Starter module adapter

A starter module adapter for a vehicle or other equipment including a starter module and a housing assembly having a pair of terminals. The starter module adapter may include a metal receiver functioning as an electrical connector defining a receptacle for receiving the starter module. The exterior dimensions of the housing assembly may be the same as the exterior dimensions of a standard battery.

The present disclosure relates to a starter module adapter for a vehicle or other equipment.

BACKGROUND

Automobiles and other vehicles and equipment typically are designed with a certain standard battery size in mind. During the design, the clearances around and above the battery, the battery tray, the method of securing the battery, the positive and negative lead lengths typically are all predetermined based on such certain standard battery size. As a result, odd size starter modules that do not have such standard battery size typically cannot be used with such equipment.

SUMMARY

The present disclosure relates to a starter module adapter for a starter module. The starter module has a first positive terminal and a first negative terminal and a distance therebetween. The starter module adapter comprises a housing assembly that includes a second positive terminal and a second negative terminal having a distance therebetween. The distance between the second positive terminal and the second negative terminal is greater than the distance between the first positive terminal and the first negative terminal. The housing assembly further includes a first electrical connector interconnecting the first positive terminal and the second positive terminal, and a second electrical connector interconnecting the first negative terminal and the second negative terminal. One of the first electrical connector and the second electrical connector may comprise a metal receiver defining a receptacle for receiving the starter module. The other of the first electrical connector and the second electrical connector may comprise any other suitable electrical connector.

The metal receiver may include a metal extension for adjusting the length of the metal receiver. For example, the metal receiver may include a base and a metal extension slidably engageable with each other and lockable to each other at a desired position for adjusting the length of the metal receiver. The starter module adapter may further include a partition receivable in the receptacle for holding the starter module in place within the receptacle and one or more hold down structures.

The starter module may be any suitable device capable of providing electrical power to the vehicle or other equipment and may be of any size that can be received by the receptacle. For example, it may be in the form of (1) an electrical energy storage device comprising a single capacitor (i.e., condenser or condensator) or an assembly of capacitors configured in series, parallel or a combination of both; (2) an electric power generating device such as a battery module comprising a single battery cell or to an assembly of battery cells configured in series, parallel or a combination of both; or (3) a combination of (1) and (2).

The exterior dimensions, length, width and height of the housing assembly when assembled may be the same or nearly the same as the exterior dimensions of a standard battery.

Features and advantages of the disclosure are set forth in part in the description which follows and the accompanying drawings.

DETAILED DESCRIPTION

FIGS. 1-9illustrate embodiments of a starter module adapter6and106including a housing assembly10and110, respectively. Each housing assembly10and110may be used for installation of the starter module16and116in a vehicle or other equipment designed to employ a specific battery size even though the starter module to be installed is sized differently from the specific battery size intended for the vehicle or other equipment.

With reference toFIGS. 1-3, the housing assembly10includes a metal receiver12that defines a receptacle14receiving the starter module16, a partition18, a first electrical connector in the form of a positive terminal busbar22, a positive terminal26and a negative terminal28. The starter module16may be of any suitable size configured to be received within the receptacle14. The starter module16includes a positive terminal44and a negative terminal46.

The positive terminal busbar22interconnects the positive terminal44of the starter module16with the positive terminal26of the housing assembly10. The positive terminal busbar22is connected and secured to the positive terminal44of the starter module16by a screw or by any other suitable joining method. The positive terminal26is connected and secured to the positive terminal busbar22by a screw or by any other suitable joining method. The positive terminal busbar22instead may be any other suitable electrical connector such as a terminal cable, a bar or other suitable connector or combination of any of the foregoing and may have any other suitable configuration. The positive terminal26shown as a post may have any other suitable configuration.

The metal receiver12functions as an electrical connector that interconnects the negative terminal46of the starter module16with the negative terminal28of the housing assembly10. The metal receiver12is connected and secured to the negative terminal46of the starter module16by a screw or by any other suitable joining method. The negative terminal28is connected and secured to the metal receiver12by a screw or by any other suitable joining method. The metal receiver12is constructed of metal with electric current carrying capacity and may have any other suitable configuration. The metal receiver12may also be constructed of any non-metal material that includes steel or other metal and that has electric current carrying capacity. The metal receiver12may have any other suitable configuration in accordance with other embodiments of the present disclosure. The negative terminal28shown as a post may have any other suitable configuration.

The partition18is received by the receptacle14and is positioned next to the starter module16to limit or eliminate movement of the starter module within the receptacle or for otherwise holding the starter module in place. The illustrated partition18is in the form of a metal frame with side rails, top and bottom rails and top and bottom brackets at right angle to the frame. The top and bottom brackets, each, incorporate two tapped holes17. The partition18may have any other configuration that complements the sides of the starter module16. The metal receiver12includes a pair of opposed walls54with two holes each19positioned to engage the partition18with securing screws. The location of the holes19depends upon the size of the starter module16received within the receptacle14. The opposed walls54may incorporate multiple hole groups to provide alternative locations for the partition18.

The metal receiver12incorporates one or more hold-down structures65. A pair of opposed hold down structures65may be interconnected by a removable bracket68. The metal receiver12may be secured to the vehicle by employing the hold down structures or by any other suitable manner in accordance with other embodiments of the present disclosure. The partition18and the bracket68incorporating the side hold-down structures65may be constructed of metal, plastic or any other suitable material and may have any suitable configuration.

The distance between the positive terminal26and the negative terminal28of the housing assembly10depends upon the vehicle and the size of the battery the vehicle was designed to accommodate. For example, the distance between positive and negative battery terminals of a standard 8.2″ long battery is about 6″. For example, if the vehicle was intended for use with such a standard 8.2″ long battery, the distance between the positive and negative terminals of the housing assembly would be about 6″. The housing assembly10can be used with starter modules16having a distance between the positive and negative terminals44and46that is less than the distance between the positive terminal26and the negative terminal28of the housing assembly. By turning the starter module 180° in the receptacle, the polarity of terminals26and28in the housing assembly10may be reversed.

The starter module16may be any suitable device capable of providing electrical power to the vehicle and may be of any size that can be received by the receptacle14. For example, it may be (1) an electrical energy storage device comprising a single capacitor (i.e., condenser or condensator) or an assembly of capacitors configured in series, parallel or a combination of both; (2) an electric power generating device such as a battery module comprising a single battery cell or to an assembly of battery cells configured in series, parallel or a combination of both; or (3) a combination of (1) and (2). The component(s) of the electrical device may or may not have a full or partial housing or enclosure.

FIG. 2illustrates the starter module16in the form of an electric power generating device comprising cylindrical battery cells90connected in series and in parallel.FIG. 3(a)illustrates the starter module16in the form of an electrical energy storage device comprising laminated pouch type capacitor cells92connected in series.FIG. 3(b)illustrates the starter module16in the form of an electrical device comprising pouch type battery cells94connected in series and cylindrical capacitor cells96connected in series. The starter module16may instead be in the form of or include one or more battery modules of any suitable size configured to be received within the receptacle14. Where there are two battery modules, the battery modules may be connected in parallel or in series and, where there are three or more battery modules, the battery modules may be connected in parallel or series or a combination of both.

In any instance where the starter module16has more than one positive terminal and/or more than one negative terminal, one of the electrical connectors interconnects at least one positive terminal of the starter module with the positive terminal26of the housing assembly10and/or the other electrical connector interconnects at least one negative terminal of the starter module16with the negative terminal28of the housing assembly.

With reference toFIGS. 4-7, a housing assembly110in accordance with another embodiment of the present disclosure includes a metal receiver112that defines a receptacle114receiving the starter module116, partition118, electrical connector in the form of a positive terminal busbar122, a positive terminal126and a negative terminal128. The metal receiver112interconnects the negative terminal128and the negative terminal of the starter module116. The metal receiver112includes a first component in the form of a metal extension130and a base component131slidably engageable with the metal extension130.

As in the case of the starter module16, the starter module116may be any suitable device capable of providing electrical power to the vehicle and may be of any size that can be received by the receptacle114. For example, it may be (1) an electrical energy storage device comprising a single capacitor (i.e., condenser or condensator) or an assembly of capacitors configured in series, parallel or a combination of both; (2) an electric power generating device such as a battery module comprising a single battery cell or an assembly of battery cells configured in series, parallel or a combination of both; or (3) a combination of (1) and (2). The component(s) of the electrical device may or may not have a full or partial housing or enclosure.

In any instance where the starter module116has more than one positive terminal and/or more than one negative terminal, one of the electrical connectors interconnects at least one positive terminal of the starter module with the positive terminal126of the housing assembly110and/or the other electrical connector interconnects at least one negative terminal of the starter module116with the negative terminal128of the housing assembly.

The positive terminal busbar122interconnects the positive terminal of the starter module with the positive terminal126of the housing assembly110. The positive terminal busbar122is connected and secured to the positive terminal of the starter module116by a screw or by any other suitable joining method. The positive terminal126is connected and secured to the positive terminal busbar122by a screw or by any other suitable joining method. The positive terminal busbar122instead may be any other suitable electrical connector such as a cable, a bar or other suitable connector or combination of any of the foregoing and may have any other suitable configuration. The positive terminal126shown as a post may have any other suitable configuration.

The metal receiver112, including the metal extension130, functions as an electrical connector that interconnects the negative terminal of the starter module with the negative terminal128. The metal extension130and the base component131are secured to each other by screws199. The metal receiver112is connected and secured to the negative terminal of the starter module by a screw or by any other suitable joining method. The negative terminal128is connected and secured to the metal extension130by a screw or by any other suitable joining method. The metal receiver112, including the extension130, is constructed of metal with electric current carrying capacity and may have any other suitable configuration. The metal receiver, including the extension, may also be constructed of any non-metal material that includes steel or other metal and that has electric current carrying capacity. The metal receiver112, including the metal extension130, may have any other suitable configuration in accordance with other embodiments of the present disclosure. The negative terminal128shown as a post may have any other suitable configuration.

The partition118is received by the receptacle114and is positioned next to the starter module to limit or eliminate movement of the starter module within the receptacle or for otherwise holding the starter module in place. The illustrated partition118is in the form of a metal frame with side rails, top and bottom rails and top and bottom brackets at right angle to the frame. The top and bottom brackets, each, incorporate two tapped holes. The partition118may have any other configuration that complements the sides of the starter module. The metal receiver112includes a pair of opposed walls154with two holes each119positioned to engage the partition118with securing screws. The location of the holes119depends upon the size of the starter module received within the receptacle. The opposed walls154may incorporate multiple hole groups to provide alternative locations for the partition118.

The metal extension130is slidingly engaged with the base component131and may be secured to each other in any suitable manner to achieve a desired length of the metal receiver112. In the illustrated embodiment, for example, the base component131incorporates four tapped holes115. The metal extension130incorporates hole groupings113, for example, which allow the extension to be adjusted to a specific overall length. The metal extension130is secured to the base component131by screws199. In the illustrated example, there are multiple hole groupings that allow for overall lengths from 8.2″ to 13.9″. Tab133is designed to be broken off along the weakened line135when the extension130is configured in 11″ or less overall length. In these positions the negatively charged tab133is deemed to be too close to the positively charged battery terminal126. The metal extension130and the base component131may be secured together at the desired position in any other manner in accordance with other embodiments of the present disclosure.

The metal receiver112may incorporate one or more hold down structures165. The metal receiver112, including the extension130, may be secured to the vehicle by employing the hold down structures or in any other suitable manner. The partition118and hold-down structures165may be constructed of metal, plastic or any other suitable material and may have any suitable configuration.

The distance between the positive terminal126and negative terminal128of the housing assembly110depends upon the vehicle and the size of the battery the vehicle was designed to accommodate. For example, the distance between positive and negative terminals of a standard 13.9″ long battery is about 11.5″. For example, if the vehicle was intended for use with such a standard 13.9″ long battery, the distance between the positive and negative terminals126and128of the housing assembly110would be about 11.5″. Since the metal extension130incorporating multiple hole groupings is slidingly engaged with the metal base component131, standard overall battery lengths of 8.2″ to 13.9″, for example, may be configured resulting in standard terminal distances of approximately 6″ to 11.5″. The housing assembly110can be used with a starter module having a distance between the positive and negative terminals that is less than the distance between the positive terminal126and the negative terminal128of the housing assembly. By turning the starter module 180° in the receptacle, the polarity of terminals126and128in the housing assembly110may be reversed.

With reference toFIG. 8, a rigid pad301may be attached to the top of the housing assembly10and110. The pad301may also include a terminal lid338to cover the positive terminal. The combined height of the housing assembly and the thickness of the rigid pad301serves as a load bearing structure in some vehicle applications. The rigid pad301and the terminal lid338may be of any suitable material. The rigid pad301may be attached to the housing assembly by any suitable means.

With reference toFIG. 9, the starter module adapter may also include a fold together insulating jacket401made out of thin non-conductive material for fully isolating the starter module adapter from the surroundings while exposing the positive and negative terminals of the housing assembly. The fold together insulating jacket401is comprised of thin non-conductive material. The fold together insulating jacket401is foldable to substantially enclose the housing assembly, and includes a pair of apertures402for receiving and exposing the positive and negative terminals of the housing assembly to facilitate access thereto. The insulating jacket401may have any other suitable configuration. The insulation of the starter module adapter may be achieved by any other suitable means.

The present disclosure provides many benefits. For example, vehicles are typically designed to accommodate specific size batteries (e.g., from 8.2″ to 13.9″ long) and therefore the size of batteries to be installed on such vehicles is typically limited to the specific size. The starter module adapter6or106comprising housing assembly10or110of the present disclosure, however, enables smaller starter modules to be used on such vehicles. The present disclosure, among other things, provides an efficient manner for using odd size devices such as batteries or other starter modules on vehicles designed to use a specific standard battery size. Reference to standard battery size herein are intended to refer to the size and dimensions of a commercially used battery as understood by one of ordinary skill in the art. For example, such references are intended to include battery sizes standardized by agreement by two or more battery manufacturers or battery sizes of any other vehicle batteries having predetermined sizes and dimensions. Similarly, one of ordinary skill in the art understands that references to “starter module” herein are intended to refer to any suitable electrical device that may be but not limited to: (1) an electrical energy storage device comprising a single capacitor (i.e., condenser or condensator) or an assembly of capacitors configured in series, parallel or a combination of both; (2) an electric power generating device such as a battery module comprising a single battery cell or to an assembly of battery cells configured in series, parallel or a combination of both; or (3) a combination of (1) and (2).

The present disclosure also provides ease of manufacture benefits because, among other reasons, the components are versatile, few in number and constructed in whole or in part of sheet metal. The receiver constructed of sheet metal merely requires forming without the need for special tooling.

While embodiments have been illustrated and described in the drawings and foregoing description, such illustrations and descriptions are considered to be exemplary and not restrictive in character. It is understood that only illustrative embodiments have been shown and described and that all changes and modifications that come within the spirit of the present disclosure are protected. The drawings and description are not intended to be construed as having or implying limitation of the disclosure to those embodiments. There is a plurality of advantages of the present disclosure arising from various features set forth in the description. It will be noted that alternative embodiments of the disclosure may not include all of the features described yet still benefit from at least some of the advantages of the present disclosure. Those of ordinary skill in the art may readily devise their own implementations of the disclosure and associated methods, without undue experimentation, that incorporate one or more of the features of the disclosure and fall within the spirit and scope of the present disclosure and the appended claims.