Abstract:
Methods and apparatus supporting an electrical connection are disclosed. Systems previously equipped with wire interfaces, such as battery terminals, can be equipped with a connector assembly to significantly reduce a hazard of electrical shock to a user. The connector assembly includes a stress relief component that attenuates a force, applied to the stress relief component, to reduce its effect on the connector assembly. By attenuating the force, the connector assembly maintains a substantially fixed position relative to the battery pack component and mitigates a potential for disruption in electrical connectivity. Techniques disclosed herein benefit users of battery packs or other devices as well as manufacturers by increasing safety, reliability, and ergonomics.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    Battery connection systems are known in the art to connect a variety of devices to batteries in order to draw power. A simple battery connection system uses electrical wire to conduct electricity between terminals of a battery and a device, respectively. Typically, a pair of wires is attached to respective positive and negative terminals of the battery and the device. 
       SUMMARY OF THE INVENTION 
       [0002]    An embodiment of the invention is a connector assembly including a plate having an upper surface and a lower surface and defining an opening extending between the upper surface and the lower surface. The connector assembly further includes a connector housing protruding below the lower surface of the plate and defining an interior of the connector housing. The interior defines a socket extending below the opening. The connector assembly further includes a stress relief component coupled to the plate to decouple a force applied to the stress relief component from the plate. 
         [0003]    The connector assembly may further include at least one first electrical terminal in the socket configured to couple electrically with at least one second electrical terminal of a battery pack component while the connector assembly is engaged with the battery pack component. The connector housing component may include multiple connector housing members, each including a corresponding electrical terminal. 
         [0004]    The stress relief component may include multiple stress relievers each in common arrangement above, below, or in a plane of the plate. The socket may be positioned between the multiple stress relievers. The stress relievers may be configured to provide a retention force to maintain the plate in a substantially fixed position in a plane of the plate. The stress relievers may be configured to provide the retention force by abutting at least one positioning member on a element adjoining the plate when the connector assembly is engaged with the battery pack component. 
         [0005]    In some embodiments, the connector housing may further protrude above the upper surface of the plate. 
         [0006]    Another embodiment is a method of supporting an electrical connection. The method includes facilitating passage of an electrical conductor from an upper surface of a plate to a socket defined by a connector housing on a lower surface of the plate and attenuating a force attempting to act on the plate to mitigate a potential for disruption in electrical connectivity between the electrical conductor and another electrical conductor associated with the socket. The method may also include supporting an electrical coupling, at the socket, between a first electrical terminal of the connector housing and a second electrical terminal associated with a structure to which the connector housing mates. 
         [0007]    Attenuating the force may include decoupling the force, applied to a stress relief component joined to the plate, from the plate. Attenuating the force may include providing a retention force by multiple stress relievers each in common arrangement above, below, or in a plane of the plate. The socket may be positioned between the stress relievers. 
         [0008]    A further embodiment is a battery pack comprising a battery pack component and a connector assembly configured to be engaged with the battery pack component. The connector assembly includes a stress relief component configured to attenuate a force from the connector assembly in a manner maintaining a position of the connector assembly relative to the battery pack component. The stress relief component is also configured to mitigate a potential for disruption in electrical connectivity of an electrical interface between the connector assembly and the battery pack component while the connector assembly is engaged with the battery pack component. 
         [0009]    The connector assembly may be configured in embodiments presented above. For example, the stress relief component may include multiple stress relievers each in common arrangement above, below, or in a plane of the plate. The stress relievers may be configured to provide a retention force to maintain the connector assembly in a substantially fixed alignment relative to the battery pack component. 
         [0010]    The connector assembly may include at least one first electrical terminal configured to couple electrically with at least one second electrical terminal of the battery pack component to provide electricity to an electrical interface between the first and second electrical terminals. 
         [0011]    The battery pack component may include a chamfer to align the connector assembly with the battery pack component during engagement of the connector assembly with the battery pack component. 
         [0012]    Another embodiment of the invention is a method of providing battery power to an electrical device. Electricity is provided to an interface between a connector assembly and a battery pack component to provide battery power to the electrical device. A force attempting to act on the connector assembly is attenuated in a manner that maintains a position of the connector assembly relative to the battery pack component to mitigate potential for disruption of the electrical connection The method may further include providing a retention force to maintain the connector assembly in a substantially fixed alignment relative to the battery pack component. 
         [0013]    The method may further include aligning the connector assembly and the battery pack component during mating to guide a first connector housing of the connector assembly to a desired alignment position relative to a second connector housing of the battery pack component 
         [0014]    Attenuating the force may include decoupling the force, applied to a stress relief component joined to a plate of the connector assembly, from the plate. 
         [0015]    Use of embodiments of the connector assembly or corresponding method significantly reduces or eliminates a potential of transmitting an electric shock to a user during electrical connection of electrical devices to each other. 
         [0016]    Another embodiment is a battery pack component that has a first housing structure configured to secure a battery and a second housing structure that has a first electrical terminal electrically coupled to the battery. The second housing structure is configured to receive a connector assembly, which includes a second electrical terminal, with sufficient mechanical play to enable stress relief related displacement effects between the second housing structure and the connector assembly while maintaining an electrical coupling between the first and second electrical terminals. 
         [0017]    The second housing structure may further include a chamfer to align the connector assembly with the battery pack component automatically during engagement of the connector assembly with the battery pack component. 
         [0018]    The displacement effects of mechanical shocks or other mechanical motions to the connector assembly or the battery pack component may be attenuated relative to the battery by stress relievers on the connector assembly that abut at least one positioning member. 
         [0019]    The battery pack component may have the at least one positioning member integrated therewith. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0020]    The foregoing will be apparent from the following more particular description of example embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating embodiments of the present invention. 
           [0021]      FIG. 1A  is a perspective view of a connector assembly and a battery pack component in an embodiment of the invention. 
           [0022]      FIG. 1B  is a perspective view of a connector assembly in an embodiment of the invention. 
           [0023]      FIG. 1C  is a top view of a connector assembly in an embodiment of the invention. 
           [0024]      FIGS. 2A-C  are side cutaway views of a connector assembly and a battery pack component at various stages of engagement in an embodiment of the invention: A) prior to engagement; B) start of engagement; C) engaged. 
           [0025]      FIG. 3  is a side cutaway view of a connector assembly engaged with a battery pack component in an embodiment of the invention. 
           [0026]      FIGS. 4A-B  are force diagrams showing a stress relief component in an embodiment of the invention: A) longitudinal force; B) lateral force. 
           [0027]      FIG. 5  is a flow diagram of an embodiment of the invention. 
           [0028]      FIG. 6  is a flow diagram of another embodiment of the invention. 
           [0029]      FIG. 7  is a side cutaway view of a battery pack component configured to receive a connector assembly in an embodiment of the invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0030]    A description of example embodiments of the invention follows. 
         [0031]    The teachings of all patents, published applications and references cited herein are incorporated by reference in their entirety. 
         [0032]    Connecting wires directly between a device and the terminals of a battery is a simple technique but is disadvantageous for several reasons. Handling wires directly can pose a hazard to the human user, because an electrical spark may occur on the first contact between the wires and the battery. Requiring users to secure electrical connections manually is inconvenient and may be cumbersome based on the spatial configuration of the device and the battery. Leaving wires exposed can result in a disruption of electrical connectivity if an external mechanical force dislodges a wire. 
         [0033]    Mechanical assemblies are known to shield users from direct contact with wires through the use of an insulator (e.g., plastic) which protects the user. However, such assemblies are vulnerable to external mechanical shocks, which may disconnect the assembly from the battery and interrupt a flow of electricity. Such mechanical shocks, even if slight in magnitude, may also damage the assembly over time. A technique that provides shock impact relief is desirable. 
         [0034]    Embodiments of the present invention address the foregoing deficiencies and provide techniques for connecting to a battery in a manner that increases usability and safety for users. 
         [0035]      FIG. 1A  is a perspective view of a connector assembly  100  and a battery pack component  150  in an embodiment of the invention. A system including the connector assembly  100  and the battery pack component  150  is referred to as a battery pack. The connector assembly may be used as a bridge to connect a battery (represented by the battery pack component  150 ) to an external device (not illustrated). The battery pack component  150  may include a battery itself including one or more battery cells, which may be employed with a device such as an uninterruptible power supply (UPS), for example. Techniques disclosed herein for battery connection may be used in other electrical contexts as well. 
         [0036]    The connector assembly  100  has a plate  105  which has an upper surface  110  and a lower surface  112 . The plate  105  defines an opening extending between the upper surface  110  and the lower surface  112  to enable passage of an electrical conductor (not illustrated) therebetween. Part of the opening is illustrated in  FIG. 1A  as  120 . The plate  105  is generally the largest piece of the connector assembly  100  oriented perpendicular to the direction of passage of the electrical conductor. The plate  105  is illustrated as planar in this embodiment but may be a curved surface or other surface that defines an opening extending between an upper surface  110  and a lower surface  112 , in which case the “plane” of the plate  105  is said to be plane perpendicular to the passage of the electrical conductor. The plate  105  is generally a structure defining an opening to enable passage of an electrical conductor, as described above. 
         [0037]    Protruding below the lower surface  112  of the plate is a connector housing  115 , illustrated in  FIG. 1A  as two separate connector housing members  115  in one embodiment. In other embodiments, the connector housing  115  may be a single protrusion or may have more than two protruding members. In some embodiments, the connector housing  115  extends upward beyond the plate  105  as well as below it. In some embodiments, the connector housing  115  and the plate  105  are integrally formed, i.e., a single piece. The connector housing  115  defines an interior of the connector housing, with the interior defining a socket  120  extending below the opening defined by the plate  105 . The socket  120  is generally a channel through which an electrical conductor may be routed to support the passage of electricity. 
         [0038]    An electrical connection is established via the socket  120  when the connector assembly  100  (specifically the connector housing  115 ) is inserted into a cavity  160  of the battery pack component  150 , which is configured to receive the connector housing  115 . The connector housing  115  of the connector assembly  100  may be referred to as a first connector housing  115  and is said to insert into a corresponding second connector housing (illustrated in  FIG. 3  as  360 ) in the battery pack component  150 . The first connector housing  115  and the second connector housing may have respective male and female characteristics, e.g., a housing member  115  inserted into a cavity  160 , as described above. In some embodiments, multiple connector housing members  115  have a polarity that enforces a particular orientation in which they may be inserted into the cavity  160 . The first connector housing  115  may also have a female part configured to mate (couple) with a corresponding male part of the second connector housing  360 , as discussed below in the context of electrical terminals. In other embodiments, the male/female attributes of the first connector housing  115  and the second connector housing  360  may be reversed. 
         [0039]    The battery pack component may include a chamfer (bevel)  155  to align the connector assembly  100  with the cavity  160  of the battery pack component  150  automatically (a process referred to as self-alignment) while the connector assembly  100  is being engaged with the cavity  160  of the battery pack component  150 . The chamfer  155  ensures that the user need not worry about alignment during insertion (mating) as with conventional technologies. The chamfer  155  enforces a particular alignment between the first connector housing  115  and the second connector housing  360 , along a common vertical axis of both, that provides a reliable electrical connection upon engagement without careful manual operation or control. The connector assembly  100  may be said to mate with the battery pack component  150 , and the mating may also be said to be between the first connector housing  115  and the second connector housing  360 . 
         [0040]    A stress relief component  130  is coupled to the upper surface  110  of the plate  105 . “Coupled” in this context means joined, either directly or indirectly, so that the stress relief component  130  is configured to decouple a force, which may be applied to the stress relief component  130 , from the plate  105 , as further described below. In some embodiments, the stress relief component  130  is physically connected to the first connector housing  115  of the connector assembly  100 , in which case it is indirectly coupled to the plate  105 . The stress relief component  130 , which is coupled to the plate  105 , absorbs an applied force attenuates its magnitude and impact on the plate  105 . Decoupling a force from the plate  105  serves to protect the plate  105  from mechanical wear and also to maintain the plate  105  in a substantially fixed position and orientation, i.e., with minimal change in position and orientation due to mechanical shock impact. Fixing the plate  105  in this way reduces the chance of the connector assembly  100  becoming dislodged from the battery pack component  150 . Such a dislodging might result in a disruption in electrical flow with conventional technology. In alternative embodiments, the stress relief component  130  may be attached to an edge of the plate  105 , bottom of the plate  105 , or combination of any aspects of the plate  105 . 
         [0041]    The stress relief component  130  is illustrated in  FIG. 1A  as multiple stress relievers  130  on the upper surface  110  of the plate  105  in one embodiment. In this embodiment, the socket  120  is positioned between the stress relievers  130 . In other embodiments, the stress relief component  130  includes a single stress reliever  130 . The stress relief component  130  may be positioned around the socket  120 , e.g., in a circular configuration with the socket  120  at the center. In other embodiments, stress relievers  130  may be positioned diagonally opposite the socket  120  or at ends of a line with the socket  120  between the ends. In some embodiments, stress relievers  130  may be polarized to orient in a particular direction or to allow a particular configuration during engagement. 
         [0042]    The stress relievers  130  have a flexible, reticulating rib-like structure configured to yield to force without breaking. The stress relievers  130  are illustrated on a common side (upper surface  110 ) of the plate  105  in one embodiment, but they may be on opposite sides in other embodiments. The stress relievers relieve stress (force per unit area) in a plane parallel to the plate  105  by providing a retention force in a direction opposite to the applied force, resulting in a reduced net force applied to the plate  105 . It should be understood by one of ordinary skill in the art that if a force not in the plane of the plate  105  (but not perpendicular to the plate  105 ) is applied to the stress relievers  130 , a corresponding component (projection) of the force will be decoupled from the plate  105 . Although a particular configuration of stress relievers  130  is illustrated in  FIG. 1A , a person of ordinary skill in the art will understand that other varieties of stress relievers may be used to isolate the plate  105  from external mechanical forces. In particular, other varieties of stress relievers may act to decouple the plate  105  primarily from forces other than parallel to the plate. 
         [0043]    In one embodiment, the connector assembly  100  is configured to insert at one end into the battery pack component  155  at the cavity  160 , and the connector assembly  100  is configured to receive a device (not illustrated) that draws power at the other end. In some embodiments, the connector assembly  100  remains stationary, and the battery pack component is moved relative to the connector assembly  100 . Either way, an electrical connection is supported between the battery (battery pack component  150 ) and the device by way of the connector assembly  100 . 
         [0044]      FIG. 1B  is a perspective view of the connector assembly  100  in an embodiment of the invention in which the stress relievers  130  are coupled to an edge of the plate  105 . In this embodiment, the connector assembly  100  is configured to slide along a slot  113  defined in a surface  170  that adjoins (but is not necessarily physically attached to) the plate  105  and that serves as a mounting chassis for the connector assembly  100 . The connector assembly may be lowered into place at the end of the slot  113  so that the stress relievers  130  abut against a positioning member (or multiple positioning members, as illustrated in  FIG. 1B )  165 , thereby providing a retention force to maintain the position and alignment of the connector assembly  100 . The positioning member (or multiple positioning members) may be on an element adjoining the plate  105  while the connector assembly  100  is engaged with the battery pack component  150 . In another embodiment, the connector assembly  100  slides along the slot  113 , e.g., compressing the stress relief component  130  to position the connector assembly  100  into place, without lowering being required. 
         [0045]      FIG. 1C  is a top view of the connector assembly  100  in an embodiment of the invention. At least one first electrical terminal  135  is in the socket  120 . The socket  120  is illustrated in this embodiment as having two parts that house respective positive and negative electrical terminals (generally  135 ). In this embodiment, positive and negative electrical terminals are in respective connector housing members  115 . It is understood in the art that one or more first electrical terminals  135  may be used in the connector assembly  100  to support an electrical connection in embodiments of the invention, and multiple connector housing members  115  may be used accordingly. The connector assembly  100  is configured to receive a device from the upper surface  110  of the plate  105  via the socket, so that such a device can be electrically coupled to the first electrical terminal(s)  135 . 
         [0046]      FIGS. 2A-C  are side cutaway views of the connector assembly  100  and of the battery pack component  150  at various stages of engagement in an embodiment of the invention.  FIG. 2A  shows a configuration prior to engagement, when the connector assembly  100  might not be aligned with the battery pack component due to varying battery sizes or packing deviation. The chamfer  155  of the battery pack component  150  is designed to remedy such misalignment. 
         [0047]      FIG. 2B  shows the connector assembly  100  engaging with the battery pack component  150 . In  FIG. 2B , the connector assembly  100  was previously guided in to proper alignment for engagement by the chamfer  155  of the battery pack component  150 . 
         [0048]      FIG. 2C  shows the connector assembly  100  engaged with the battery pack component  150 . The alignment is maintained by the stress relief component  130  of the connector assembly  100 . 
         [0049]      FIG. 3  is a side cutaway view of a connector assembly engaged with a battery pack component in an embodiment of the invention. The first connector housing  115  is configured to insert into (engage) a second connector housing  360  of the battery pack component  100  by sliding sideways, e.g., as in  FIG. 1B . A fastening element  340  provides support during the sliding. One of ordinary skill in the art should recognize that there are numerous ways to design the fastening element  340 . In this embodiment, the first connector housing  115  enshrouds a second electrical terminal  370  of the battery pack component, thereby providing an electrical coupling and securing it, between a first terminal  135  and a second terminal  370 . Thus, the first connector housing  115 , while being essentially male in nature, may have a female part that receives a male part (the male part being the second terminal  370 ). A suitable mechanical means (not illustrated) for securing (locking) the male connector housing  115  to the female connector housing  370  in a fully engaged position may be provided. The electrical coupling is maintained by fixing the connector assembly  100  relative to the battery pack component  150  (specifically, the male connector housing  115  relative to the female connector housing  370 ), even in the event of an external mechanical force (shock), e.g., via the stress relief component  130 . Thus, the connector assembly  100  provides shock impact relief. A suitable mechanical means (not illustrated) for disengaging the respective housings may be provided to disconnect the connector assembly  100  from the battery pack component  150 . In some embodiments, it is sufficient to pull the connector assembly  100  and/or the battery pack component for disengagement. 
         [0050]      FIGS. 4A-B  are force diagrams showing the stress relief component (depicted as a pair stress relievers)  130  in an embodiment of the invention.  FIG. 4A  shows that stress relievers  130  may yield (undergo positional displacement) due to an applied longitudinal force (i.e., a force parallel to a main axis  405  of the plate  105  as illustrated), so as to result in minimal or no displacement by the plate  105 . In other words, the stress relievers  130  decouple a force applied to the stress relief component from the plate. Stated yet another way, the stress relievers  130  attenuate a force attempting to act on the plate. In this way, the stress relievers  130  mitigate a potential for disruption in electrical connectivity, e.g., between electrical conductors at the socket  120 .  FIG. 4A  shows a particular computational simulation in which 26 N of force results in approximately 1.515 mm displacement at a particular point  401  on the stress relief component  130 , with negligible displacement on the part of the plate  105 . It should be understood that other force attenuation characteristics may be employed to relieve stress (force per unit area) on the connector assembly  100 . 
         [0051]      FIG. 4B  shows a similar simulation result corresponding to a lateral force (i.e., a force transverse to a main axis  405  of the plate  105  as illustrated). In this example, 22 N of applied force results in 1.56 mm displacement of a particular point  402  on the stress relief component  130 . One of ordinary skill in the art immediately understands that the stress relief component  135  attenuates forces acting in directions combining longitudinal and lateral aspects, since such forces can be broken up into respective components. 
         [0052]      FIG. 5  is a flow diagram of an embodiment of the invention that is a method of supporting an electrical connection. After beginning process  500 , passage of an electrical conductor is facilitated ( 510 ) from the upper surface  110  of plate  105  to the socket  120 . A force attempting to act on the plate  105  is attenuated ( 520 ) to mitigate a potential for disruption in electrical connectivity between the electrical conductor and another electrical conductor associated with the socket  120 . It should be understood that the force may be a longitudinal force  410 , a lateral force  420 , or another force with a component in the plane of the plate  105 . 
         [0053]      FIG. 6  is a flow diagram of another embodiment of the invention that is a method of supporting an electrical connection. After beginning process  600 , electricity is provided ( 610 ) to an interface  380  between the connector assembly  100  and the battery pack component  150 . The electricity is provided from a source within the battery pack component  150 , e.g., a battery associated with the battery pack component  150 . The electrical connection is enabled ( 620 ) at the interface  380  between a first electrical terminal  135  of the connector assembly  100  and a second electrical terminal  370  of the battery pack component. In some embodiments, less than one or more than one first electrical terminal is used, and less than one or more than one second electrical terminal is used. Passage of electricity is facilitated ( 630 ) from the first electrical terminal  135  through the socket  120  (not illustrated in  FIG. 6 ). A force attempting to act on the plate  105  is attenuated ( 640 ) to mitigate a potential for disruption of the electrical connection. 
         [0054]      FIG. 7  is a side cutaway view of a battery pack component  750  configured to receive a connector assembly  700  in an embodiment of the invention. The battery pack component  750  has a first housing structure  762  configured to secure a battery  764 . The battery pack component  750  also has a second housing structure  760  that includes a first electrical terminal  770  electrically coupled to the battery  764 . The second housing structure  760  is configured to receive the connector assembly  700 , which has a second electrical terminal  735 , with sufficient mechanical play to enable stress relief related displacement effects between the second housing structure  760  and the connector assembly  700  while maintaining an electrical coupling between the first electrical terminal  770  and the second electrical terminal  735 . 
         [0055]    Embodiments of the invention find broad applicability in systems providing electricity to devices. Adapters or plugs for various devices that draw electricity and that might need to be connected to a battery source can be configured according to embodiments of the invention. The battery pack component  150  need not be a conventional battery but may be a source of power resembling battery power. While this invention has been particularly illustrated and described with references to example embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims.