Battery Assembly Device

Abstract

To provide a battery assembly device which is used with a device for jump start of a vehicle, and to provide the device for jump start of the vehicle including the battery assembly device.SOLUTION: A battery jump start device 10 has a battery assembly device. The battery assembly device maximizes conductivity from a battery pack of the battery jump start device 10 to an on-vehicle battery of a vehicle to be charged.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a battery assembly apparatus for use, for example, in a battery jump start device. [Background technology]

[0002] Portable vehicle battery jump starting devices exist, such as that disclosed in U.S. Patent No. 9,007,015 to Nook et al., which uses a lithium ion battery pack. In this type of device, it is necessary to maximize the electrical conductivity from the device's battery pack to the on-board battery of the vehicle being jump started.

[0003] There are two main factors that determine the success of jump starting an automobile. The first is the amount of power delivered by the Li-Ion battery pack, and the second is the maximum electrical conductivity. Both factors are necessary to have the best chance of jump starting a large engine. One factor without the other is insufficient. Summary of the Invention

[0004] The subject matter relates to a battery assembly apparatus for use with an apparatus for jump-starting a vehicle, and an apparatus for jump-starting a vehicle that includes the battery assembly apparatus.

[0005] The subject matter relates to the following subjects:

[0006] A battery assembly apparatus comprising or consisting of a battery having at least one battery conductor connected to a terminal of the battery.

[0007] A battery assembly apparatus comprising or consisting of a battery having at least one battery conductor connected to a terminal tab of the battery.

[0008] A battery assembly apparatus comprising or consisting of a battery having a positive battery conductor connected to the positive terminal contact of the battery and a negative battery conductor connected to the negative terminal contact of the battery.

[0009] 1. A battery assembly apparatus comprising or consisting of a battery having a positive battery conductor connected to a positive terminal contact of the battery and a negative battery conductor connected to a negative terminal contact of the battery, the battery conductors being soldered to their respective terminal contacts of the battery.

[0010] A battery assembly apparatus comprising: a battery having a positive battery conductor connected to a positive terminal contact of the battery and a negative battery conductor connected to a negative terminal contact of the battery; and a relay connected to one of the battery conductors of the battery.

[0011] A battery assembly device comprising: a battery having a positive battery conductor connected to the positive terminal contact of the battery and a negative battery conductor connected to the negative terminal contact of the battery; and a relay connected to the negative battery conductor.

[0012] A battery assembly device comprising: a battery having a positive battery conductor connected to the positive terminal contact of the battery and a negative battery conductor connected to the negative terminal contact of the battery; and a relay connected to the negative battery conductor.

[0013] A battery assembly apparatus comprising: a battery having a positive battery conductor connected to a positive terminal contact of the battery and a negative battery conductor connected to a negative terminal contact of the battery; and a plurality of relays connected to the negative battery conductor.

[0014] A battery assembly apparatus comprising a battery having a positive battery conductor connected to the positive terminal contact of the battery and a negative battery conductor connected to the negative terminal contact of the battery, and a positive cable connected to the positive battery conductor. [Brief description of the drawings]

[0015] [Figure 1] FIG. 2 is a front perspective view of the battery jump start device with the clamps undeployed. [Diagram 2] FIG. 2 is a rear perspective view of the battery jump start device shown in FIG. 1. [Diagram 3] 3 is an end perspective view of the battery jump start device shown in FIGS. 1 and 2; FIG. [Figure 4] 2 is a front perspective view of the battery jump start device shown in FIG. 1, but with the clamps deployed; FIG. [Diagram 5] 2 is a perspective view of the battery assembly device housed within the battery jump starting device shown in FIG. 1 (when installed in the battery jump starting device, but without the negative cable installed yet); [Figure 6] FIG. 6 is a plan view of the battery assembly device shown in FIG. 5. [Figure 7] FIG. 6 is a front view of the battery assembly device shown in FIG. 5 . [Figure 8] 1 is a side view of the bent cable connector of the positive cable; [Figure 9] 6 is a perspective view of the battery assembly device shown in FIG. 5 with a negative cable connected. [Figure 10] 6 is a perspective view of the battery assembly arrangement shown in FIG. 5 with a diode device installed on the positive cable. [Figure 11] 2 is a perspective view of a battery assembly device connected with other components or devices of a battery jump start device; [Figure 12] 2 is a perspective view of a battery pack device housed within the battery jump start device shown in FIG. 1 (when installed within the battery jump start device); DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0016] A battery jump starter apparatus 10 is shown in Figures 1 and 2. The battery jump starter apparatus 10 includes a casing 12 having a display 14 with an array of light emitting diodes (LEDs) 16. The battery jump starter apparatus 10 further includes a positive cable 18 having a positive clamp 20 and a negative cable 22 having a negative clamp 24. The positive and negative cables 18 and 22 are routed through openings 12a, 12b in the casing 12 to internally located components (i.e., the battery assembly apparatus) which will be described in more detail below.

[0017] The clamps 20, 24 are stowed or secured in the undeployed condition by each of the clamps 20, 24 being clamped to a respective side post 26 extending outwardly from either end of the casing 12, as shown in Figure 1. The side posts 26 are shown in Figure 2. The clamps 20, 24 are secured when the battery jump starter device 10 is not in use and are unclamped from the side posts 26 during use.

[0018] The battery jump start device 10 is configured to jump start a vehicle battery, and may be, for example, the secured portable vehicle jump start device disclosed in U.S. Patent No. 9,007,015, which is incorporated herein by reference in its entirety, or a similar device.

[0019] The battery jump-start device 10 includes various electrical components or parts disposed inside a casing 12. For example, the battery jump-start device 10 includes a battery assembly 110 shown in Figures 5-10 and internal electrical components shown in Figure 11.

[0020] 5-10, the battery assembly 110 includes a battery 112. The battery 112 may be, for example, a rechargeable lithium ion battery. The battery assembly 110 is configured to maximize electrical conductivity from the battery 112 to the cables 18, 22 and clamps 20, 24 of the battery jump starter device 10. The battery 112 includes a casing, for example, a rectangular casing 112a.

[0021] The battery assembly 110 further includes a positive terminal conductor bar 114. One end of the positive terminal conductor bar 114 is connected (e.g., soldered) to a positive tab (i.e., contact) of the battery 112. The other end of the positive terminal conductor bar 114 is provided with a conductor ring 116. The conductor ring 116 is wrapped around and connected (e.g., crimped and / or soldered) to the exposed conductor end 18a of the cable conductor of the positive cable 18.

[0022] As shown in Figures 5 and 6, the positive terminal conductor bar 114 may be, for example, L-shaped so as to wrap around a square corner of the rectangular casing 112a of the battery 112 (for example, when the battery 112 is viewed in plan).

[0023] The L-shaped positive terminal conductor bar 114 extends along one end of the battery 112 and also extends along at least a portion of a side of the battery 112, as shown in FIG.

[0024] The positive terminal conductor bar 114 may be mechanically coupled and / or adhered to the outer surface of the battery casing 112a to provide additional structural support and stability (e.g., to withstand mechanical shock if the battery jump starter device 10 is accidentally dropped). For example, the positive terminal conductor bar 114 may be mechanically connected to the battery casing 112a by adhesive (e.g., silicone adhesive), double-sided tape, double-sided foam tape, insulating plastic or ceramic connectors with snap-fit ​​connections, and / or mechanical fasteners.

[0025] The positive cable 18 includes a bent cable portion 118 that connects the positive cable 18 to the positive terminal conductor bar 114. The bent cable portion 118 includes an outer sleeve portion 118a that connects to a flexible sleeve 120. The flexible sleeve 120 includes an outer sleeve portion 120a that is positioned on the outside relative to the casing 112 of the battery jump starter device 10, and a flexible inner sleeve portion 120b that is positioned on the inside relative to the casing 112 of the battery jump starter device 10.

[0026] The flexible sleeve 120 is configured to reinforce the connection between the positive cable 18 and the casing 12 of the battery jump starter device 10 while maintaining flexibility. For example, the flexible sleeve 120 includes one or more grooves 124 (three in FIG. 3 ) that expose the outer sleeve 18a of the positive cable 18. The one or more grooves 124 function as hinges to facilitate folding of the positive cable 18 at the flexible outer sleeve portion 120.

[0027] The flexible sleeve 120 further comprises an outer flange 124 spaced apart from an inner flange 126, the inner flange 126 defining a groove 125 therebetween. For example, the outer flange 124 is spaced apart from the inner flange 126 by a distance equal to the wall thickness of the casing 12. The flanges 124, 126 are configured to secure the flexible connector 120 together with the positive cable 18 to the casing 12 of the battery jump start device 10. A sleeve portion 128 (FIG. 6) of the flexible connector 120 is connected together with the outer flange 124 and the inner flange 128. For example, the flexible sleeve 120 may be molded separately and assembled onto the positive cable 18, or may be molded to the positive cable 18 to form a single unit. For example, the flexible outer sleeve portion 120 may be insert injection molded onto a portion of the positive cable 18 that is inserted into a mold during the molding process. Alternatively, the flexible outer sleeve portion 120 may be manufactured (e.g., molded) separately and then installed or assembled onto a portion of the positive cable 18. For example, the positive cable 18 may include an inner conductor (e.g., a solid or multi-strand metal wire conductor, e.g., made of copper or aluminum) and an outer insulating sleeve 18a (e.g., a molded plastic sleeve). The flexible sleeve 120 may be attached (e.g., molded or installed or assembled) over and around the outer sleeve 18a of the positive cable 18.

[0028] The battery assembly 110 further includes a negative terminal conductor bar 130. One end of the negative conductor bar 130 is connected (e.g., soldered) to a negative terminal tab (i.e., contact) of the battery 112. The other end of the negative terminal conductor bar 130 includes a negative terminal conductor bar connection portion 132, as shown in FIG.

[0029] 6, the negative terminal conductor bar 130 may be L-shaped so as to wrap around a corner of the rectangular battery 112. The L-shaped negative terminal conductor bar 130 extends along the end of the battery 112 and also extends along at least a portion of the side of the battery 112.

[0030] The negative terminal conductor bar 130 may also be mechanically coupled and / or adhered to the outer surface of the battery casing 112a to provide additional support and stability (e.g., to withstand mechanical shock if the battery jump starter device 10 is accidentally dropped). For example, the negative terminal conductor bar 114 may be mechanically connected to the battery casing 112a by adhesive (e.g., silicone adhesive), double-sided tape, double-sided foam tape, insulating plastic or ceramic connectors with snap-fit ​​connections, and / or mechanical fasteners.

[0031] 5, the battery assembly 110 further includes a smart switch battery interface 134. The smart switch battery interface 134 includes a circuit board 136 having a first circuit board conductor bar 138. The first circuit board conductor bar 138 is spaced apart from a second circuit board conductor bar 140, and the first circuit board conductor bar 138 and the second circuit board conductor bar 140 are located on one side of the circuit board 136, as shown in FIG.

[0032] A pair of relays 142 are mounted on opposite sides of the circuit board 136. The relay 142 includes a number of relay anchor pins 142a extending through a slot 136a in the board 136 (FIG. 5). The relay 142 further includes a first relay connector pin 142b. The first relay connector pin 142b extends through a number of slots disposed on both sides of the circuit board 136 and extends through a slot 132a in the negative terminal conductor bar connection portion 132. The relay 142 further includes a second relay connector pin 142c. The second relay connector pin 142c extends through a number of slots disposed on both sides of the circuit board 136 and a window 138a in the first circuit board conductor bar 138, and through the slot 132a in the first conductor bar 138. The relay anchor pins 136a are soldered in place to mechanically connect the relay 142 to the board 136. Relay connector pins 142b, 142c are soldered in place to mechanically and electrically connect relay 142 to circuit board conductor plates 138, 140, respectively.

[0033] The slot 136a of the circuit board 136 is, for example, rectangular (FIG. 5) and receives the rectangular relay anchor pin 142a.

[0034] Specifically, the base of relay anchor pin 142a is rectangular and terminates in a square end that is dimensionally narrower than the base, which forms lateral edges that are flush with the exterior surface of circuit board 136. When solder is applied to the exposed end of relay anchor pin 142a, the solder connects the ends of the square end and the lateral edges to secure and lock relay anchor pin 142a to circuit board 136.

[0035] A slot 132a is provided in the negative terminal conductor bar connector portion 132, and a slot 138a in the first circuit board conductor bar 138 is rectangular. The slot 140a in the second circuit board conductor bar 140 (FIG. 5) is T-shaped and accommodates three horizontally oriented relay connector pins 142b. The ends of the relay connector pins 142b are shown flush with the outer surface of the negative terminal conductor bar connector portion 132. When solder is applied to the exposed ends of the relay connector pins 142b, the solder fills the slots 132a in the negative terminal conductor bar connector portion 132 and the slots 138a in the first circuit board conductor bar 138, connecting the ends of the connector pins 142b to the inner edges of the slots 132a and 138a, and securing the relay 142 to the circuit board 136 and the negative terminal conductor bar connector portion 132. The applied solder also electrically connects the negative terminal conductor bar connector portion 132 to the first circuit board conductor bar 138 .

[0036] The slot 140a in the second circuit board conductor bar 140 is T-shaped and accommodates three vertically aligned second relay connector pins 142c. The second relay connector protrusion 142c extends outward from the outer surface of the circuit board 136 and connects with the exposed cable end 14a of the negative cable 14, as shown in FIG. 9. When solder is applied to the end of the second relay connector protrusion 142c, the solder fills the T-shaped slot 140a (FIG. 5) and electrically connects the second relay connector protrusion 140c to the second circuit board conductor bar 140. As shown in FIG. 9, the exposed cable end 22a of the negative cable 22 is soldered to the second relay connector protrusion 142c (FIG. 5).

[0037] The negative terminal conductor bar connector portion 132 of the negative terminal conductor bar 130 is connected (e.g., by soldering) to a first circuit board conductor bar 138 of a circuit board 136. Additionally, as shown in Figure 9, the exposed cable end 22a (i.e., with the insulating sleeve removed) of the negative cable 22 is connected (e.g., by soldering) to a second circuit board conductor bar 140. As shown in Figure 11, the negative cable 22 is attached to a flexible sleeve 118.

[0038] As an alternative to the configuration of the flex cable connector 118 (FIG. 5), as shown in FIG. 10, a diode device 150 is mounted (i.e., inserted) onto the flexible cable connector 118. The diode device 150 comprises a circuit board 152 having a set of backcharge diodes 154 disposed on one side of the circuit board 152, and a conductor bar 156 on the opposite side of the circuit board 152.

[0039] (assembly) As shown in FIG. 11, the battery jump start device 10 includes a casing 12 having an upper casing portion 12a and a lower casing portion 12b. The upper casing portion 12a and the lower casing portion 12b are configured to be connected to one another when the battery jump start device 10 is assembled.

[0040] The battery jump start device 10 further includes a battery assembly 110 and a controller assembly 210, both of which are disposed within the casing 12 when the battery jump start device 10 is assembled, as shown in Figure 11. The controller assembly 210 includes a circuit board 212, which is disposed adjacent to another circuit board 214.

[0041] The positive terminal of the battery assembly 110 is connected to the circuit board 212 via a positive power wire 216, as shown in Fig. 11. For example, the positive power wire 216 is soldered to the positive conductor bar 114 (Fig. 5). The negative terminal of the battery assembly 110 is connected to the circuit board 214 via a negative power wire 218.

[0042] The relay circuit board 136 includes a wire set 220 having a connector 222, as shown in FIG 11. The connector 222 is configured to mate with a relay board connector 224 that is located on the circuit board 212 of the controller assembly 210 during assembly of the battery jump start device 10, as shown in FIG 11.

[0043] 11, the battery assembly 110 further includes a wire set 226 having a connector 228. The connector 228 is configured to connect to a battery cell charging / measuring connector 230 disposed on the circuit board 212 of the controller assembly 220.

[0044] 11, the battery assembly 110 further includes a battery temperature sensor having a wire set 232 with a connector 234. The connector 234 is configured to connect to a temperature sensor connector 236 disposed on the circuit board 212 of the controller assembly 220.

[0045] 11, the circuit board 212 includes a charging power resistor 240 and an output relay 242. In addition, the lower casing part 12a includes a main user output connector 244 having a wire set 246 connected to the circuit board 214, and a main user input connector 248 having a wire set 250 connected to the circuit board 214.

[0046] The battery assembly 110 is connected to the battery jump start device 10 as shown in Figure 11. The battery connector device 110 is installed inside the casing 12 of the battery jump start device 10 when assembled.

Claims

1. 1. A rechargeable battery assembly apparatus for use in a battery jump start device having a first battery cable and a second battery cable, a lithium ion rechargeable battery pack having a first terminal tab and a second terminal tab; a first terminal conductor bar extending along one end of the lithium ion rechargeable battery pack and oriented transversely to a length of the lithium ion rechargeable battery pack, the first terminal conductor bar being electrically connected at one end to the first terminal tab of the lithium ion rechargeable battery pack and the other end of the first terminal conductor bar being electrically connected to the first battery cable of the battery jump start device, the other end of the first terminal conductor bar being configured to wrap around an exposed end of the first battery cable of the battery jump start device; a second terminal conductor bar extending along an opposite end of the lithium ion rechargeable battery pack and oriented transversely to a length of the lithium ion rechargeable battery pack, the second terminal conductor bar being connected to the second terminal tab of the lithium ion rechargeable battery pack, the second terminal conductor bar having one end electrically connected or connectable to the second battery cable of the battery jump start device; An apparatus comprising:

2. The apparatus of claim 1 , wherein both the first terminal conductor bar and the second terminal conductor bar are conductive plate structures.

3. The apparatus of claim 1 , wherein both the first terminal conductor bar and the second terminal conductor bar have a width greater than a thickness.

4. 2. The device of claim 1, wherein the first terminal conductor bar is soldered to the first terminal tab of the lithium ion rechargeable battery pack and the second terminal conductor bar is soldered to the second terminal tab of the lithium ion rechargeable battery pack.

5. the lithium ion rechargeable battery pack is a rectangular lithium ion rechargeable battery; 2. The apparatus of claim 1, wherein the first terminal conductor bar and the second terminal conductor bar are L-shaped and wrap around respective corners of the rectangular lithium ion rechargeable battery.

6. 6. The apparatus of claim 4 or 5, wherein the first terminal conductor bar and the second terminal conductor bar are coupled to an outer surface of the lithium ion rechargeable battery pack.

7. The apparatus of claim 1 , wherein the first battery cable is connectable to the first terminal conductor bar by a flexible cable connector.

8. 8. The apparatus of claim 7, wherein the flexible cable connector comprises a flexible outer sleeve portion and a flexible inner sleeve portion.

9. the flexible outer sleeve portion includes an outer flange; the flexible inner sleeve portion includes an inner flange; 9. The apparatus of claim 8, wherein the outer flange and the inner flange sandwich a casing wall of the battery jump start device.

10. 2. The apparatus of claim 1, wherein both the first terminal conductor bar and the second terminal conductor bar are flat conductive metal plates each having a length greater than a width of the conductor bar.

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