Abstract:
An adaptable battery tray for supporting a battery includes a body having a pair of end walls and side walls, with each end wall rotatably attached to an adapter. The adapter is rotatable between a first position and a second position. In the first position, the adapters are external to the interior of the battery tray and permits the battery tray to support a battery having dimensions approximating the dimensions between the side walls and the end walls. When a battery of lesser length is to be supported, the adapters are rotated into the second position, and include a pair of stop plates which define therebetween a wall suitable for housing the battery of lesser dimensions.

Description:
BACKGROUND OF THE INVENTION 
     The invention relates generally to trays for batteries, and in particular, to an adaptable battery tray capable of securely supporting batteries of different dimension. 
     Lead acid batteries are used in a wide variety of vehicles powered by a combustion engine. In order to assure safe and reliable operation, the battery is normally positioned in some form of receptacle which is secured to the vehicle, while a securing member such as a tie or clamp is used to secure the battery to the receptacle. 
     Depending upon the vehicle in which it is used, the receptacle may take the form of a container which completely encloses the battery. The container is formed with orifices dimensioned to permit battery&#39;s the electrical contacts to extend therethrough. More often than not, in the interest of cost and safety, the receptacle assumes the form of a tray dimensioned to receive the particular battery. 
     In marine applications, given the particular hazards caused by the potential for exposure to water, the tray includes side walls of sufficient height to prevent the splashing of water onto the battery itself. Moreover, the use of receptacles in the form of a container are prohibited as they present a fire hazard. This fire hazard stems from the possibility of combustible gases, in particular, hydrogen gas released by the battery, becoming trapped by the container. Electrical shorts or sparks from the battery may in turn ignite the combustible gases, resulting in an explosion. Thus, current regulations require the use of a battery tray which enables the majority of the battery to be exposed to the environment and prohibits the use of encapsulating or encasing receptacles. 
     Competition among battery manufacturers has resulted in the availability of batteries having different dimensions. Batteries of different dimension have presented a problem for the manufacturers of the battery trays in that such manufacturers are relegated to producing a battery tray for each particular battery size, or a single tray with a removable insert dimensioned to accommodate batteries of lesser size than the original dimensions of the tray. Neither of these solutions is acceptable, as both require the battery tray manufacturer to incur additional costs either in the production of separate trays, or the removable inserts. 
     In marine applications, the two most common sizes are a Group 30, and Group 24 battery, as defined by the Battery Council International. Group 24 batteries express a smaller length from end-to-end, but are substantially equal in length from front-to-back as a Group 30 battery. Furthermore, manufacturers of marine battery trays are required to conform to the criteria set out by Title 33 Code of Federal Regulations §183.420 set forth below: 
     (a) Each installed battery must not move more than one inch in any direction when a pulling force of 90 pounds or twice the battery weight, whichever is less, is applied through the center of gravity of the battery as follows: 
     (1) Vertically for the duration of one minute. 
     (2) Horizontally and parallel to the boat&#39;s center line for a duration of one minute fore and one minute aft. 
     (3) Horizontally and perpendicular to the boat&#39;s center line for a duration of one minute to starboard and one minute to port. 
     (b) Each battery must be installed so that metallic objects cannot come in contact with the ungrounded battery terminals. 
     (c) Each metallic fuel line and fuel system component within 12 inches and above the horizontal plane of the battery surface as installed must be shielded with dielectric material. 
     (d) Each battery must not be directly above or below a fuel tank, fuel filter, or fitting in a fuel line. 
     (e) A vent system or other means must be provided to permit the discharge from the boat of hydrogen gas released by the battery. 
     (f) [Reserved] 
     (g) Each battery terminal connector must not depend on spring tension for its mechanical connection to the terminal. 
     Consequently, there exists in the industry a need for a battery tray configured to adaptively receive batteries of different dimension, which is cost effective to manufacture. 
     SUMMARY OF THE INVENTION 
     According to one aspect of the invention, an adaptable battery tray comprises a body having a bottom, and a pair of opposing end walls defining an interior. At least one adapter is movably attached to the body and is movable from a first position external to the interior of the body, to a second position wherein the at least one adapter is positioned within the interior of the body. Utilizing at least one adapter which, when in use, is external to the body, and which can be moved into the interior of the body to define a second, or use, position provides a cost effective and reliable adaptable battery tray capable of effectively accommodating batteries of differing dimension. 
     According to another aspect of the invention, an adaptable battery tray comprises a body having a bottom, a pair of opposing side walls, and a pair of opposing end walls defining an interior. The body is dimensioned to receive a first battery, and includes a pair of adapters, with each adapter being rotatably attached to an end wall of the pair of end walls. The adapters are rotatable to a use position within the interior of the body, and are configured to permit the body to receive a second battery having a length less than the first battery. The use of a pair of adapters rotatably attach to the body permits the battery tray of the present invention to accommodate batteries of different size without using a separate insert, and thus reduces the cost of manufacturing. 
     According to yet another aspect of the invention, a battery tray comprises a bottom, a pair of end walls, and a pair of side walls extending from the bottom, and a pair of adapters. Each adapter is rotatably attached to an end wall, and is rotatable into a use position. Each adapter includes at least one hinge member rotatably attached to one of the end walls, and a stop plate coupled to the at least one hinge member. The stop plate is substantially parallel to the pair of opposing end walls when the adapter is in the use position. The use of a pair of adapters, each of which is formed with a stop plate collectively defines a pair of secondary end walls which reliably secure a battery having a length less than the length between the opposing end walls. 
     According to a further aspect of the invention, an adaptable battery tray comprises a body having an interior, an interior surface, a pair of opposing ends and at least one adapter movably attached to the body. The at least one adapter is movable from a first position external to the interior of the body to a second position wherein the at least one adapter is positioned within the interior of the body. The body and the at least one adapter are formed of a polymeric material in a unitary construction and meet the requirements of Title 33 C.F.R. §183.420. The unitary, polymeric construction of an adaptable battery tray having at least one adapter configured to accommodate batteries of different dimension which also meets the criteria outlined in 33 C.F.R. §183.420 represents an advancement in the art in that the battery tray of the present invention is economical to manufacture, safe and reliable. 
     These and other objects, advantages, purposes and features of the invention will become apparent upon review of the following specification in conjunction with the drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of a battery tray with a battery positioned therein and illustrated in phantom with the adapters illustrated in a first position, according to the invention; 
     FIG. 2 is the same view as FIG. 1, with the adapters illustrated in a second position and supporting a battery having different dimensions than the battery of FIG. 1; 
     FIG. 3 is a plan view of the battery tray of FIGS. 1 and 2; 
     FIG. 4 is a bottom view of the battery tray of FIGS. 1 through 3; 
     FIG. 5 is a detailed plan view of the adapter; 
     FIG. 5 a  is the same view as FIG. 5, according to an alternative preferred embodiment; 
     FIG. 6 is a sectional view taken along the line VI—VI of FIG. 2 with the adapter shown in phantom in the first position; 
     FIG. 7 is a detailed perspective view illustrating the adapter engaging a receiving pin; and 
     FIG. 8 is a sectional view taken along the line VIII—VIII of FIG.  7 . 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The present invention is an adaptable battery tray which can be adapted to accept batteries of different dimension. The battery tray of the present invention ray be used in conjunction with any battery for any type of vehicle, however, it is particularly suited for marine vehicle batteries, and in one preferred form, is adaptable to accept either a Group 24 or a Group 30 battery. 
     Referring now to the drawings, and the illustrative embodiments depicted therein, a battery tray  10  is of generally a rectangular shape and includes a bottom  20 , a pair of opposing side walls  22  and a pair of opposing end walls  24 . Side walls  22 , and end walls  24  project substantially orthogonally from bottom  20  and collectively with bottom  20  define an interior  26 . Preferably, the intersection of side walls  22  and end walls  24  define rounded corners  28 . Each end wall  24  is a attached to an adapter  30 . 
     As depicted in FIG. 1, adapters  340  are positioned external to interior  26  of tray  10 , and when so positioned, permits tray  10  to receive a battery  100 . Battery  100  is of a conventional type having positive and negative terminals  102 . Battery  100  is securely held within interior  26  of battery tray  10 , with the distance between ends  104  of battery  100  being slightly less than the distance between the interior surfaces of end walls  24 . Moreover, the distance between sides  106  is slightly less than the distance between the interior surfaces of side walls  22  such that ends  104  and sides  106  of battery  100  are proximate to end walls  24  and side walls  22 , respectively of battery tray  10 . 
     Interior surface,  32  of battery tray  10  includes a plurality of ribs  34 . The top surfaces  36  of rib  34  lie generally in a single plane, and together define a floor upon which the bottom of battery  100  is supported. Ribs  34 , as they provide an elevated floor upon which battery  100  sits, permit any water within tray  10  to reside below battery  100 . Ribs  34  also provide structural integrity and increase the strength of battery  10 . Preferably, ribs  34  extend in a generally modified radial pattern with ends  34 ′ being substantially co-planar, while ends  34 ″ are also substantially co-planar. However, it will be recognized by those with ordinary skill in the art that other configurations for ribs  34  may be employed without departing from the spirit and scope of the invention. 
     Battery tray  10  includes a plurality of securing members  40  for attachment to a generally planar surface of a vehicle (not shown). Securing members  40  are defined by a first member  42  extending from exterior surfaces  23  of side walls  22 . The bottom of each first member  42  is molded to a second member  44 . Second members  44  are attached to, and depend a preselected distance from, exterior surface  38  of bottom  20 . A pair of tie down members  46  are formed on side walls  22  and bottom  20 . Each tie down member  46  includes a pair of spaced securing members  40 ′ having substantially the same construction as securing members  40 . A bridge member  47  is attached between securing members  40 ′ and is substantially parallel to side walls  22  and positioned a preselected distance therefrom to define a channel  48 . A plurality of ribs  50  project from exterior surface  38  of bottom  20 . Second members  44  of securing members  40 ,  40 ′ define a generally planar contact surface which engages the floor of the vehicle (not shown) in which battery tray  10  is positioned. As shown in FIG. 6, the bottom surface  44 ′ of second members  44  lie in a plane below edges  51  of ribs  50 . Ribs  50  project in a modified radial pattern from exterior surface  38  of bottom  20 , with ends  50 ′ of ribs  50  defining a channel  55  therebetween. 
     In order to secure battery  100  to battery tray  10 , a securing member  108 , normally in the form of a belt, is positioned around exterior surface  107  of battery  100  and is threaded through channels  48  formed by bridge members  47 . Securing member  108  fits within the channel  55  formed by ribs  50 . Thereafter, securing member  108  can be tightened about battery  100  to thereby securely hold battery tray  10  to battery  100 . Each securing member  40 ,  40 ′ is formed with an aperture  58  with an axis generally parallel to side walls  22 . Apertures  58  are formed to receive fasteners (not shown) so that battery tray  10  may be secured to a vehicle. Once secured, the contact surface defined by second members  44  of securing members  40 ,  40 ′ raise battery tray  10  a preselected distance above the vehicle floor so that any fluids positioned under exterior surface  38  of bottom  20  may evaporate. It will be recognized by those with ordinary skill in the art that securing member  108  is but one illustrative securing method, and that the present invention is not limited thereby. Other securing methods may be substituted for securing member  108  without departing from the spirit and scope of the invention. 
     Each adapter  30  includes a pair of hinged members  60  placed in spaced relation along top edge  62  of end wall  24 . Hinging attachment between hinge member  60  and edge  62  of end wall  24  is accomplished by any hinge  63  commonly encountered in the art. Preferably, hinging attachment between hinge member  60  and edge  62  is accomplished by a living hinge defined by pair of spaced apart regions  64  of reduced thickness, within region  64 ′ attached to edge  62 . Hinge members  60  are attached to a connector or first member  66  at ends  61 . First member  66  is a substantially planar and projects substantially orthogonally from ends  61  of hinge members  60 . Surface  67  of first member  66  has projecting therefrom, in a substantially orthogonal direction, a stop member or plate  68 . Stop plate  68  has a front surface  69  which is essentially planar with edge  67 ′ of first member  66  (FIG.  5 ). Reinforcing members  70  are attached to rear surface  71  of stop plate  68  and surface  67  of first member  66 . 
     A pair of tabs  72 , placed in spaced relation, extend from edge  67 ′ of first member  66  and are substantially orthogonal to stop plate  68 . Tabs  72  are generally rectangular in shape. In the alternative preferred embodiment, as shown in FIG. 5 a,  tabs  72   a  have a generally linear section  80  defined by parallel edges  81  and a tapered section  82  defined by tapering edges  84  which terminate at end  73 . Tabs  72   a  are longer in length, as defined between front surface  69  of stop plate  68  and end  73 , than tabs  72 . The greater length of tabs  72   a  enable battery tray  10  to accommodate batterys having a smaller lengthwise direction. Interior surface  32  of bottom  20  is formed having receiving pins  74  placed a preselected distance from end walls  24 . Each receiving pin  74  preferably has a half-moon shape with the linear section  75  facing end walls  24 . Receiving pins  74  are located in interior surface  32  such that they frictionally receive or provide an interference fit with ends  73  of tabs  72 ,  72   a.  Also, as illustrated in FIG. 8, preferably, linear section  75  of receiving pin  74  is not vertical, or is slanted towards end wall  24 . The slant of linear section  75  provides a barrier to the removal of adapters  30  from the use position by requiring a force to be exerted on tabs  72 ,  72   a  to move them in an upward direction. 
     In operation, if a battery having the dimensions of battery  100  is to be used, adapters  30  are rotated to a first or external position as depicted in FIG.  1 . When in the first position, battery  100  is positioned within interior  26  of tray  10  with ends  102  positioned proximate to interior surfaces  24 ′ of end walls  24  and sides  106  positioned proximate to interior surfaces  22 ′ of side walls  22 . Thereafter, battery  100  may be secured to battery tray  10  using securing member  108 , or other securing method commonly utilized in the art. Once battery  100  is secured to battery tray  10 , battery tray  10  may be secured to a vehicle by placing fasteners throughout apertures  58  of securing members  40 ,  40 ′. 
     If adapters  30  are unnecessary, as when a battery  100  is supported, adapters  30  can be removed from battery tray  10 , by cutting or manually tearing adapters  30  from battery tray  10  along region  64  of reduced thickness of hinge  63 . 
     As depicted in FIG. 2, if a battery  110  is to be placed within battery tray  10 , adapters  30  are rotated into a second or use position with tabs  72  or  72   a  frictional gaging receiving pins  74 . In the use position, as depicted most clearly in FIG. 6, bottom surface  67 ″ of first member  66  and bottom surface  72 ′ of tabs  72  or  72   a  are in abutting contact with interior surface  32  of bottom  20 , while stop plate  68  is substantially parallel with end walls  24 . Also when in the use position, top surface  72 ″ of tabs  72  or  72   a  are substantially co-planar with top surfaces  36  of ribs  34 , and top surface  76  of receiving pins  74 . Once adapters  30  are in the use position, battery  110  is placed in battery tray  10  and secured as detailed above. 
     In the most preferred embodiment, battery tray  10  has a length from end wall  24  to end wall  24  of approximately 12.435 inches, a length between opposing side walls  22  of approximately 7.200 inches, while the length of stop plate  68  as measured between ends  68 ′ is approximately 4.23 inches. In addition, in the most preferred embodiment, the distance between front surfaces  69  of stop plates  68 , when adapters  30  are in the use position, is approximately 11.125 inches. These dimensions, in the most preferred embodiment, permit battery tray  10  to support either a Group 30 or Group 24 battery. 
     Battery tray  10  is preferably monolithic, i.e., formed in one piece of a unitary construction of a polymeric material, by any manufacturing method commonly utilized in the art. Any polymeric material having the requisite strength and rigidity to securely support a battery may be used to form battery tray  10 . Furthermore, battery tray  10  meets the requirements detailed in Title 33 Code of Federal Regulations §183.420. 
     Changes and modifications in the specifically described embodiments can be carried out without departing of the principals of the invention. Therefore, the invention is intended to be limited only by the scope of the appended claims, as interpreted according to the principals of patent law, including the doctrine of equivalents.