Abstract:
An application for a battery shield including a set of walls made of a resilient, elastomeric material and a base made of the same resilient, elastomeric material. A bottom edge of the walls connects to an edge of the base forming a rectangular cavity having a width and a depth. The width is substantially equivalent to the width of a battery pack and the depth is substantially equivalent to the depth of the battery pack, thereby the battery shield snuggly fits around the battery pack, reducing shock and vibration of the battery pack from external shock and vibration and insulating the battery pack from ambient temperature extremes.

Description:
FIELD 
       [0001]    This invention relates to the field of batteries and more particularly to a system for insulating, protecting and absorbing shocks related to battery packs. 
       BACKGROUND 
       [0002]    Battery packs such as flooded lead-acid, absorbed-glass-matt (AGM) and lead-acid perform best at certain temperature ranges and are susceptible to extreme shock and vibration often found in applications such as aviation, automotive, space and other transportation applications. External heat or cold often interact with internally generated heat causing reduced capacity and or failure of one or more cells of the battery pack. Many battery pack chemistries are not tolerant of shock and vibration, also leading to damaged cells or cell structures, resulting in reduced output power and/or total failure of one or more cells. 
         [0003]    What is needed is a system that will reduce external temperature effects on the battery packs while also reducing shock and vibration exerted on the battery pack from the battery pack&#39;s environment. 
       SUMMARY 
       [0004]    A battery shield is disclosed including a set of walls made of a resilient, elastomeric material and a base made of the same resilient, elastomeric material. A bottom edge of the walls connects to an edge of the base forming a rectangular cavity having a width and a depth. The width is substantially equivalent to the width of a battery pack and the depth is substantially equivalent to the depth of the battery pack, thereby the battery shield snuggly fits around the battery pack, reducing shock and vibration of the battery pack from external shock and vibration and insulating the battery pack from ambient temperature extremes. 
         [0005]    In another embodiment, a battery shield is disclosed including a resilient, elastomeric material formed into a set of walls and a base such that a bottom edge of the walls interfaces to an edge of the base, thereby forming a rectangular cavity. The rectangular cavity has a width and a depth that are substantially equivalent to a width and a depth of a battery pack, respectively, thereby the battery shield snuggly fits around the battery pack, reducing shock and vibration of the battery pack from external shock and vibration and insulating the battery pack from ambient temperature extremes. 
         [0006]    In another embodiment, a battery shield system is disclosed including a set of walls made of a resilient, elastomeric material and a base also made of the resilient, elastomeric material. Bottom edges of the walls are connected to an edge of the base, thereby forming a rectangular cavity. A battery pack is held between the walls and rests on the base and, therefore, the battery pack is insulated from ambient temperature extremes by the walls and the base and the walls and the base dampen at least some external shock and vibration from reaching the battery pack. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]    The invention can be best understood by those having ordinary skill in the art by reference to the following detailed description when considered in conjunction with the accompanying drawings in which: 
           [0008]      FIG. 1  illustrates a perspective view of a typical battery pack installed within a battery shield. 
           [0009]      FIG. 2  illustrates a perspective view of a typical battery pack being inserted into a battery shield. 
           [0010]      FIG. 3  illustrates a bottom plan view of a battery shield. 
           [0011]      FIG. 4  illustrates a side sectional view of a battery shield. 
           [0012]      FIG. 5  illustrates a perspective view of a typical battery pack held within a battery shield. 
           [0013]      FIG. 6  illustrates a perspective view of a typical battery pack being inserted into a second battery shield. 
           [0014]      FIG. 7  illustrates a top plan view of the second battery shield. 
           [0015]      FIG. 8  illustrates a side sectional view of the second battery shield. 
       
    
    
     DETAILED DESCRIPTION 
       [0016]    Reference will now be made in detail to the presently preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. Throughout the following detailed description, the same reference numerals refer to the same elements in all figures. 
         [0017]    Referring to  FIG. 1 , a perspective view of a typical battery pack  30  installed within a battery shield  40  is shown. Many batteries  30  such as lead-based (e.g. flooded lead-acid, absorbed-glass-matt, lead-acid and lead-acid derivatives) have a positive  10  and negative  20  battery terminal for delivering power to applications and accepting charge current. Many or most batteries  30  are sensitive to temperature and vibration and are often used in harsh environments having high amounts of vibration and extreme ambient temperatures. For example, a battery  30  used in automotive applications often are exposed to random vibration from uneven road surfaces and cyclic vibration from the vehicle engines. Such batteries are often subject to extremely cold outdoor temperatures and very high temperatures from ambient impacted by heat from the engine. Similarly, a battery  30  used in aeronautic applications is often exposed to similar vibration such as random vibration from uneven runway surfaces or air turbulence and cyclic vibration from the airplane engines. These batteries are also subject to extremely cold high-altitude temperatures and very high temperatures from ambient impacted by heat from the engine and other electronics. 
         [0018]    To reduce the vibration and temperature exposure, the battery  30  is placed into a battery shield  40  made of an insulative, resilient elastomeric material that provides isolation from ambient temperature extremes, shock and vibration. Many different materials are anticipated including rubber, rubber derivatives, foams, thermoplastic-elastomeric, thermoplastic-urethane etc. Such material must be sturdy so as not to prematurely fail due to excessive heat and constant vibration. These materials partially insulate the battery  30  from the ambient air temperature and also dampen shock and vibration, reducing shock and vibration damage to the battery back  30 . 
         [0019]    It is anticipated that the thickness of the walls  43  and base  42  (see  FIGS. 3 and 4 ), ribbing (see  FIGS. 5-8 ) and material composition of the battery shield  40  are selected to optimize dampening of a specific frequency range of vibration. For example, in an automotive application in which the peak vibration is at 1000 Hz, the thickness, material and construction are selected to optimally dampen that frequency. 
         [0020]    Referring to  FIG. 2 , a perspective view of a typical battery pack  30  being inserted into a battery shield  40  is shown. For improved protection, it is preferred, though not required, that the width of the battery shield  40  be similar to the width of the battery pack  30  and the length of the battery shield  40  be similar to the length of the battery pack  30 . Although this is not required, by making the inner dimensions of the battery shield  40  similar to the outer dimensions of the battery  30 , a tight fit is provided, limiting movement of the battery pack  30  within the battery shield  40 . In such, the outer walls  31  of the battery  30  substantially contact the inner walls  41  of the battery shield  40 . 
         [0021]    The battery shield  40  is made of any shape to conform to the shape of the battery pack  30 . The battery shield  40  has walls  43  and a base  42  (see  FIGS. 3 and 4 ). Although it is preferred that the battery shield  40  be formed as a monolithic device, it is anticipated that, in some embodiments, the base  42  is fabricated separately and an outer edge of the base  42  is affixed to the bottom edge of the walls  43  by ways known in the industry such as using adhesives, ultrasonic welding, etc. 
         [0022]    The battery  30  is insulated from ambient temperature extremes by the battery shield  40 . Since the battery shield  40  is made of a material such as rubber that at least partially insulates the battery  30  from ambient temperatures, the battery  30  is less effected by, for example, engine compartment heat. Since the battery shield  40  is made of a soft, malleable material such as rubber, shock and vibration from the environment is dampened, increasing the life of the battery  30 . 
         [0023]    Referring to  FIG. 3 , a bottom plan view of a battery shield  40  is shown. In this view, the bottom thickness  42  of the battery shield  40  is greater than that of the thickness of the walls  43 . Since, is typical or most battery  30  installations, the battery is installed with the terminals  10 / 20  facing upward, most of the mass of the battery  30  rests on the bottom surfaces  42  of the battery  30 . The increased bottom thickness of the base  42  provides a thicker cushion of material between the bottom surface of the battery  30  and the holder or base to which the battery  30  rests. This increases the amount of vibration and shock dampening. 
         [0024]    Referring to  FIG. 4 , a side sectional view of a battery shield is shown. In this view as well, the optional increased bottom thickness  42  of the battery shield  40  is visible. Since, is typical or most battery  30  installations, the battery is installed with the terminals  10 / 20  facing upward, most of the mass of the battery  30  rests on the bottom surfaces of the battery  30 . The increased bottom thickness  42  provides a thicker cushion of material between the bottom surface of the battery  30  and the holder or base to which the battery  30  rests. This improves the amount of vibration and shock dampening. 
         [0025]    Referring to  FIG. 5 , a perspective view of a typical battery pack  30  held within a second battery shield  50  is shown. This battery shield has ribs  45  that both increase the wall thickness of the battery shield  50  and increase the insulation due to air gaps  47 , being that air doesn&#39;t conduct heat as well as many other materials. The increased thickness from the ribs  45  as well as having two different material densities (one towards the outer surface of the battery shield  50  and the other at the ribs  45 ) further improves on the battery shields&#39;  50  dampening properties. For example, the ribs  45  dampen on frequency of vibration while the solid outer surface of the shield  50  dampens a second frequency of vibration. Any configuration of ribs  45  is anticipated including irregular width ribs  45  and ribs  45  of varying geometries (rectangular or square geometries are shown in  FIG. 5 ). 
         [0026]    Referring to  FIG. 6 , a perspective view of a typical battery pack  30  being inserted into a second battery shield  50  is shown. Although not required, it is anticipated that the inner dimensions of the battery shield ribs  45  are similar to the outer dimensions of the battery  30 , thereby providing a tight fit. In such, the outer surfaces of the battery  30  substantially contact the inner surfaces of the battery shield ribs  45 . The battery  30  is insulated from ambient temperature extremes by the battery shield  50  with ribs  45  (and air gaps  47 ). Since the battery shield  50  is made of a material such as rubber that at least partially insulates the battery  30  from ambient temperature extremes, the battery  30  is less effected by, for example, engine compartment heat. Since the battery shield  50  is made of a soft, malleable material such as rubber, shock and vibration from the environment is dampened, increasing the life of the battery  30 . 
         [0027]    Referring to  FIG. 7 , a top plan view of the second battery shield  50  is shown. Although the ribs  45  are shown as having a general rectangular shape, any shape is anticipated. For example, in another embodiment, the ribs  45  are of semi-circular cross-section, etc. 
         [0028]    Referring to  FIG. 8 , a side sectional view of the second battery shield  50  is shown. In this view, it is shown that the ribs  45  are vertical along the inside surfaces of the battery shield  50 . It is anticipated that, in other embodiments, the ribs  45  are at any other orientation and/or the ribs  45  are on any inner surface of the battery shield  50 . Furthermore, it is anticipated that, in some embodiments, the ribs  45  vary directions, intersect each other, are shorter in length, etc. In the embodiment of  FIG. 8 , the base  42  is shown thicker, providing increased cushioning and, hence, dampening of shock and vibration. 
         [0029]    Equivalent elements can be substituted for the ones set forth above such that they perform in substantially the same manner in substantially the same way for achieving substantially the same result. 
         [0030]    It is believed that the system and method as described and many of its attendant advantages will be understood by the foregoing description. It is also believed that it will be apparent that various changes may be made in the form, construction and arrangement of the components thereof without departing from the scope and spirit of the invention or without sacrificing all of its material advantages. The form herein before described being merely exemplary and explanatory embodiment thereof. It is the intention of the following claims to encompass and include such changes.