Car battery with embossed electrical contact socket

Abstract

The automotive battery includes positive and negative battery contact sockets on the battery surface, each battery contact socket including a socket shell slot within the socket shell with conductive traces extending from the socket shell slots to the respective battery terminals so that polarized electrical connector protrusions inserted into designated socket shell slots make electrical contact with the corresponding battery terminals.

Description

[Technical Field]

[0001] The present invention relates generally to automotive lead-acid batteries incorporating embossed electrical contact sockets for receiving the prongs of an electrical connector. [Background technology]

[0002] Automotive lead-acid batteries are manufactured with positive and negative battery terminals attached to the battery casing. Conventional booster cables typically include battery terminal clamps with spring-loaded serrated jaws, which dent and scratch the lead-alloy battery terminals and engine battery clamps. Over time, repeated application of booster cable clamps degrades these lead-alloy surfaces. What is needed is a battery charging device that overcomes the limitations of the background art by: (i) providing a method for electrically connecting an automotive battery without causing surface damage to the battery terminals and engine battery clamps; (ii) ensuring proper electrical polarity when connecting a source battery to a discharged battery; and (iii) reducing the occurrence of electrical sparks that could lead to the ignition of hydrogen gas.

[0003] (Industrial Applicability) A new method of establishing an electrical connection between automotive batteries uses a jumper plug and embossed electrical contact sockets instead of the traditional serrated jaw booster cable battery terminal clamps.

[0004] DISCLOSURE OF THE INVENTION The present invention arose from the observation that electrical connection to battery terminals on a battery housing can be made by inserting an electrical plug of a jumper cable into an electrical contact socket electrically connected to the battery terminal. These electrical contact sockets are attached to or formed as part of the surface of the battery housing. The present invention is an automotive battery comprising: (i) a positive battery contact socket attached to the battery housing adjacent to the positive battery terminal, such that a positive electrical lug can be inserted into the positive socket shell slot to make electrical contact with the positive battery terminal; and (ii) a negative battery contact socket attached to the battery housing surface adjacent to the negative battery terminal, such that a negative electrical lug can be inserted into the negative socket shell slot to make electrical contact with the negative battery terminal. [Brief explanation of the drawings]

[0005] [Figure 1] This is a system for charging mobile batteries using a new battery jumper plug cable inserted into the embossed battery contact sockets on the source and load batteries.

[0006] [Figure 2] FIG. 2 is an isometric detailed cross-sectional view of the positive source battery contact socket and positive source battery terminal shown in FIG. 1.

[0007] [Figure 3] FIG. 1 is an isometric cross-sectional detail view of a battery dimple contact socket with socket conductive traces, a socket shell, and a socket shell sill.

[0008] [Figure 4] FIG. 1 is an isometric view of a battery including a positive battery contact socket and a negative battery contact socket.

[0009] [Figure 5]FIG. 5 is an exploded isometric view of the positive battery contact socket of FIG. 4, showing the positive battery socket shell, positive lug retaining insert, socket shell sill, and positive socket conductive traces.

[0010] [Figure 6] FIG. 5 is an isometric cross-sectional detail view of the positive battery contact socket and positive battery terminal of FIG.

[0011] [Figure 7] Figure 7 shows the insertion of the positive jumper electrical plug into the positive socket shell slot of the positive battery contact socket.

[0012] [Figure 8] FIG. 10 is an isometric detailed cross-sectional view of an angled battery contact socket electrically connected to a battery terminal.

[0013] [Figure 9] FIG. 1 is a cross-sectional isometric view of a battery contact socket.

[0014] [Figure 10] A battery contact socket electrically connected to the battery terminals by conductive traces.

[0015] [Figure 11] This battery has the contact socket of FIG. 10 at the positive battery terminal and the battery contact socket of FIG. 9 at the negative battery terminal.

[0016] [Figure 12] FIG. 10 is an isometric detailed cross-sectional view of a battery contact socket electrically connected to a battery-side terminal.

[0017] [Figure 13] FIG. 10 is a detailed view of the battery contact socket and improved battery side terminal.

[0018] [Figure 14]1 shows a side terminal battery with positive and negative battery contact sockets.

[0019] [Figure 15] A portable battery lug contact socket.

[0020] [Figure 16] A portable battery spade contact socket.

[0021] [Figure 17] A portable battery tab contact socket. DETAILED DESCRIPTION OF THE INVENTION

[0022] (Mode for Carrying Out the Invention) FIG. 1 illustrates a mobile battery charging system and method according to an embodiment of the present invention. A novel battery jumper plug cable 100 is used to conduct charging current supplied from a source battery 120 to a load battery 140. Both batteries 120, 140 are configured and manufactured according to the disclosed features of the present invention. The battery jumper plug cable 100 includes a positive insulated electrical conductor 106 and a negative insulated electrical conductor 108. Each of the insulated electrical conductors 106, 108 has a cross-sectional area sufficient to safely conduct high-amperage engine starter current. The parallel lengths of the positive insulated electrical conductor 106 and the negative insulated electrical conductor 108 are physically coupled by a conductor pair section 110, which facilitates handling and storage of the battery jumper plug cable 100 and minimizes tangling. One end of the positive insulated electrical conductor 106 is electrically connected to a source jumper plug 102. The other end is connected to a load jumper plug 112. One end of the negative insulated electrical conductor 108 is electrically connected to the source jumper plug 104. The other end is connected to the load jumper plug 114.

[0023] The source battery 120 includes a source battery contact socket 132 embossed or otherwise attached to the surface of the source battery housing 130 adjacent the positive battery terminal 122. A source battery contact socket 134 is embossed adjacent the negative battery terminal 124. The source battery contact sockets 132, 134 may be separate components formed from a non-conductive material such as plastic and then attached to the source battery housing 130 during manufacturing. The load battery 140 includes a load battery contact socket 152 provided on the surface of the load battery housing 150 adjacent the positive battery terminal 142 and a load battery contact socket 154 adjacent the negative battery terminal 144. The load battery contact sockets 152, 154 may be formed from an electrically insulating material such as plastic or other composite material and may be glued, heat-bonded, or otherwise attached to the load battery housing 150. The load battery contact sockets 152, 154 may alternatively be fabricated as embossed socket components integrally formed with the load battery housing 150.

[0024] FIG. 2 is an isometric detailed cross-sectional view 01-01 of the source battery contact socket 132 and the battery terminal 122. The source battery contact socket 132 includes a conductive trace 160, a socket shell 162, and a socket shell sill 166 that defines a socket shell slot 164. The socket shell slot 164 is a substantially rectangular parallelepiped slot opening through the socket shell 162. The source battery contact socket 132 may be fabricated from a non-conductive material, such as a plastic or plastic composite. One end of the socket conductive trace 160 includes a protruding contact trace 161, i.e., a conductive trace segment that resides at least partially within the socket shell 162. A second end of the socket conductive trace 160 includes a terminal contact trace 163 that is electrically connected to the positive source battery terminal 122. The entire length of the metal or metal alloy strip that forms the socket conductive trace 160 has a cross-sectional area sufficient to safely conduct high amperage engine starter current. In an alternative embodiment not shown, the socket shell slot 164 may be configured as an internal slot or closed cavity open only in the socket shell sill 162, with the socket shell slot 164 extending to expose the protruding contact trace 161 to the prongs of the electrical plug.

[0025] The source battery contact socket 132 can be thermally or chemically bonded to the surface of the source battery housing 130 of FIG. 1. The socket conductive trace 160 extends from the socket shell sill 166 and is electrically connected to the positive battery terminal 122 by a conductive epoxy 123, a solder composition, or the like. The socket conductive trace 160 can be fabricated from a copper alloy or can be a lead alloy fabricated as a single element that comprises the battery terminal 122. The thickness of the socket conductive trace 160 is preferably greater than the thickness of the socket shell sill 166, resulting in a relatively small trace sill offset 168. The source battery contact socket 134 of FIG. 1 is configured similarly to the source battery contact socket 132.

[0026] The source jumper plug 102 includes a substantially rectangular plug protrusion 170 formed from a curved protrusion blade 172 and a substantially matching protrusion blade 174, which may be curved or flat. Each protrusion blade 172, 174 is fabricated from a conductive material, such as a copper alloy. The curved protrusion blade 172 provides a spring-like action relative to the adjacent protrusion blade 174. The plug protrusion 170 is electrically connected to the positive insulated electrical conductor 106 within a non-conductive jumper plug grip 176. The source jumper plug 104 of FIG. 1 is similarly configured.

[0027] 3 is an isometric cross-sectional detail view of an alternatively configured contact socket 180 including conductive traces 160, a socket shell 182, and a socket shell sill 186 defining a socket shell slot 184. The contact socket 180 includes a shell sill bevel 188 provided to facilitate insertion of the source jumper plug 102. The socket shell 182 includes a socket shell dimple 185 that protrudes into the socket shell slot 184 to increase the force that the plug protrusion 170 exerts on the socket's conductive traces 160. A conventional engine battery clamp 129 may be placed over the battery terminal 122.

[0028] FIG. 4 is an isometric view of a load battery 140 showing the positive and negative battery terminals 142, 144, and the load battery contact sockets 152, 154 mounted near the front end 149 of the load battery. The load battery contact socket 152 includes a battery socket shell 190 configured as an inverted U-shaped channel and surrounding a boss retaining insert 192. A socket shell slot 194 is defined between the boss retaining insert 192 and a socket shell sill 196. A conductive trace 202 is mounted on the surface of the load battery housing 150 between the positive battery terminal 142 and the socket shell sill 196. The conductive trace 202 may be fabricated from a conductive material. The load battery contact socket 154 includes a battery socket shell 210 configured as an inverted U-shaped channel and surrounding a boss retaining insert 212. A socket shell slot 214 is defined between the boss retaining insert 212 and a socket shell sill 216. The conductive trace 204 is attached to the surface of the load battery housing 150 between the negative battery terminal 144 and the socket shell sill 216. The load battery contact socket 154 is similar to the load battery contact socket 152.

[0029] FIG. 5 is an exploded isometric view of the positive battery contact socket 152, including the battery socket shell 190, the lug retaining insert 192, the socket shell sill 196, and the conductive trace 202. The battery socket shell 190 is a plastic part configured essentially as an inverted U-shaped channel with a planar socket shell top 232, a first socket shell side 234, and a second socket shell side 236. The lug retaining insert 192 is an inverted U-shaped channel made of resilient plastic or metal and is sized and shaped to attach to the shell insert support surface 233 of the battery socket shell 190. The lug retaining insert 192 includes a generally planar insert top cap 222 with a first insert flange 224 and a second insert flange 226. Either or both of the insert flanges 224, 226 may have a side indent 228. The conductive trace 202 has a terminal contact end 242, which may be curved, and a socket sill end 244, which may be straight. The thickness of the socket shell sill 196 is less than the thickness of the socket conductive traces 202, forming a trace sill offset 246. An insert cap dimple 198 in the insert top cap 222 functions to press the inserted load jumper plug 112, FIG. 1, against the conductive trace contact surface 248.

[0030] FIG. 6 is an isometric cross-sectional detail view 02-02 of the positive battery contact socket 152 and positive battery terminal 142. The socket shell sill 196 includes a socket sill bevel 195. An insert cap dimple 198 protrudes from the insert cap underside 199 of the protrusion retainer insert 192 and recesses into the socket shell slot 194. A trace sill offset 246 ensures that the inserted load jumper plug 112, FIG. 7, makes solid contact with the conductive traces 202. The conductive traces 202 include a protrusion contact trace 206 within the battery socket shell 190 and a terminal contact trace 208 electrically connected to the positive battery terminal 142.

[0031] FIG. 7 illustrates the insertion of the load jumper plug 112 into the socket shell slot 194 of the load battery contact socket 152. The load jumper plug 112 includes an electrical prong 252 electrically connected to the positive insulated electrical conductor 106 within the non-conductive jumper plug grip 178. To facilitate insertion of the electrical prong 252 into the socket shell slot 194, the prong tip 258 may have a rounded prong corner 256. Upon insertion, the electrical prong contact surface 254 makes electrical contact with the conductive trace contact surface 248, completing an electrical conduction path between the positive insulated electrical conductor 106 and the positive battery terminal 142. The terminal contact end 249 is electrically connected to the positive battery terminal 142 at the terminal trace interface 259. Alternatively, the conductive trace 202 may be fabricated as part of the positive battery terminal 142.

[0032] FIG. 8 is an isometric detailed cross-sectional view of an angled battery contact socket 260 configured to mount to a surface of a battery housing and electrically connect to a battery terminal 272. The angled battery contact socket 260 has a substantially wedge-shaped battery socket shell 262 with an angled socket shell sill 264 defining a socket shell slot 266. A socket shell dimple 267 is provided to frictionally retain an inserted plug protrusion in the socket shell slot 266. The angled battery contact socket 260 is supported on a planar socket shell base 276. The socket's longitudinal axis 268 is angled relative to the planar socket shell base 276, as indicated by angle 273. The angled battery contact socket 260 includes conductive traces 270 including planar terminal contact traces 274 extending from planar protrusion contact traces 272. The terminal contact traces 274 form an obtuse angle with the protrusion contact traces 272. The terminal contact traces 274 are in the same plane as the planar socket shell base 276, and the protruding contact traces 272 are parallel to the longitudinal axis 268 of the socket.

[0033] 9 is a cross-sectional isometric view of a compact battery contact socket 280 including a battery socket shell 282 with a socket angled slot 286 adjacent to a socket shell sill 284. One end of an electrically conductive trace 288 is electrically connected to the negative battery terminal 274. An electrical prong inserted into the socket angled slot 286 makes electrical contact with a prong contact trace 287, a terminal contact trace 289, and the negative battery terminal 274.

[0034] 10 shows a compact battery contact socket 290 connected to the positive battery terminal 276 by a conductive trace 298. The conductive trace 298 includes a protruding contact trace 297 that is perpendicular to a terminal contact trace 299. The battery socket shell 292 includes a socket shell slot 296 adjacent to a socket shell sill 294. The socket shell slot 296 forms a closed cavity.

[0035] 11 shows a battery 300 with compact battery contact socket 280 and compact battery contact socket 290 on a battery housing 302. A jumper plug 304 is positioned to be inserted into socket shell slot 296 to connect the positive insulated electrical conductor 106 to the positive battery terminal 276. A jumper plug 306 is positioned to be inserted into socket angled slot 286 to connect the negative insulated electrical conductor 108 to the negative battery terminal 274.

[0036] 12 is an isometric detailed cross-sectional view of a battery contact socket 310 electrically connected to a positive battery-side terminal 328. The battery contact socket 310 includes a wedge-shaped socket shell 312 with a socket shell sill 314 that defines a socket angled slot 316. The socket angled slot 316 extends completely through the battery socket shell 312 as shown, or alternatively may form a blind hole in the battery socket shell 312. The battery contact socket 310 includes a planar socket shell base 318 and includes a conductive trace 320 angled at an angle 326 relative to the planar socket shell base 318. The conductive trace 320 may be electrically connected to the positive battery-side terminal 328 using a conductive epoxy 324 or a solder compound.

[0037] 13 is a detailed view of the battery contact socket 330 and the improved battery-side terminal 340. The battery contact socket 330 includes a battery socket shell 332 and a socket sill 334 that defines a socket angled slot 336. The socket sill 334 has a shell sill slope 338 with a socket shell dimple 337 inside the socket angled slot 336. A conductive trace 342 extends from the socket sill 334 and can be manufactured from the same material as the improved battery-side terminal 340. The conductive trace 342 includes a trace base 344 that is coplanar with a socket shell base 346.

[0038] 14 shows a side terminal battery 350 that includes a positive battery side terminal 328 and a negative battery side terminal 362. A battery contact socket 310 is secured to the battery housing 352 near a battery corner 354. A negative battery contact socket 360 is formed as part of the battery housing 352 near the battery's front end 356. A positive jumper plug 367 is positioned for insertion into the socket angled slot 316. A negative jumper plug 368 is positioned for insertion into the negative socket slot 366 and contacting the conductive trace 364.

[0039] It is understood that conventional automotive batteries will remain commonplace and that it will take some time for them to be replaced by batteries incorporating the electrical connector battery contact sockets disclosed herein. To aid in this transition, portable battery lug contact sockets can be placed on unmodified conventional automotive batteries to accommodate the use of the battery jumper plug cable 100 of FIG. 1. FIG. 15 shows a portable battery lug contact socket 370 placed on a battery terminal 380. The battery lug contact socket 370 can be removed from the included battery terminal 380 and attached to a different battery terminal, if desired. The battery lug contact socket 370 includes a cylindrical battery socket shell 374 made of an electrically insulating material. The battery socket shell 374 is rectangular in cross-section and has a socket shell slot 376 extending therethrough along the shell's longitudinal axis 372. The socket shell slot 376 is sized and configured to receive and retain an electrical prong, such as the electrical prong 112 of FIG. 7. Conductive traces 386 are secured within the battery socket shell 374, are parallel to the socket shell slots 376, and terminate at a socket shell sill 378. The conductive traces 386 include protruding contact traces 384 secured within the battery socket shell 374 and terminal contact traces 388 extending from the socket shell sill 378. The terminal contact traces 388 include planar terminal contact lug rings 382 disposed on the battery terminals 380.

[0040] Another portable battery contact socket is a battery spade contact socket 390 shown in FIG. 16. The battery spade contact socket 390 includes a cylindrical battery socket shell 392 having a rectangular cross-sectional shape and a socket shell slot 396 extending therethrough. The conductive traces 404 include a protruding contact trace 406 secured within the battery socket shell 392 and a terminal contact trace 408 extending from the socket shell sill 394 to a battery terminal 400. The protruding contact trace 406 forms an obtuse angle with the terminal contact trace 408. The terminal contact trace 408 includes one or two terminal contact spade legs 402 that partially surround the battery terminal 400.

[0041] 17 shows a portable battery contact socket 410 including a cylindrical battery socket shell 412 with a rectangular cross-sectional shape and a socket shell slot 414 extending to the positive battery socket shell 412. The conductive traces 424 include a protruding contact trace 426 secured within the battery socket shell 412 and extending from a socket shell sill 416, and a terminal contact trace 428 in electrical contact with the battery terminal 420. The protruding contact trace 426 forms an obtuse angle with the terminal contact trace 428. The terminal contact trace 428 includes a terminal contact convex tab 422 that partially surrounds the battery terminal 420.

Claims

1. A battery for an automobile having a positive battery terminal and a negative battery terminal on a surface of a battery housing, the battery comprising: a positive battery contact socket attached to a surface of the battery housing adjacent the positive battery terminal, the positive battery contact socket including a positive socket shell with a positive socket shell slot extending therethrough, wherein a positive electrical protrusion can be inserted into the positive socket shell slot to make electrical contact with the positive battery terminal; a negative battery contact socket attached to a surface of the battery housing adjacent the negative battery terminal, the negative battery contact socket including a negative socket shell with a negative socket shell slot extending therethrough, a negative electrical protrusion insertable into the negative socket shell slot to make electrical contact with the negative battery terminal.

2. 2. The automotive battery of claim 1, wherein the positive battery contact socket includes a socket shell sill at a first end of the positive socket shell slot, the socket shell sill serving to facilitate insertion of the positive electrical protrusion into the positive socket shell slot.

3. 3. The automotive battery of claim 2, wherein the socket shell sill includes a shell sill bevel to further facilitate insertion of the positive electrode electrical projection into the positive electrode socket shell slot.

4. 2. The automotive battery of claim 1, wherein the positive socket shell includes a socket shell dimple that protrudes into the positive socket shell slot to retain the positive electrical protrusion inserted into the positive socket shell slot.

5. 10. The automotive battery of claim 1, further comprising an inverted U-shaped protrusion retaining insert secured within the positive battery socket shell to retain the positive electrical protrusion inserted within the socket shell slot.

6. 10. The automotive battery of claim 1, further comprising a positive conductive trace disposed on a surface of the battery housing, a first end of the positive conductive trace electrically connected to the positive battery terminal, and a second end of the positive conductive trace extending within the positive socket shell slot.

7. 7. The automotive battery of claim 6, wherein the second end of the positive conductive trace extends to a socket shell sill at a first end of the positive socket shell slot.

8. 7. The automotive battery of claim 6, wherein the positive conductive trace comprises an angled strip of metal or metal alloy having a cross-sectional area sufficient to safely conduct high amperage engine starter current.

9. 7. The automotive battery of claim 6, wherein the positive conductive trace is configured to at least partially surround the positive battery terminal and comprises one of a terminal contact lug ring, a terminal contact spade leg, or a terminal contact convex tab.

10. 10. The automotive battery of claim 1, wherein the positive electrode electrode lug comprises a rectangular parallelepiped of conductive material.

11. 2. The automotive battery of claim 1, wherein the positive socket shell is configured as an inverted U-shaped channel including a socket shell top, a first socket shell side attached to the socket shell top and the battery housing surface, and a second socket shell side attached to the socket shell top and the battery housing surface.

12. 1. An automotive battery adapted to be connected to electrical lugs for charging, said automotive battery comprising a battery housing with battery terminals on a surface of the battery housing, said automotive battery comprising: a battery contact socket comprising a socket shell slot, the battery contact socket being attached to a surface of the battery housing, the socket shell slot being configured to receive the electrical protrusion into the battery contact socket; a conductive trace, the conductive trace comprising: terminal contact traces attached to a surface of the battery housing, the terminal contact traces secured in electrical contact with the battery terminals; a protrusion contact trace electrically connected to the terminal contact trace, the protrusion contact trace being at least partially secured within the socket shell slot; 1. A battery for an automotive vehicle, comprising: conductive traces having a cross-sectional area sufficient to safely conduct high amperage engine starter current.

13. 13. The automotive battery of claim 12, wherein the battery contact socket is configured as an inverted U-shaped socket shell including a socket shell top, a first socket shell side attached to the socket shell top and to a battery housing surface, and a second socket shell side attached to the socket shell top and to a battery housing surface, the socket shell top, the first socket shell side, and the second socket shell side being sized and configured to allow the electrical protrusions to be inserted therethrough.

14. 13. The automotive battery according to claim 12, wherein the socket shell slot has a through hole in the battery contact socket, and the socket shell slot has a rectangular parallelepiped shape.

15. a second battery contact socket having a second socket shell slot extending therethrough, the second battery contact socket being attached to a surface of the battery housing; 13. The automotive battery of claim 12, further comprising: a second conductive trace attached to the battery housing surface and having one end in electrical contact with a second battery terminal, the second end of the second conductive trace being at least partially secured within the second socket shell slot.

16. 16. The automotive battery of claim 15, wherein the second socket shell slot extends from a second slot opening in the second battery contact socket, the second slot opening having an aspect ratio different from an aspect ratio of a first slot opening in the battery contact socket.

17. 1. An automotive battery adapted to be electrically connected to electrical lugs for supplying charging current to battery terminals on a battery housing, said automotive battery comprising:

1. An automotive battery comprising: a battery contact socket mounted adjacent to the battery terminal, the battery contact socket including an internal slot extending from a slot opening on the battery contact socket into the battery contact socket, the internal slot configured such that insertion of the electrical protrusion into the slot opening allows the electrical protrusion to make electrical contact with one end of an electrically conductive trace within the internal slot, a second end of the electrically conductive trace being electrically connected to the battery terminal.

18. 18. The automotive battery of claim 17, wherein the conductive trace comprises a strip of metal or metal alloy having a cross-sectional area sufficient to safely conduct high amperage engine starter current.

19. 18. The automotive battery of claim 17, wherein the conductive traces are attached to a surface of the battery housing.

20. 20. The automotive battery of claim 17, wherein the battery contact socket comprises a unitary component integrally formed with the battery housing.

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