Polarized battery clamp and booster cable

• US 9,815,378 B2
• Filed: 11/03/2015
• Issued: 11/14/2017
• Est. Priority Date: 11/20/2013
• Status: Expired due to Fees

• Current Assignee: Joseph Stecewycz
• Original Assignee: Joseph Stecewycz
• Inventors: Stecewycz, Joseph
• Primary Examiner(s): Zarroli, Michael
• Application Number:
  US14/931,813
• Publication Number:
  US 20160185242A1
• Time in Patent Office: 742 Days
• CPC Class Codes: B60L 53/16 Connectors, e.g. plugs or sockets, specially adapted for charging electric vehicles
• CPC Class Codes: H01R 11/282 comprising means for facilitating engagement or disengagement, e.g. quick release terminal
• CPC Class Codes: H01R 4/489 spring force increased by screw, cam, wedge, or other fastening means
• CPC Class Codes: H01R 4/5008 using rotatable cam
• CPC Class Codes: H02J 7/0042 characterised by the mechanical construction
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 90/14 Plug-in electric vehicles
• CPC Class Codes: Y10T 29/49174 Assembling terminal to elongated conductor

Abstract

A polarized battery clamp includes a contact handle with an internal electrical path connecting a handle electrical connector at one end of the contact handle to a terminal contact pad at a second handle end, the contact handle also having an internal electrical contact bus connected to the electrical connector; and a contact arm having a terminal contact pad at a first arm end and a stepped pivot pin at a second arm end, the contact arm also having an electrical conductor electrically connected to the arm terminal contact pad; wherein the electrical conductor is placed into electrical contact with the electrical contact bus by inserting the stepped pivot pin into a handle positional slot.

Claims

1. A polarized battery clamp suitable for attachment to a high-amperage, two-conductor, insulated electrical cable for charging a battery, said battery clamp comprising:

a contact handle with at least one positional slot, said contact handle having a ground-side conductive path electrically connecting an electrical connector at a first end of said contact handle to a contact handle terminal contact pad at a second end of said contact handle, said contact handle further having an electrical contact bus with a first bus end connected to said electrical connector; and

a contact arm having a contact arm terminal contact pad at a first end of said contact arm and a stepped pivot pin at a second end of said contact arm, said contact arm further having an electrical conductor with a first electrical conductor end electrically connected to said contact arm terminal contact pad;

wherein a second end of said electrical conductor is placed into electrical contact with a second end of said electrical contact bus by inserting said stepped pivot pin into said at least one positional slot.

2. The polarized battery clamp of claim 1 wherein said contact handle comprises a ground fault interrupter coupled to said electrical contact bus.

3. The polarized battery clamp of claim 1 wherein said at least one positional slot comprises a first slot opening region, a first necked-down detent region adjacent said first slot opening region, and a first pin terminus adjacent said first necked-down detent region, said first pin terminus having a diameter substantially the same as a diameter of a first stepped-down pin section of said stepped pivot pin.

4. The polarized battery clamp of claim 3 wherein said contact handle electrical contact bus extends into said pin terminus region such that said contact arm electrical conductor is placed into electrical contact with said electrical contact bus when said contact arm stepped pivot pin is placed into said contact handle pin terminus.

5. The polarized battery clamp of claim 3 wherein said contact handle further comprises a second positional slot with a second pin terminus opposed to said first pin terminus, such that insertion of said first stepped-down pin section of said stepped pivot pin into said first pin terminus enables insertion of a second stepped-down pin section of said stepped pivot pin into said second pin terminus.

6. The polarized battery clamp of claim 5 wherein said contact handle further comprises a first sidewall and a second sidewall, such that said contact handle has a substantially U-shaped cross section, wherein said at least one positional slot is disposed in said first sidewall and said second positional slot is disposed in said second sidewall.

7. The polarized battery clamp of claim 6 wherein said contact arm is configured to fit inside said contact handle.

8. The polarized battery clamp of claim 1 wherein said electrical connector comprises two leads such that said ground-side conductive path is electrically connected to said first lead in said electrical connector, and said electrical contact bus is electrically connected to said second lead in said electrical connector.

9. The polarized battery clamp of claim 1 wherein said contact arm comprises an electrical trace disposed on an inside surface of said contact arm, said electrical trace electrically connecting said contact arm terminal contact pad to said stepped pivot pin.

10. The polarized battery clamp of claim 9 wherein said contact arm further comprises a polarity indicator coupled to said electrical trace, said polarity indicator functioning to indicate at least one of (i) correct placement of said polarized battery clamp on the battery, and (ii) charge status of the battery.

11. The polarized battery clamp of claim 1 wherein said contact arm further comprises an opening at said second end of said contact arm such that an electrical conductor second end terminates in a cantilever conductive segment that is accessible to selectively contact said second end of said contact bus through said contact arm opening.

12. A method suitable for attaching a battery clamp to battery terminals, said method comprising the steps of:

obtaining a contact handle having a conductive path electrically connecting a first lead in an electrical connector at a first end of said contact handle to a contact handle terminal contact pad at a second end of said contact handle, said contact handle further having an electrical contact bus with a first bus end connected to a second lead in said electrical connector, said contact handle additionally having a first positional slot in a first sidewall and an opposed second positional slot in a second sidewall;

obtaining a contact arm having a contact arm terminal contact pad at a first end of said contact arm and a stepped pivot pin fixed to a second end of said contact arm, said contact arm further having an electrical conductor with a first electrical conductor end electrically connected to said contact arm terminal contact pad;

placing said contact handle terminal contact pad against a first battery terminal;

placing said contact arm terminal contact pad against a second battery terminal; and

removably attaching said contact arm to said contact handle by inserting a first stepped-down pin section of said stepped pivot pin into said first positional slot and a second stepped-down pin section of said stepped pivot pin into said second positional slot in said contact handle so as to form a battery clamp.

13. The method of claim 12 further comprising the step of, if a polarity indicator in said contact arm indicates an incorrect polarity placement of said battery clamp on the battery when said stepped pivot pin is placed into said first positional slot and said second positional slot, removing said contact arm terminal contact pad from said first battery terminal and repositioning said contact handle terminal contact pad against said second battery terminal.

14. The method of claim 12 further comprising the step of, if a polarity indicator in said contact arm indicates an incorrect polarity placement of said battery clamp on the battery when said stepped pivot pin contacts an electrical trace in said contact arm, removing said contact arm terminal contact pad from said first battery terminal and repositioning said contact handle terminal contact pad against said second battery terminal.

15. The method of claim 12 further comprising the step of, if a polarity indicator in said contact arm indicates a correct polarity placement of said battery clamp on the battery when said stepped pivot pin contacts an electrical trace in said contact arm, pushing down said contact handle over said contact arm so that (i) said first stepped-down pin section is moved into a first pin terminus in said first positional slot and said, and (ii) said second stepped-down pin section is moved into a second pin terminus in said second positional slot.

16. The method of claim 15 wherein said step of pushing down said contact handle comprises the step of moving a cantilever conductive segment of said contact handle electrical conductor against said contact handle electrical contact bus so as to complete an electrical path between said electrical connector and said contact arm terminal contact pad.

17. The method of claim 12 further comprising the step of, if a polarity indicator in said contact arm indicates an incorrect polarity placement of said battery clamp on the battery, preventing a surge of electrical current flow through said battery clamp by coupling a ground fault interrupter to one of said contact handle conductive path or said contact handle electrical contact bus.

18. A polarized battery clamp comprising:

an electrical connector configured for attachment to a high-amperage, two-conductor, insulated electrical cable;

a contact handle having a first contact handle end connected to said electrical connector, said contact handle further including a conductive path, said conductive path connecting a first lead in said electrical connector to a contact handle terminal contact pad at a second end of said contact handle, said contact handle further having an electrical contact bus, said contact bus having a first bus end connected to a second lead in said electrical connector; and

a contact arm having a contact arm terminal contact pad at a first end of said contact arm and a stepped pivot pin attached at a second end of said contact arm, said contact arm further including an electrical conductor disposed on an inside surface of said contact arm, such that a first electrical conductor end is electrically connected to said contact arm terminal contact pad, said contact arm also including an electrical trace disposed on an inside surface of said contact arm, said electrical trace electrically connecting said contact arm terminal contact pad to said stepped pivot pin.

19. The polarized battery clamp of claim 18 wherein said contact handle comprises a substantially U-shaped channel cross section with a first sidewall, a channel bottom, and a second sidewall, said conductive path disposed on an inside surface of said first contact handle sidewall and said electrical contact bus disposed on a channel bottom surface inside said contact handle.

20. The polarized battery clamp of claim 19 wherein said contact handle further comprises a first positional slot disposed in said first sidewall, and a second opposed positional slot disposed in said second sidewall.