Apparatus for interconnecting wheelchair batteries

• US 5,522,734 A
• Filed: 04/15/1994
• Issued: 06/04/1996
• Est. Priority Date: 04/15/1994
• Status: Expired due to Term

• Current Assignee: Invacare Corporation
• Original Assignee: Invacare Corporation
• Inventors: Goertzen, Gerold G.
• Primary Examiner(s): Pirlot, David L.
• Application Number:
  US08/228,118
• Time in Patent Office: 781 Days
• Field of Search: 439/500, 439/384, 439/388, 180/68.5, 180/65.1, 180/907, 429/97-100
• US Class Current: 439/500
• CPC Class Codes: A61G 5/045 Rear wheel drive
• CPC Class Codes: H01M 50/202 Casings or frames around the primary casing of a single cell or a single battery
• CPC Class Codes: H01M 50/204 Racks, modules or packs for multiple batteries or multiple cells
• CPC Class Codes: H01M 50/244 Secondary casings; Racks; Suspension devices; Carrying devices; Holders characterised by their mounting method
• CPC Class Codes: H01M 50/249 specially adapted for aircraft or vehicles, e.g. cars or trains constructional details of batteries specially adapted for electric vehicles B60L50/64
• CPC Class Codes: H01M 50/264 for cells or batteries, e.g. straps, tie rods or peripheral frames
• CPC Class Codes: H01M 50/271 Lids or covers for the racks or secondary casings
• CPC Class Codes: H01M 50/296 characterised by terminals of battery packs terminals of batteries H01M50/543
• CPC Class Codes: H01M 50/298 characterised by the wiring of battery packs
• CPC Class Codes: H01M 50/50 Current conducting connections for cells or batteries
• CPC Class Codes: H01R 13/28 Contacts for sliding cooperation with identically-shaped contact, e.g. for hermaphroditic coupling devices H01R24/84 takes precedence
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

An apparatus for interconnecting wheelchair batteries having a pair of boxes with flanges extending from side walls thereof, and a wheelchair sub-frame assembly which provides concise placement of the boxes in an electrically interconnected suspended position. The sub-frame assembly has an open end into which the boxes are inserted, a pair of spaced apart parallel guide rails each having a smooth surface for slidably receiving and supporting the boxes by their flanges, and a closed end having a cross-brace rigidly connected therebetween. A first pair of mateable electrical connectors are connected to the first and second boxes, respectively and conduct current between batteries thereof. A second pair of mateable electrical connectors are connected to the first box and the cross-brace and conduct electricity between the battery of the first box and the electric motor.

Claims

1. An apparatus for interconnecting at least one battery with an electric motor, comprising:

at least one box for housing the one battery, the box having a base, side walls, end walls, a removable lid and at least one flange securely connected to each side wall;

a frame assembly effecting a precise placement of the box in an electrically interconnected suspended position, said frame assembly having an open end into which the box is inserted, a pair of spaced-apart parallel guide rails each having a smooth surface slidably receiving and supporting the box by its flanges, and a closed end having a cross-brace rigidly connected between the guide rails;

a pair of detachably mated electrical connectors for conducting current between the one battery and the electric motor, the first detachably mated electrical connector being fastened to the box and being electrically connected to the one battery, and the second detachably mated electrical connector being located on said frame assembly and being electrically connected to the motor, each detachably mated electrical connector including at least one mating terminal, each mating terminal including a sliding surface and a mating surface formed at an obtuse angle with respect to one another, each mating terminal formed such that when the sliding surface of a first mating terminal is pushed into contact with the sliding surface of a second, conversely positioned mating terminal, the sliding surface of the first mating terminal slides upwardly and over the sliding surface of the second mating terminal until the mating surface of the first mating terminal slides downwardly into contact with the mating surface of the second mating terminal such that the mating surfaces are closely engaged.

2. The apparatus of claim 1 further comprising an alignment pin mated with an alignment socket for precisely aligning the pair of detachably mated electrical connectors, one of the alignment pin and alignment socket being attached to the box.

3. The apparatus of claim 2 wherein the alignment pin includes an elongated shaft positioned parallel to the parallel guide rails.

4. The apparatus of claim 3 wherein the alignment pin shaft has a smooth outer surface to facilitate sliding movement with the alignment socket.

5. An apparatus for interconnecting at least two batteries with an electric motor, comprising:

at least two boxes for housing batteries, each box having a base, side walls, end walls, a removable cover and at least one flange securely connected to each side wall;

a frame assembly for effecting a precise placement of the boxes in an electrically interconnected suspended position, said sub-frame assembly having an open end into which the boxes are inserted, a pair of spaced-apart parallel guide rails each having a smooth surface for slidably receiving and supporting the boxes by their flanges, and a closed end having a cross-brace rigidly connected between the guide rails;

a first pair of mateable electrical connectors for conducting current between a battery of the first box and a battery of the second box, the first pair of mateable electrical connectors being secured to the first and second boxes, respectively;

a second pair of mateable electrical connectors for conducting current between the battery of the first box and the electric motor, the second pair of mateable electrical connectors being secured to the first box and the cross-brace, respectively;

a first alignment pin and socket for concisely aligning the first pair of mateable electrical connectors prior to the first pair of mateable electrical connectors being mated, the first alignment pin being secured to one of the first and second boxes, and the first socket being secured to the other of the first and second boxes; and

a second alignment pin and socket for concisely aligning the second pair of mateable electrical connectors prior to the second pair of mateable electrical connectors being mated, the second alignment pin being secured to one of the first box and the cross-brace, and the second socket being connected to the other of the first box and cross-brace.

6. The apparatus of claim 5 further comprising a first alignment pin bracket for attaching the first alignment pin to one of the first and second boxes, a first socket bracket for attaching the first socket to the other of the first and second boxes, a second alignment pin bracket for attaching the second alignment pin to one of the first box and the cross-brace, and a second socket bracket for attaching the second socket bracket to the other of the first box and the cross-brace.

7. The apparatus of claim 5 wherein each mateable electrical connector includes at least one mating terminal through which current is conducted, each mating terminal including a sliding surface and a mating surface formed at an obtuse angle with respect to one another, each mating terminal formed such that when the sliding surface of a first mating terminal is pushed into contact with the sliding surface of a second, conversely positioned mating terminal, the sliding surface of the first mating terminal slides upwardly and over the sliding surface of the second mating terminal until the mating surface of the first mating terminal slides downwardly into contact with the mating surface of the second mating terminal such that the mating surfaces are closely engaged.

8. The apparatus of claim 5 wherein each box cover comprises side and end flaps which engage corresponding side and end walls of the box, respectively, the first box cover having a recessed portion defined in each end flap through which extends one mateable electrical connector of the first pair of mateable electrical connectors and the second pair of mateable electrical connectors, and the second box cover having a recessed portion defined in one of the end flaps through which extends one mateable electrical connector of the first pair of mateable electrical connectors.

9. The apparatus of claim 5 further comprising a first wiring harness contained within the first box for electrically connecting the first box battery to one of the first pair of mateable electrical connectors and to one of the second pair of mateable electrical connectors, and a second wiring harness contained in the second box for electrically connecting second box battery to one of the second pair of mateable connectors.

10. An apparatus for interconnecting at least two wheelchair batteries with a wheelchair electric motor, the apparatus comprising:

two boxes each housing at least one wheelchair battery, respectively, each box having a rectangular base, side walls having inner and outer surfaces, end walls having inner and outer surfaces, a removable cover, and at least one flange extending from each side wall outer surface;

a wheelchair sub-frame assembly for effecting a precise placement of the boxes in an electrically interconnected suspended position so that one of the first box outer end wall surfaces is parallel with one of the second box outer end wall surfaces, said wheelchair sub-frame assembly having an open end into which the boxes are sequentially inserted, a pair of spaced-apart parallel guide rails each having a flat surface for slidably receiving and supporting the boxes by their flanges, and a closed end having a cross-brace rigidly connected between the parallel guide rails;

a first pair of mateable electrical connectors for conducting current between the wheelchair batteries of first and second boxes, the first pair of electrical connectors being attached to the first and second boxes, respectively;

a second pair of mateable electrical connectors for conducting current between the wheelchair battery of the first box and an electric wheelchair motor, the second pair of electrical connectors being attached to the first box and the cross-brace, respectively;

a first pair of alignment pins and a first pair of alignment sockets for aligning the first pair of mateable electrical connectors into mating engagement, the first pair of alignment pins being attached to one of the first and second boxes and extending along first and second axes, respectively, and the first pair of sockets attached to the other of the first and second boxes in alignment with the first and second axes, respectively, the first pair of alignment sockets being adapted to receive the first pair of alignment pins; and

a second pair of alignment pins and a second pair of alignment sockets for aligning the second pair of mateable electrical connectors into mating engagement, the second pair of alignment pins being attached to one of the first box and the cross-brace and extending along the first and second axes, respectively, and the second pair of sockets attached to the other of the first box and the cross-brace in alignment with the first and second axes, respectively, the alignment sockets being adapted to receive the second pair of alignment pins.

11. The apparatus of claim 10 wherein each mateable electrical connector includes at least one mating terminal through which current is conducted, each mating terminal including a sliding surface and a mating surface formed at an obtuse angle with respect to one another, each mating terminal formed such that when the sliding surface of a first mating terminal is pushed into contact with the sliding surface of a second, conversely positioned mating terminal, the sliding surface of the first mating terminal slides upwardly and over the sliding surface of the second mating terminal until the mating surface of the first mating terminal slides downwardly into contact with the complementary mating surface of the second mating terminal such that the mating surfaces are closely engaged.

12. The apparatus of claim 10 wherein the sub-frame assembly is fastened to a wheelchair mainframe assembly.

13. The apparatus of claim 10 wherein each box cover comprises side and end flaps which engage corresponding side and end wall outer surfaces of the box, respectively, the first box cover having a recessed portion defined in each end flap, the box further including a recessed portion defined in each end wall, the second box cover having a recessed portion defined in one of the end flaps, the second box further including a recessed portion defined in a corresponding end wall, wherein the recessed portions of each box and box cover are positioned to align with the first and second axes.

14. The apparatus of claim 10 wherein the first pair of alignment pins are attached to one of the first and second box covers, the first pair of alignment pins are attached to the other of the first and second box covers, and one of the second pairs of alignment pins and second pairs of alignment sockets are attached to the first box cover.

15. The apparatus of claim 14 wherein the first pair of mateable electrical connectors are attached to the first and second box covers, respectively, and one of the second pair of mateable electrical connectors is attached to the first box cover, said first and second pairs of mateable electrical connectors arranged in linear alignment between the first and second axes.

16. The apparatus of claim 10 further comprising a first wiring harness for electrically connecting the first wheelchair battery of the first box to one of the first pair of mateable electrical connectors and to one of the second pair of mateable electrical connectors, and a second wiring harness for electrically connecting the second wheelchair battery of the second box to one of the second pair of mateable connectors.

17. The apparatus of claim 16 wherein the wheelchair batteries are electrically connected in series.

18. The apparatus of claim 17 further comprising an in-line fuse electrically connected to the second wiring harness, for limiting current flow between the wheelchair batteries and the wheelchair electric motor.

19. An apparatus for conducting current between at least one battery and an electric motor, comprising:

at least one box for housing the one battery, the box having a base, sidewalls, endwalls, and at least one flange securely connected to each sidewall;

a frame effecting a precise placement of the box in a suspended position, said frame assembly having an open end into which the box is inserted, and a pair of spaced guide rails receiving and supporting the box by its flanges;

first and second detachably mated electrical connectors for conducting electric current between the at least one battery and the electric motor, the first detachably mated electrical connector being fastened to the box, each detachably mated electrical connector including a mating terminal, each mating terminal including a sliding surface and a mating surface formed at an obtuse angle with respect to one another, each mating terminal formed such that when the sliding surface of a first mating terminal engages the sliding surface of a second, conversely positioned mating terminal, the sliding surface of the first mating terminal slides over the sliding surface of the second mating terminal until the mating surface of the first mating terminal engages the mating surface of the second mating terminal.