have connectors (e.g., end connectors) for coupling to the
charging or recharging device. Rather, the charging or recharging
device is coupled directly to the two open terminals of the battery
group (e.g., by a wire or other device).
[0144] The sequence in which the devices to secure the connector
and terminal connectors to the battery are attached to the battery
may be varied. The operation of attaching the connectors to the
batteries may be carried out by a human operator or by a
machine.
[0145] The system is intended to provide a relatively efficient and
convenient connector for use in a manufacturing facility. The
system includes members that may be connected to and disconnected
from batteries in a relatively quick and easy manner, which is
intended to provide increased manufacturing efficiency.
[0146] Additional structural elements may be provided to provide
enhanced structural rigidity for a system (e.g., a connector such
as a battery formation connector). For example, FIGS. 26-29 show a
system 600 in the form of a connector such as a battery formation
connector that includes a handle portion 622 that includes a top or
upper portion 623, a bottom or lower portion 625, and a bridge 627
connecting top portion 623 and bottom portion 625. System 600
includes arms 624 and 626 and projections 630, 632 extending from
top portion 623. A brace or bracket 634 including an extension 636
and a base 638 is provided on arm 624.
[0147] To provide enhanced structural rigidity, webs of material
are used in system 600. For example, webs 628, 629 are provided
adjacent bridge 627 between top portion 623 and bottom portion 625.
A web 631 is provided in an aperture defined by protrusion 630, and
a web 643 is provided in an aperture defined by protrusion 632.
Additional webs 625 and 641 are also provided in areas where
components of member 620 come together.
[0148] Similarly, FIGS. 30-31 show a system 700 having a member 720
that includes webs 728 and 729 provided adjacent a bridge 727
connecting a top portion 723 and a bottom portion 725 of a handle
portion 722, a web 731 provided in an aperture defined by a
protrusion 730 and a web 743 provided in an aperture formed by a
protrusion 732, and webs 726, 741 formed in regions where other
components of member 720 come together.
[0149] According to an exemplary embodiment, the thickness of the
various webs provided in members 620 and 720 have a thickness of
between approximately 0.18 and 0.22 inches. Such thickness is less
than the depth of the component to which the webs are adjacent
(e.g., the thickness of web 628 is less than the width of top
portion 623, bottom portion 625, and bridge 627, with the thickness
being taken between the front of member 620 shown in FIG. 26 to the
back of member 620 shown in FIG. 29). The size, shape, thickness,
and configuration of the various webs may differ according to other
exemplary embodiments without departing from the scope of the
inventions described herein. According to an exemplary embodiment,
each of the webs has a substantially identical thickness. According
to another exemplary embodiment, one or more of the webs may have a
different thickness than other webs provided in a particular
member. Webs are intended to provide enhanced structural rigidity
and strength for the various members.
[0150] Other features such as ribs or extensions may also be
provided to provide enhanced structural rigidity and strength for
the various members. For example, as shown in FIGS. 26-27, a brace
634 not only includes an extension 636 and a base 638, but also
includes a number of ribs 633, 635, 637, and 639 intended to
provide enhanced structural rigidity and strength for member 630.
Similarly, a brace 734 shown in FIGS. 30-31 includes an extension
736 and a base 738, as well as ribs 733, 735, 737, and 739. The
number, size, shape, and configuration of the various ribs may vary
according to various other exemplary embodiments.
[0151] It should be noted that features shown and/or described with
respect to one or more embodiments may be included in other
embodiments. For example, the webs shown and described with respect
to FIGS. 26-31 may be included in any of the variety of embodiments
(e.g., extending between top portion 22 and arm 24 in the
embodiment shown in FIG. 1, etc.). In another example, couplers
such as those shown and described, for example, with respect to
FIG. 22 may be used in place of member 36 shown in FIG. 1. Those of
ordinary skill in the art will appreciate that various other
configurations may be possible according to a variety of other
exemplary embodiments.
[0152] It will be apparent to one of ordinary skill in the art that
various advantages may be obtained using one or more of the
embodiments described herein. For example, a system or connector
(e.g., a formation connector) may be provided that can be coupled
and decoupled to or from a battery with relative ease and
convenience for an operator (e.g., in a relatively ergonomic or
low-impact manner), such that an electrical connection is achieved
between the connector and the terminal without the use of a
threaded connection. Such connectors may also include features
(e.g., protrusions from a handle portion) that prevent the hand of
the operator from slipping in relation to the connector.
[0153] A coupler may be provided that allows movement (e.g.,
"play") between the contact and the formation connector so that an
electrical connection may be maintained between the contact and the
battery terminal with the structure of the connector in a variety
of positions relative to the battery terminal. Such connectors may
have a relatively simple design that is intended to be capable of
relatively low-cost manufacturing, and may be constructed of
materials and elements that are generally resistant to corrosion
and/or degradation in the environment in which the connector is
used.
[0154] According to an exemplary embodiment, a connector may be
provided that reduces the time needed to connect a plurality of
batteries during a charging/recharging application. The connector
may allow for variable spacing between a plurality of batteries
while coupled together, and/or may be used with a variety of
batteries that are provided in a variety of sizes.
[0155] It is important to note that the construction and
arrangement of the elements of the battery formation connector as
shown and described in the preferred and other exemplary
embodiments is illustrative only. Although only a few embodiments
of the present inventions 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 herein. For example, elements shown as
integrally formed may be constructed of multiple parts or elements
(e.g., the couplers may be produced separately and coupled to an
arm of the member), the position of elements may be reversed or
otherwise varied (e.g., the cable may be routed through features
provided in projections extending from the member or may extend
directly between the contacts without being routed through a
feature in the member), and the nature or number of discrete
elements or positions may be altered or varied (e.g., each
connector may have more than two members, such as three or more
members). It should be noted that the elements and/or assemblies of
the system may be constructed from any of a wide variety of
materials that provide sufficient strength or durability, including
any of a wide variety of moldable plastic materials (such as
high-impact plastic) in any of a wide variety of colors, textures
and combinations. Other substitutions, modifications, changes and
omissions may be made in the design, operating conditions and
arrangement of the preferred and other exemplary embodiments
without departing from the scope of the present inventions.
* * * * *