Abstract:
A battery assembly is provided for electrical concatenation in series. The battery assembly includes a plurality of battery packs; a switch; a receiver; and an actuator. Each battery pack includes a plurality of rechargeable battery cells electrically connected in series. The switch electrically connects and disconnects first and second battery packs together. The receiver transmits power from the switch. The actuator operates the switch to connect and disconnect the battery packs. In preferred embodiments, the switch includes first and second buses and a deflector. The first bus electrically contacts the first battery pack. The second bus electrically contacts the second battery pack. The deflector moves the first bus electrically connect and disconnect with the second bus in response to communication with the actuator. An electrical connector is further provided for mechanical engagement and disengagement of electrical conduction to a terminal. The connector includes a block and a plurality of contacts. The block includes a plurality of openings. Each contact is disposed into a corresponding opening in the block.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
   The invention is a Continuation-in-Part of, claims priority to and incorporates by reference in its entirety U.S. patent application Ser. No. 10/457,698 filed May 16, 2003, titled “Battery Mechanism” to Joseph F. Sharrow, Kurt W. Solomon, Frank E. Peterkin, Jack S. Bernandes and Brian J. Hankla, and assigned Navy Case 832237. 

   STATEMENT OF GOVERNMENT INTEREST 
   The invention described was made in the performance of official duties by one or more employees of the Department of the Navy, and thus, the invention herein may be manufactured, used or licensed by or for the Government of the United States of America for governmental purposes without the payment of any royalties thereon or therefor. 

   BACKGROUND 
   The invention relates generally to the battery mechanisms, and more particularly to such mechanisms that preferably can safely, reliably and remotely combine multiple battery assemblies. 
   High-powered electrical devices at least occasionally require portable operation. This means that the devices must be able to be used off battery power. Such high-powered electrical devices include those used in pulsed power systems, which may find applicability in both military and non-military scenarios. 
   The high voltage needed to power the electrical devices means that battery packs which power such electrical devices must themselves be able to provide high voltage. Such high-voltage battery packs are inherently dangerous, however. Incorrect installation or assembly of the battery packs, or defective battery packs, can potentially severely injure personnel or even cause fatalities. 
   SUMMARY 
   Conventional battery assemblies yield disadvantages addressed by various exemplary embodiments of the present invention. In particular, various exemplary embodiments provide a battery assembly for safe and controllable electrical concatenation in series. The battery assembly includes a plurality of battery packs, a switch, a receiver, and an actuator. 
   In various exemplary embodiments provide for each battery pack to include a plurality of rechargeable battery cells electrically connected in series. The switch electrically connects and disconnects first and second battery packs of the plurality together. The receiver transmits power from the switch. The actuator operates the switch to connect and disconnect the battery packs. 
   In preferred embodiments, the switch includes first and second buses and a deflector. The first bus electrically contacts the first battery pack. The second bus electrically contacts the second battery pack. The deflector moves the first bus to electrically connect and disconnect with the second bus in response to communication with the actuator. 
   An electrical connector is further provided for mechanical engagement and disengagement of electrical conduction to a terminal. The connector includes a block and a plurality of contacts. The block includes a plurality of openings. Each contact is disposed into a corresponding opening in the block. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     These and various other features and aspects of various exemplary embodiments will be readily understood with reference to the following detailed description taken in conjunction with the accompanying drawings, in which like or similar numbers are used throughout, and in which: 
       FIG. 1  is an isometric view of a battery assembly with the front battery unit shown from the port side, as exemplified by a compass-rose; 
       FIG. 2  is an isometric view of the battery assembly with the front battery unit shown from the starboard side; 
       FIG. 3  is an isometric view of the battery assembly from the perspective of  FIG. 1  with power conditioner and four battery packs removed; 
       FIG. 4  is an isometric view of the front battery unit shown from the fore and port sides; 
       FIG. 5  is an isometric view of a battery pack shown from the aft side of the front battery unit; 
       FIG. 6  is an isometric view of the battery pack from the perspective of  FIG. 5  with plastic, safety and fuse covers removed; 
       FIG. 7  is an isometric view of a switch assembly shown from the fore side of the front battery unit; 
       FIG. 8  is an isometric view of the switch assembly from the perspective of  FIG. 7  with cover plate removed; 
       FIG. 9  is an isometric view of the switch assembly shown from the aft side of the front battery unit; 
       FIG. 10  is an isometric view of a switch mechanism, including a cam, in the switch assembly shown from the port side of the front battery unit; 
       FIG. 11  is an isometric view of a switch mechanism from the perspective of  FIG. 10  with the cam rotated; 
       FIG. 12  is an isometric view of a brass busbar in the switch mechanism with a pair of contact assemblies; 
       FIG. 13  is an isometric view of a contact assembly shown from the exposed side; 
       FIG. 14  is an isometric view of the contact assembly shown from the mounting side; 
       FIG. 15  is an isometric view of a contact block; 
       FIG. 16  is an isometric view of a contact pin; 
       FIG. 17  is an isometric view of a power conditioner shown from the fore side of the front battery unit; and 
       FIG. 18  is an isometric view of the power conditioner shown from the aft side of the front battery unit. 
   

   DETAILED DESCRIPTION 
   In the following detailed description of exemplary embodiments of the invention, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration specific exemplary embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention. Other embodiments may be utilized, and logical, mechanical, and other changes may be made without departing from the spirit or scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the appended claims. 
   Conventional battery power switching mechanisms lack capabilities of scalable connectivity with multiple battery cell packs that provide reasonable levels of safety for personnel for installation and other pre-activation operations. Various exemplary embodiments address these limitations. 
   A battery assembly  100  including a pair of battery units  110  is illustrated in isometric view in  FIGS. 1 and 2  shown from port (left) and starboard (right) sides, respectively, of the front battery unit&#39;s perspective, as illustrated with a compass-rose. Each battery unit  110  includes a pair of cell section packs  120  (shown in  FIGS. 3 and 4 ) disposed at top and bottom. Except for orientation in relation to the drawings, the front and rear battery units  110  may be identical. 
   The illustrated configurations show the battery assembly  100  having the pair of fore and aft back-to-back pairs of battery units  110 . The configuration of each displayed battery unit  110  provides the pair of top and bottom section packs  120 . As will be apparent to those of ordinary skill, the embodiments illustrated and described in detail herein are exemplary only and do not limit the scope of the invention. 
   The battery assembly  100  may include an aluminum (Al) enclosure that mechanically couples the battery units  110  back-to-back. The battery units  110  may include a complementary pair of enclosure plates  130  for the respective port and starboard sides. 
   The enclosure may include a pair of mounting elbows  132  for installation and a pair of handles  134 , one each on the port and starboard sides. Each enclosure plate  130  may incorporate a plurality of portholes  136  thereon. 
   An aluminum cover plate  140  may protect the section pack  120  on its fore side. The cover plate  140  may include windows  142  that show portions of battery subpacks described further herein infra. 
     FIG. 3  illustrates the battery assembly  100  with the enclosure plate  130  and four subpacks removed from the front battery unit  110  for improved clarity. A central enclosure  150  straddles between the top and bottom section packs  120 . 
   The central enclosure  150  includes an outer plate  152  at top and bottom ends of the battery unit  110  and a central support  154 . Parallel rails  156  may be aligned fore and aft along the plate  152  and the support  154  to guide and maintain subpack assemblies  200  disposed therebetween. Each plate  152  may further include a slot key  158  to orient the subpack assemblies  200  for insertion. 
   Consequently, the subpack assemblies  200  may be disposed in linear groupings, as shown in these exemplary embodiments, to facilitate controllable connectivity as well as to minimize encumbered volume. However, as artisans of ordinary skill will be aware, other arrangements may be contemplated without departing from the scope of the claims. Each subpack assembly  200  contains a plurality of battery cells, as described in further detail herein infra. 
     FIG. 4  shows the front battery unit  110  isolated from the battery assembly  100 . As shown, the battery unit  110  includes two section packs  120  separated by the central enclosure  150  (shown in  FIG. 3 ). 
     FIG. 5  illustrates an isolated subpack assembly  200  oriented in relation to the front battery unit  110 . A plastic cover  210  is disposed to protect the cells disposed within. Safety and fuse covers  220 ,  225  are disposed to protect aft facing electrical connections.  FIG. 6  shows the subpack assembly  200  with the covers  210 ,  220 ,  225  removed for clarity. 
   A plastic tray  230  contains electrical power storage components, described in further detail herein. The tray  230  includes a fore wall  232 , an aft wall  234 , a bottom (inboard) wall  236  and a top (outboard) wall  238 . A portion of the fore wall  232  may be observed through the window  142  in  FIG. 4 . The safety cover  220  may slide from the bottom side and latches to the fuse cover  225 . 
   The top wall  238  may include a groove  239  that aligns with the slot key  158  on the outer plate  152  for inserting the subpack assembly  200  into the section pack  120 . The aft wall  234  may include terminals  240  and a blade-type fuse  250  beneath the fuse cover  225 . Each subpack  200  is readily removable from the section pack  120  for recharging at a separate equipment station. 
   The tray  230  may contain a plurality of rechargeable nickel-cadmium (NiCd) cells  260  for storing electrical energy. The cells  260  may be arranged in a 5×7 rectangular planar array, as shown. These thirty-five cells  260  may be connected in series to concatenate their individual voltage contributions for greater power than available from a single cell. Each cell  260  may provide 1.25 V DC  (volts-direct current), for a total of 43.75 V DC  available from each subpack assembly  200 . 
     FIG. 7  illustrates a switch assembly  300  in greater detail, as nominally depicted in  FIG. 3 . On the port side, the switch assembly  300  connects to a keyhole  310  for manual engagement or disengagement. On the starboard side, the switch assembly  300  connects to a pneumatic actuator  320  for electrically or pneumatically commanded engagement or disengagement. The pneumatic actuator  320  is exemplary only, and other actuators may be employed. 
   The switch assembly  300  incorporates a base  330  and a housing  340 . A cover plate  342  protects internal components contained within the housing  340 . Support posts  344  contribute structural integrity to the housing  340  along the longitudinal sides and provide continuation of the rails  156  ( FIG. 3 ). 
     FIG. 8  shows the switch assembly  300  without the cover plate  342 . Within the housing  340 , the switch assembly  300  includes a shaft  350  extending between the keyhole  310  and the actuator  320  and rotating around its longitudinal axis along the port-to-starboard direction. The pneumatic actuator  320  operates at about 100 psi (pounds-per-square inch) to rotate the shaft  350  on command. 
   A plurality of cams  352  (with six shown in the exemplary configuration) may be disposed to rotate with the shaft  350 . Counterpart pluralities of beryllium-copper (BeCu) leaf springs  360  and brass busbars  370  may be disposed adjacently outward (top and bottom) from the corresponding cams  352  within the housing  340 . 
     FIG. 9  shows the switch assembly  300  from the aft side. A secondary busbar  380  may connect two subpack assemblies  200  in the top and bottom assembly sections at the starboard side of the front battery unit  110 , for example. A tertiary busbar  382  may connect these subpack assemblies  200  at the port side of the front battery unit  110 , for example. 
   Returning to  FIG. 7 , a plurality of spring connectors  390  may be disposed along the base  330  (along the port-starboard axis) and neighboring the port end of the housing  340 . Except for their respective positions and orientations, the connectors  390  may all be identical to each other. 
   A positive and negative pair of connectors  390  may correspond to the each of four subpack assemblies  200  (forming a quad) in the top section pack  120 , as shown on the base  330  ( FIG. 3 ). A complementary pair of connectors  390  may similarly be distributed for a subpack quad in the bottom section pack  120 , but are obscured in  FIG. 7  by the housing  340 . 
     FIGS. 10 and 11  illustrate operation of a switching mechanism within the switch assembly  300 , showing a portion of the base  330  and the housing  340 . This portion is depicted from the vantage of the port side of the front battery unit  110 . Contained within this portion are one of the pairs of connectors  390  disposed on the base  330  and one of the support posts  344  on the housing  340 . 
   From the base  330  at the starboard end of the shown portion, one of the springs  360  extends towards the top and may flex along the top-to-bottom direction. In the exemplary embodiments described, the busbar  370  may be comparatively stiffer than the spring  360 . The spring  360  may be partially shrouded by a leaf spring mount  362  connected to the base  330 . 
   Beyond the mount  362 , the spring  360  bends towards the fore end, extending beyond one of the cams  352  and a helical spring or coil  364 . The spring  360  may be interposed between the cam  352  and the connector  390  disposed on the busbar  370 . The coil  364  may extend towards the top, shrouded by a hollow cylinder  366  connected to the housing  340 . 
   Also from the base  330  at the port end of the shown portion, one of the busbars  370  extends from its lower portion  372  ( FIG. 12 ) towards the top. This busbar  370  bends towards the fore end and then extends towards starboard, with one of the connectors  390  disposed at the busbar&#39;s free end at its upper portion  374  ( FIG. 12 ). 
     FIG. 10  depicts the cam  352  with its major axis aligned along the fore and aft direction from the perspective of the front battery unit  110 . The cam  352  exhibits radial extensions or ridges or lobes (aligned with the cam&#39;s major axis) that smoothly transition from radial depressions or valleys. With the cam  352  having the lobes in this relative “vertical” position, the spring  360  and the coil  364  remain at rest (in relaxation) to inhibit un-commanded connection with the busbar&#39;s connector  390 . 
     FIG. 11  depicts the cam  352  with its major axis aligned along the top and bottom direction from the perspective of the front battery unit  110 . The cam  352  in  FIG. 11  is depicted as turned by rotation of the shaft  350  in relation to its angular position shown in  FIG. 10 . With the lobes in this relative “horizontal” position, an engaging lobe of the cam  352  displaces the spring  360  and the coil  364  to be cantilevered and compressed, respectively. The cam&#39;s lobe deflects the spring  360  towards the bottom sufficiently to electrically communicate with the busbar&#39;s connector  390 . 
   The spring  360  and the busbar  370  may each be connected to one of the base&#39;s pair of connectors  390 , as shown in  FIGS. 10 and 11 . The spring  360  and busbar  370  may represent complementary connections engaged and disengaged concurrently with each other by the rotating position of the cam  352 . 
   Each combination of corresponding cam  352 , spring  360  and busbar  370 , whether along the bottom or top sides of the housing  340 , may produce a switch to connect adjacent subpack assemblies  200  in electrical communication with the corresponding pair of connectors  390  on the base  330 . The cams  352  may be aligned to connect selected groups of or all of the cell assemblies together. 
   The cam  352  depicted in  FIGS. 10 and 11  have a pair of opposing radial extensions or lobes. However, this configuration is exemplary only, and other configurations can be envisioned within the scope of the claims. The cams  352  along the shaft  350  may have sundry configurations depending on the fraction of the subpack assemblies  200  to be electrically connected together. 
   For example, a first cam  352  may have one or more first lobes that align with a one or more second lobes on a second cam  352  so that both sets of lobes engage their counterpart springs  360  concurrently to concatenate power from a combined set of battery subpacks  200 . Alternatively, the first cam  352  may have one or more third lobes that do not align with one or more fourth lobes on the second cam  352 , to combine power from only a select portion of connected battery subpacks  200 . 
   The secondary and tertiary busbars  380 ,  382  connect the remainder of the switching circuit in the switch assembly  300 . Thus, the shaft  350  may be rotated through the keyhole  310  or the pneumatic actuator  320  to open or close the switch assembly&#39;s circuit on command. Turning the cam  352  to connect and disconnect the springs  360  with the busbar&#39;s connector  390  respectively closes and opens the switching circuit. 
     FIG. 12  shows the busbar  370 , with its lower portion  372  being contained within the base  330  and the upper portion  374  extending across from the cam  352 , both shown in  FIG. 10  in situ. The busbar  370  includes a pair of mounting holes  376  into which the connector  390  may be disposed, one at either end  372 ,  374  of the busbar  370 . 
     FIGS. 13 and 14  show an exemplary connector  390  from above and below, respectively. The connector  390  includes a brass block  392  with six contact pins  394  arranged in a 2×3 array. The pins  394  are inserted into corresponding countersunk through-holes  396 . The pins  394  distribute electrical current from a device to which they electrically communicate and transmit the current by electrical conduction to the block  392  from which the current may be carried to complete a circuit. 
   The underside of the block  392  includes a pair of pegs  398  at the underside ends for insertion into mounting holes  376  of the busbar  370 . Persons having ordinary skill in the art will recognize that the pattern and number of pins  394  within the block  392  are exemplary only, and that other configurations may be contemplated without departing from the scope of the invention. 
     FIG. 15  shows the block  392  with through-holes  396 .  FIG. 16  shows the pin  394 , which contains a shaft within a hollow cylinder. An example commercial versions of the pin  394  is available as model 100045 battery contact probe from Interconnect Devices Inc. (IDI), of Kansas City, Kans. 
   This model probe for the pin  394  has a gold-plated nickel silver (Ni—Ag) barrel, a stainless steel spring and a gold-plated beryllium-copper plunger having a diameter of 0.045 inch and a travel length of 0.060 inch. The plunger may be deflected along its longitudinal axis for compression into the barrel to compensate proximate distance variations between components within mechanical tolerance. Its performance characteristics include operation at 3 A (amps) continuous (with 10 A intermittent peaks) and maximum resistance of 50 mΩ). Assembled into the connector  390 , the six pins  394  may channel current intermittently at about 40 A. 
     FIG. 17  illustrates a power conditioner  400  from the vantage of the fore side of the front battery unit  110 . The power conditioner  400  includes a plastic external face  410  with terminals  412  from which to transmit electrical power for a designated and intended use. The external face  410  may be directed towards port side of the battery assembly  100 . 
   A panel  420  on the reverse side of  FIG. 17  (and more apparent in  FIG. 4 ) faces towards the fore end of the front battery unit  110 . A top cover  430  and an aluminum enclosure  440  shroud the conditioner&#39;s interior components. A pair of brass contacts  450  protrudes towards the fore direction opposite the panel  420  and is insulated from the enclosure  440  by plastic inserts. 
     FIG. 18  shows the power conditioner  400  from the vantage of the aft side of the front battery unit  110 . The cover  430  and a portion of the enclosure  440  are removed in  FIG. 18  to show the interior components. In particular, the power conditioner  400  may include a module relay  460  and electronics  470 . 
   An opposite panel  480  that faces towards starboard partially encloses the electronics  470 . A signal from the opposite panel  480  may be transmitted through the electronics  470  and the relay  460  to provide power through the terminals  412  on the external face  410 . The signal may also be employed to modulate a proportion of the total available power. 
   The switch assembly  300  operates to electrically connect the subpack assemblies  200  within each section pack  120  in both battery units  110  of the battery assembly  100 . The combined electrical power from the subpack assemblies  200  may be channeled through the power conditioner  400 . 
   As described supra, each subpack assembly  200  with thirty-five cells  260  connected together in series can provide 43.75 V DC . Installed together within their respective section pack  120 , the subpack assemblies  200  transmit no power unless the switch assembly  300  is engaged. The connectors  390  provide convenient and reliable distributed electrical conduits for channeling electrical power from the subpack assemblies  200 . 
   Concatenated together by the switch assembly  300 , each battery unit  110  can provide 350 V DC . Consequently, the combined battery assembly  100  with a pair of switch assemblies  300  for their corresponding battery units  110  may provide 700 V DC  safely and on command. 
   Electrical connection of the battery unit  110  may be commanded for activation or deactivation by a signal submitted to the pneumatic actuator  320 . Manual override of such a command may be performed through the keyhole  310  using an appropriate tool. 
   The materials disclosed for particular components represent practical representative substances having appropriate structural, electrical, thermal and/or chemical properties for the applicable function. Artisans of ordinary skill will recognize that alternate materials may be selected for these components as optional design choices without any claim scope departure. 
   In general, while certain features of the embodiments of the invention have been illustrated as described herein, many modifications, substitutions, changes and equivalents will now occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the embodiments.