Connection arrangement for battery monitoring circuits

• US 5,449,570 A
• Filed: 09/30/1994
• Issued: 09/12/1995
• Est. Priority Date: 09/30/1994
• Status: Expired due to Fees

• Current Assignee: Johnson Controls Technology Company (Johnson Controls International plc)
• Original Assignee: Globe-Union Inc.
• Inventors: Lenhardt, Brett M., Inkmann, Mark S., Reher, Michael T., Koeppel, Bradley N.
• Primary Examiner(s): Skapars, Anthony
• Application Number:
  US08/316,616
• Time in Patent Office: 347 Days
• Field of Search: 429/90-93, 429/121, 429/123, 429/175, 429/178, 429/179, 429/7, 340/636, 364/483, 364/550, 364/551.01, 320/43, 320/48
• US Class Current: 429/92
• CPC Class Codes: H01M 10/48 Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte constructional details of current conducting connections for detecting conditions inside cells or batteries, e.g. details of voltage sensing terminals, H01M50/569
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

An arrangement for mounting a battery monitoring circuit on the cover of the battery and for connecting the terminal ends of first and second lead wires of a battery monitoring circuit to the positive and negative terminals of the battery, the arrangement including a cavity formed in the battery cover for mounting the battery monitoring circuit, first and second battery terminal bushings which are molded integrally with the cover and are adapted to be mounted on and connected to the positive and negative battery terminals when the battery cover is installed on the battery, each of the battery terminal bushings including a pad having an upwardly directed mounting post that is adapted to receive and secure the terminal end of one of the lead wires of the battery monitoring circuit, the battery cover having first and second lead wire slots in its surface which extend from the cavity in which the battery monitoring circuit is mounted, to the locations of the battery terminal bushings for directing the lead wires to the mounting posts and for protecting the leads from damage during use.

Claims

1. An arrangement for mounting a battery monitoring circuit on a battery cover and for connecting terminal ends of first and second lead wires of the battery monitoring circuit to the positive and negative terminals of the battery, said arrangement comprising:

first and second battery terminal bushings carried by said battery cover,

said first battery terminal bushing including a body portion adapted for connection to said positive battery terminal and a first extension projecting from said body portion of said first battery terminal bushing and having a mounting site spaced apart laterally from said body portion of said first battery terminal bushing and from said battery monitoring circuit, said mounting site of said first extension being adapted to receive said terminal end of said first lead wire,

said second battery terminal bushing including a body portion adapted for connection to said negative battery terminal and a second extension projecting from said body portion of said second battery terminal bushing and having a mounting site spaced apart laterally from said body portion of said second battery terminal bushing and from said battery monitoring circuit, said mounting site of said second extension being adapted to receive said terminal end of said second lead wire;

said battery cover including securing means cooperating with said battery monitoring circuit for securing said battery monitoring circuit to said battery cover;

a first lead wire slot provided in said battery cover and extending from the location of said battery monitoring circuit to a location adjacent to said first mounting site;

said first lead wire of said battery monitoring circuit being positioned in said first wire slot and extending from said battery monitoring circuit to said first mounting site with its terminal end located adjacent to said first mounting site;

a second lead wire slot provided in said battery cover and extending from the location of said battery monitoring circuit to a location adjacent to said second mounting site,

said second lead wire of said battery monitoring circuit being positioned in said second lead wire slot and extending from said battery monitoring circuit to said second mounting site with its terminal end located adjacent to said second mounting site;

and means for connecting said terminal ends of said first and second lead wires electrically and mechanically to said mounting sites of said first and second extensions of said first and second battery terminal bushings, respectively.

2. The arrangement according to claim 1, wherein each of said lead wire slots includes lead wire retaining means for retaining said lead wires in said lead wire slots.

3. The arrangement according to claim 2, wherein said lead wire retaining means includes inwardly directed portions of the side wall of the lead wire slot, said inwardly directed portions being disposed in pairs along the length of the lead wire slot, defining pinch points for the lead wires, said pinch points being disposed spaced apart along the length of said lead wire slot.

4. The arrangement according to claim 1, wherein said battery cover includes a cavity in an upper surface thereof for receiving said battery monitoring circuit, and wherein said cover includes first and second openings in said upper surface, said first and second lead wire slots being formed in said upper surface of said battery cover and terminating at said first and second openings, respectively, and wherein said first and second mounting sites include first and second mounting posts located in said first and second openings, respectively, in alignment with said first and second lead wire slots.

5. The arrangement according to claim 4, wherein said connecting means includes a solder connection between said mounting posts and said terminal ends of said lead wires at said mounting sites.

6. The arrangement according to claim 5, including means for encapsulating said mounting sites at which the connections are made between the terminal ends of said lead wires and said mounting posts.

7. The arrangement according to claim 4, wherein the depth of each of said lead wire slots is such that the lead wire positioned therein is recessed relative to said upper surface of said battery cover.

8. The arrangement according to claim 4, wherein said battery monitoring circuit is enclosed within a housing having first and second sidewall portions, and wherein said securing means comprises projections formed on said first and second sidewall portions of said housing that cooperate with recessed portions of the sidewall of said cavity that are adjacent to said sidewall portions of said housing.

9. The arrangement according to claim 4, wherein said body portions of said first and second battery terminal bushings are generally cylindrical in shape and have a central aperture for receiving the associated battery terminals, and wherein each of said extensions includes a generally flat, flange-like portion that extends outwardly from the base of said body portion, and wherein said mounting post extends outwardly relative to said flange and has a cross-sectional area that is less than the area of said flange-like portion.

10. The arrangement according to claim 1, wherein said battery monitoring circuit includes output means for providing an output that is indicative of the status of a condition being monitored by said battery monitoring circuit, and means coupled to said battery monitoring circuit for providing an indication of the status of said monitored condition at a location remote from the location of the battery being monitored.

11. The arrangement according to claim 10, wherein said output means includes light emitting means for producing a visual output indicative of the status of said monitored condition, and wherein said means for providing an indication includes light conducting means and means for connecting said light conducting means to said housing of said battery monitoring circuit in close proximity to said light emitting means to permit said light conducting means to conduct a light emitted by said light emitting means to said location remote from the location of the battery being monitored.

12. The arrangement according to claim 10, wherein said output means includes means for providing an electrical output signal that is indicative of the status of said monitored condition, and wherein said means for providing an indication includes an electrical signal conducting means and an electrical socket means for connecting said electrical signal conducting means to said battery monitoring circuit to permit said electrical signal to be conducted to said location remote from the location of the battery being monitored.

13. An arrangement for mounting a battery monitoring circuit on the upper surface of a battery cover of a battery and for connecting terminal ends of first and second lead wires of the battery monitoring circuit to the positive and negative terminals of the battery, said arrangement comprising:

first and second battery terminal bushings, said first battery terminal bushing having a body portion adapted for connection to said positive battery terminal and a first extension of a conductive material formed integrally with said body portion of said first battery terminal bushing, said first extension having an upwardly extending mounting post which is adapted to receive said terminal end of said first lead wire;

said second battery terminal bushing having a body portion adapted for connection to said negative battery terminal and a second extension of a conductive material formed integrally with said body portion of said second battery terminal bushing, said second extension having an upwardly extending mounting post which is adapted to receive said terminal end of said second lead wire;

said battery cover having a cavity in said upper surface for receiving said battery monitoring circuit and including securing means cooperating with said battery monitoring circuit for securing said battery monitoring circuit to said battery cover;

a first lead wire slot in said upper surface of said battery cover and extending from said cavity to a location adjacent to said first mounting post;

said first lead wire of said battery monitoring circuit being positioned in said first lead wire slot and extending from said cavity to said mounting post of said first extension with its terminal end located adjacent to said mounting post of said first extension;

a second lead wire slot in said upper surface of said battery cover and extending from said cavity to a location adjacent to said second mounting post;

said second lead wire of said battery monitoring circuit being positioned in said second lead wire slot and extending from said cavity to said second mounting post with its terminal end located adjacent to said mounting post of said second extension;

and means for connecting said terminal ends of said first and second lead wires electrically and mechanically to said mounting posts of said first and second extensions, respectively.

14. The arrangement according to claim 13, wherein said battery cover is molded and first and second wells are molded into said upper surface of said battery cover, and wherein said first and second battery terminal bushings are molded into said battery cover during said molding process with said first and second mounting posts located in said first and second wells and exposed to the upper surface of said battery cover, said first and second lead wire slots terminating at said first and second wells, respectively and said terminal ends of said lead wires extending into said wells for connection to said mounting posts.

15. The arrangement according to claim 14, wherein said means for connecting includes a solder connection between said mounting posts and said terminal ends of said lead wires, and including means for encapsulating at least said wells in which the connections are made between the terminal ends of said lead wires and said mounting posts.

16. The arrangement according to claim 13, wherein said battery monitoring circuit is enclosed within a housing having first and second sidewall portions, and wherein said securing means comprises projections formed on said first and second sidewall portions of said housing that cooperate with recessed portions of the sidewall of said cavity that are adjacent to said sidewall portions of said housing.

17. The arrangement according to claim 16, wherein said housing includes first and second apertures through said sidewall portions, said apertures being aligned with said lead wire slots to guide said lead wires into said lead wire slots.

18. The arrangement according to claim 13, wherein each of said lead wire slots includes wire retaining means for retaining the lead wires within the lead wire slot.

19. The arrangement according to claim 18, wherein each of said lead wire slots includes parallel opposing sidewalls each having a plurality of inwardly directed portions along the length of said lead wire slots, said inwardly directed portions projecting inwardly in pairs defining pinch points for the lead wires.

20. The arrangement according to claim 13, wherein the depth of each of said lead wire slots is such that the lead wire positioned therein is recessed relative to said upper surface of said battery cover.

21. The arrangement according to claim 13, wherein said battery monitoring circuit includes output means for providing an output that is indicative of the status of a condition being monitored by said battery monitoring circuit, and means coupled to said battery monitoring circuit for providing an indication of the status of said monitored condition at a location remote from the location of the battery being monitored.

22. The arrangement according to claim 21, wherein said output means includes light emitting means for producing a visual output indicative of the status of said monitored condition, and wherein said means for providing an indication includes light conducting means and means for connecting said light conducting means to said housing of said battery monitoring circuit in close proximity to said light emitting means to permit said light conducting means to conduct a light emitted by said light emitting means to said location remote from the location of the battery being monitored.

23. The arrangement according to claim 21, wherein said output means includes means for providing an electrical output signal that is indicative of the status of said monitored condition, and wherein said means for providing an indication includes an electrical signal conducting means and an electrical socket means for connecting said electrical signal conducting means to said battery monitoring circuit to permit said electrical signal to be conducted to said location remote from the location of the battery being monitored.