Battery terminal jumper clip

• US 6,391,489 B1
• Filed: 03/29/2000
• Issued: 05/21/2002
• Est. Priority Date: 03/29/2000
• Status: Expired due to Term

• Current Assignee: Eaton Intelligent Power Limited (Eaton Corporation PLC.)
• Original Assignee: Powerware Corporation (Eaton Corporation PLC.)
• Inventors: Mears, Gregory, Edevold, Craig, Winch, Cary
• Primary Examiner(s): CHANEY, CAROL DIANE
• Application Number:
  US09/538,052
• Time in Patent Office: 783 Days
• Field of Search: 429/121, 429/1, 429/100, 439/500, 439/761, 439/770
• US Class Current: 429/121
• CPC Class Codes: H01R 11/288 Interconnections between batteries
• CPC Class Codes: H01R 4/48 utilising a spring, clip, or other resilient member H01R4/52 takes precedence

Abstract

A battery terminal jumper clip is presented that is capable of providing series battery connection between adjacent batteries in a battery stack useful for an uninterruptible power supply. The battery terminal jumper clip accommodates tab type terminal connectors and utilizes a single piece unitary construction. Once inserted to provide series coupling between adjacent batteries, the battery terminal jumper clip prevents inadvertent removal by providing a snap-on locking surface for the tab terminal connectors. Lateral removal is also inhibited via axial retention surfaces on either side of the battery terminal jumper clip. A bus surface provides a current path between adjacent tab connectors in the series coupling, and mechanical connection is insured through the provision of at least tab retention clip. Relative vertical movement between adjacent batteries is accommodated by providing two tab retention clips, one for each tab terminal connector, and may be enhanced by providing multiple constituent retention clip segments for each tab terminal connector. A auxiliary connection terminal may be included to provide easy access for diagnostic equipment. This auxiliary connection terminal may be integrally formed in a top bus surface, or may alternatively be formed on an edge.

Claims

1. A battery terminal jumper clip for providing electrical coupling between two adjacent batteries, the batteries having tab type terminal connectors to allow connection thereto, comprising:

a unitary, conductive structure defining a bus surface and at least one tab retention clip positioned in relation to said bus surface to provide an interference fit with a tab terminal connector of a battery inserted therebetween; and

wherein said unitary conductive structure further forms two axial retention surfaces at opposite ends of said bus surface and in perpendicular relationship thereto, said axial retention surfaces being spaced one from another to accommodate tab terminal connectors from two batteries therebetween; and

wherein said unitary conductive structure further forms a snap-on retention surface along a forward edge of said bus surface in perpendicular relationship thereto.

2. The battery terminal jumper clip of claim 1, wherein said tab retention clip forms a guided insertion surface in relation to said snap-on retention surface.

3. The battery terminal jumper clip of claim 2, wherein an axial distance L′

from an inner surface of said snap-on retention surface to a forward-most point of contact of said tab retention clip that forms said interference fit with the tab terminal connector is less than a length of the tab terminal connector.

4. The battery terminal jumper clip of claim 3, wherein an axial distance L from an inner surface of said snap-on retention surface to a surface formed between said bus surface and said tab retention clip is greater than a length of any tab terminal connector, thereby allowing the battery terminal jumper clip to accommodate batteries that utilize tab terminal connectors.

5. The battery terminal jumper clip of claim 2, wherein an axial distance L′

from an inner surface of said snap-on retention surface to a surface formed between said bus surface and said tab retention clip is greater than a length of the tab terminal connector.

6. The battery terminal jumper clip of claim 1, wherein the tab terminal connector is coated with a metal, and wherein at least a portion of said unitary, conductive structure that is adapted to contact the tab terminal connector is coated with a like metal with which the tab terminal connector is coated.

7. The battery terminal jumper clip of claim 6, wherein said like metal is tin.

8. The battery terminal jumper clip of claim 1, wherein a distance W between said axial retention surfaces is adapted to accommodate lateral movement of the tab terminal connectors of the batteries when installed thereon.

9. The battery terminal jumper clip of claim 1, wherein a distance W between said axial retention surfaces is greater than a distance between the two tab terminal connectors of two batteries to be coupled thereby, thereby allowing the battery terminal jumper clip to accommodate batteries that utilize tab terminal connectors.

10. The battery terminal jumper clip of claim 1, wherein a surface formed between said bus surface and said tab retention clip is rounded.

11. The battery terminal jumper clip of claim 1, wherein said unitary, conductive structure forms at least two tab retention clips positioned to individually contact one of a battery'"'"'s tab terminal connectors when installed thereon.

12. The battery terminal jumper clip of claim 1, wherein said unitary, conductive structure forms at least two groups of tab retention clips, each group comprising a plurality of individual tab retention clips sized to contact only a portion of a battery'"'"'s tab terminal connector.

13. The battery terminal jumper clip of claim 1, wherein said unitary, conductive structure forms an auxiliary connection terminal.

14. The battery terminal jumper clip of claim 13, wherein said auxiliary connection terminal is formed integrally with said bus structure.

15. The battery terminal jumper clip of claim 13, wherein said auxiliary connection terminal is formed integrally with one of said axial retention surfaces.

16. The battery terminal jumper clip of claim 13, wherein said auxiliary connection terminal includes an aperture formed therein.

17. A battery terminal jumper clip, comprising:

a solid conductive bus structure;

at least one tab retention clip integrally formed with said bus structure, said tab retention clip operative in relation to said bus structure to establish mechanical and electrical contact with a battery tab type terminal connector when positioned thereon; and

a forward surface integrally formed with said bus structure and positioned in perpendicular relation thereto, said forward surface extending toward said tab retention clip.

18. The battery terminal jumper clip of claim 17, further comprising axial retention surfaces integrally formed with said conductive bus structure and positioned in perpendicular relation thereto, said axial retention surfaces extending toward said tab retention clip to inhibit removal of said battery terminal jumper clip once installed on a battery tab type terminal connector.

19. The battery terminal jumper clip of claim 18, wherein said bus structure has a width W defined between said axial retention surfaces sufficient to allow axial movement of the battery tab type terminal connectors of two adjacent batteries when said battery terminal jumper clip is installed thereon.

20. The battery terminal jumper clip of claim 17, wherein said bus structure has a length L defined between said forward surface and a reward surface formed between said bus structure and said tab retention clip sufficient to accommodate battery tab type terminal connectors of different lengths.

21. The battery terminal jumper clip of claim 17, wherein a length L′

defined between an inner surface of said forward surface and a forward contact point of said tab retention clip is sufficient to accommodate battery tab type terminal connectors of different lengths.

22. The battery terminal jumper clip of claim 17, wherein a surface between said bus structure and said tab retention clip is coated with a similar metal to the battery tab type terminal connectors.

23. The battery terminal jumper clip of claim 17, wherein said tab retention clip forms a guided insertion surface at a forward end thereof.

24. The battery terminal jumper clip of claim 17, wherein said tab retention clip is bifurcated to accommodate vertical movement of adjacent batteries when installed thereon.

25. The battery terminal jumper clip of claim 17, further comprising an integrally formed auxiliary connection terminal.

26. The battery terminal jumper clip of claim 25, wherein said auxiliary connection terminal is integrally formed within said bus structure.

27. The battery terminal jumper clip of claim 25, wherein said auxiliary connection terminal is integrally formed with one of said axial retention surfaces.

28. A battery pack, comprising

at least two batteries positioned adjacent one another, each of said batteries having at least one tab type terminal connector for providing electrical connection thereto;

and

a battery terminal jumper clip coupled to said tab type terminal connector of each battery to provide electrical connection therebetween, said battery terminal jumper clip comprising a solid conductive bus structure, at least one tab retention clip integrally formed with said bus structure, said tab retention clip operative in relation to said bus structure to establish mechanical and electrical contact with said batteries'"'"' tab type terminal connectors positioned therebetween, and a forward surface integrally formed with said bus structure, said forward surface extending over said tab type terminal connector to inhibit removal of said battery terminal jumper clip from said tab type terminal connectors.

29. The battery pack of claim 28, wherein said tab type connectors and said battery terminal jumper clip are coated with like metals.

30. The battery pack of claim 28, wherein said battery terminal jumper clip further comprises axial retention surfaces integrally formed with said conductive bus structure and positioned to inhibit axial removal of said battery terminal jumper clip from said tab type terminal connectors.

31. The battery pack of claim 30, wherein said axial retention surfaces are positioned so as to allow axial movement of said batteries inhibiting movement of said tab type terminal connectors.