Patent Publication Number: US-7591692-B1

Title: Battery clamp and associated method

Description:
RELATED APPLICATIONS 
   This is a divisional of U.S. patent application Ser. No. 11/420,759 entitled “MECHANICALLY ADVANTAGED BAND CLAMP AND ASSOCIATED METHOD” filed on May 28, 2006 (issuing as U.S. Pat. No. 7,329,157 on Feb. 12, 2008), which was a divisional of U.S. patent application Ser. No. 10/948,328 entitled “SYMMETRICALLY ADJUSTABLE CORROSION-RESISTANT BATTERY CABLE CONNECTOR” filed on Sep. 22, 2004 (now U.S. Pat. No. 7,052,331 issued May 30, 2006), which claimed priority to U.S. Provisional Patent Application No. 60/505,475 with filing date Sep. 25, 2003—each of which is incorporated herein in its entirety by reference. 

   FIELD OF THE INVENTION 
   This invention relates generally to battery power systems and more specifically to symmetrically adjustable corrosion-resistant battery cable connectors and connection methods for automotive and marine battery power systems. 
   BACKGROUND OF THE INVENTION 
   Batteries typically are connected to their loads using a wire of suitable gauge terminated with a connector that is removably connectable to a battery terminal. Some conventional battery-post connectors provide a split-ring connector made of lead metal, having a tapered cylindrical primary opening, connected at a closed end to a cable wire, and having a steel nut-and-bolt fastener that passes through the open end and draws the two edges of the open end together when tightened, in order to provide a tight connection around the tapered cylindrical post of, for example, a lead-acid twelve-volt battery of a vehicle or watercraft. 
   Such battery-cable terminations historically have had problems with mechanical fit and deformation, material fatigue and breakage with use, and corrosion due to reactions with the battery electrolyte, road salt and fumes, and/or contact of dissimilar metals. Often, the nut and/or bolt will corrode, making removal and reattachment difficult. Even in cases where the bolt can be loosened, the C-shaped lead connector does not loosen by itself, but must be pried apart at its open end in order to remove it from a battery&#39;s post or to reinstall it. The loose fit of the cable-end connector on the post allows the interface between post and connector to oxidize, increasing resistance and making the battery difficult to charge and discharge properly. These problems result in either partial or complete failure of the terminal&#39;s primary function, which is to distribute adequate power to the battery-powered systems and loads. 
   Although there have been improvements made to help reduce the above problems by various means in the industry, the problems mentioned above still exist. Therefore, there still exists a need to make further improvements, especially in applications which are deemed critical as with military vehicles and civilian rescue vehicles. 
   SUMMARY OF THE INVENTION 
   The present invention addresses the aforementioned problem areas including mechanical fit, material fatigue and corrosive behavior. It also provides features to the connector that make it easier for the user to install, remove, and/or replace in the field. 
   The present connector provides symmetrical clamping to the battery-terminal post, ensuring good electrical contact. The configuration and the materials used in construction of the connector of the present invention reduce the tendency for it to fail as compared to other battery-terminal connectors. The tendency for corrosion to take place is reduced by the materials used and by limiting chemical seepage routes with the connector&#39;s symmetrically tight contact. The present design includes the added benefit of extreme ease of installation and removal with any one of several different tools. In some embodiments, the present invention uses materials that are less toxic and less harmful to the environment, as compared to conventional lead-based connectors. 
   In some embodiments, a replaceable conventional band clamp is used to surround the connector and the battery post of the lead-acid battery to which it is connected. In some embodiments, the band, the screw holder, and the screw that tightens the clamp are made of stainless steel, while the connector includes tin-coated copper for improved conductivity. In other embodiments, the conductor includes lead-brass alloy, lead-copper alloy, or a beryllium alloy, and optionally includes a radius contact plated with tin, silver, or brass. 
   As used herein, “band” and “strap” mean the same thing: a strong, relatively thin, strip of metal or other suitable material. In some embodiments, such a band is made of stainless steel and typically has a plurality of crosswise or diagonal slots that interface with a worm-drive screw&#39;s threads. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The present invention is described in detail below with reference to the following drawings. 
       FIG. 1A  is a perspective view that illustrates connector assembly  100  of some embodiments, including a worm drive adjustment assembly  112 , a slotted adjustment strap  114 , and a radius electrical contact  116 . 
       FIG. 1B  is a perspective view that provides detail of the worm drive adjustment assembly  112 , illustrating the worm drive screw housing  110 , and the adjustment strap guide  102 . 
       FIG. 1C  is a side view illustrating worm-drive screw  104  mounted within assembly  112 . 
       FIG. 1D  is a plan view that illustrates the slotted adjustment strap  114 . 
       FIG. 1E  is a perspective view of worm-drive screw  104 . 
       FIG. 1F  is a side view of worm-drive screw  104 . 
       FIG. 1G  is a perspective view of radius electrical contact  116 . 
       FIG. 2A  is a perspective view of a connector assembly  200  of some embodiments of the invention. 
       FIG. 2B  is a perspective view of electrical contact  201  of connector assembly  200 . 
       FIG. 3A  is a perspective view of a connector assembly  300  of some embodiments of the invention. 
       FIG. 3B  is a perspective view of electrical contact  301  of connector assembly  300 . 
       FIG. 4A  is a partially-cut-away perspective view of a connector assembly  400  of some embodiments of the invention. 
       FIG. 4B  is a partially-cut-away side view of a connector assembly  400  of some embodiments of the invention. 
       FIG. 4C  is a perspective view of electrical contact  401  of connector assembly  400 . 
       FIG. 4D  is a perspective view of electrical contact  451  that can be substituted in connector assembly  400 . 
       FIG. 5  is a perspective view of electrical contact  501  that can be substituted in connector assembly  200  of  FIG. 2A . 
       FIG. 6A  is a perspective view of a connector assembly  600  of some embodiments of the invention. 
       FIG. 6B  is a top view of electrical contact  610  of connector assembly  600 . 
       FIG. 6C  is a side view of electrical contact  610  of connector assembly  600 . 
       FIG. 6D  is a side view of electrical contact  620  that can be substituted in connector assembly  600 . 
       FIG. 6E  is a side view of electrical contact  630  that can be substituted in connector assembly  600 . 
       FIG. 6F  is a perspective view of electrical contact  620  that can be substituted in connector assembly  600 . 
       FIG. 7A  is a perspective exploded view of top-driven clamp  700  that allows actuating beveled-gear worm-drive screw  704  with vertically oriented beveled-gear head  730 . 
       FIG. 7B  is a side view of beveled-gear worm-drive screw  704 . 
       FIG. 7C  is a side view of vertical beveled-gear head  730 . 
       FIG. 8A  is a plan view, before folding, of a stamped-metal radius conductor  802 . 
       FIG. 8B  is an end view, before folding, of a stamped-metal radius conductor  802 . 
       FIG. 8C  is a side view, before folding, of a stamped-metal radius conductor  802 . 
       FIG. 8D  is a perspective view, after folding, of a stamped-metal radius conductor  802 . 
       FIG. 8E  is a top view, after folding, of a stamped-metal radius conductor  802 . 
       FIG. 8F  is a top cut-away view of a battery connector  800 . 
       FIG. 8G  is a perspective exploded view of a battery connector  800 . 
       FIG. 9A  is a side view, before folding, of a stamped-metal radius conductor  901 . 
       FIG. 9B  is a side view, before folding, of a stamped-metal radius conductor  902 . 
       FIG. 9C  is a plan view, before folding, of a stamped-metal radius conductor  902 . 
       FIG. 9D  is a perspective exploded view of a replaceable-clamp battery connector  900 . 
       FIG. 9E  is a perspective exploded view of a replaceable-clamp battery connector  904 . 
       FIG. 10A  is a top cut-away view of a battery connector  1000 . 
       FIG. 10B  is a perspective exploded view of a battery connector  1000 . 
       FIG. 11A  is a top cut-away view of a battery connector  1100 . 
       FIG. 11B  is a perspective exploded view of a battery connector  1100 . 
       FIG. 11C  is a plan view, before folding, of a stamped-metal radius conductor  1110 . 
       FIG. 12  is a perspective view of a vehicle  1200  that includes one or more battery connectors of the present invention. 
       FIG. 13A  is a perspective view of a connector assembly  1300  of some embodiments of the invention. 
       FIG. 13B  is a perspective view of electrical contact  1310  of connector assembly  1300 . 
       FIG. 14A  is a top perspective view of top-driven clamp connector assembly  1400  that allows actuating beveled-gear worm-drive screw  1404  with a mechanically advantaged gear ratio, vertically or side oriented, via beveled-gear head  1430 . 
       FIG. 14B  is a side perspective view of clamp  1400  showing the gear end of beveled-gear worm-drive screw  1404 . 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings that form a part hereof, and in which are shown by way of illustration specific embodiments in which the invention may be practiced. It is understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the present invention. 
   The leading digit(s) of reference numbers appearing in the Figures generally corresponds to the Figure number in which that component is first introduced, such that the same reference number is used throughout to refer to an identical component which appears in multiple Figures. Signals and connections may be referred to by the same reference number or label, and the actual meaning will be clear from its use in the context of the description. 
     FIG. 1A  is a perspective view that illustrates connector assembly  100  of some embodiments, including a worm drive adjustment assembly  112 , a slotted adjustment strap  114 , and a radius electrical contact  116 . Connector assembly  100  illustrates an exemplary battery-cable connector that makes significant improvements to battery power distribution systems in historically problematic areas. The assembly  100  includes a worm-drive adjustment assembly  112  that is mechanically coupled to a slotted adjustment strap  114 . As slotted adjustment strap  114  is tightened, its circumference is reduced and it compresses around a battery&#39;s electrical power post  99  (see  FIG. 9D ) and a radius electrical contact  120 , which provides a primary electrical current carrying site as well as an attachment site  116  for the battery cable&#39;s electrical conductor wires. 
   One important feature of assembly  100  is its ability to conform to the round battery post. In some embodiments, the opening at the center of this connector assembly  100  is substantially round and cylindrical (or, in some embodiments, a tapered cylindrical shape, such as a conical section). As the worm drive screw  104  (see  FIG. 1E  and  FIG. 1F ) is rotated, the diameter of the connector is either expanded or contracted maintaining a substantially round opening. The slotted adjustment strap  114  (see  FIG. 1D ) has an opening  117  for post  127  of electrical contact  116  to fit through, and is symmetrically expanded or contracted so as to equally distribute the stress of this action across its entirety. This prevents premature material fatigue experienced by some other connectors. In addition, since the shape of the opening can be substantially circular, for battery electrical power posts that are circular, mechanical fit or interfacing is optimized. Further, since a portion of the circumference of the battery post has only the band clamp, this portion can more easily conform to a post that happen not to be cylindrical (for example, if the post has been damaged). 
   Another important feature of assembly  100  is its ability to release from the battery post when the screw is loosened without having to pry apart the ends of the electrical conductor  116 . Some conventional battery-cable connectors are made from lead which is deformed in the process of attachment. This makes reattachment difficult, and the lead can be an environmental hazard. Some other connectors are assembled into a split-ring arrangement which places high stress 180 degrees from the split when detached. With both of these arrangements, future good fit is not guaranteed as deformation is likely to have taken place. With the connector  100 , deformation is small or does not occur with detachment and reattachment, so good fit is ensured. 
   To maintain good electrical contact, good fit is very important, since electrical conductance is defined by the resistance of the electrical contact area. Since mechanical fit is ensured by the subject connector  100 , electrical contact is improved. 
   In addition to mechanical fit, the condition of the interfacing materials influences the electrical resistance of those materials. The subject connector  100  is designed to have a primary and secondary conduction path to ensure conduction. The inner radius  121  of electrical contact  116  is the primary conduction path, and is in direct electrical contact with the battery post. In some embodiments, the material to be used for its construction is tin-coated copper. In other embodiments, brass plated copper, silver plated lead-copper alloy, silver plated copper, silver plated lead-brass alloy, or silver plated beryllium are used. The copper is used to be galvanically compatible with copper wire cables. The battery-contact surface is coated with and/or alloyed with tin so as to be galvanically compatible with a typical lead battery post. These materials reduce the tendency for corrosion to take place due to metal dissimilarity. In some embodiments, the primary contact is a highly electrically conductive material that is galvanically compatible with the battery terminal material and corrosion resistant, and the lug is a highly electrically conductive material that is galvanically compatible with the conductive cable and corrosion resistant. 
   At end  127  opposite the battery terminal contact surface  121 , the electrical contact  116  is adapted for connection to a wire cable for power distribution such as a solder-in socket, a set screw, a crimp connection, etc. 
   A secondary conduction path is provided by the slotted adjustment strap  114 . In some embodiments, strap  114  is in contact with the battery terminal over a large surface area. In some embodiments, this strap is made of a material that includes stainless steel. The stainless steel material, though initially having a higher resistivity than the radius electrical contact  116  material, will remain substantially uncorroded, and if the primary path is compromised, will provide a secondary conduction path. Extra assurance of a conduction path is especially important for certain battery-power installations that service human survival issues (i.e., military and emergency vehicles). 
   Since a tight mechanical fit is ensured, there is less tendency for foreign material to seep into the interfacing surfaces of the connector and the battery terminal. This is another element that ensures good electrical contact and conduction. 
   The present invention describes connectors that are inexpensive to build and easy to use, and have advantages over other conventional connectors. Embodiments if the invention such as shown in  FIGS. 1A-1G  and  FIGS. 8A-8G  have been tested in the vehicle of one of the inventors and been found to function better than other connectors he had encountered in the following ways: 
   It is extremely easy to install and remove using several different varieties of tools; 
   It conforms to the battery post better than the other connectors, at least in part because the slots in the clamp allow for some amount of a tapered clamping, so that even if the walls of the conductor (e.g., surfaces  120  and  121  if conductor  116  of  FIG. 1G , or surfaces  912  and  193  of  FIG. 9D ) are parallel to one another, the surrounding band clamp ( 112  and  114  of  FIG. 1A , or  95  of  FIG. 9D ) can tighten to a tapered-cylindrical shape, in some embodiments. 
   It does not deform like lead connectors and is symmetrically adjustable, which others are not. 
   The clamp strap distributes the strain around in a hoop, so stress is not concentrated in one location like it is with other non-symmetrically adjusting connectors, and it will not break as soon as they ultimately do. 
   The copper contact is tin coated which keeps the contact from corroding and tin is close to lead on the galvanometric scale so electrolysis does not appreciably occur. 
   The stainless clamp provides a secondary electrical current path, which by his own experience in test, stays substantially corrosion-free, so reliability is much improved compared to other connectors. (After a year of test the connector showed “no” visible evidence of corrosion, electrolysis, discoloration due to heat, etc.) 
   It also is environmentally friendly, whereas the popular lead connector is environmentally hazardous (e.g., the popular battery-terminal-cleaning wire brushes, when used to clean the inner surfaces of conventional lead-based connectors, scrape off and drop tiny particles of lead, lead oxides, and other lead corrosion, which end up falling to the floor or a garage or to the ground, where they may be ingested by a child or pet, or contaminate the soil). 
   Due to these advantages, the “mean time between failure” should be much greater than other connectors and qualify connectors of the invention for service in adverse and critical situations (e.g., military, marine, aircraft, rescue vehicles, etc.). 
     FIG. 1B  is a perspective view of adjustment housing  112 , showing detail of one embodiment of the worm-drive-screw housing  110  and the adjustment-band guide  102 . These parts hold the worm-drive screw  104  and the slotted-adjustment band  114  in mechanical communication and alignment. As discussed earlier, the rotation of the worm-drive screw  104  expands or contracts the diameter of the connector opening. This arrangement provides a connector that is much more easily attachable and detachable as compared to conventional connectors. To further enhance its ease of use, some embodiments of worm-drive screw  104 , as shown in  FIG. 1E , provide a slot for use with a conventional slotted screw driver, a cross slot for use with a conventional Phillips-type screw driver and a hexagonal head for use with conventional hexagonal box end and sockets, open end and/or adjustable wrenches. This ease of use will be important in the field where choice of tools is restricted. 
     FIG. 1B  is a perspective view that provides detail of the worm-drive adjustment assembly  112 , illustrating the worm drive screw housing  110 , and the adjustment strap guide  102 . In some embodiments, strap guide  102  provides one or more tabs  103  that attach to band  114  through opening  113 . One or more other tabs  101  fasten strap guide  102  to housing  110 . 
     FIG. 1C  is a side view illustrating worm-drive screw  104  mounted within assembly  112 . Housing  110  has ends that secure to grooves in screw  104  and hold it in place while allowing it to rotate about its longitudinal axis. 
     FIG. 1D  is a plan view that illustrates the slotted adjustment strap or band  114 . In some embodiments, band  114  includes a thin stainless-steel strap  115  having a plurality of slots or embossed grooves  118  that interface to the threads of screw  104  to tighten or loosen the clamp, a hole  117  through which post  116  is inserted, and a hole  113  through which tabs  103  of strap guide  102  are bent to fixedly attach the band guide  102  to the band  114 . 
     FIG. 1E  is a perspective view of worm-drive screw  104 . In some embodiments, head  107  is made to allow driving from any one of a plurality of different tools; e.g., by providing a hex outside head, and inner grooves for both flat and Phillip&#39;s head screwdrivers, in order to allow more flexibility in tool selection in field repairs. 
     FIG. 1F  is a side view of worm-drive screw  104 , showing hex head  107 , head groove  108  that rides in a slot in one end of housing  110 , and tip groove  106  that rides in a slot in the opposite end of housing  110 . Threads  105  interface to slots  118  in strap  114 . 
     FIG. 1G  is a perspective view of radius electrical contact  116 . Electrical contact  116  includes an inner radius surface  121  that has a concave cylindrical or tapered cylindrical shape to match the shape of post  99  to which it contacts, and a convex cylindrical shape to conform to the shape of the tightened band  114  while minimizing stresses that can occur if a non-cylindrical shape is used. Post  127  has a shape suitable to fit through hole  117 , while leaving a substantial width of band on either side for band strength. In some embodiments, a rectangular cross section is used, having a hole  123  into which the wire-conductor end  82  (see  FIG. 2A ) of the battery cable  80  is inserted, and a threaded hole  122  into which a bolt  150  can be inserted to clamp against the wire-conductor end  82 . In other embodiments, other wire connection means are used, such as, for example, welding, soldering and/or crimping. 
     FIG. 2A  is a perspective view of a connector assembly  200  of some embodiments of the invention. In some embodiments, connector assembly  200  uses a conventional prior-art worm-drive band clamp  70  having a strap  71  that surrounds two complementary conductors  201  and  202 . In other embodiments, any other suitable types of band clamps (which are well known) can be substituted for worm-drive band clamp  70 . 
     FIG. 2B  is a perspective view of electrical conductor or contact  201  of connector assembly  200 . In some embodiments, conductor  201  includes a cylindrical or tapered cylindrical groove  221  that conforms to and tightens against a section of battery post  99 , and a cylindrical or tapered cylindrical groove  230  that conforms to and tightens against a section of wire conductor end  82 . In some embodiments, grove  230  includes one or more projecting ridges that help prevent wire end  82  from being pulled out, and enhance the conductivity of the connection. Band clamp  70  tightens conductor  201  towards conductor  202 , tightening against both battery post  99  in groove  221 , and against wire end  82  in groove  230 . In some embodiments, the outer surface  220  of conductors  201  and  202  are formed such that when installed on a post  99  and wire end  82 , the outer circumference forms a cylindrical shape to minimize stress on band clamp  70  and even out the forces applied. 
     FIG. 3A  is a perspective view of a connector assembly  300  of some embodiments of the invention. Connector assembly  300  is similar to connector assembly  200  of  FIG. 2A , however conductors  301  and  302  do not have a groove (such as  230 ) for wire end  82 , but instead present substantially flat surfaces between which the wire end  82  is clamped. In some embodiments, a top-drive band clamp  700 , such as described in  FIG. 7A  is used, allowing tightening and loosening from the top using a vertically-oriented screwdriver or other tool. This is particularly useful to enhance safety where geometric considerations preclude safe use of metal tightening tools (which can short electrical current to surrounding metal structures in a car) to a horizontal head  107  such as shown in  FIG. 2A . 
     FIG. 3B  is a perspective view of electrical contact  301  of connector assembly  300 , according to some embodiments of the invention. Note that in some embodiments, the outer surface  320  is a cylindrical shape, but not oriented around a vertical axis. Rather, the cylinder of the outer surface is tilted at an angle alpha, to provide a more convenient angle to the drive head  737  of clamp  700 , and to provide more clearance between the bottom end  739  of the worm screw and the top surface of the battery  90 . In some embodiments, inner battery-post groove  321  is cylindrical, while in other embodiments, groove  321  is a tapered cylinder to conform to the shape of battery post  99 . Because of the tilt of cylindrical surface  320 , the right-most lower edge of band  71  is closer to the top surface of battery  90  than is its left-most lower edge. Since the right-most upper edge is also lower, this allows the wire  80  to exit towards the left just above the upper edge of band  71 . 
     FIG. 4A  is a partially-cut-away perspective view of a connector assembly  400  of some embodiments of the invention. In some embodiments, a conventional horizontal-screw worm-drive band clamp  70  is used. In other embodiments, a top-drive band clamp  700 , such as described in  FIG. 7A  is used, allowing tightening and loosening from the top using a vertically-oriented screwdriver or other tool. Connector assembly  400  is similar to connector assembly  300  in having a tilted-cylinder outer surface on conductors  401  and  402 , however the left edge of this outer cylinder  420  is shifted (or “shaved”) to the right, and thus intersects the inner groove  421  leaving a much smaller portion of surface  421  to contact battery post  99 . This exposes a portion of post  99  to make direct contact to band clamp  70 , and provide an alternate current path through band  71  and other portions of clamp  70 . 
     FIG. 4B  is a side view of a connector assembly  400  of some embodiments of the invention. Connector assembly  400  includes a conventional band clamp  70  surrounding conductors  401  and  402  that press against post  99  of battery  90 , and against the conductors of wire  80 . 
     FIG. 4C  is a perspective view of electrical contact  401  of connector assembly  400 . Inner post groove  421  is made to only partially surround its half of post  99 , and intersects with cylinder surface  420  at a line that allows clamp  70  to contact post  99  as well. Groove  430  is provided to clamp against wire  80 . 
     FIG. 4D  is a perspective view of electrical contact/conductor  451  that can be substituted in connector assembly  400 . Conductor  451  provides a bent grove  435  that allows the sideways exit of wire  80  and provides enhanced holding of the wire which is also bent when inserted. Otherwise, conductor  451  is identical to conductor  401  and can be substituted into the connector assemblies of  FIG. 2A ,  3 A, or  4 A. 
     FIG. 5  is a perspective view of electrical contact/conductor  501  that can be substituted in connector assemblies of  FIG. 2A ,  3 A, or  4 A, according to some embodiments of the invention. Conductor  501  is similar to conductor  201 , except that it includes a bent groove to which wire  80  is permanently affixed (e.g., by welding or soldering). 
     FIG. 6A  is a perspective view of a connector assembly  600  of some embodiments of the invention. Connector assembly  600  includes a top-drive band clamp  700  (or a conventional band clamp  70  can be substituted) surrounding a single-piece conductor  610 . Unlike conductor  116  of  FIG. 1A , conductor  610  does not need a hole in band clamp  700 , but provides a wire connection that passes above band clamp  700 . 
     FIG. 6B  is a top view of electrical contact/conductor  610  of connector assembly  600 . In some embodiments, conductor  610  includes an inner surface  621  that conforms to a battery post  99 , an outer cylindrical surface  625  that band clamp  700  tightens against, a groove  624  to allow band clamp  700  to ride higher on the battery post, giving more clearance at the bottom for screw end  739 , and a hole  623  in side post  627  for the cable wire end  82 . 
     FIG. 6C  is a side view of electrical contact/conductor  610  of connector assembly  600 . The features are described above. 
     FIG. 6D  is a side view of electrical contact/conductor  620  that can be substituted in connector assembly  600 . Conductor  620  eliminates the groove  624  of conductor  610 , but has post  627  higher relative to the top of the battery post  99 . 
     FIG. 6E  is a side view of electrical contact/conductor  630  that can be substituted in connector assembly  600 . Conductor  630  is a combination of conductor  620  and conductor  610 . 
     FIG. 6F  is a perspective view of electrical contact/conductor  620  of  FIG. 6D  that can be substituted in connector assembly  600 . 
     FIG. 7A  is a perspective exploded view of top-driven clamp  700  that allows actuating beveled-gear worm-drive screw  704  with vertically oriented beveled-gear head  730 , according to some embodiments of the invention. Top-driven clamp  700  has a tightening mechanism having a vertical head (at right angles to the plane of the band clamp  114 ) for connector adjustment. In the event that there is physical interference so that adjustment from the side of the connector is difficult, this embodiment allows the user to adjust the connector from above. A beveled-gear head  730  is employed in the vertical position, in mating contact with the worm drive screw  704  which now has a gear head  707 . 
   In some embodiments, strap guide  702  permanently holds a conventional slotted band  71  by inserting tabs  703  into hole  72 . Groove  701  mates with groove  708  of screw  704  allowing the screw to rotate, while groove  705  mates with groove  735  of beveled-gear head  730  allowing the beveled-gear head  730  to rotate. The opposite end groove  706  of screw  704  is held and rides in groove  716  of housing  710 , while the opposite end groove  739  of beveled-gear head  730  fits in hole  719  of housing  710 . The slotted end of band  71  is urged against screw  704 , such that the slots  79  of the band interface to the threads  709  of the screw. The tabs of strap guide  701  are attached through corresponding slots in housing  710  to assemble the clamp  700 . 
     FIG. 7B  is a side view of beveled-gear worm-drive screw  704 , used in some embodiments. Screw  704  includes a bevel gear  707  that meshes with gear  733  of the head  730 . Grooves  708  and  706  provide sleeve-bearing surfaces that rotate within groove  716  of housing  710  and groove  701  of strap guide  702 . 
     FIG. 7C  is a side view of vertical beveled-gear head  730 . Beveled-gear head  730  includes a bevel gear  733  that meshes with gear  707  of screw  704 . Grooves  735  and  739  provide sleeve-bearing surfaces that rotate within groove  715  of housing  710  and groove  705  of strap guide  702 , and hole  719  of housing  710 . Collar  738  holds the beveled-gear head  730  on top of hole  719 . In some embodiments, a multi-tool capable hex head  737  is provided. 
     FIG. 8A  is a plan view, before folding, of a stamped-metal radius conductor  802 . Conductor  802  includes ears  816  for bending into a cylindrical opening for wire end  82 , tab  815  for folding into a U-shape to align hole  814  to hole  818  and surround an end of slotted strap  895 . A strap end  812  is bent to a semi-cylindrical shape such that an inner surface  813  conforms to and outer surface of the battery post  99 . In some embodiments, conductor  802  is made of a metal, e.g., primarily or substantially totally copper. In some embodiments, at least inner surface  813  is coated or alloyed with tin.  FIG. 8B  is an end view, before folding, of stamped-metal radius conductor  802 .  FIG. 8C  is a side view, before folding, of stamped-metal radius conductor  802 .  FIG. 8D  is a perspective view, after folding, of stamped-metal radius conductor  802 .  FIG. 8E  is a top view, after folding, of a stamped-metal radius conductor  802 . 
     FIG. 8F  is a top cut-away view of a battery connector  800 , according to some embodiments of the invention, which utilizes conductor  802 . In some embodiments, connector  800  uses a worm-drive screw assembly  897  similar to that of top-drive band clamp  700  or of a conventional band clamp  70 , however the band or strap is split into two parts: strap  896  that is permanently attached to worm-drive screw assembly  897  and is held by bolt  86 , and slotted strap  895  that interfaces with the worm screw of worm-drive screw assembly  897 , and is held at its other end in the U-slot of conductor  802  by bolt  86  as attached to nut  85 .  FIG. 8G  is a perspective exploded view of a battery connector  800 . 
     FIG. 9A  is a side view, before folding, of a stamped-metal radius conductor  901 . When bent and folded, ears  916  and  915  of end  910  form a cylinder to hold wire end  82 , ears  912  form a cylinder having an inner surface  913  to hold battery post  99  and an outer surface  914  around which a band clamp  70  or  700  is placed, and neck  911  that can be left in a vertical orientation as shown in  FIG. 9E , or folded over as shown in  FIG. 9D . 
     FIG. 9B  is a side view, before folding, of a stamped-metal radius conductor  902  (that can be substituted in some embodiments, for conductor  901 ) that includes a beveled surface  913 , which, when bent to form a tapered cylindrical shape to conform to the battery post  99 , allows the outer surface  914  to conform to a cylindrical shape against which a band clamp is applied. 
     FIG. 9C  is a plan view, before folding, of a stamped-metal radius conductor  902 . This plan view would also be applicable to conductor  901 . Ears  915  and  916  of cable connection end  910  are bet to form a cylindrical opening (see  FIG. 9D ). 
     FIG. 9D  is a perspective exploded view of a replaceable-clamp battery connector  900 , according to some embodiments of the invention. In some embodiments, connector  900  is provided to the user as a kit of parts including some or all of those shown. In some embodiments, connector  900  includes an insulated compliant rubber or plastic cover  70  having an opening for cable  80  to pass through, and sides and a top to cover the connector once installed. Cable  80  includes conductor  82  (such as stranded copper wire) covered by a compliant insulator such as rubber or plastic. Band clamp  94  is fit around cylindrical end  910  to compress it onto wire end  82 , forming a mechanical and electrical connection to cable  80 . In some embodiments, insulator cover  70  is shaped to substantially cover band clamp  94  and  95  once assembled, and to be removable for service, if needed. Inner surface  913  of conductor  902  conforms to battery post  99 , and is urged against post  99  by band clamp  95  (which can be a conventional band clamp  70  as shown, or can be a top-drive band clamp  700  as shown in  FIG. 7A . 
     FIG. 9E  is a perspective exploded view of a replaceable-clamp battery connector  904 . Connector  904  is identical to connector  900  described above, but is left in a vertical configuration for applications that would benefit from that configuration. 
     FIG. 10A  is a top cut-away view of a battery connector  1000 , according to some embodiments of the invention.  FIG. 10B  is a perspective exploded view of battery connector  1000 . In some embodiments, connector  1000  includes a machined or cast shaped solid block  1010  of copper, that, in some embodiments, is coated with tin, at least on inner radius surface  1012 . Bolt  1020  passes through hole  1044  of slotted strap  1040 , and threads into threaded hole  1014 , such that its tip also presses against and holds wire end  82  of cable  80  into hole  1013 . In some embodiments, screw housing  1034  has tabs  1035  that are stapled into tab slots  1015  in block  1010  to hold it in place. Worm screw  1032  has threads  1031  that interface with slots  1041  in band  1040 , and when rotated, tighten or loosen the band clamp. 
     FIG. 11A  is a top cut-away view of a battery connector  1100 .  FIG. 11B  is a perspective exploded view of battery connector  1100 . In some embodiments, connector  1100  includes a stamped and folded bar  1110  of copper, that, in some embodiments, is coated with tin, at least on inner radius surface  1112 . Bolt  1120  passes through hole  1144  of slotted strap  1140 , and threads into nut  1121  (or, in other embodiments, into a tapped threaded hole  1117  of bar  1110 . Cylindrical bent end  1113  of bar  1110  holds wire end  82  of cable  80  (in some embodiments, this connection is crimped, soldered, spot welded, or compressed by a band clamp  94  as shown in  FIG. 9D . In some embodiments, screw housing  1134  has tabs  1035  that are stapled around conductor  1110  to hold it in place. Worm screw  1132  has threads  1131  that interface with slots  1141  in band  1140 , and when rotated, tighten or loosen the band clamp. 
     FIG. 11C  is a plan view, before folding, of stamped-metal radius conductor  1110 . Once folded into the shape shown in  FIG. 11B , holes  1117  and  1118  align with each other on either side of hole  1144  of strap  1140 . 
     FIG. 12  is a perspective view of a vehicle  1200  that includes one or more battery connectors  1201  of the present invention, connecting electrical power from battery  90  to vehicle  1200 . In vehicle embodiments, vehicle  1200  can be a military vehicle as shown (either a land vehicle, or a boat, ship, aircraft, etc.) or a civilian automobile, truck, boat, or airplane. Other applications include connection to the power posts of solar installations, battery-powered backup energy sources such as for computer uninterruptible power supplies. 
     FIG. 13A  is a perspective view of a connector assembly  1300  of some embodiments of the invention. In some embodiments, connector assembly  1300  includes a plurality of conductor elements  1310 ,  1330 , and/or a direct (e.g., stainless-steel) connection  1371  to wire  80 .  FIG. 13B  is a perspective view of electrical contact  1310  of connector assembly  1300 . In some embodiments, each one of the plurality of conductor elements  1310  (and  1330 ) is a copper (or other suitable conductive material) having an inner concave surface  1321  that conforms to a portion of the outer surface on battery post  80 , and an outer surface  1320  that conforms to the band clamp (e.g.,  1370 ) when that is tightened, and a formed wire receptacle  1311  (e.g., of stamped copper bent to form a cylindrical opening though which wire end  82  is passed) that can be attached to the wire, such as by crimping, welding, soldering, or band clamping. In some embodiments, the housing of band clamp  1370  includes a cylindrical opening  1371  though which the wire end  82  is passed and attached. In some embodiments, a horizontally oriented worm-drive screw  1304  is provided, while in other embodiments, a top-drive band clamp (such as shown in  FIG. 3A ) or a mechanically advantaged top or side drive band clamp (such as shown in  FIG. 14A ) is used. In some embodiments, one or more of the plurality of conductors  1310 ,  1330  are riveted or welded  1340  to band  71 . Improved reliability is achieved by having a plurality of wire connection points ( 1311  and/or  1371 ) to the wire end  82 , such that redundant conduction paths and connections are provided. 
     FIG. 14A  is a top perspective view of mechanically advantaged top-driven clamp connector assembly  1400  that allows hand actuating beveled-gear worm-drive screw  1404  with a mechanically advantaged gear ratio, vertically or side oriented, via beveled-gear head  1430 .  FIG. 14B  is a side perspective view of connector assembly  1400  showing the gear end of beveled-gear worm-drive screw  1404 . The gear configuration of bevel gear  1433  and larger bevel gear  1407  provides a mechanical advantage that allows band clamp  1470  to be hand-tightened without tools. In some embodiments, band clamp  1470  includes a first housing  1410  that holds grooves near both ends of worm-drive screw  1404 , and a second housing  1411  that holds grooves near both ends of hand-actuated drive head  1430 , and hold bevel gear  1433  against larger bevel gear  1407 . Head  1437  can be any suitable form, such as a wing nut or a knurled knob, and in some embodiments, includes a feature such as a slot for use with a screwdriver if extra leverage is needed. In some embodiments, band clamp  1470  contacts directly against battery post  99  to provide a redundant current path. In some embodiments, a hole  1430  is provided in conductor  1401  for inserting wire end  82 , and a set screw  61  or other suitable clamp is provided to hold wire end  82  in place. In some embodiments, the outer cylindrical (or oval prism) shape of conductor  1401  is tilted to provide clamping pressure  62  at the lower portion of post  99  (on the lower right side of the  FIG. 14B ), while having the worm-screw end  63  raised relative to the battery surface and post  99 , in order to provide more vertical clearance for bevel gear  1407 . 
   One further consideration of material usage is that of its environmental impact. The materials used here have far less negative environmental impacts in comparison to the traditional lead-containing connectors. 
   In some embodiments, the invention provides a connector apparatus for use in connecting a battery-power cable to a battery-terminal post. This connector includes a tightenable adjustment band that provides for connector installation, removal and tension adjustment, a band-tightness-adjustment assembly operatively coupled to the band and a radius electrical conductor that provides a primary electrical current path and includes a cable-wire-attachment feature to enable power distribution through a cable, wherein the band-tightness-adjustment assembly, the band, and the radius electrical conductor form a tightenable inner opening that can surround and tighten on the battery-terminal post. 
   In some embodiments, the adjustment band includes a plurality of slots, and the band-tightness-adjustment assembly includes a worm-drive screw that interfaces with the slots to tighten the banc, the screw having a drive head that includes a slot configured for use with a conventional slot-drive screwdriver, a cross slot configured for use with a conventional Phillips screwdriver and a hexagonal head configured for use with a conventional hexagonal wrench. 
   In some embodiments, the slotted adjustment strap includes slots restricted to about one centimeter or less to maximize mechanical strength and electrical contact. 
   In some embodiments, the band-tightness-adjustment assembly includes a stainless steel slotted adjustment strap, providing a relatively corrosion resistant secondary electrical current path. 
   In some embodiments, the radius electrical conductor includes a copper radius contact at least partially coated with tin to make the contact galvanically compatible with the battery-terminal post and copper-wire cable. 
   In some embodiments, the worm-drive adjustment assembly includes a radius contact bonded in electrical communication with the slotted adjustment strap. 
   In some embodiments, the band-tightness-adjustment assembly includes a worm-drive screw having a beveled gear head, and a tool-interface head that mates with and provides screw actuation to the screw through a perpendicularly oriented beveled gear drive head. 
   Some embodiments further include the battery-power cable attached to the connector. 
   Some embodiments further include a motor vehicle having a battery, the battery having a battery-terminal post, and a battery-power cable connected to the connector to electrically connects the battery to the vehicle. 
   Another aspect of the invention, in some embodiments, is a connector kit for use in the connection of a power cable to a power terminal post. The kit includes a band clamp and an electrical-contact conductor that provides a primary electrical current path and having a concave surface configured to conform to an outer surface of the post, a convex outer surface that is configured to conform to an inner surface of the band clamp when tightened, and a cable attachment to enable power distribution through the cable. 
   In some embodiments, the band clamp includes a worm-drive screw with a head providing a slot for use with a conventional slotted screwdriver, a cross slot for use with a conventional Phillips screwdriver and a hexagonal head for use with a conventional hexagonal wrench. 
   In some embodiments, the band clamp includes slots in a slotted adjustment strap that are restricted to about 1.25 cm or less for adjustment to increase mechanical and electrical contact. 
   In some embodiments, the band clamp includes a stainless-steel slotted adjustment strap, providing a relatively corrosion proof secondary electrical current path. 
   In some embodiments, the electrical-contact conductor is bonded in electrical communication with the band clamp. 
   In some embodiments, the electrical-contact conductor includes a tin-coated copper concave electrical contact bonded in electrical communication with the slotted adjustment strap. 
   In some embodiments, the band clamp includes a worm-drive screw having a beveled gear head that mates with and provides screw actuation through a perpendicularly oriented beveled gear drive head. 
   Yet another aspect of the invention, in some embodiments, is method of connecting a battery cable to a battery post. The method includes providing an electrical-contact conductor having a concave surface configured to conform to an outer surface of the post, and a convex outer surface that is configured to conform to an inner surface of a band clamp when tightened, attaching a cable to the electrical-contact conductor, and band-clamping the electrical-contact conductor to the battery post to enable power distribution through the cable. 
   In some embodiments, the band clamping includes providing a mechanically advantaged rotation to a worm screw to tighten the conductor-to-post contact. 
   In some embodiments, the attaching of the cable further comprises band clamping the electrical-contact conductor to the cable. 
   Also described, in some embodiments, is a apparatus for use in the connection of a power cable to a power-terminal post, the apparatus including an electrical-contact conductor that provides a primary electrical current path and having a concave surface configured to conform to an outer surface of the post, a convex outer surface that is configured to conform to an inner surface of the band clamp when tightened, and a cable attachment to enable power distribution through the cable; and clamping means to exert force to connect the electrical-contact conductor to the power-terminal post. 
   It is to be understood that the above description is intended to be illustrative, and not restrictive. Although numerous characteristics and advantages of various embodiments as described herein have been set forth in the foregoing description, together with details of the structure and function of various embodiments, many other embodiments and changes to details will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should be, therefore, determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein,” respectively. Moreover, the terms “first,” “second,” and “third,” etc., are used merely as labels, and are not intended to impose numerical requirements on their objects.