Abstract:
A front access battery module for supporting batteries during seismic stress, comprising a pair of spaced side panels, a rear panel spanning the side panels and connected thereto at opposing side edges, a shelf forming a base for supporting batteries and means for securing the module to a support structure and fastening means for securing modules together to form a multi-tier battery rack system wherein the anchoring means and connecting means are accessible from the open front access end of the module.

Description:
[0001]     This application claims the benefit of Provisional Application Ser. No. 60/498,235 entitled, FRONT ACCESS BATTERY TRAY, filed Aug. 27, 2003. 
     
    
     FIELD OF THE INVENTION  
       [0002]     The present invention relates to a modular tray system and apparatus for supporting batteries designed to survive seismic forces during earth tremors and the like.  
       BACKGROUND OF THE INVENTION  
       [0003]     There is a need particularly in the telecommunications industries for back-up power source to maintain operations when the primary source shuts down. These systems generally comprise a plurality of valve regulated lead acid batteries (VRLA), generally of a two (2) volt size which are typically connected in series in various numbers such as 24 batteries to provide a 48 volt system. Typically, these batteries are supported in battery rack systems of the type shown, for example, in U.S. Pat. No. 6,719,150 issued Apr. 13, 2004 entitled BATTERY RACK AND SYSTEM and owned by the Assignee of the present invention. This prior system is generally effective for the purposes intended. However, there are some installations where the space requirements for the racks are tight and where assembly and mounting of the rack system in these confined areas is difficult and time consuming.  
       SUMMARY OF THE INVENTION  
       [0004]     The modular tray system and apparatus of the present invention are characterized by novel features of construction and arrangement providing for easy and quick assembly of a multi-tiered tray assembly in a tight space wherein the components of the assembly can be assembled and bolted in place through the front of the module. Broadly, the module comprises a pair of identical interchangeable side panels, a J shaped rear panel having a configuration to accommodate battery cables, a shelf configured to provide a rigid base for the batteries and various corner stiffener channel members creating vertical columns for structural stiffness and a top corner stiffener angle to strengthen tray to tray bolting joints. The various components have strategically located slots and holes to enhance optimum air flow for passive convection cooling.  
         [0005]     With the foregoing in mind, it is an object of the present invention to provide an improved modular tray system characterized by novel features of construction and arrangement providing certain structural advantages over the prior art and systems discussed above.  
         [0006]     A further object of the present invention is to provide a modular battery tray system wherein the components comprising the modules are designed in such a fashion to facilitate assembly of the components and installation at a site utilizing only the front access opening of the module to thereby permit assembly and installation even in small and confined areas.  
         [0007]     A still further object of the present invention is to provide a novel modular tray assembly and system which includes novel relatively rigid components defining vertical strength and stability in the assembled relation which are easily accessible to secure the assembly on a concrete floor and the like.  
         [0008]     Still another object of the present invention is to provide a novel combination of components including interchangeable and identical side panels and a back panel of J-shaped cross section which in the assembled relation ties the side panels together and supports the shelf forming the base on which the batteries are mounted.  
         [0009]     A still further object of the present invention is to provide a modular battery tray system and apparatus including a novel arrangement for routing battery cables from front to back so that they may be connected utilizing only the open front end of the module as an access.  
         [0010]     Still another object of the present invention is to provide a modular battery tray system and apparatus which meets the high, stringent seismic requirements for tray systems of this type prescribed by Telcordia Technologies.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0011]     These and other objects of the present invention and the features and details of the operation and construction thereof are hereinafter more fully set forth with reference to the accompanying drawings wherein:  
         [0012]      FIG. 1  is a perspective view of a front access battery tray system embodying the present invention wherein the system comprises three tiers or trays;  
         [0013]      FIG. 1   a  is a perspective view similar to  FIG. 1  with portions of the side panel removed to show the anchor bolts and bolts securing adjacent modules;  
         [0014]      FIG. 2  is a perspective view of a front access battery tray system showing an eight (8) tier arrangement;  
         [0015]      FIG. 3  is a perspective view of one of the trays or tiers;  
         [0016]      FIG. 4  is a perspective view of one of the trays or tiers as viewed from the end and rear panel;  
         [0017]      FIG. 5  is a perspective view as viewed from the front with the bottom panel or shelf removed;  
         [0018]      FIG. 6  is an exploded perspective view of the components comprising the tray including the rear panel and side panels;  
         [0019]      FIG. 7  is a perspective view of the battery retainer which mounts on the open front of the tray in the manner shown in  FIGS. 1 and 2 ;  
         [0020]      FIG. 7   a  is a perspective view of an alternate embodiment of battery retainer which mounts on the open front of the tray in the manner shown in  FIG. 22 ;  
         [0021]      FIG. 8  is a top and bottom plan view of the cover;  
         [0022]      FIG. 9  is the top and bottom view of a modified cover for supporting an electronic relay rack;  
         [0023]      FIG. 10  is a top plan view showing the tray system of the present invention mounted from the front in a confined space;  
         [0024]      FIG. 11  is a perspective view showing the batteries mounted and connected in a battery tray in accordance with the present invention;  
         [0025]      FIG. 12  is an exploded perspective view of the components comprising a battery tray in accordance with the present invention;  
         [0026]      FIG. 13  are perspective views of the identical left and right side panels of the battery tray of the present invention;  
         [0027]      FIG. 14  is a partially assembled view showing the left and right side panels and the rear panel spanning the left and right side panels;  
         [0028]      FIG. 15  is a perspective view similar to  FIG. 14  showing the front connecting channel which also supports the bottom shelf for the batteries;  
         [0029]      FIG. 16  is a perspective view similar to  FIG. 15  as viewed from the rear panel showing the front corner stiffener;  
         [0030]      FIG. 17  is a perspective view as viewed from one of the side panel showing the upper corner stiffener;  
         [0031]      FIG. 18  is a perspective view of the tray with the battery shelf installed;  
         [0032]      FIG. 19  is a perspective view of the battery shelf;  
         [0033]      FIG. 20  is a perspective view of the tray;  
         [0034]      FIG. 20   a  is an enlarged view of the portion circled in  FIG. 20  showing the means for connecting the cable channel to the rear panel;  
         [0035]      FIG. 21  is a perspective view of the full compliment of batteries mounted in the tray;  
         [0036]      FIG. 22  is a perspective view showing the mounting configuration of the battery retainers.  
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0037]     Referring now to the drawings and particularly to  FIGS. 1-2  thereof, there are shown multi-tier battery tray systems in accordance with the present invention comprised of a plurality of modules M which are generally similar in terms of components and arrangement which may be stacked and secured to one another in the manner shown.  
         [0038]     Considering first the broad components of a module M, and with specific reference to  FIGS. 12 and 13 , each module M comprises left and right side panels  10 ,  10  of identical construction and thus the parts thereof bear identical reference numerals. Each side panel  10  has an inwardly directed top and bottom flange  12  and  14  and front and rear flanges  16  and  18  connecting the top and bottom flanges. The tray module M has a back or rear panel  20  spanning the side panels  10 . A base or shelf  22  for supporting batteries B is mounted on a series of cross channels extending between the side panels  10 . The shelf  22  has means defining spaces or rows for the batteries B. A retainer  26  holds the batteries B in place in the manner shown in  FIG. 11  to complete the assembly. Cables C connected to the positive and negative terminals are routed through the tray module M in the manner shown in  FIG. 11  and extend upwardly through a rear cable bracket  29  to connect to a terminal (see  FIG. 10 ).  
         [0039]     Considering now more specifically, the components of the modular tray M, the face of the side panel  10  adjacent the bottom flange  14  has a series of spaced ventilation holes  30  and elongated oval shaped slots  32 . The top flange  12  has a series of bolt holes  34  in the present instance three (3) and the bottom flange has aligned bolt holes  36  for securing and mounting the trays together to form a multi-tier tray system (see  FIG. 1   a ). Note that the bolt holes  36  in the lower flange are oversized, i.e. oval shaped to provide a greater margin for anchoring purposes when mounting a stack of modules to the support surface such as a concrete floor. An alternate anchoring hole  37  is provided in the bottom flange to accommodate anchoring to a support surface having an anchoring rail. Side flanges  16  and  18  have aligned holes  40  for mounting the cable channel  42  in the manner shown in  FIGS. 20 and 20   a . Note the cable channel  42  has depending tangs  44  at opposite ends to accommodate securing it in place to the side flanges  16 ,  18  of the side panels  10  via screws  45  engaging in holes  8 . The side flanges also have holes  5  and  6 , adjacent the corners, the holes  6  accommodating bolts for securing the rear cable bracket  29  (See  FIG. 10 ). The holes  5  are for mounting the retainer  26 ,  27 . As noted above, the side panels  10  are identical in construction and configuration which provides economies in manufacturing and simplicity of assembly and installation.  
         [0040]     The rear panel  20  as best illustrated in  FIG. 14  is of J shaped cross section and is secured by a weldment to the side panels to tie them together. The generally rectangular rear panel  20   a  nests in the side panels in the manner shown and has complementary holes  6   a  matching those in the rear connecting flange  18  of the side panels  10 . The leg of the J also has a hole  51  to match one of the anchor holes  36  in the bottom flange  14 . The upstanding portion of the rear panel is cut back across its top edge to define an opening  49  to provide access to the back of the module M and ventilation. A series of slotted ventilation holes  46  are formed in the rectangular portion  20   a . A pair of transversely slotted holes  50  receive locating tabs  60  of the shelf in a manner described in more detail hereafter.  
         [0041]     Considering now the shelf  22 , which is best illustrated in  FIGS. 12 and 19 , the shelf is of generally rectangular configuration and has a series of battery rows or zones defined by transversely extending, alternating rows of spaced slots  52  and a series of upwardly projecting dimples  54 . The dimples  54  space the rows of batteries leaving the slots  52  open for airflow to enhance battery performance. The shelf  22  has a pair of laterally spaced upstanding side flanges  56  to restrain the batteries B in a side to side direction. The front lip  62  of the shelf  22  depends from the front edge to engage over laterally extending u-shaped front support channel  58 . The back edge of the shelf  22  has a pair of spaced tabs  60  which register with and engage in slots  50  to further rigidify the structure and prevent bowing or sagging of the shelf  22 . The ventilation slots  52  provide even vertical airflow for passive convection cooling. The dimples  54  locate the batteries laterally on the shelf and help insertion of the batteries from the open front end of the module M. The shelf  22  has a slot  55  to receive tab  59  projecting upwardly from front support channel  58  to center the shelf properly and rigidify the structure.  
         [0042]     The tray module M of the present invention is characterized by novel features of construction arrangement including essentially doubling the material thickness at predetermined corner locations to create structural columns. Thus, an elongated generally rectangular front corner stiffener  66  is welded to the side panel  10  adjacent the front connecting flange  16  creating the vertical column for structural stiffness which engages between the flanges  68  and  70  of the front u-shaped channel  58 . The stiffener  66  has a series of holes complementing the holes in the front connecting flange  16 . Further, an elongated angle brace  72  having complementary holes to the top flange  14  of the side panel is welded interiorly thereof. As noted previously, the rear panel  20  seats inside the front and rear connecting flanges  16  and  18  to provide vertical column strength at this corner.  
         [0043]     The modules M described above may be manufactured and are assembled or assembled and formed into multi-tier tray systems at the site.  
         [0044]     Summarizing the features of the modular battery tray system of the present invention, once the modules are pre-wired, no rear access is required and building a multi-tier tray system can be completely through the front access opening. Thus, the anchor holes and the bolt holes for stacking modules M are completely accessible from the front of the module M. The particular configuration and arrangement of the components of the module M such as the J-shaped channel which ties the side panels together and supports the shelf and the front corner stiffeners create a vertical column for structural stiffness and the top corner stiffener strengthen tray to tray bolting joints. Additionally, the configuration of the shelf including the front flange adds stiffness and provides a good weld joint, the shelf side flanges restraining batteries in a side to side direction.  
         [0045]     Consider now assembly of the components comprising the modular tray system of the present invention and the installation of a multi-tier battery tray system in a relatively small confined alcove A as shown in  FIG. 10 . The modules M described above may be manufactured and preassembled or assembled and formed into a multi-tier tray systems at the site.  
         [0046]     Considering first assembly of the components, the J shaped rear panel  20  is positioned between side panels  10  overlying the rear connecting flanges  18  so that the various holes in the rear panel  20  align and register with the complementary holes in the rear and bottom flange as shown in  FIG. 14 . The parts are welded at preselected, predetermined locations. As noted above, the side panels are identical and interchangeable simplifying manufacture and assembly. The rear J-shaped panel  20  ties the side panels  10  together and as noted hereafter J portion provides a U shaped channel section supporting the shelf  22 . Nesting of the side edges of the rear panel in confronting overlying relationship to the rear connecting flange  18  of the side panel  10  provides a double thickness creating a vertical column for structural stiffness at the rear corners of the module M. Further the slotted holes  51  in the J portion of the rear panel  20  overlap and register with the anchor holes  36  in the bottom flange  14  of the side panels to create double material thickness for anchor loads.  
         [0047]     The next step in the assembly process is the positioning and welding of the front U-shaped support channel  58  and welding it in place as shown in  FIG. 15 . The front corner stiffeners  66  are then positioned in place with the various holes aligned with and in registry with holes in the front connecting flanges  16 . The corner stiffener  66  is then welded at preselected locations as shown in  FIG. 16 . The front corner stiffener  66  create vertical columns for good structural stiffness of the entire module.  
         [0048]     The shelf  22  is then positioned in place whereby the tabs  60  in the rear edge of the shelf  22  register and engage in slotted openings  50  in the rear panel  20 . In this position, the depending front lip  62  of the shelf embraces and overlies the front U shaped cross channel  58  and the tab  59  engages through slot  55 . The shelf  22  is then secured in place by welding at predetermined, preselected suitable locations.  
         [0049]     The module M can now simply be positioned in the alcove A and secured to the floor by suitable bolts as shown in  FIG. 10 . These bolts as illustrated are easy to insert and secure from the front of the module. A multi-tier system can be created by simply positioning another module on top of the first module whereby the bottom flange of the second module confronts and engages the top flange  12  of the underlying module M. In this position, the bolt holes and the confronting flanges register and are aligned and securing of the two modules together is easily accomplished simply by tightening the locking bolts in place. The only access needed is through the front of the module M. After completion of a module system such as the three-tier module of  FIG. 1  or the eight-tier system of  FIG. 2 , the top panel  80 ,  82  are bolted in place and thereafter the batteries are slid into the open front end of the modules so that the terminal portion of the batteries B protrude from the open front end of the modules in the manner shown in  FIG. 21 . The battery cables which have been prethreaded through the channel are then connected to the batteries. Thereafter the retainer  26 ,  27  is locked in place in the manner shown in  FIG. 11 . As shown in  FIG. 7 , the side flanges of the retainer  26  have upper and lower bolt holes  26   a  matching and registering with bolt holes  5  in the front connecting flange  16  of the side panel and a key hole slot  26   b  registering with the center channel hole  40  in the front connecting flange. The key hole slot  26   b  provides a clearance for the channel screws  45 . In a modified embodiment shown in  FIG. 7   a , reference numeral  27 , the key hole slot  27   b  extends out to the edge of the retainer side flange to facilitate removal of the retainer without disconnecting the cables C. A flat tie-bar  27   c  is bolted across the open slot to maintain retainer rigidity.  
         [0050]     Even though particular embodiments of the present invention have been illustrated and described herein, it is not intended to limit the invention and changes and modifications may be made therein within the scope of the following claims.