Patent Publication Number: US-2004048142-A1

Title: Power management and distribution assembly mountable to a battery

Description:
FIELD OF THE INVENTION  
       [0001] The present invention relates generally to battery power management and distribution devices. In particular, the present invention discloses a battery mounted power distributing junction box assembly combining energy management and power cutoff subassemblies, pluralities of output connectors for wire harnesses and the like, and provision for fuses and relays for circuit protection, all being incorporated into a housing capable of being secured directly to any face of the battery and connected to its positive and negative terminals.  
       BACKGROUND OF THE INVENTION  
       [0002] Current vehicle battery power distribution and battery power management technology contemplates the provision of stand-alone modules at locations throughout a vehicle. Such modules are necessary for monitoring certain parameters of the battery including current flow, battery temperature and the like. It is also required that a battery cut-off switch be provided which can cut power to the battery in the event of an accident or when a sub-system of the battery requires repair.  
       [0003] It has further been determined that the provision of such power distribution centers in varied locations adds to both trouble shooting problems and downtime for vehicle repairs. Existing connections to battery power feed to the vehicle are also not of the “plug-in” variety, resulting in the requirement that an entire vehicle harness be replaced or, at the very least, spliced when repairs are required. Existing power feed connections are also currently made through the use of a stud, ring terminal, and nut these not being of the quick-disconnect variety.  
       [0004] Attempts have been made in the relevant art to centralize certain aspects of power distribution and management technology proximate the battery and a first example of this is set forth in U.S. Pat. No. 5,882,213, issued to Witek et al., which teaches a junction box with a housing mounted directly to a battery. The junction box includes a plurality of electrical outlets for receiving the electrical output from a terminal connected to the battery and such that the junction box is attached to the battery through the terminal. The terminal and outputs are preferably mounted and supported directly on the battery, such as by the terminal being mounted to a battery post of the battery in order to secure the junction box.  
       [0005] Witek further teaches a plurality of electrical outputs coupled to a printed circuit board for distribution of the electrical power. A second plurality of outputs direct the electrical power from the circuit board to the wiring harnesses for further distribution. The circuit board and at least a portion of the terminal are enclosed within a sealed housing, in turn secured closely and adjacently to the battery by the terminal and supported by the battery.  
       [0006] U.S. Pat. No. 5,645,448, issued to Hill, teaches a battery connecting module mountable to an automotive vehicle battery. The module provides electrical connection between a battery post, a cable leading to an alternator, one or more cables leading to vehicle electrical systems such as a fuse box and a starter motor, and a main fuse located inside the module and connecting the alternator cable with the other components. The battery connecting module protects the major engine compartment electrical connections from solid and liquid contaminants and locates the main fuse in a manner which protects the alternator cable from short circuit conditions. Two of the cables are connected to the module by cable terminals which extend downward and into close proximity with the vertical battery side walls, thereby adding to the security of the battery connecting module&#39;s mounting on the battery.  
       [0007] Finally, U.S. Pat. No. 5,643,693, also issued to Hill, discloses another and similar variant of an electrical power distribution module mounted to a top surface of a battery. A battery terminal connector is in electrical contact with a battery terminal and a plurality of fuse receptacles. A bus bar electrically connects the battery terminal connector to the fuse receptacles lying in a substantially horizontal plane in close proximity to the battery top surface and in order to contribute to the overall low profile created by the device. Starter and alternator cables are disclosed as being connectible to the battery terminal connector and bus bar, respectively. A cover is attached to the power distribution module and has hinged sections which may be opened to provide access to the battery terminal connector and fuse receptacles.  
       SUMMARY OF THE INVENTION  
       [0008] The present invention is a battery mounted housing assembly combining energy management, power cutoff, pluralities of output connectors for power connector plugs, wire harnesses and the like, as well as the provision of fuses and relays for circuit protection. The housing is secured directly to any face of the battery (including sides, bottom or top) and the associated energy management and power switch cut-off subassemblies connected (according to a preferred application) to its negative and positive terminals, respectively. The present invention is again an improvement over the prior art in that it provides a more capable and sophisticated assembly for accomplishing power management (i.e., load control) and distribution of the battery power, as well as the localized ability to both manually trip and reset the battery power output, all of these features being incorporated into the housing.  
       [0009] A main cover is securable over an exposed face of the housing and further includes an access door defined therein for revealing the various fuse, relay and controller components incorporated into the assembly. Additional battery terminal covers are assembleable over the first and second terminals and, in cooperation with the main cover, substantially enclose and protect the housing assembly. An additional feature of the housing is the provision of an extending and planar base for the purpose of securing against an associated bottom surface of the battery and which, in combination with pedestal engaging portions extending from a top surface of the housing, fixedly secure the same to the face of the battery.  
       [0010] The energy management subassembly accomplishes functions such as emitting a diagnostic output signal representative of a measured condition of the battery and generating an overload signal in the event that the maximum operating parameters of the battery have been exceeded. The cut-off switch subassembly includes features such as tripping power from the battery in the instance of a signal received from the energy management module or, alternatively, from the deployment of such as vehicle crash sensor, evidencing a collision. Both manual trip and reset buttons are positioned at exposed locations proximate and in communication with the cut-off switch subassembly.  
       [0011] A plurality of connector outputs are provided at selected locations of the housing and include among them powere feed connectors in operative communication with the cut-off switch assembly. Additional wire harness connectors are located along a front fase of the housing, the overlaying main cover being configured with an outwardly flared opening at one location and in order to permit the associated and extending wire harness and input plugs to communicate with the connectors. An additional pair of connectors are associated with the energy management subassembly and include at least one input connector for receiving signals from remotely located accessories. 
     
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
     [0012]FIG. 1 is a perspective view of the housing incorporating the power management and distribution assembly according to the present invention, secured to the battery, and specifically illustrating the features of the main power output ports as well as the fuses, relays and controllers accessible through the main housing access door;  
     [0013]FIG. 2 is a sectional view of an exposed portion of the housing and illustrating the features of the power feed connectors, common bus bar and high current fuse elements according to the present invention;  
     [0014]FIG. 3 is a further enlarged sectional view in side profile of the illustration also shown in FIG. 2 and better illustrating the engaging pins associated with the power feed connectors according to the present invention;  
     [0015]FIG. 4 is another enlarged sectional view of a further exposed portion of the housing and illustrating a plurality of front housing male connectors and battery energy management module connectors according to the present invention;  
     [0016]FIG. 5 is a further rotated perspective of the affixed housing also shown in FIG. 1, and further illustrating in exploded fashion the main housing cover and positive and negative battery terminal covers according to the present invention;  
     [0017]FIG. 6 is a top sectional view of a stamped terminal, such as the terminal associated with the positive battery terminal and securing to an end of the housing corresponding to the placement of the battery cut off switch module according to the present invention;  
     [0018]FIG. 7 is an exploded view of a further variant of the present invention and incorporating an alternative terminal design associated with both the battery and power management and distribution assembly according to the present invention; and  
     [0019]FIG. 8 is an enlarged partial view illustrating a selected battery terminal according to the design of FIG. 7 with interengaging assembly terminal extending from the assembly of the present invention.  
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS  
     [0020] Referring now to FIG. 1, a power management and distribution assembly is illustrated at  10  according to a preferred embodiment of the present invention. The assembly  10  is configured as a three dimensional and substantially enclosed housing which is secured both mechanically and electrically to a battery  12 .  
     [0021] The battery  12 , as is typically known in the art, exhibits a three dimensional and substantially rectangular configuration with top, bottom, front, rear and side faces. For sake of ease of illustration, the battery  12  is illustrated with a fairly narrow profile, however the phantom designations  13  indicated in FIGS. 1 and 5 reference a more accurate configuration of most conventional batteries  12  and as their overall width. It is also understood that a particular construction or shape of a battery is not dictated by the present invention and that the assembly  10  is amenable for adapting to numerous different configurations of the battery  12 .  
     [0022] The battery further includes a negative terminal  14  and a positive terminal  16 . The assembly  10  is particularly suited for use with conventional battery designs rated for providing power commonly known as 12V DC output power, and is also clearly capable of interfacing to other battery designs of higher voltages. The higher voltage rating of the new battery design has been determined to be necessary to offset the additional power demands resulting from the increase in electrically related components incorporated within the vehicle architecture, however it is understood and appreciated that the power management and distribution assembly of the present invention is capable of being utilized with conventional batteries of any voltage rating.  
     [0023] Referring again to the illustrations, and in particular to FIGS. 1 and 5, the assembly  10  is configured as a housing having a substantially planar shaped portion  18  having a given width, height, and depth and which corresponds generally to the dimensions of a selected face of the battery  12 , such as a front face but also contemplating top, side or even bottom faces thereof, and against which the assembly  10  abuts. The planar shaped portion  18  (also known as a front housing) includes a pair of upwardly extending pedestal portions  20  and  22 , extending from ends of which are angled and engaging tab portions  24  and  26 , respectively.  
     [0024] The pedestal portions  20  and  22  and engaging tab portions  24  and  26 , in combination, engage a substantially planar top portion  28  associated with the battery  12 . In particular, the planar top portion  28  may consist of a separate portion of the overall housing  10  and which is secured to the corresponding top surface of the battery  12  by means of screws, fasteners or the like insertable through engagement holes  30  and  32 . It is also contemplated that the top portion  28  may form a permanent part of the top battery surface or, alternatively, may be removed and the pedestal portions  20  and  22  reconfigured to engage a recessed top surface (see at  34  in FIG. 1) of the battery  12 . Also, and the above said, it is also envisioned that a number of alternately configured attaching means may be employed for securing the assembly  10  to a selected face of the battery  12  within the scope of the present invention and beyond that disclosed herein.  
     [0025] Extending from a bottom corresponding location of the planar shaped portion  18  is a planar base  36  (see again FIGS. 1 and 5 and which is otherwise known as a battery support bracket), which is configured to support a corresponding bottom surface of the battery  12 . As best shown again in FIG. 5, upward side  38  and rear  40  projections may extend from specified locations of the planar base  36  and, in combination again with the configuration and location of the upper pedestal and engaging tab portions, secure the housing and assembly to the side face of the battery  12  in the manner indicated in the drawing illustrations. Additionally, and although not clearly shown, it is understood that the planar shaped portion  18  may include bosses on its bottom surface to serve as positioning aids when installing the housing assembly to the planar base  36 .  
     [0026] Due further to the nature of the battery  12  being an energy source, and given present technology, the battery  12  being of substantial weight normally secures it against movement. Adequate means are normally taken to specifically locate, support and otherwise prevent movement of the battery. As such, the assembly  10  may also be positioned relative to an alignment means contained within battery support or retention and/or to features incorporated directly on the battery.  
     [0027] Referring again to FIG. 5, first  42  and second  44  terminals are illustrated which engage, respectively, with the negative  14  and positive  16  terminals of the battery  12 . Each of the terminals  42  and  44  are constructed, in the preferred embodiment, of an elongated and stamped conductive alloy. Referring in particular to the enlarged view of FIG. 6, the terminal  44  is again illustrated in use with the positive terminal (see again post  16 ) of the battery  12 .  
     [0028] Additional structural features such as a terminal draw-down/engagement assembly  46  is provided for securing and electrically communicating the terminal  44  with the battery terminal  16  as well as assisting in engaging the battery  12  to the assembly  10 . Also included is a separate connector  48  extending from the elongated stamping portion of the terminal  44  and extending to an inlet  50  defined in a top surface of the assembly housing. The stamping portion of the terminal  44  also extends into the inlet  50  and communicates to components within the housing assembly as will be subsequently described. The first connector  42 , as also shown in exposed fashion in FIG. 5, is constructed substantially identically to the enlarged illustration of the terminal  44  and again includes a draw-down/engagement assembly  52  and an inlet  54  for receiving the extending stamping portion of the terminal  44 .  
     [0029] Referring again to FIGS. 1 and 5, an energy management subassembly is illustrated at  56  and a cut-off switch subassembly at  58  at first and second locations upon the main housing portion  18  of the assembly. Each of the subassemblies  56  and  58  are affixable to the main housing portion  18  and such that the energy management subassembly (or module  56 ) is secured in proximate and electrically communicating fashion with the terminal  42  (negative battery terminal  14 ), whereas the resettable cut-off switch subassembly (or module  58 ) is likewise mounted in proximate and electrically communicating fashion with the terminal  44  (positive battery terminal  16 ). It is further understood that the terminal connections described above, while preferred, may be reversed and such that the energy management and cut-off switch subassemblies may communicate with the reversed battery terminals. It is further contemplated that the battery energy management subassembly may also incorporate directly the cut-off switch subassembly.  
     [0030] Referencing first the energy management subassembly  56 , it includes many possible interface protocols such as a Communication Access Network (CAN) interface circuit and associated processing technology for measuring specific conditions of the battery  12  (such as again including but not limited to current flow, temperature, etc.). The energy management subassembly  56  is further capable of issuing an output signal illustrative of the measured condition of the battery  12  (such as to a dashboard display of the vehicle) or, alternatively or in addition, the energy management subassembly  56  can issue tripping/shut-off (overload) signal to the cut-off switch subassembly  58  to in turn disconnect the main battery  12  load or selected distributed loads in support of load management.  
     [0031] The battery cut-off switch module  58  is wired into the assembly  10  such that it accomplishes fast and effective disconnect of the battery power through the positive terminal  16  and in the event of a tripping/overload signal received from the energy management module  56 . Alternately the cut-off switch module or subassembly  58  can trip the battery  12  in the event of a separate input signal from such as a circuit associated with a vehicle airbag (or again through the energy management module  56  is the same is calibrated to first detect an airbag inflation condition). Also included with the cut-off switch subassembly  58  is a first manual trip button  60  and a second reset button  62 , each of which are located in proximate and electrically communicable locations with the cut-off switch subassembly  58 . The trip  60  and reset  62  buttons permit a user to manually disengage and then subsequently reengage the battery  12  according to Original Equipment Manufacturers (OEM) guidelines and so that repairs such as those illustrated in OEM repair manuals (e.g. also including without limitation wire harness replacement and line splicing) may be accomplished.  
     [0032] Located at a substantially central area of the housing portion  18  are a plurality of electrical components, these securing to a circuit distributing means incorporated into the housing (i.e., such as stamped metal frets, conductors, PC boards, etc.) and which are referenced by relays  64  and  66 , bi-stable relay  68  (which can switch/stay off or on), pluralities of fuses  70 , and fuel pump controller  72 . Although not clearly shown in the exploded illustration of FIG. 5, the circuit distributing means arrangement incorporated within the housing is accessible by the various electrical components such as through input apertures defined in a forward facing surface and corresponding to  74  (for relays such as  64  and  66 ), apertures  76  (corresponding to fuses  70 ) and apertures  78  (corresponding to such as the bi-stable relay  68 ). As is known in the art, the arrangement of the fuses, relays and controllers is necessary for ensuring the various functions of such as the energy management subassembly  56  and cut-off switch subassembly  58 , as well as the various output connector functions as will be described.  
     [0033] Referring again to FIGS. 1 and 5, as well as to the sectional illustrations of FIGS. 2 and 3, a first plurality of power feed output connectors are illustrated at  80 ,  82 ,  84  and  86  and which may or may not be in electrical communication with the cut-off switch subassembly  58  and typically extend from a proximate and sidewise manner from the housing assembly  10 . The power feed connectors  80 ,  82 ,  84  and  86  are accessed by suitable and conventional input plugs (not shown) and a fuse arrangement is illustrated at  88 , such as which includes a plurality of fuses interconnected by a common bus bar. The fuse arrangement  88  further includes a plurality of individual fuses (such as at  90 ,  92 , and  94  in the enlarged sectional view of FIG. 2) and which are set according to a desired rating, such as in one variant at 150 Amps per fuse.  
     [0034] A further plurality of output connectors is illustrated by front mounted input/output connectors  96 ,  98 ,  100 ,  102 ,  104 ,  106 ,  108  and  110 . The connectors  96 - 110  are electrically communicable with the input and output functions of the vehicle electrical system and are typically slaved to the relays  64 ,  66  and  68  and fuses  70  as well as the battery energy management subassembly  56 . Although not shown, the connectors  96 - 110  are engaged by such as 8 mm and 6 mm power feeds extending from wire harnesses.  
     [0035] The enlarged sectional view of FIG. 4 illustrates the receptor pin arrangements of the connectors  96  and  98  and also shown in enlarged fashion are first  108  and second  110  connectors. The connectors  108  and  110  can receive corresponding input terminals (again not shown) associated with either input or output functions of the energy management subassembly  56 .  
     [0036] Referring once again to FIGS. 1 and 5, a main cover  112  is illustrated and which is securable over the front face of the housing portion  18 . The cover  112  includes a unique configuration (as best shown in FIG. 5) which corresponds to the configuration of the housing portion  18  and accommodates the placement of the energy management  56  and switch cut-off  58  subassemblies. Interlocking tab receipt portions  114  and  116  are illustrated at a top edge location of the main cover  112  and which are engaged by corresponding tabbed portions  118  and  120  (see again FIG. 5) projecting from the corresponding upper edge of the main housing portion  18 .  
     [0037] An access door  122  is defined at a generally centralized location of the main cover  112  and includes a latch  124  engageable with a corresponding location  126  in the main cover. Extending from an opposite side of the door  122  are a pair of hinge portions  128  and  130  such that, upon securing the main cover  112  over the housing, the access door  122  may be opened to reveal the various relays  64 ,  66  and  68 , fuses  70  and controller  72 . In this fashion, these elements may be more easily serviced or replaced.  
     [0038] A side extending location  132  of the main cover  112  is further outwardly flared so as to define a sideways extending opening  134  for receiving, in inserting fashion therethrough, the associated wire harnesses (again not shown) corresponding to the I/O connectors  96 - 110 . First  136  and second  138  battery terminal covers are provided and which, in cooperation with the main cover  112 , secure over the associated stamped terminals  42  and  44  and corresponding battery posts (terminals)  14  and  16 . Latch assemblies  140  and  142  are also illustrated along a corresponding side face of each of the battery terminals covers  136  and  138 , respectively, and to secure the covers in place. Although not specifically shown in the exploded illustration of FIG. 5, it is understood that a fuse element access door is provided over the opening generally defined by the fuse arrangement  88  (150A fuses  90 ,  92 , and  94 ) and in order to provide additional protection.  
     [0039] Referring to FIG. 7, an exploded view is illustrated at  144  of a further variant of the present invention and which incorporates an alternative terminal design associated with both a battery  146  and a power management and distribution assembly  148  according to the present invention. In particular, the modified battery design  146  includes, in substitution of the conventional terminal posts (see such as at  16  in FIG. 6), provision of first  150  and second  152  recessed terminals, and such as which correspond to negative and positive terminals of the battery (or the reverse thereof).  
     [0040] An enlarged partial of the first recessed battery terminal  150  is also illustrated in FIG. 8 and includes a recessed cavity  152  communicable with a front edge location of the battery  146 . It is also envisioned that the recessed cavities associated with the terminals at  150  and  152  may be located in any facing direction of the battery and such as again further including the front, rear, sides, top and even bottom faces of the battery.  
     [0041] Terminal inputs, such as again referenced in enlarged fashion by selected terminal  150 , include a first pin input  154  (such as again corresponding to either the negative or positive aspect of the associated battery terminal  150  or  152 ). Also included in the terminal input design is a second voltage sensor input pin, see at  156  for first terminal  150 . The sensor input pin  156  is further known to incorporate a pass through loop inside of the battery so that, upon experiencing a disconnect condition, it causes the batteries potential load to drop out and to prevent inadvertent arcing during power shut-off and disconnect. Also included inside the voltage input sensor pin  156  is a veristor element, i.e., that part of the battery intelligence circuitry which assists in changing the resistance in relationship to changes such as in temperature, electrical load (current/voltage) and the like. While not as clearly shown in FIG. 7, the second terminal  152  also includes a first pin input  158  (again corresponding to a selected positive or negative terminal of the battery) and an identically constructed and functioning second voltage sensor input pin  160 .  
     [0042] Referencing again FIG. 7, the modification  148  of the power management and distribution assembly further is constructed substantially as previously described in reference at  10  in the first disclosed embodiment, with the exception of its associated terminals (such as previously illustrated by example at  44 ) being substituted by terminals  162  and  164 . Referring once again to the enlarged view of FIG. 8, the selected terminal  162  (typically corresponding to the negative battery terminal  150 ) includes a cord or line  164  (such as may further communicated to the battery energy management subassembly). A male insertion element  166  is also shown and includes a lever  168 . Upon inserting extending pin portions (not shown) of the element  166  into the associated pin inputs  154  and  156  of the selected recessed terminal  150 , the lever is rotated to lock the terminal  162  in place and in a substantially level/flush manner in reference to a top surface of the battery  146 . It is also understood that, beyond the configuration of the battery terminals  150  and  152  and associated assembly terminals  162  and  164  illustrated in FIGS. 7 and 8, other and additional configurations and designs for mating positive and negative inputs of the assembly to the associated inputs of the battery are contemplated within the ordinary skill of one in the art.  
     [0043] In view of the description above, it is evident that the present invention discloses a novel and unique power management and distribution assembly which incorporates numerous and varied stand-alone components into a single housing. The centralized assembly results in a reduction of costs by not requiring the various stand-alone devices and associated wiring extending to and from the remote devices and the battery. The further ability to integrate the energy management and cut-off switch subassemblies into the housing enables the devices to work together to monitor the battery power, update the automobile computer as to the status of battery power, and can be used to cut the battery power to the electrical system when deemed necessary by the processor technology interfacing with the system. Other future considerations include DC to DC converter integration to support the migration from 12V to 42V and higher load applications, as well as the provision of solid state load switching.  
     [0044] Having described the presently preferred embodiments, it is to be understood that the invention may be otherwise embodied within the scope of the appended claims.