Patent Publication Number: US-10784488-B2

Title: Battery assembly

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a Continuation-in-Part of copending U.S. application Ser. No. 16/027,832, filed Jul. 5, 2018, the contents of which are incorporated herein by reference in their entirety. 
     The present disclosure relates to a battery assembly for a vehicle or other equipment. 
    
    
     BACKGROUND 
     Automobiles and other vehicles and equipment typically are designed with a certain standard battery size in mind. During the design, the clearances around and above the battery, the battery tray, the method of securing the battery, the positive and negative lead lengths typically are all predetermined based on such certain standard battery size. As a result, battery modules that do not have such standard battery size typically cannot be used with such equipment. 
     SUMMARY 
     The present disclosure relates to a battery assembly for a vehicle or other equipment comprising at least one battery module having a first positive battery terminal and a first negative battery terminal and a distance therebetween. The battery assembly further comprises a housing assembly that includes a receiver defining a receptacle for receiving the battery module and a second positive battery terminal and a second negative battery terminal. The distance between the second positive battery terminal and the second negative battery terminal is greater than the distance between the first positive battery terminal and the first negative battery terminal. The battery assembly further comprises a first electrical connector for interconnecting the first positive battery terminal and the second positive battery terminal, and a second electrical connector for interconnecting the first negative battery terminal and the second negative battery terminal. The distance between the second positive battery terminal and the second negative battery terminal may be the same as the distance between a positive battery terminal and a negative battery terminal of a standard battery. The said at least one battery module may be a single battery module or multiple battery modules. Where there are two battery modules, the battery modules may be connected to each other in parallel or in series and, where there are three or more battery modules, the battery modules may be connected to each other in parallel or series or a combination of both. 
     The housing assembly of the battery assembly may also include a lid for enclosing the receptacle. The exterior dimensions, length, width and height of the housing assembly when assembled may be the same or nearly the same as the exterior dimensions of a standard battery. 
     The housing assembly of the battery assembly may include one or more partitions, receivable in the receptacle for holding the battery module in place within the receptacle, and engaging structure for engaging the receiver and the partition. For example, the receiver may define a pair of opposed walls with the engaging structure formed on the walls that may define at least one slot for receivingly engaging the partition. 
     The housing assembly of the battery assembly may also comprise an extension engaged with the receiver. The extension defines an aperture for receiving either the second positive battery terminal or the second negative battery terminal. The extension may be slidably engaged with the receiver. For example, the receiver may include a wall having an outside that defines a slot and the extension includes an embossment slidingly receivable within the slot. The extension may define an aperture for receiving the terminal cable. 
     Features and advantages of the disclosure will be set forth in part in the description which follows and the accompanying drawings described below, wherein an embodiment of the disclosure is described and shown, and in part will become apparent upon examination of the following detailed description taken in conjunction with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a housing assembly of a battery assembly in accordance with an embodiment of the present disclosure; 
         FIG. 2  is an exploded view of the battery assembly of  FIG. 1  also illustrating the battery modules contained in the housing assembly; 
         FIG. 3  is a perspective view of a housing assembly of a battery assembly in accordance with another embodiment of the present disclosure; 
         FIG. 4  is a partially exploded view of the battery assembly of  FIG. 3  also illustrating the battery modules contained in the housing assembly; 
         FIG. 5  is another partially exploded view of the battery assembly of  FIG. 3 ; 
         FIG. 6  is a perspective view of the extension and the negative battery terminal of the battery assembly of  FIG. 3 ; 
         FIG. 7  is a perspective view of a housing assembly of a battery assembly in accordance with another embodiment of the present disclosure; 
         FIG. 8  is a partially exploded view of the battery assembly of  FIG. 7  also illustrating the battery modules contained in the housing assembly; 
         FIG. 9  is another partially exploded view of the battery assembly of  FIG. 7  from another perspective also illustrating the battery modules contained in the housing assembly; and 
         FIG. 10  is a perspective view of the extension and the negative battery terminal of the housing assembly of  FIG. 7 . 
     
    
    
     DETAILED DESCRIPTION 
       FIGS. 1-10  illustrate three embodiments of a battery assembly  8 ,  108  and  208  including a housing assembly  10 ,  110  and  210 , respectively, for a battery module. Each housing assembly  10 ,  110  and  210  includes a battery module for installation of the battery module in a vehicle or other equipment designed to employ a specific battery size even though the battery module to be installed is sized differently from the specific battery size intended for the vehicle or other equipment. 
     With reference to  FIGS. 1-2 , the housing assembly  10  includes a receiver  12  that defines a receptacle  14  receiving a pair of battery modules  16 , one or more partitions  18 , a first electrical connector in the form of a positive terminal busbar  22 , a second electrical connector in the form of a negative terminal busbar  24 , a positive battery terminal  26 , a negative battery terminal  28  and a lid  32  that encloses the top of the receptacle  14 . The lid  32  defines a pair of apertures  36  and  38  for receiving the positive battery terminal  26  and the negative battery terminal  28 . The lid  32  also may include a handle. 
     The battery modules  16  may be of any suitable size configured to be received within the receptacle  14  and may instead be a single battery module or multiple battery modules. Each battery module  16  includes a positive battery terminal  44  and a negative battery terminal  46 . Where there are two battery modules  16 , the battery modules may be connected to each other in parallel as illustrated on  FIG. 2  or in series and, where there are three or more battery modules, the battery modules may be connected to each other in parallel or series or a combination of both. 
     The positive terminal busbar  22  interconnects the positive battery terminal  44  of at least one of the battery modules  16  with the positive battery terminal  26  of the housing assembly  10 . The positive terminal busbar  22  is connected and secured to at least one of the positive battery terminals  44  of the battery modules  16  by one or more button screws or by any other suitable joining method. The positive terminal busbar  22  is connected and secured to the positive battery terminal  26  of the housing assembly  10  by a button screw or any other suitable joining method. The positive terminal busbar  22  instead may be any other suitable electrical connector such as a cable, a bar or other suitable connector or combination of any of the foregoing. 
     The negative terminal busbar  24  interconnects the negative battery terminal  46  of at least one of the battery modules  16  with the negative battery terminal  28 . The negative terminal busbar  24  is connected and secured to at least one of the negative battery terminals  46  of the battery modules  16  by one or more button screws or by any other suitable joining method. The negative terminal busbar  24  is connected and secured to the negative battery terminal  28  by a button screw or by any other suitable joining method. The negative terminal busbar  24  instead may be any other suitable electrical connector such as a cable, a bar or other suitable connector or a combination of any of the foregoing. 
     The partition  18  is received by the receptacle  14  and is positioned next to the battery modules  16  to limit or eliminate movement of the battery modules within the receptacle or for otherwise holding the battery modules in place. The illustrated partition  18  is in the form of a frame with side rails, top and bottom rails, and a rail interconnecting the side rails. The partition  18  may have any other configuration that complements the side of the battery modules  16 . The receiver  12  includes two pairs of opposed walls  54  and  56 . The receiver  12  includes engaging structure for engaging the partition  18 . In the illustrated embodiment, for example, the engaging structure defines a pair of opposed slots  64  on the opposed walls  54  for slidingly engaging the partition  18 . The location of the slots  64  depends upon the sizes of the battery modules  16  received within the receptacle  14 . The engaging structure may be in any other suitable form and, in accordance with other embodiments, provide alternative locations for the partition  18  for adjustably positioning the partition  18  at the suitable location. 
     The receiver  12  may incorporate up to four hold-down brackets  65 . One on each side. They may be removable as illustrated on  FIG. 2 . The receiver  12  may be secured to the vehicle in any other suitable manner in accordance with other embodiments of the present disclosure. 
     The receiver  12 , the partition  18 , the lid  32  and the detachable hold-down brackets may be constructed of plastic or any other suitable material and may have any suitable configuration. The first and second electrical connectors may be constructed of metal or any other suitable material and may have any suitable configuration. 
     The distance between the positive battery terminal  26  and negative battery terminal  28  of the housing assembly  10  depends upon the vehicle and the size of the battery the vehicle was designed to accommodate. For example, the distance between positive and negative battery terminals of a standard 8.2″ battery is about 6″. For example, if the vehicle was intended for use with such a standard 8.2″ battery, the distance between the positive and negative battery terminals of the housing assembly would be about 6″. The housing assembly  10  can be used with battery modules  16  having a distance between the positive and negative terminals  44  and  46  of the battery modules that is less than the distance between the positive battery terminal  26  and the negative battery terminal  28  of the housing assembly. By turning the battery modules 180° in the receptacle, the polarity of terminals  26  and  28  in the housing assembly  10  may be reversed. 
     With reference to  FIGS. 3-6 , the housing assembly  110  includes a receiver  112  that defines a receptacle  114  receiving a pair of battery modules  116 , one or more partitions  118 , a first electrical connector in the form of a positive terminal busbar  122 , a second electrical connector in the form of negative terminal busbar  124  and terminal cable  120 , a positive battery terminal  126 , a negative battery terminal  128 , an extension  130  and a lid  132  that encloses the top of the receptacle  114 . The lid  132  defines an aperture  136  for receiving the positive battery terminal  126 . The lid  132  also may include a handle  134 . The lid  132  may also include a battery terminal lid  138  to enclose the positive battery terminal  126 . 
     The battery modules  116  may be of any suitable size configured to be received within the receptacle  114  and may instead be a single battery module or multiple battery modules. Each battery module  116  includes a positive battery terminal and a negative battery terminal. Where there are two battery modules  116 , the battery modules may be connected to each other in parallel or in series and, where there are three or more battery modules, the battery modules may be connected to each other in parallel or series or a combination of both. 
     The positive terminal busbar  122  interconnects the positive battery terminal of at least one of the battery modules  116  with the positive battery terminal  126  of the housing assembly  110 . The positive terminal busbar  122  is connected and secured to at least one of the positive battery terminals of the battery modules  116  by one or more button screws or by any other suitable joining method. The positive terminal busbar  122  is connected and secured to the positive battery terminal  126  by a button screw or any other suitable joining method. The positive terminal busbar  122  instead may be any other suitable electrical connector such as a cable, a bar or other suitable connector or combination of any of the foregoing. 
     The terminal cable  120  interconnects the negative busbar  124  and the negative battery terminal  128 . The negative terminal busbar  124  includes a crimp connection  150  for engaging the terminal cable  120 . The negative terminal busbar  124  is connected and secured to at least one of the negative battery terminals of the battery modules  116  by one or more button screws or any other suitable joining method. The terminal cable  120  is flexible and may be comprised of copper or other suitable metal or material. The terminal cable  120  is shaped to extend into the extension  130 . The terminal cable  120  terminates in an eyelet crimp connector  162 . The eyelet crimp connector  162  is connected and secured to the negative battery terminal  128  by a button screw, a washer, a lock washer and a nut or by any other suitable joining method. The terminal cable  120  and the negative terminal busbar  124  each instead may be any other suitable electrical connector such as a cable, a bar or other suitable connector or combination of any of the foregoing. 
     The partition  118  is received by the receptacle  114  and is positioned next to the battery modules  116  to limit or eliminate movement of the battery modules within the receptacle or for otherwise holding the battery modules in place. The receiver  112  includes two pairs of opposed walls  154  and  156  and engaging structure for engaging the partition  118 . In the illustrated embodiment, for example, the engaging structure defines a pair of opposed slots  164  on the opposed walls  154  for slidingly engaging the partition  118 . The location of the slots  164  depends upon the sizes of the battery modules  116  received within the receptacle  114 . The engaging structure may be in any other suitable form and, in accordance with other embodiments, provide alternative locations for the partition  118  for adjustable positioning the partition  118  at the suitable location. 
     The extension  130  and the receiver  112  each have engaging structure to engage the extension and receiver in any suitable manner. In the illustrated embodiment, for example, the extension  130  includes engaging structure in the form of an embossment  170  that extends along its inner side  172  and the receiver  112  includes engaging structure in the form of an outer wall  168  that defines a slot  174  for slidingly engaging the embossment. The embossment  170  includes a pair of walls  176  that extend parallel at an outward angle from the inner side  172  of the extension  130 . The slot  174  has an open bottom end and is defined by two parallel walls  178  that extend inward at an angle to facilitate the sliding engagement of the embossment  170  into the slot. 
     The inner side  172  of the extension  130  defines an aperture  180 . The top surface  182  of the extension  130  includes a wall  184  defining a corner notch  186  and defines an aperture  190  within the notch for receiving the negative battery terminal  128 . The terminal cable  120  extends through an aperture  194  defined by the lid  132 , and aperture  180  to the negative battery terminal location where the eyelet crimp connector end of terminal cable  120  is secured inside extension  130  to the negative battery terminal  128  by a button screw, a washer, a lock washer and a nut or by any other suitable joining method. 
     The receiver  112  may incorporate up to three hold-down brackets  165 . One on each exposed side. They may be removable as illustrated on  FIG. 5 . The extension  130  may also incorporate a hold-down bracket  166  with a window (not shown) above to secure the assembly within the vehicle. The receiver  112  may be secured to the vehicle in any other suitable manner in accordance with other embodiments of the present disclosure. 
     The receiver  112 , the partition  118 , the extension  130 , the lid  132 , the handle  134 , the terminal lid  138  and the detachable hold-down bracket  165  may be constructed of plastic or any other suitable material and may have any suitable configuration. The first and second electrical connectors may be constructed of metal or any other suitable material and may have any suitable configuration. 
     The distance between the positive battery terminal  126  and negative battery terminal  128  of the housing assembly  110  depends upon the vehicle and the size of the battery the vehicle was designed to accommodate. For example, the distance between positive and negative battery terminals of a standard 11″ battery is about 8.5″. For example, if the vehicle was intended for use with such a standard 11″ battery, the distance between the positive and negative battery terminals  126  and  128  of the housing assembly  110  would be about 8.5″. The housing assembly  110  can be used with battery modules  116  having a distance between the positive and negative terminals of the battery modules that is less than the distance between the positive battery terminal  126  and the negative battery terminal  128  of the housing assembly. By turning the battery modules 180° in the receptacle, the polarity of terminals  126  and  128  in the housing assembly  110  may be reversed. 
     With reference to  FIGS. 7-10 , the housing assembly  210  includes a receiver  212  that defines a receptacle  214  receiving a pair of battery modules  216 , one or more partitions  218 , a first electrical connector in the form of a positive terminal busbar  222 , a second electrical connector in the form of a negative terminal busbar  224  and terminal cable  220 , a positive battery terminal  226 , a negative battery terminal  228 , an extension  230  and a lid  232  that encloses the top of the receptacle  214 . The lid  232  defines an apertures  236  for receiving the positive battery terminal  226 . The lid  232  also may include a handle  234 . The lid  232  may also include a battery terminal lid  238  to enclose the positive battery terminal  226 . 
     The battery modules  216  may be of any suitable size configured to be received within the receptacle  214  and may instead be a single battery module or multiple battery modules. Each battery module  216  includes a positive battery terminal and a negative battery terminal. Where there are two battery modules  216 , the battery modules may be connected to each other in parallel or in series and, where there are three or more battery modules, the battery modules may be connected to each other in parallel or series or a combination of both. 
     The positive terminal busbar  222  interconnects the positive battery terminal of at least one of the battery modules  216  with the positive battery terminal  226  of the housing assembly  210 . The positive terminal busbar  222  is connected and secured to at least one of the positive battery terminals of the battery modules  216  by one or more button screws or by any other suitable joining method. The positive terminal busbar  222  is connected and secured to the positive battery terminal  226  by a button screw or any other suitable joining method. The positive terminal busbar  222  instead may be any other suitable electrical connector such as a cable, a bar or other suitable connector or combination of any of the foregoing. 
     In the illustrated embodiment, for example, the terminal cable  220  interconnects the negative busbar  224  and the negative battery terminal  228 . The negative terminal busbar  224  employs a crimp connection  250  for engaging the terminal cable  220 . The negative terminal busbar  224  is connected and secured to at least one of the negative battery terminals of the battery modules  216  by one or more button screws or any other suitable joining method. The terminal cable  220  is flexible and may be comprised of copper or other suitable metal or material. The terminal cable  220  is shaped to extend into the extension  230 . The terminal cable  220  terminates in an eyelet crimp connector  262 . The eyelet crimp connector is connected and secured to the negative battery terminal  228  by a button screw, a washer, a lock washer and a nut or by any other suitable joining method. The terminal cable  220  and the negative terminal busbar  224  each instead may be any other suitable electrical connector such as a cable, a bar or other suitable connector or combination of any of the foregoing. 
     The partition  218  is received by the receptacle  214  and is positioned next to the battery modules  216  to limit or eliminate movement of the battery modules within the receptacle or for otherwise holding the battery modules in place. The receiver  212  includes two pairs of opposed walls  254  and  256  and engaging structure for engaging the partition  218 . In the illustrated embodiment, for example, the engaging structure defines a pair of opposed slots  264  on the opposed walls  254  for slidingly engaging the partition  218 . The location of the slots  264  depends upon the sizes of the battery modules  216  received within the receptacle  214 . The engaging structure may be in any other suitable form and, in accordance with other embodiments, provide alternative locations for the partition  218  for adjustable positioning the partition  218  at the suitable location. 
     The extension  230  and the receiver  212  each have engaging structure to engage the extension and receiver in any suitable manner. In the illustrated embodiment, for example, the extension  230  includes engaging structure in the form of an embossment  270  that extends along its inner side  272  and the receiver  212  includes engaging structure in the form of an outer wall  268  that defines a slot  274  for slidingly engaging the embossment. The embossment  270  includes a pair of walls  276  that extend parallel at an outward angle from the inner side  272  of the extension  230 . The slot  274  has an open bottom end and is defined by two parallel walls  278  that extend inward at an angle to facilitate the sliding engagement of the embossment  270  into the slot. 
     The inner side  272  of the extension  230  defines an aperture  280 . The top surface  282  of the extension  230  includes a wall  284  defining a corner notch  286  and defines an aperture  290  within the notch for receiving the negative battery terminal  228 . The terminal cable  220  extends through an aperture  292  defined by the lid  232 , and aperture  280  to the negative battery terminal location where the eyelet crimp connector end of terminal cable  220  is secured inside extension  230  to the negative battery terminal  228  by a button screw, a washer, a lock washer and a nut or by any other suitable joining method. 
     The receiver  212  may incorporate up to three hold-down brackets  265 . One on each exposed side. They may be removable. The extension  230  may also incorporate a hold-down bracket  266  with a window (not shown) above to secure the assembly within the vehicle. The receiver  212  may be secured to the vehicle in any other suitable manner in accordance with other embodiments of the present disclosure. 
     The receiver  212 , the partition  218 , the extension  230 , the lid  232 , the handle  234 , the terminal lid  238  and the detachable hold-down bracket  265  may be constructed of plastic or any other suitable material and may have any suitable configuration. The first and second electrical connectors may be constructed of metal or any other suitable material and may have any suitable configuration. 
     The distance between the positive battery terminal  226  and negative battery terminal  228  of the housing assembly  210  depends upon the vehicle and the size of the battery the vehicle was designed to accommodate. For example, the distance between positive and negative battery terminals of a standard 14″ battery is about 11.5″. For example, if the vehicle was intended for use with such a standard 14″ battery, the distance between the positive and negative battery terminals of the housing assembly would be about 11.5″. The housing assembly  210  can be used with battery modules  216  having a distance between the positive and negative terminals of the battery modules that is less than the distance between the positive battery terminal  226  and the negative battery terminal  228  of the housing assembly. By turning the battery modules 180° in the receptacle, the polarity of terminals  226  and  228  in the housing assembly  210  may be reversed. 
     The present disclosure provides many benefits. For example, vehicles are typically designed to accommodate specific size batteries (e.g., 8.2″, 11″ or 14″) and therefore the size of batteries to be installed on such vehicles is typically limited to the specific size. The battery assembly  8 ,  108  or  208  comprising housing assembly  10 ,  110  or  210  of the present disclosure, however, enables smaller batteries (battery modules) to be used on such vehicles. The present disclosure, among other things, provides an efficient manner for using odd size batteries (battery modules) on vehicles designed to use a specific standard battery size. References to standard battery size herein are intended to refer to the size and dimensions of a commercially used battery as understood by one of ordinary skill in the art. For example, such references are intended to include battery sizes standardized by agreement by two or more battery manufacturers or battery sizes of any other vehicle batteries having predetermined sizes and dimensions. Similarly, one of ordinary skill in the art understands that references to “battery module” herein are intended to refer to a single battery cell or to an assembly of battery cells configured in series, parallel or a combination of both. The battery cell or the assembly of battery cells comprising the battery module may or may not have a housing or enclosure. 
     While embodiments have been illustrated and described in the drawings and foregoing description, such illustrations and descriptions are considered to be exemplary and not restrictive in character, it being understood that only illustrative embodiments have been shown and described and that all changes and modifications that come within the spirit of the disclosure are desired to be protected. The description and figures are intended as illustrations of embodiments of the disclosure, and are not intended to be construed as having or implying limitation of the disclosure to those embodiments. There is a plurality of advantages of the present disclosure arising from various features set forth in the description. It will be noted that alternative embodiments of the disclosure may not include all of the features described yet still benefit from at least some of the advantages of such features. Those of ordinary skill in the art may readily devise their own implementations of the disclosure and associated methods, without undue experimentation, that incorporate one or more of the features of the disclosure and fall within the spirit and scope of the present disclosure and the appended claims.