BATTERY ASSEMBLY DEVICE

• US 20180342891A1
• Filed: 03/29/2016
• Published: 11/29/2018
• Est. Priority Date: 02/11/2016
• Status: Active Grant

• Current Assignee: The NOCO Company, Inc.
• Original Assignee: The NOCO Company, Inc.
• Inventors: NOOK, Jonathan Lewis, NOOK, William Knight, STANFIELD, James Richard, UNDERHILL, Derek Michael
• Granted Patent: US 11,601,004 B2
• Time in Patent Office: Days
• CPC Class Codes: F02N 11/12 Starting of engines by means of mobile, e.g. portable, starting sets
• CPC Class Codes: F02N 11/14 Starting of engines by means of electric starters with external current supply F02N11/12 takes precedence
• CPC Class Codes: H01M 50/553 Terminals adapted for prismatic, pouch or rectangular cells
• CPC Class Codes: H01M 50/566 by welding, soldering or brazing
• CPC Class Codes: H01R 11/24 with gripping jaws, e.g. crocodile clip
• CPC Class Codes: H02J 1/122 Provisions for temporary connection of DC sources of essentially the same voltage, e.g. jumpstart cables
• CPC Class Codes: H02J 7/14 for charging batteries from dynamo-electric generators driven at varying speed, e.g. on vehicle
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

A battery assembly device for a battery jump starting device. The battery assembly is configured to maximize electrical conductivity from a battery pack of the battery jump starting device to a battery to be recharged.

Claims

1. A rechargeable battery assembly device for a battery jump starting device, the device comprising:

a rechargeable battery comprising a positive terminal and a negative terminal;

a positive terminal conductor bar connected to the positive terminal of the rechargeable battery; and

a negative terminal conductor bar connected to the negative terminal of the rechargeable battery.

4. The device according to claim 1, wherein both the positive terminal conductor bar and negative terminal conductor bar have rectangular-shaped cross-sections.

5. The device according to claim 1, wherein both the positive terminal conductor bar and the negative terminal conductor bar have a width greater that a thickness thereof.

6. The device according to claim 5, wherein the the positive conductor bar and negative conductor bar are located adjacent to opposite ends of the rechargeable battery.

7. The device according to claim 1, wherein one end of the positive terminal conductor bar wraps around an exposed end of a positive cable.

8. The device according to claim 1, wherein the positive terminal conductor bar is ultrasonically welded to the positive terminal of the battery and the negative terminal conductor bar is ultrasonically welded to the negative terminal tab of the rechargeable battery.

9. The device according to claim 1, wherein the battery is rectangular-shaped, and the positive terminal conductor bar and the negative terminal conductor bar are L-shaped and wrap around respective corners of the rechargeable battery.

10. The device according to claim 8, wherein the terminal conductor bars are mounted flush with an outer surface of a casing of the rechargeable battery.

11. The device according to claim 1, wherein a positive cable is connected to the positive terminal conductor bar by a flexible cable connector.

12. The device according to claim 11, wherein the flexible cable connector comprises a flexible outer sleeve portion and a flexible inner sleeve portion.

13. The device according to claim 12, wherein the flexible outer sleeve portion comprises an outer flange, and the flexible inner sleeve portion comprises an inner flange, the outer flange and inner flange sandwiching a casing wall of the battery jump starting device.

14. The device according to claim 11, wherein the flexible cable connector comprises an inner serpentine cable portion.

15. The device according to claim 14, wherein the flexible cable connector is configured to accommodate the positive cable oriented at an angle relative to a casing wall of the battery jump starting device, and the inner serpentine cable portion is configured to accommodate a misalignment between the angle relative to the casing wall and an angle of attachment of the inner serpentine cable portion with the positive terminal conductor bar.

16. The device according to claim 1, wherein the positive terminal conductor bar and the negative terminal conductor bar are both flat conductive metal plates each having a length greater than a width of the conductor bars, and wherein the width is greater than a thickness of the conductor bars.

17. The device according to claim 16, wherein a width dimension of the conductor bars is multiple times a thickness dimension of the conductor bars.

18. The device according to claim 17, wherein the width dimension of the conductor bars is aligned with a thickness dimension of the rechargeable battery, and wherein the length dimension of the conductor bars is aligned with at least one of the length dimension and width dimension of the rechargeable battery.

20. The device according to claim 15, wherein the relay is multiple relays connected in parallel between the first circuit board conductor bar and the second circuit board conductor bar.

2. A rechargeable battery assembly device for a battery jump starting device, the device comprising:

a rectangular-shaped rechargeable battery comprising a positive terminal and a negative terminal;

a positive terminal conductor bar connected to the positive terminal of the rectangular-shaped rechargeable battery, the positive terminal conductor bar being located adjacent to a side of the rectangular-shaped battery; and

a negative terminal conductor bar connected to the negative terminal of the rectangular-shaped battery, the negative terminal conductor bar being located adjacent to an opposite side of the rectangular-shaped battery.

3. A rechargeable battery assembly device for a battery jump starting device, the device comprising:

a rectangular-shaped rechargeable battery comprising a positive terminal and a negative terminal each located at opposite ends of the rectangular-shaped rechargeable battery;

an L-shaped positive terminal conductor bar connected to the positive terminal tab of the rectangular-shaped rechargeable battery, the L-shaped positive terminal bar located adjacent to at least two adjacent sides of the rectangular-shaped rechargeable battery, the L-shaped positive terminal conductor bar bending around a corner of the rectangular-shaped rechargeable battery and extending along at least a portion of each of the at least two adjacent sides of the rectangular-shaped rechargeable battery;

an L-shaped negative terminal conductor bar connected to the negative terminal of the battery, the L-shaped negative terminal bar located adjacent to at least two other adjacent sides of the rectangular-shaped rechargeable battery, the L-shaped negative conductor bar bending around a corner of the rectangular-shaped rechargeable battery and extending along at least a portion of each of the at least two other adjacent sides of the rectangular-shaped rechargeable battery.

19. A battery jump starting device having a smart switch controller, the device comprising:

a rechargeable battery comprising a positive terminal and a negative terminal;

a positive terminal conductor bar connected to the positive terminal of the rechargeable battery;

a negative terminal conductor bar connected to the negative terminal of the rechargeable battery;

a positive cable having one end connected to the positive terminal conductor bar;

a positive clamp connected to an opposite end of the positive cable;

a smart switch interface connected to and controlled by the smart switch controller, the smart switch interface comprising a circuit board having a first circuit board conductor bar connected to the negative terminal conductor bar of the rechargeable battery and a second circuit board conductor spaced apart from the first circuit board conductor bar on the circuit board, the smart switch interface further comprising one or more relays connected between the first circuit board conductor bar and the second circuit board conductor bar for providing isolation between the negative terminal of the rechargeable battery and a battery being jump started by the battery jump starting device;

a negative cable having one end connected to the second circuit board conductor bar; and

a negative clamp connected to an opposite end of the negative cable.