Abstract:
A battery switch including a housing having a removable side panel, a base, and two terminals located within the housing. Each terminal has a fixed end and a free end. Each terminal extends upwardly from the base. Each free end is positioned in a space between the base and the housing. Wherein the free ends of each of the terminals are accessible by removing the side panel.

Description:
RELATED APPLICATION 
       [0001]    The present application claims priority to U.S. Provisional Application 61/901,879, filed Nov. 8, 2013, and U.S. patent application Ser. No. 14/537,485, filed Nov. 10, 2014, the entire contents both of which are incorporated herein by reference. 
     
    
     BACKGROUND 
       [0002]    The invention relates to a battery switch, and more specifically, a battery switch for a low-voltage, direct-current (DC) electrical systems such as systems found on yachts, recreational vehicles, trucks, and other vehicles. 
         [0003]    Vehicle systems such as yachts and recreational vehicles have become bigger; as such their DC electrical systems have evolved to meet the increased electrical power demand. Therefore, many of these electrical systems incorporate two banks of batteries. A first bank of batteries may be used for starting the engine, as well as powering other necessary engine functions, while a second bank of batteries may be isolated and used for powering non-engine related functions, such as but not limited to, heating, cooling, water pump, television, and radio. 
         [0004]    Typically, such DC electrical systems are low-voltage, for example, six, twelve, or twenty-four volts, however, because of the significant power requirements, the DC electrical systems require high amperage conductors to be run throughout the vehicle. 
       SUMMARY 
       [0005]    In one embodiment, the invention provides a battery switch configured to control a first bank of batteries and a second bank of batteries, the first and second bank of batteries having at least one battery. The battery switch includes a housing; a first bank terminal supported by the housing; a second bank terminal supported by the housing and connectable to the first bank terminal; a first load terminal supported by the housing and connectable to the first bank terminal; a second load terminal supported by the housing and connectable to the second bank terminal; and a selector supported by the housing and rotatably mounted to the housing. The selector has four positions, including, a first position in which the first and second bank terminals are disconnected from the first and second load terminals, a second position in which the first bank terminal is connected to the first load terminal and the second bank terminal is disconnected from the second load terminal, a third position in which the first bank terminal is connected to the first load terminal, the second bank terminal is connected to the second load terminal, and the first bank terminal is disconnected from the second bank terminal, and a fourth position in which the first bank terminal is connected to the first load terminal and the second bank terminal and the second bank terminal is connected to the second load terminal. 
         [0006]    In another embodiment, the invention provides a battery switch including a housing having a removable side panel; a base; and two terminals within the housing. Each terminal has a fixed end and a free end. The two terminals extend upwardly from the base. Each free end is positioned in a space between the base and the housing. The free ends of each of the terminals are accessible by removing the side panel. 
         [0007]    In another embodiment, the invention provides a method of selectively connecting a first bank terminal, a second bank terminal, a first load terminal, and a second load terminal. The method including selecting a first position of a rotary selector in which the first and second bank terminals are disconnected from the first and second load terminals, selecting a second position of the rotary selector in which the first bank terminal is connected to the first load terminal and the second bank terminal is disconnected from the second load terminal, selecting a third position of the rotary selector in which the first bank terminal is connected to the first load terminal, the second bank terminal is connected to the second load terminal, and the first bank terminal is disconnected from the second bank terminal, and selecting a fourth position of the rotary selector in which the first bank terminal is connected to the first load terminal and the second bank terminal and the second bank terminal is connected to the second load terminal. 
         [0008]    Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]      FIG. 1  is a perspective view of a battery switch according to one embodiment. 
           [0010]      FIG. 2A  is a perspective view of the battery switch of  FIG. 1  having a side panel removed. 
           [0011]      FIG. 2B  is a side view of the battery switch of  FIG. 2A . 
           [0012]      FIG. 3  is an exploded view of the battery switch of  FIG. 1 . 
           [0013]      FIG. 4A  is an exploded top-perspective view of a battery switch without a housing according to another embodiment. 
           [0014]      FIG. 4B  is an exploded bottom-perspective view of the battery switch of  FIG. 4A . 
           [0015]      FIG. 5A  is a partially exploded top-perspective view of the battery switch of  FIG. 4A . 
           [0016]      FIG. 5B  is a partially exploded bottom-perspective view of the battery switch of  FIG. 4A . 
           [0017]      FIG. 6A  is a partially exploded top-perspective view of the battery switch of  FIG. 4A . 
           [0018]      FIG. 6B  is a partially exploded bottom-perspective view of the battery switch of  FIG. 4A . 
           [0019]      FIG. 7A  is a partially exploded top-perspective view of the battery switch of  FIG. 4A  including the housing. 
           [0020]      FIG. 7B  is a partially exploded bottom-perspective view of the battery switch of  FIG. 4A  including the housing. 
           [0021]      FIG. 8  is a perspective view of a fastener of the battery switch of  FIG. 1 or 4A . 
           [0022]      FIG. 9  is a perspective view of the fastener of  FIG. 8  connecting to the housing of the battery switch of  FIG. 1 or 4A . 
           [0023]      FIG. 10  is a perspective view of the housing of the battery switch of  FIG. 1 or 4A  receiving the fasteners of  FIG. 8 . 
           [0024]      FIG. 11  is a cross-sectional view of the battery switch of  FIG. 1 or 4A  illustrating the fasteners in an unlocked position. 
           [0025]      FIG. 12  is a perspective view of the housing of the battery switch of  FIG. 1 or 4A  illustrating the fasteners in an unlocked position. 
           [0026]      FIG. 13  is a cross-sectional view of the battery switch of  FIG. 1 or 4A  illustrating the fasteners in an locked position. 
           [0027]      FIG. 14  is a perspective view of the housing of the battery switch of  FIG. 1 or 4A  illustrating the fasteners in an locked position. 
           [0028]      FIG. 15  is a partially exploded top-perspective view of the battery switch of  FIG. 1 . 
           [0029]      FIG. 16  is a block diagram illustrating the battery switch of  FIG. 1  electrically connected to an electrical device. 
           [0030]      FIG. 17  is top view of a plurality of contact plates of the battery switch of  FIG. 4A . 
           [0031]      FIG. 18  is a top view of the plurality of contact plates of  FIG. 17  in a position in which all four terminals are disconnected from one another. 
           [0032]      FIG. 19  is a top view of the plurality of contact plates of  FIG. 17  in a position in which two of the four terminals are connected to each other. 
           [0033]      FIG. 20  is a top view of the plurality of contact plates of  FIG. 17  in a position in which two terminals are connected to each other and the other two terminals are connected to each other. 
           [0034]      FIG. 21  is a top view of the plurality of contact plates of  FIG. 17  in a position in which all four terminals are connected to each other. 
       
    
    
     DETAILED DESCRIPTION 
       [0035]    Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. 
         [0036]      FIGS. 1 and 2A-2B  illustrate one embodiment of a battery switch  100 . The battery switch  100  connects a first battery B 1 , a second battery B 2 , a first load L 1 , and a second load L 2  in a plurality of configurations. The battery switch  100  includes a base  105  and a housing  110  having a plurality of side panels  115 . As illustrated in  FIGS. 2A and 2B , in some embodiments, the interior of the battery switch  100  is accessible by removing one or more of the side panels  115 . 
         [0037]    The battery switch  100  further includes a rotary selector, or selector knob,  120 . The selector knob  120  rotates between a plurality of positions. In one embodiment, the selector knob  120  rotates between four positions described in more detail below: an off-position; a first load on-position; a first and second load on-position; and a first and second load connected in parallel position. In other embodiments, the selector knob  120  rotates between more or less positions. 
         [0038]      FIG. 3  is an exploded perspective view of the battery switch  100 . As illustrated, the battery switch  100  may further include a plurality of fasteners  125  connecting the housing  110  to the base  105 . The battery switch  100  may further include a contact carrier subassembly  130  and a terminal plate subassembly  135 . 
         [0039]    The contact carrier subassembly  130  is connected to the base  105  via a shaft, or stub shaft,  140  and, in some embodiments, a first O-ring  145 . The contact carrier subassembly  130  may include a carrier plate  150 . The stub shaft  140  extends through, and is non-rotatably coupled to, the carrier plate  150 , such that turning of the stub shaft  140  turns the carrier plate  150  and thus the contact carrier subassembly  130 . 
         [0040]    The terminal plate subassembly  135  is in rotatable contact with the contact carrier subassembly  130  and non-rotatably coupled to the base  105 . In some embodiments, the terminal plate subassembly  135  is coupled to the base  105  via a plurality of second fasteners  152 . The terminal plate subassembly  135  may include, among other things, a terminal plate  155  and a plurality of terminals, or terminal studs,  160  coupled to the terminal plate  155 . Although illustrated as having two terminals  160 , in other embodiments (for example as illustrated in  FIGS. 4-6 ) there may be more terminals  160 . 
         [0041]    The terminal plate  155  includes an aperture  165 . The stub shaft  140  extends through the aperture  165  and couples to a selector shaft  170 , which is non-rotatably coupled to the selector knob  120 . In some embodiments, a second O-ring  175  may be provided between the base  100  and the terminal plate  155  in order to seal against dirt and moisture. In some embodiments, the battery switch  100  may further include a plurality of third fasteners  180  and a plurality of washers  185  for securing and/or coupling the terminals  160  to an outside device (discussed in more detail below in  FIG. 16 ). In such an embodiment, the terminals  160  may be threaded. 
         [0042]      FIGS. 4A-6B  illustrate various exploded, or partially exploded, views of the contact subassembly  130  and the terminal plate subassembly  135 , including exploded top-perspective views and exploded bottom-perspective views. As illustrated, the contact carrier subassembly  130  may further include compression springs  190 , a contact support plate  195 , and lobed contacts  200   a ,  200   b . 
         [0043]    The contact support plate  195  is snap fit to the carrier plate  150  in such a manner that the contact support plate  195  floats relative to the carrier plate  150  in order to permit the compression springs  190  to be compressed. The contact support plate  195  couples to the lobed contacts  200   a ,  200   b . The contact support plate  195  may include dimples  212 , which press against the bottom side of the lobed contacts  200   a ,  200   b  in order to allow the lobed contacts  200  to rock relative to the contact support plate  195 . The lobed contacts  200   a ,  200   b  may include contact lobes  205   a ,  205   b ,  205   c ,  205   d ,  205   e , and  205   f . 
         [0044]    The terminal plate subassembly  135  may further include contact plates  210   a ,  210   b ,  210   c , and  210   d  coupled to the plurality of terminals  160   a ,  160   b ,  160   c , and  160   d  respectively. The terminals  160   a - 160   d  are inserted through the terminal plate  155  and are staked, welded, or otherwise mechanically and electrically connected to the respective contact plates  210   a - 210   d . In some embodiments, the contact plates  210   a - 210   d  are insulated from one another via an insulation material (e.g., rubber, plastic, etc.). 
         [0045]    When the contact subassembly  130  and the terminal plate subassembly  135  are in contact, the contact lobes  205   a - 205   f  selectively contact the bottoms of the contact plates  210   a - 210   d . The contact of the contact lobes  205   a - 205   f  with the contact plates  210   a - 210   d  is promoted by the compression springs  190 . 
         [0046]      FIGS. 7A and 7B  illustrate an exploded view of the battery switch  100  with the contact subassembly  130  and the terminal plate subassembly  135  coupled to the base  105 . In one embodiment, as illustrated, the housing  110  is connected to the base  105  via the two or more fasteners  125  (further detailed below in  FIGS. 8-14 ). In other embodiments, the housing  110  may be connected to the base  105  by other suitable means. As discussed above, the stub shaft  140  extends through the aperture  165  and is non-rotatably coupled to both the contact carrier subassembly  130  (located under the terminal plate subassembly  135 ) and the selector shaft  170 . Thus, when the selector shaft  170  is turned (via the selector knob  120 ), the contact carrier subassembly  130  turns as well, while the terminal plate subassembly  135  maintains position. 
         [0047]      FIGS. 8-15  illustrate connection of the one of the fasteners  125  to the base  105  and housing  110 . The fastener  125  may include slots  220 , grooves  225 , and a ramped surface  230 . The slots  220  are located at a top end of the fastener  125 . The slots  220  receive keys  235  of the housing  110  and when the fastener  125  is turned clockwise, the keys  235  catch in the grooves  225  in order to secure the fastener  125  to the housing  110 . The ramped surface  230  is located at a bottom end of the fastener  125  and couples the fastener  125  to the base  105 . When the fastener  125  is turned clockwise, the ramped surface  230  of the fastener  125  catches on a ledge  240  of the base  105 . 
         [0048]      FIGS. 11 and 12  illustrate the fasteners  125  in an unlocked position. In the unlocked position, keys  235  of the fasteners  125  are not caught in the grooves  225  of the housing  110  and the ramped surfaces  230  of the fasteners  125  are not caught on the ledges  240  of the base  105 .  FIGS. 13 and 14  illustrate the fasteners  125  in a locked position. In the locked position, keys  235  are caught in the grooves  225  and the ramped surfaces  230  are caught on the ledges  240 , thereby securing the housing  110  to the base  105 . 
         [0049]      FIG. 15  illustrates a partially exploded top-perspective view of the battery switch  100 . As illustrated, the terminals  160  each include a fixed end  245  and a free end  247 . The terminals  160  are connected to the base  105  via the fixed ends  245 . The free ends  247  are located in a space between the base  105  and the housing  110 . The free ends  247  of the terminals  160  are accessible by removing one or more side panels  115 . 
         [0050]      FIG. 16  illustrates the battery switch  100  electrically connected to an electrical device, such as but not limited to, a fuse block  250 . As discussed above, in some embodiments, the free ends  247  of the terminals  160  are accessible by removing one or more of the side panels  115 . The terminals  160  are electronically connected to the fuse block  250  via a connection link  255 . In some embodiments, the connection link  255  engages the terminal  160  over the top of the free ends  247  in a direction from the housing  110  to the base  105 . In some embodiments, the connection link  255  is mechanically secured to the terminal  160  via the third fasteners  180  and washers  185  ( FIG. 3 ). 
         [0051]      FIG. 17  is a top view of the contact plates  210   a ,  210   b ,  210   c , and  210   d  coupled to the plurality of terminals  160   a ,  160   b ,  160   c , and  160   d  respectively, with the terminals  160   a ,  160   b ,  160   c , and  160   d  electrically coupled to the first battery B 1 , the second battery B 2 , the first load L 1 , and the second load L 2  respectively. In the illustrated embodiment, contact plate  210   a  and its corresponding terminal  160   a  may be identified as first load, or first load terminal, L 1 ; contact plate  210   b  and its corresponding terminal  160   b  may be identified as second load, or second load terminal, L 2 ; contact plate  210   c  and its corresponding terminal  160   c  may be identified as first battery, or first bank terminal, B 1 ; and contact plate  210   d  and its corresponding terminal  160   d  may be identified as second battery, or second bank terminal, B 2 . 
         [0052]      FIGS. 18-21  illustrate the various positions of operation of the battery switch  100 .  FIG. 18  illustrates the battery switch  100  in the off-position. In the off-position, all three lobes  205   a - 205   c  of lobed contact  200   a  are in contact with contact plate  210   c  (B 1 ), while all three lobes  205   d - 205   f  of lobed contact  200   b  are in contact with contact plate  210   b  (L 2 ). Therefore, there is no electrical connection between the first load L 1 , the second load L 2 , the first battery B 1 , and the second battery B 2 . 
         [0053]      FIG. 19  illustrates the battery switch  100  in the first load on-position (i.e., L 1  is electrically connected to B 1 ). Upon turning the knob  120  forty-five degrees from the off-position, the battery switch  100  is placed in the first load on-position with the first load L 1  being electrically connected to the first battery B 1 . As illustrated, when in the first load on-position, lobe  205   b  is in contact with contact plate  210   a  (L 1 ), while lobes  205   a  and  205   c  are in contact with contact plate  210   c  (B 1 ). Additionally, all three lobes  205   d - 205   f  are in contact with contact plate  210   b  (L 2 ). Therefore, the first load L 1  and the first battery B 1  are electrically connected, while there is no electrical connection between the second load L 2  and the second battery B 2 . 
         [0054]      FIG. 20  illustrates the battery switch  100  in the first and second load on-position (i.e., L 1  is electrically connected to B 1  and L 2  is electrically connected to B 2 ). Upon turning the knob  120  forty-five degrees from the first load on-position, the battery switch  100  is placed in the first and second load on-position. As illustrated, when in the first and second load on-position, lobes  205   b  and  205   c  are in contact with contact plate  210   a  (L 1 ), while lobe  205   a  is in contact with contact plate  210   c  (B 1 ). Additionally, lobes  205   d  and  205   f  are in contact with contact plate  210   d  (B 2 ), while lobe  205   c  is in contact with contact plate  210   b  (L 2 ). Therefore, the first load L 1  is electrically connected to the first battery B 1  and the second load L 2  is electrically connected to the second battery B 2 . 
         [0055]      FIG. 21  illustrates the battery switch  100  in the first and second load connected in parallel position (i.e., L 1  and L 2  are connected in parallel with B 1  and B 2 ). Upon turning the knob  120  forty-five degrees from the first and second load on-position, the battery switch  100  is placed in the first and second load connected in parallel position. As illustrated, when in the first and second load connected in parallel position, lobe  205   c  is in contact with contact plate  210   a  (L 1 ), lobe  205   b  of lobed contact  200   a  and lobe  205   d  of lobed contact  200   b  are in contact with contact plate  210   b  (L 2 ), lobe  205   a  of lobed contact  200   a  and lobe  205   f  of lobed contact  200   b  are in contact with contact plate  210   c  (B 1 ), and lobe  205   e  is in contact with contact plate  210   d  (B 2 ). Therefore, the first load L 1  and the second load L 2  are connected in parallel with the first battery B 1  and the second battery B 2 . 
         [0056]    Thus, the invention provides, among other things, a battery switch configured to control a first bank of batteries and a second bank of batteries, the first and second bank of batteries having at least one battery. Various features and advantages of the invention are set forth in the following claims.