Abstract:
A dry cell battery holder with the ability to output the total voltage of the installed batteries, even when less than fully populated. Cost is reduced by the absence of holes in the walls of the battery holder case and thereby reducing molding complexity. Cost is also reduced by all battery interconnections being of pre-pre-formed spring temper wire that are installed by snap in and spring back. A non-linear compression pad at the negative end of the battery improves shock resistance.

Description:
[0001]    The present patent application is a continuation in part of patent application Ser. No. 11/472,932. 
         [0002]    This patent application incorporates items from pending patent application Ser. No. 11/213,029. 
     
     BACKGROUND OF THE INVENTION 
       [0003]    1. Field of the Invention 
         [0004]    2. Description of the Prior Art 
         [0005]    It can be appreciated that battery holders have been in use for years. Typically, battery holders are pre-determined to accommodate a given number of batteries and are susceptible to intermittent voltage in shock and vibration. 
         [0006]    The main problem with conventional battery holders is that the absence of even one battery breaks the serial chain and no voltage at all is available at the battery holder output terminals. 
         [0007]    Another problem with conventional battery holders is that extra operations are required for assembly in the subsequent installation of contact terminals and interconnections. 
         [0008]    Another problem with conventional battery holders is that battery retention is dependant upon covers or the outside two batteries being partially covered by a retainer. Retaining straps are available but are less retentive on the batteries remote from the outside walls. 
         [0009]    Another problem with conventional battery holders is that the removal of batteries generally requires fingernail extracting rather than being pressed out. 
         [0010]    Another problem with conventional batter holders is that molding costs of the battery holder case are increased by the requirement for holes in the battery holder case walls. 
         [0011]    Another problem with conventional battery holders is that when exposed to shock and/or vibration, battery movement can intermittently open even one circuit in the battery chain resulting in the problem stated above in paragraph 0004. 
         [0012]    Another problem with conventional battery holders is the expense incurred in complex molding operations, contacts installation and wiring interconnects. 
         [0013]    Another problem with conventional battery holders is that when used to supply power to an Electrostatic Discharge sensitive circuit, removal of the battery, or batteries, leaves the circuit input open circuit and Susceptible to Electrostatic Discharge, ESD, damage. 
         [0014]    Another problem with prior art battery holders is that they are limited in output voltage to the total voltage of the totally populated battery holder. 
         [0015]    While these devices may be suitable for the particular purpose to which they address, they are not as suitable for the provision of a battery holder that provides economy of production and reliable output voltage as a function of the number of batteries installed. 
         [0016]    In view of the disadvantages inherent in the known types of battery holders now present in the prior art, the present invention provides a new and less expensive UNINTERRUPTABLE BATTERY HOLDER with incremental voltage, capable of more reliable service under extreme acceleration movement conditions. It has many of the advantages of the holders mentioned heretofore and many novel features that result in a new ruggedized incremental and selectable voltage battery holder which is not anticipated, rendered obvious, suggested, or even implied by any of the prior art, either alone or in any combination thereof. 
       SUMMARY OF THE INVENTION 
       [0017]    My battery holder may be considered uninterruptible as the loss of one battery drops the supplied voltage by only the voltage of that one battery. The battery holder is comprised of an injection molded battery holder case containing no holes in the walls, thereby reducing the molding operation to one male and one female mold only. The said holder is able to do this by the use of my invented battery contact and interconnect of pre-formed wire, or stamped metal strip, disposed into positioning retainers molded into the battery holder case  30  and possibly captured by heat staking, spring back or other means. 
         [0018]    A given battery is electrically entered into the serially connected battery array by the interconnecting pre-formed wire being contiguous with the positive end of the prior battery and with the negative end of said given battery, which eliminates the need for wall mounted interconnects. 
         [0019]    The subsequent battery pre-formed wire forms a normally closed contact with this pre-formed wire that bypasses said given battery position in the event no battery is installed in that position. Each battery position may or may not contain a battery and thereby the serial chain can provide output voltage as a function of the sum of number of batteries present and the voltage of each. 
         [0020]    For example, a battery holder of four battery positions can actually supply  14  output voltages by mixing and/or removing 1.5 volt and 1.2 volt batteries. 
         [0021]    Shock induced intermittent contact separation protection is increased by the inclusion of my patent pending self-expanding, but resistant to sudden collapsing, bubble. 
         [0022]    Shock induced intermittent contact protection is made less critical by the reduction of the severity of losing only 1/n (where “n” is the number of batteries in the chain) of the total voltage as opposed to losing the total voltage. 
         [0023]    Battery retention is enhanced by the inclusion of a path for an optional over battery strap, which secures each battery to its adjacent battery case walls. 
         [0024]    The general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new incremental voltage battery array holder that has many of the advantages of the holders mentioned heretofore and many novel features that result in a new battery holder which is not anticipated, rendered obvious, suggested, or even implied by any of the prior art, either alone or in any combination thereof. 
         [0025]    For the purpose of demonstration of battery economy from experimental results, assume an AA battery costs $1.00. 
         [0026]    For an incandescent bulb rated 6 volts:
       At 4 batteries, the bulb consumes 0.355 amps at 5.93 volts. Rated life of the 4 batteries is 3.5 hours (Ray-O-Vac Corp). Cost for 4 batteries is $4.00/3.5=$1.14 per hour.   At 3 batteries, and still quite bright, the bulb consumes 0.304 amps at 4.47 volts. Rated battery life is: 5.5 hours. Cost of 3 batteries is $3.00/5.5=$0.55 per hour.   A prior art  4  cell holder would require a 4.87 ohm resistor to drop the voltage to 4.47 volts and 0.304 amps, while still using 4 batteries. Cost is $4.00/5.5=$0.73 per hour plus the resistor cost.   My holder with 2 cells, a soft glowing light, at 0.237 amps and 2.91 volts is rated 7.5 hours or $2.00/7.5=$0.27 per hour.   A prior art 4-cell holder would cost $4.00/7.5=$0.53 per hour plus a 12.7-ohm resistor.   (Powering a 5VDC fan yields even more striking results with less noise).       
 
         [0033]    There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof may be better understood, and in order that the present contribution to the art may be better appreciated. 
         [0034]    In this respect, before explaining at least one embodiment of the invention in detail, i.e. a four battery holder, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and have being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of the description and should not be regarded as limiting. 
         [0035]    This invention may be embodied in the form illustrated in the accompanying drawings, attention being called to the fact, however, that the drawings are illustrative only, and that changes may be made in the specific construction illustrated. It is assumed that the pre-formed wire is approximately 0.035 diameter, square or rectangular spring temper metal. The length of wire required per battery is less than the length used for that battery&#39;s coil spring of prior art battery holders. 
     
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0036]    Various other objects, features and attendant advantages of the present invention will become fully appreciated as the same becomes better understood when considered in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the several views, and wherein: 
           [0037]      FIG. 1  is the schematic of each battery position when no battery is present. 
           [0038]      FIG. 2  is the schematic of each battery position when a battery is present. 
           [0039]      FIG. 3  is the schematic of a battery holder of 6 positions when only two batteries are present. 
           [0040]      FIG. 4  illustrates a battery in position and displacing my positive contact  50  away from being contiguous with the subsequently contiguous pre-formed wire  50 . 
           [0041]      FIG. 5  illustrates the absence of a battery in position and my pre-formed wires  50  form a bypassing circuit  20 , bypassing that battery position. 
           [0042]      FIG. 6  is an isometric view of pre-formed wire contacts  49 , 50  and  51  before installing into a four-battery holder. 
           [0043]      FIG. 7  is my reduced cost battery holder  10  with my pre-formed wire contacts  50  installed. 
           [0044]      FIG. 8  is a four-battery holder with a retaining strap woven over each battery, securing them to the battery case. 
           [0045]      FIG. 9  is a four battery holder with one battery removed from service by being urged away from that positive portion of the pre-formed wire by the insertion of the “OFF” device  200 . 
           [0046]      FIG. 10  is a cross section of my self expanding bubble showing the one vent hole as described in my patent pending Ser. No. 11/213,029. 
           [0047]      FIG. 11  graphs the difference between a normal rate of compression verses a shock rate deflection of the bubble of  FIG. 10 . 
           [0048]      FIG. 12  the bubble of  FIG. 10  is used to resist sudden movement of a battery away from the positive pre-formed wire. 
           [0049]      FIG. 13  shows by graph how the output voltage of a prior art four-battery holder can go to zero during shock acceleration impact. 
           [0050]      FIG. 14  shows by graph how the output voltage of a my invented batter holder can drop to probably greater than zero volts during a shock or vibration acceleration impact. 
           [0051]      FIG. 15  shows by graph how the output voltage of my invented batter holder can be smoothed to a lesser voltage variation during shock or vibration impact acceleration by use of an output capacitor. 
           [0052]      FIG. 16  is a four-battery holder with a fifth position added for the accommodation of a smoothing capacitor as described in  FIG. 15 . 
           [0053]      FIG. 17  is effectively the schematic of the battery holder of  FIG. 16 . 
       
    
    
     INDEX TO ITEM NUMBERS 
       [0000]    
       
           10 —The basic battery holder case assembly complete with all battery contact wire pre-forms and ready for battery installation. 
           20 —The Normally Closed connection between two pre-formed wires. 
           30 —The molded battery case with no attachments. 
           49 —A specially pre-formed wire used as the positive battery connection of battery “A”. 
           50 —The basic pre-formed wire that conducts electrical current from the negative terminal of a battery to the positive terminal of the next battery. 
           1 —Partial of wire number  50  conducting current from the negative of battery “D” to external usage. 
           70 —Finger access holes in the bottom of battery holder case, item  30  for battery ejection. 
           75 —Recess gaps in the walls for battery retaining straps to pass below the walls. 
           80 —Recess in each wall for the pre-formed wire to pass through en route to the next battery. 
           90 —Pre-formed wires guide molded into case  30  to position and retain pre-formed wires,  49 ,  50  and  51 . 
           100 —A basic cylindrical battery such as, but not limited to an “AA” size. 
           100  (OFF)—A battery  100 , that has been moved longitudinally away from the positive portion of the pre-formed wire contact and is no longer in the serial circuit. 
           130 —My invented self-expanding but resistant to sudden compression bubble per cited pending application. 
           140 —Foam contained in bubble to cause maximum inflation to available confines of skin or installation. 
           150 —A flexible but non-stretchable skin enclosing foam. 
           160 —A small air leak in bubble  130 . 
           170 —Resistance to compression curve by bubble undergoing normal battery insertion. 
           180 —Installed point of bubble during normal service. 
           190 —Resistance curve very firm when a high acceleration shock force tries to rapidly move the battery longitudinally away from the positive contact and toward the bubble. A bubble can be installed at the positive end of the battery  100  but must not interfere with the operation of contacts  20 . 
           200 —Plastic clip or device that slides onto wall of battery case  30 ,and disposes battery number  100  (OFF) away from the positive portion of pre-formed wire contact  50 , allowing closure of the bypassing contact  20  and thereby removing said battery from the serial circuit. 
           210 —A capacitor occupying a space in the battery holder case  30 , connected across the battery holder output terminals and smoothing output voltage of assembly  10  during intermittent contact separation from batteries. 
           220 —alternate configuration using a single pole-double throw switch or relay. 
       
     
       DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0076]    Turning now descriptively to the drawings, in which similar reference characters denote similar elements throughout the several views, the attached figures illustrate a battery holder of optional quantity of batteries with reduced manufacturing costs and ruggedized for military and industrial applications. 
         [0077]      FIG. 1  depicts the schematic of a single battery holder  10  in the absence of an installed battery. Item  20  is a Normally Closed contact that is closed, thereby bypassing the battery position. 
         [0078]      FIG. 2  depicts the schematic of a single battery holder in the presence of an installed battery  100 . Item  20  has been forced open, by the presence of the installed battery  100  thereby deleting conductivity across the battery position. At this time battery voltage appears across the battery position and its voltage is added to the total voltage of the battery holder  10 . 
         [0079]      FIG. 3  is a 6-position battery holder  10 . A battery  100  is installed in two random positions. Output voltage of the array is the sum of the two batteries due to the normally closed, N.C. contacts passing current through unused positions. 
         [0080]      FIG. 4  is a cross section of the battery holder  10 , showing how the presence of a battery  100  has opened the circuit at  20  so that the pre-formed wire  50  of positive contact with battery  100  is no longer contiguous with the wire  50  from the negative of the previous battery. Without this bypassing current path, the voltage of the battery  100  is contributed to the voltage of the total serial array. Item  75  is a recess in the battery case  30  walls between battery shown and adjacent battery through which  50  passes. 
         [0081]      FIG. 5  is a cross section of the battery holder  10 , showing how the movement, or removal of battery  100  removes it from service  100  (OFF) and it no longer contributes its voltage to the serial array. N.C. contact  20 , is now closed, thereby connecting the negative of the previous battery to the positive of the subsequent battery. With this current path, the voltage of the battery  100  is bypassed and does not contribute to the voltage of the total. 
         [0082]      FIG. 6  shows the basic interconnecting pre-formed wire  50  that typically connects the negative end of battery “A” to the positive end of battery “B”. Said pre-formed wire is available at  20  for conduction, in the absence of battery “B”, to the positive end of battery “C”. Wire  49  connects only to battery “A” positive with the opportunity for conduction to pre-formed wire  50  in the absence of battery “A”. 
         [0083]    Pre-formed wire  51  is the same as wire  50  but with the next positive position removed. This wire conducts from the negative of battery “D”, or others, to outside usage of the battery holder as the negative terminal. These outputs can be directed downward for installation onto a printed wiring board. 
         [0084]      FIG. 7  shows the battery holder case  30 , with pre-formed wire  50  positioning channels  90 . Also shown are finger holes  70 , for battery removal. These holes are extended into slots  75  in the bottom of the walls for lacing  110  the batteries into place. The pre-formed wires  50  are disposed into the receiving channels whereupon they are secured into position possibly by heat staking, spring back into retainers or bonding into the channels. Note there are no holes required in the walls of the battery holder case  30 , greatly simplifying molding and final assembly. 
         [0085]    The positive contact of battery “A”  49  is configured to accommodate securing into the battery holder case  30  and provides the positive voltage output of the battery holder  10 . Battery contact wire  51  is a partial Pre-formed wire  50  and provides the negative output of the battery holder  10 . The flanged extended bottom is optional for mounting the battery holder assembly. 
         [0086]      FIG. 8  shows a four-battery holder with the batteries  100 , secured by ribbon  110 . This ribbon can be a “Tie Wrap”, self-bonding tape such as Velcro tape, elastic ribbon or other. One battery  100  is removed for illustration but the ribbon would not retain shape at that battery position unless ribbon was installed with that battery absent. 
         [0087]    If it is not desired to use the ability to slide a battery away from the positive wire  50  in order to turn it off, the inside planar surface of the battery holder case  30 , can be coated with a high friction material such as 3140 RTV from DOW CORNING. It will flow off the surface, leaving a thickness of less than 0.010 inches thick with very high frictional characteristics to aid retention in high acceleration forces environments. 
         [0088]      FIG. 9  shows an optional “OFF” clip device  200 , which when inserted onto the wall of  10 , moves that battery  100  (OFF), toward its negative terminal and away from its positive contact as shown in  FIG. 5 . The battery is now out of the circuit and that battery position is electrically bypassed. 
         [0089]    Note that an “OFF” clip  200  at each of all battery positions renders the battery holder assembly  10  electrically off and its outputs are shorted together. A side rail could be added to the molded case  30  that would store one clip  200  per battery for use as desired. 
         [0090]      FIG. 10  is an illustration of my shock resisting bubble  130  per pending application Ser. No. 11/213,029. The basic bubble is similar to commercially available packaging bubbles except it contains resilient foam for self-expansion and a small vent hole  160  to allow bubble expansion to fill available confining volume. 
         [0091]      FIG. 11  is a LOAD-DEFLECTION graph showing bubble compressibility at a normal rate  170 . It is assumed that an installed battery per  FIG. 12  brought the bubble to point  180 . A sudden high acceleration shock force tending to compress the bubble more finds the vent hole too small to rapidly exhaust the contained air and therefore the bubble presents a high resistance to greater compression  190  thereby preventing the battery from separating from  50  at the positive end. 
         [0092]      FIG. 12  shows the bubble  130  installed at the negative end of a battery  100  in a battery holder assembly  10 . The bubble will supply high resistance to sudden battery movement away from the faying surfaces between the positive terminal of battery  100  and the pre-formed wire  50 . Due to the venting of the bubble, changes in air pressure, such as altitude, does not inflate or deflate said bubble, moving it away from graph point  180  and it stays ready for shock protection. 
         [0093]      FIG. 13  is a graph of voltage output of a prior art four battery holder when experiencing high acceleration shock or vibration forces. When faying surfaces of battery terminals and battery holder contacts separate, output voltage of the battery box drops to zero. This could be damaging or cause operation difficulty in the device using this supplied power. 
         [0094]      FIG. 14  is a graph of my invented battery holder showing that the loss of one or two batteries does not totally stop the flow of all supplied current. It is assumed that statistically not more than one battery would be lost at any given instant. Probably the consuming device could accept the resulting varying direct current from the supply. 
         [0095]      FIG. 15  it is assumed that the battery holder output is parallel connected with a large capacitance that lessens the amount of voltage variation delivered to the using device during high acceleration loads. See  FIG. 16 . 
         [0096]      FIG. 16  is a battery holder assembly  10  with an added space for installation of a large capacitor  210  that can be incorporated parallel connected across the battery output as shown in  FIG. 17 . Output voltage of this battery holder assembly should be highly reliable and low noise. 
         [0097]      FIG. 17  is the schematic of a four-battery holder assembly  10  with the additional output capacitor  210  of  FIG. 16 . The alternate to battery actuated bypassing contacts  20 ,  220  is shown as a switch for each battery.