Abstract:
An improved battery cable clamp is provided with an integral T shaped connecting rod mounted in the handle of the clamp.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates to an improved battery cable connector of the type utilizing a boss rotating against a cam seat to effect a quick clamping or releasing action. 
       BACKGROUND OF THE INVENTION 
       [0002]    It is well known that most automobiles and motor vehicles, inboard boats, some outboard boats, and many recreational and commercial vehicles are started by battery power. The standardized modern battery is a 12 volt battery having metal posts for the opposing polarities of the battery to which connector cables are attached. Typically the battery cable is connected to one end of a connector and a yoke portion of the connector is fitted over the battery post and clamped down onto the battery post by tightening a nut onto a bolt passing through the two ends of the yoke. Other battery cables are fitted with conductive eyelets at the end and those eyelets are bolted directly to battery terminals having apertures, as in the case of lawn and garden batteries, or to side terminals adapted to receive bolts in the case of side terminal batteries. 
         [0003]    Many batteries will last for several years and when the batteries are finally spent, the old battery must be removed and replaced with a new one. Under these circumstances, the battery cable clamp must be loosened and often corrosion must be broken to remove the clamp from the post. Similarly, in some cases, corrosion may build up in the junction between the battery clamp and the battery post and impair proper transmission of battery power from the battery post through the connector to the battery cable and diminish the electrical power available. A variety of quick clamping designs have been proposed to address the corrosion issues including those depicted in U.S. Pat. Nos. 6,802,747; No. 7,029,338, and No. 7,189,123, each of which is incorporated herein by reference. In each of these prior art designs, a pin is mounted in a cammed handle, a connecting rod is affixed to the pin, a cam seat is placed over the connecting rod, and the connecting rod is then used as a bolt to either fit into a side terminal or to be passed through an aperture and fastened to a threaded nut. In practice, these battery cable clamps provide good functionality, however, they are difficult to manufacture at optimal cost. In particular, the assembly of the clamp by placing the pin in the openings in the wings of the handle then applying thread lock material to one threaded end of the connecting rod and then fastening the connecting rod into an opening within the pin is labor intensive. It is also expensive to machine the metal parts comprising the pin and the connecting rod. Furthermore, unless skilled and attentive labor is utilized, connecting rods may be fastened within the opening of the pin at different lengths. The preferred metals for these components have also resulted in the thread lock being inadequate to hold through periods of rigorous use in a significant percentage of the cases. This thread lock failure sometimes is attributable to the failure to completely remove the machine oil used in fashioning the metal parts before their assembly. An additional expense in the prior art clamps is that the end cap must be fitted with an internal metal threaded section in order to have sufficient strength to hold its position on the connecting rod when the clamp is tightened by rotating the cammed boss on the cam seat. 
         [0004]    What is needed then is a battery cable clamp that can be manufactured in a more uniform fashion at less expense than the prior art devises. 
       SUMMARY OF THE INVENTION 
       [0005]    Instead of a two part pin and connecting rod assembly, a unitary pin and connecting rod is cast resulting in an integral T-shaped component. Instead of inserting a pin through openings in the wings, the wings may be formed without openings and the T-shaped pin and connecting rod may be introduced through a window in the handle opposite of a slot through which the connecting rod is passed. Because the connecting rod and pin are formed as a single piece, there is no labor required to assemble the two parts, no issues with obtaining uniform threadlock between the parts, and no issues of different length connecting rods due to variations in the tightening of fastening rods within the opening of the prior art pins. Furthermore, because the pin and connecting rod are cast, the threads on the connecting rod may be cast as Acme threads or square threads and the plastic end nut can be cast with the corresponding square mating threads. These Acme threads provide relatively greater strength than tapered threads and accordingly it may not be necessary to utilize a metal insert within the nut. Additional modifications may include building a cam seat into a nonlead style yoke so that the cam seat element is not required as a part of the battery cable clamp assembly. When using nonlead yokes a heel may be formed at the open end of the yoke, or included on the cam seat of battery cable clamp, to provide better connection between the yoke and battery terminal posts when the battery cable clamp is tightened, and an insulated boot may be included as a part of the battery cable clamp assembly. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]    The invention may be better understood with reference to the following drawings in which the numerals designate like parts and wherein: 
           [0007]      FIG. 1  is an exploded perspective view of an exemplary clamp according to the invention. 
           [0008]      FIG. 2A  is a perspective view of an integral T-shaped connecting rod; 
           [0009]      FIG. 2B  is a distal end view of the T-shaped connecting rod of  FIG. 2A . 
           [0010]      FIG. 2C  is a top plan view of the T-shaped connecting rod of  FIG. 2A . 
           [0011]      FIG. 2D  is a side plan view of the T-shaped connecting rod of  FIG. 2A . 
           [0012]      FIG. 3A  is a perspective view of an exemplary cam seat with heel section according to an embodiment of the invention. 
           [0013]      FIG. 3B  is a side plan view of the cam seat of  FIG. 3A . 
           [0014]      FIG. 3C  is a top plan view of the cam seat of  FIG. 3A . 
           [0015]      FIG. 3D  is a front sectional view of the cam seat of  FIG. 3A . 
           [0016]      FIG. 4A  depicts a perspective view, and reverse angle perspective view of an exemplary handle according to an embodiment of the invention. 
           [0017]      FIG. 4B  is a distal end view of the handle of  FIG. 4A . 
           [0018]      FIG. 4C  is a sectional view of the handle taken along the line B-B. 
           [0019]      FIG. 4D  is a top plan view of the handle of  FIG. 4A . 
           [0020]      FIG. 4E  is an enlarged sectional view of the base of the handle within Circle C of  FIG. 4C . 
           [0021]      FIG. 5A  is a perspective view and reverse angle perspective view of an insulating boot adapted to be used with a handle of the type shown in  FIG. 4A . 
           [0022]      FIG. 5B  is a side plan view of the insulating boot of  FIG. 5A . 
           [0023]      FIG. 5C  is a back plan view of the insulating boot of  FIG. 5A . 
           [0024]      FIG. 5D  is a top plan view of the cover of  FIG. 5A . 
           [0025]      FIG. 5E  is a top sectional view taken along line A-A in  FIG. 5B . 
           [0026]      FIG. 5F  is an end sectional view taken along line B-B in  FIG. 5B . 
           [0027]      FIG. 6A  is an enlarged distal end view of an end nut adapted for use with a connecting rod at the type shown in  FIG. 2A . 
           [0028]      FIG. 6B  is a perspective view of the end nut of  FIG. 6A . 
           [0029]      FIG. 6C  is an enlarged sectional view of the end nut of  FIG. 6A  taken along line A-A. 
           [0030]      FIG. 7A  is a perspective view of a cover to be used with a handle of the type shown in  FIG. 4A . 
           [0031]      FIG. 7B  is a side plan view of the cover of  FIG. 7A . 
           [0032]      FIG. 7C  is an end plan view of the cover of  FIG. 7A . 
           [0033]      FIG. 10A  is a perspective view of a nonlead yoke connector of the type having a crimping ring. 
           [0034]      FIG. 10B  is a top plan view of the yoke connector of  FIG. 10A . 
           [0035]      FIG. 11A  is a perspective view of a nonlead yoke connector of the type having a mounting plate. 
           [0036]      FIG. 11B  is a top plan view of the yoke connector of  FIG. 11A . 
           [0037]      FIG. 12A  is a perspective view of a nonlead yoke connector of the type having a tabbed channel and heel. 
           [0038]      FIG. 12B  is a top plan view of the yoke connector of  FIG. 12A . 
           [0039]      FIG. 13A  is a perspective view of the clamp of  FIG. 1  as assembled for clamping by rotating the boss of the handle. 
           [0040]      FIG. 13B  is a perspective view of the clamp of  FIG. 13A  with the handle and insulating boot rotated approximately half-way to the clamped position. 
           [0041]      FIG. 13C  is a perspective view of the clamp of  FIG. 13A  with the handle and boot rotated to the clamped position. 
           [0042]      FIG. 14  is an exploded perspective view of an exemplary clamp according to the invention designed to fasten to an L post terminal as might be found on a lawn and garden battery. 
           [0043]      FIG. 15  is an exploded perspective view of an exemplary clamp according to the invention adapt to fasten on an L post without an insulating boot. 
           [0044]      FIG. 16  is an exploded perspective view of an exemplary clamp according to the invention for use in a lead yoke style connector. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0045]    A description of preferred embodiments of the present invention will be best understood by referring to  FIGS. 1-16  of the accompanying drawings where like reference numerals refer to like parts. 
         [0046]    Turning then to  FIG. 1 , an exploded view of an insulated quick release clamp can be seen where the battery yoke  17  is designed to encompass an outstanding battery terminal while the pin  45  has a threaded end  30  that extends into opening  55  to extend through handle  50  and through the seat  40  and the legs  19 ,  18  of yoke  17  so that the threaded end  30  is received within end nut  36  and finger tightened. Then the handle  50  can be rotated so that boss  58  is interposed and tightens the clamp assembly and yoke  17  about the terminal. Each of the components may then be examined in greater detail. 
         [0047]      FIG. 2A  reflects a perspective view of T-shaped pin  45 . One end of pin  45  is threaded  30  while the other end is a cylindrical head  32  that is received and remains within the opening  55  of handle  50 . The threads on end  30  are preferably square or acme threads to provide improved griping with matching threads in the end nut  36 . When manufactured, T-shaped pin  45  is preferably cast of a zinc alloy that can be inexpensively made in large quantities. 
         [0048]    Turning then to  FIG. 3A , a perspective view of the seat  40  with heel  41  is shown. The seat has an opening  43  through which the threaded end  30  of T-shaped pin  45  can pass and a curved surface  42  to facilitate rotation of the bossed section  58  of handle  50 . The heel  41  is optional, but as shown in  FIG. 1 , heel  41  may be placed between the legs  18 ,  19  of yoke  17  with the notch  44  retaining open leg  19  and the body of the heel  41  serving to prevent the ends of legs  18 ,  19  from being that close together. Such bending is not desirable because it distorts the circular form of yoke  17  about the terminal causing gaping between the terminal and the yoke and thereby reducing conductivity between the two. The heel  41  forces the pressure applied by the clamp to be applied at the ends of the legs  18 ,  19  proximate to the yoke  17  so that the yoke  17  is securely fastened about the terminal. 
         [0049]    Turning then to  FIG. 4A , the handle  50  is shown in isolation and it can be seen that handle  50  has an opening  55  in its rear and a forward facing slot on the opposite side approximately bossed section  58 . This enables the cylindrical end  32  of the T-shaped pin  45  to rest within the handle while the handle can rotate about the pin to position the boss  58  to tighten or loosen the clamp. As shown in  FIGS. 5A  through F, an insulated boot  70  is provided with a slot  71  to receive the distal end  51  of handle  50 . In this fashion, the insulated boot  70  rotates as the handle is placed into clamping or loosening position to cover or expose the battery terminal respectively, as shown in  FIG. 13A-C . 
         [0050]      FIGS. 6A-C  illustrate the end nut  36  and particularly threaded aperture  37  that is preferably made fitted with square or acme threads. Alternatively, the end nut may be fitted with a metal insert to provide the necessary strength to support clamping action. Preferably, the surface of nut  36  is knurled to facilitate grasping and turning. 
         [0051]      FIGS. 7A  and B illustrate the handle cover  48  that covers opening  55  after T-shaped pin  45  has been inserted. This optional piece is provided for aesthetic reasons. 
         [0052]      FIG. 10A  illustrates a yoke connecter  17  having a crimping ring  20  for use in fastening to a battery cable.  FIG. 11A  illustrates a yoke  117  having a mounting plate  120  to which a battery cable having an eyelet end connector may be bolted. 
         [0053]      FIGS. 12A  and B illustrate a yoke  217  having a tabbed open channel connector  220  in which a cable is placed and tabs folded to clamp the cable in position. In addition, this yoke  217  has an integral heel  141  that prevents the clamping of the sections of legs  118 ,  119  distal from the yoke portion which would otherwise distort the fit of the yoke&#39;s about the terminal post. 
         [0054]      FIGS. 13A-C  show the movement of handle  50  from the unbossed ( FIG. 13A ) into the bossed position ( FIG. 13C ) thereby tightly clamping the battery clamp about the terminal post while simultaneously closing the insulating boot  70  over the terminal and clamp apparatus to protect the connection from the elements and corrosion, and to prevent invertent short circuits and sparks. 
         [0055]      FIG. 14  is an exploded perspective view of a clamp having T shaped pin  45  received within handle  50  that engages with boot  70 . Pin  45  proceeds through seat  40  over  47  and through terminal T and end cap  36  is finger tightened onto the pin. This is a typical terminal configuration for a lawn and garden battery clamp. A very similar clamp could be used within an end camp  36  to fasten a battery cable to a side terminal. 
         [0056]      FIG. 15  is an exploded view of the clamp of  FIG. 14  without the insulating hood  70 .  FIG. 16  is an exploded perspective view of battery clamp with handle  50  having a unitary pin  45  received through the handle to engage across the legs  18 ,  19  of yoke  17 . The oblong ring  39  engages with the number  38  to provide leverage to break any rust or corrosion that might bind the clamp or cable to the battery post. 
         [0057]    All publications, patent, and patent documents mentioned herein are incorporated by reference herein as though individually incorporated by reference. Although preferred embodiments of the present invention have been disclosed in detail herein, it will be understood that various substitutions and modifications may be made to the disclosed embodiment described herein without departing from the scope and spirit of the present invention as recited in the appended claims.