Systems and methods for separating batteries
First Claim
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1. A system for separating a main battery and an auxiliary battery of a vehicle electrical system, comprising:
- a housing;
a first stud for connecting one of the main battery and the auxiliary battery to a contactor and a second stud for connecting one of the main battery and the auxiliary battery to the contactor;
the contactor retained within the housing switchably contactable with the first stud and the second stud, wherein the contactor may hold a position in at least one of an open-contactor state and a closed-contactor state;
a first stud-to-printed circuit board terminal located within the housing electrically connecting the first stud to the printed circuit board and a second stud-to-printed circuit board terminal located within the housing electrically connecting the second stud to the printed circuit board;
at least one of said first stud-to-printed circuit board terminal and said second stud-to-printed circuit board terminal having a bend, wherein said bend allows for thermal expansion without stress to a solder joint connecting at least one of said first stud-to-printed circuit board terminal and said second stud-to-printed circuit board terminal to said printed circuit board;
a pair of coil terminals located within the housing electrically connecting the contactor to the printed circuit board;
the printed circuit board providing for a microprocessor retained within the housing;
the microprocessor monitoring independent voltages of the main battery and the auxiliary battery and opening the contactor where the main battery voltage is below a first voltage limit;
the microprocessor monitoring independent voltages of the main battery and the auxiliary battery and closing the contactor where the main battery voltage is above a second voltage limit; and
the contactor, the printed circuit board, the microprocessor, a portion of the first stud, and a portion of the second stud sealed inside the housing.
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Accused Products
Abstract
Systems and methods for a battery separator system integrating a DC contactor (solenoid) plus control electronics and all required interconnects into a single sealed enclosure for the purpose of selectively connecting and disconnecting a main and auxiliary battery under predetermined conditions. Battery monitoring and control includes programmable time delays that immunize the system from reacting to transient conditions as well as monitoring for and correcting unintended states and disabling operation when voltage conditions fall outside of prescribed limits.
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Citations
17 Claims
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1. A system for separating a main battery and an auxiliary battery of a vehicle electrical system, comprising:
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a housing; a first stud for connecting one of the main battery and the auxiliary battery to a contactor and a second stud for connecting one of the main battery and the auxiliary battery to the contactor; the contactor retained within the housing switchably contactable with the first stud and the second stud, wherein the contactor may hold a position in at least one of an open-contactor state and a closed-contactor state; a first stud-to-printed circuit board terminal located within the housing electrically connecting the first stud to the printed circuit board and a second stud-to-printed circuit board terminal located within the housing electrically connecting the second stud to the printed circuit board; at least one of said first stud-to-printed circuit board terminal and said second stud-to-printed circuit board terminal having a bend, wherein said bend allows for thermal expansion without stress to a solder joint connecting at least one of said first stud-to-printed circuit board terminal and said second stud-to-printed circuit board terminal to said printed circuit board; a pair of coil terminals located within the housing electrically connecting the contactor to the printed circuit board; the printed circuit board providing for a microprocessor retained within the housing; the microprocessor monitoring independent voltages of the main battery and the auxiliary battery and opening the contactor where the main battery voltage is below a first voltage limit; the microprocessor monitoring independent voltages of the main battery and the auxiliary battery and closing the contactor where the main battery voltage is above a second voltage limit; and the contactor, the printed circuit board, the microprocessor, a portion of the first stud, and a portion of the second stud sealed inside the housing. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11)
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12. A method for separating a main battery and an auxiliary battery of a vehicle electrical system having,
a housing; -
a first stud for connecting one of a main battery and an auxiliary battery to a contactor and a second stud for connecting one of the main battery and the auxiliary battery to the contactor; the contactor retained within the housing switchably contactable with the first stud and the second stud in a bi-stable connection, wherein the contactor may hold a position in at least one of an open-contactor state and a closed-contactor state; a first stud-to-printed circuit board terminal located within the housing electrically connecting the first stud to the printed circuit board and a second stud-to-printed circuit board terminal located within the housing electrically connecting the second stud to the printed circuit board; at least one of said first stud-to-printed circuit board terminal and said second stud-to-printed circuit board terminal having a bend, wherein said bend allows for thermal expansion without stress to a solder joint connecting at least one of said first stud-to-printed circuit board terminal and said second stud-to-printed circuit board terminal to said printed circuit board; and a pair of coil terminals located within the housing electrically connecting the contactor to the printed circuit board, the method comprising the steps of; measuring at least one of a main battery voltage and an auxiliary battery voltage; determining a state of a contactor; opening the contactor where the main battery voltage is below a first voltage limit; closing the contactor where the main battery voltage is above a second voltage limit; and mechanically pulsing the contactor to a correct state where the contactor is in an incorrect state. - View Dependent Claims (13, 14, 15, 16)
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17. A system for separating a main battery and an auxiliary battery of a vehicle electrical system, comprising:
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a housing, a first stud for connecting one of the main battery and the auxiliary battery to a contactor and a second stud for connecting one of the main battery and the auxiliary battery to the contactor; the contactor retained within the housing switchably contactable with the first stud and the second stud in a bi-stable connection, wherein the contactor may hold a position in at least one of an open-contactor state and a closed-contactor state; a first stud-to-printed circuit board terminal located within the housing electrically connecting the first stud to the printed circuit board and a second stud-to-printed circuit board terminal located within the housing electrically connecting the second stud to the printed circuit board; at least one of said first stud-to-printed circuit board terminal and said second stud-to-printed circuit board terminal having a bend, wherein said bend allows for thermal expansion without stress to a solder joint connecting at least one of said first stud-to-printed circuit board terminal and said second stud-to-printed circuit board terminal to said printed circuit board; a pair of coil terminals located within the housing electrically connecting the contactor to the printed circuit board; the printed circuit board providing for a microprocessor retained within the housing; the microprocessor monitoring independent voltages of the main battery and the auxiliary battery and opening the contactor where the main battery voltage is below a first voltage limit; the microprocessor monitoring independent voltages of the main battery and the auxiliary battery and closing the contactor where the main battery voltage is above a second voltage limit; and the contactor, the printed circuit board, the microprocessor, a portion of the first stud, and a portion of the second stud sealed inside the housing.
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Specification