Patent Document

FIELD OF THE INVENTION 
     The invention relates generally to electrical terminal connectors, and more specifically to terminal connectors adapted to provide multi-battery couplings for batteries that utilize tab type terminals. 
     BACKGROUND OF THE INVENTION 
     As more and more segments of the business environment enter the information age, more and more computers and computing power are required. As businesses move from the old to the new economy, their reliance on the processing, transference, and storage of digital information is becoming a more and more critical aspect of their overall business strategy. While in the past, computer crashes were seen as a mere nuisance, the loss of computing power and business data may well devastate a business&#39;s ability to survive in this new economy. As such, the need for reliable, uninterruptible electric power to maintain the operational status of the computing equipment and the integrity of the digital data continues to rise. 
     To meet these requirements, uninterruptible power supplies (UPS) have been developed that utilize a bank of electric storage batteries and solid-state conversion equipment to provide continuous electric power to a business&#39;s computer systems in the event of a loss of power from the utility. The number of batteries contained within an UPS is dependent upon the business&#39;s length of time that it needs to operate in the event of a utility power system failure. However, with many utilities requiring rolling brownouts during peak electric usage periods, the number of batteries being utilized continues to increase. 
     A typical UPS includes multiple banks of series connected batteries that supply DC electric power to a solid state power inverter. The inverter converts the direct current battery power to alternating current power for use by computing utilization equipment. As illustrated in FIG. 15, a typical battery configuration includes two tab type output connectors  200 ,  202  from which their DC power is supplied. The batteries  204   a-n  are placed side-by-side to form a battery bank for the UPS. The series coupling between each of the individual batteries in the bank is accomplished by providing a series coupling device  206 . This device  206 , as illustrated in greater detail in FIG. 16, consists of a simple assembly of two tab type connectors  208 ,  210  that are crimped to the ends of a jumper wire  212 . While this simple apparatus  206  provides adequate series connections between each of the batteries in the battery bank, it suffers from a number of disadvantages. 
     Specifically, while the material costs of the apparatus  206  are fairly low, its construction and installation labor requirements are quite high. First, after the jumper wire  212  has been cut to the proper length, the insulation on each end must be removed to allow for proper electrical connection with the tab connectors  208 ,  210 . The bare wire  214  must then be inserted into the crimping end  216  of the tab connector  208 ,  210  and crimped. The crimping must be controlled to supply the electrical connection to the wire  212 , and to mechanically secure the bare wire  214  therein. This operation typically requires a special crimping tool to insure that the crimp is sufficient to meet industry standards for the pull requirement for this connection. Once this operation has been performed for each end of the jumper wire  212 , the apparatus  206  must be installed to complete the series coupling of the batteries in the battery bank. 
     The installation of the apparatus  206  presents the second problem area for this configuration, that being the labor intensity required. Specifically, the tab connectors  208 ,  210  typically provide a friction or interference fit on the battery tab connectors  200 ,  202 . As such, they can be fairly difficult to install, requiring that the assembly personnel grip one of the connectors  208  and force it onto one of the terminals  202 . This process is often aided by a wiggling type motion of the connector  208  while pushing it on the battery&#39;s tab connector  202 . While this wiggling type movement does not present a significant problem for the installation of the first of the two connectors of apparatus  206 , a similar motion during the installation of the second such connector may fatigue the wire  214  at the junction with the crimping end  216  at one or both of these junctions. This results from the fact that one of the connectors is already fixed on a battery terminal while the other end is being manipulated in a wiggle fashion. 
     Further, once installed, these jumpers  206  present loops of wire that may be easily caught on the chassis, by monitoring equipment, maintenance personnel, etc. during installation, operation, or maintenance of the UPS. If such were to occur, once again the crimped couplings of the wire  214  to the connector crimp end  216  would be stressed. Eventually, such continued stressing and fatigue could lead to a failure of the jumper wire connection  206 . Even if the jumper  206  did not actually break, it is possible that equipment catching the wire loop of this jumper  206  could dislodge one or both of the connections to the battery&#39;s tab terminals. 
     In addition to these problems, the installation of these jumpers  206  may also be uncomfortable for the assembly personnel who must literally install hundreds of such connections in a day. While the assembly personnel may wear gloves to protect his or her fingers from developing calluses, or may use an insertion tool such as a pair of needlenose or other type pliers, each of these personnel aids have their own drawbacks. Specifically, gloves may make it harder to grip the small connectors  208 ,  210 , and may also reduce the assembler&#39;s ability to feel when the coupling is fully seated. This may result possibly in bending the tab connectors  200 ,  202  on the battery. Likewise, the use of pliers or other like tools to grip the connectors  208 ,  210  during the insertion onto connectors  200 ,  202  may result in damage to or even breakage of the connectors  200 ,  202 . As may well be appreciated, once the connector  200 ,  202  is broken off of a battery, that battery cannot be used unless or until it can be repaired. Further, the use of pliers or other like tools may flatten or otherwise damage the connection surfaces on the connectors  208 ,  210 . This would inhibit or diminish the connector&#39;s ability to maintain both electrical and mechanical contact on the battery&#39;s tab connectors  200 ,  202 . 
     Therefore, there exists a need in the art to provide a simple, reliable, and cost effective apparatus to provide the series coupling between adjacent batteries in a UPS which overcomes these and other known problems existing in the art. 
     SUMMARY OF THE INVENTION 
     It is a feature of the battery terminal jumper clip of the invention to provide a single piece, unitary construction capable of electrically coupling adjacent batteries having tab type electrical terminals thereon. It is a further feature that the battery terminal jumper clip provides a snap-on, locking mechanism to inhibit the removal of the clip once installed on adjacent batteries in a battery bank. Further, it is a feature of the battery terminal jumper clip to provide a guided insertion surface to ease the installation of the clip on adjacent batteries during the battery bank manufacturing process. Additionally, the battery terminal jumper clip also includes axially retention surfaces to prevent the battery terminal jumper clip from working off the tab connectors from one side or another while still allowing limited axially movement of the connector due to shifting of the equipment or other causes of battery movement. 
     It is also a feature of the battery terminal jumper clips to provide a solid conductive bus for the conduction of current between adjacently mounted batteries in a battery bank. Preferably, the bus provided by the battery terminal jumper clip maintains a flat profile that is not prone to catching on other equipment, like the prior use of a loop of wire to provide this coupling. Additionally, it is a feature of the battery terminal jumper clips to provide a tab retention clips. These clips provide both electrical and mechanical coupling to the tab terminals of each of the two adjacent batteries to which the clip is attached. Preferably, an independently moveable retention clip is included for each of the two tab type terminals for the two adjacent batteries. Alternatively, it is a feature of the battery jumper clips to provide bifurcated tab retention clips to allow for greater movement of the individual batteries within the battery bank, while still maintaining electrical and mechanical contact therewith. It is also a feature of the battery terminal jumper clips to provide an integrated auxiliary connection terminal to allow external monitoring equipment to monitor the battery voltage at the coupling or to allow the supplying of power therefrom. This auxiliary connection terminal may preferably be integrated in to the top surface bus work, or may alternatively be provided as an integral portion of one of the axially retention surfaces. 
     Other features and advantages of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present invention, and together with the description serve to explain the principles of the invention. In the drawings: 
     FIG. 1 is a front perspective illustration of a portion of a battery stack utilizing the battery terminal jumper clip of the invention; 
     FIG. 2 is a rear perspective illustration of the battery stack of FIG. 1 illustrating additional aspects of the battery terminal jumper clip of the invention; 
     FIG. 3 is an expanded sectional view of a portion of the battery stack of FIG. 1 illustrating certain aspects of the battery terminal jumper clip of the invention in greater detail; 
     FIG. 4 is an expanded sectional view of a portion of the battery stack of FIG. 2 illustrating additional features of the battery terminal jumper clip of the invention in greater detail; 
     FIG. 5 is a top view of the battery terminal jumper clip of the invention installed on adjacent batteries in a battery stack forming a portion of an uninterruptible power supply; 
     FIG. 6 is a side sectional view of the battery terminal jumper clip of the invention mounted on a battery tab terminal; 
     FIG. 7 is an expanded front perspective view of an alternate embodiment of the battery terminal jumper clip of the invention having a auxiliary connection terminal integrally formed therewith; 
     FIG. 8 is a rear perspective view of the embodiment of the battery terminal jumper clip of the invention illustrated in FIG. 7; 
     FIG. 9 is a front perspective illustration of an additional alternate embodiment of the battery terminal jumper clip including an integrally formed side voltage monitor terminal; 
     FIG. 10 is a rear perspective illustration of the battery terminal jumper clip illustrated in FIG. 10; 
     FIG. 11 is a bottom view of an embodiment of the battery terminal jumper clip of the invention having a separate tab retention clip for each battery terminal; 
     FIG. 12 is a bottom view of an alternate embodiment of the battery terminal jumper clip having a single tab retention clip spanning both batteries&#39; tab terminals; 
     FIG. 13 is a bottom view of a further alternate embodiment of the battery terminal jumper clip of the invention illustrating separate bifurcated tab retention clips; 
     FIG. 14 is a perspective view illustration of an alternate embodiment of the battery clip of the invention; 
     FIG. 15 is a perspective illustration of a portion of a battery bank of an uninterruptible power supply utilizing a prior jumper connection to provide series coupling between adjacent batteries; and 
     FIG. 16 is a perspective illustration of the prior jumper apparatus illustrated in FIG.  15 . 
     While the invention will be described in connection with certain preferred embodiments, there is no intent to limit it to those embodiments. On the contrary, the intent is to cover all alternatives, modifications and equivalents as included within the spirit and scope of the invention as defined by the appended claims. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     An embodiment of the battery terminal jumper clip  20  of the invention, as illustrated in FIG. 1, provides series coupling between a plurality of batteries  204   a-e  forming a battery stack  22  suitable for use in an uninterruptible power supply (UPS). Such a configuration is typical for an uninterruptible power supply to which this invention is particularly well suited. However, it should be understood that the applicability to other components, products, and industries is not to be excluded by reference to a preferred implementation. While FIG. 1 illustrates a battery stack  22  including five batteries  204   a-e , one skilled in the art will recognize that greater or fewer batteries may be included in the battery stack  22  depending on the system requirements of the UPS. Additional couplings may be added in like manner as will be described in greater detail below without deviating from the spirit and scope of the invention. 
     As may be seen and understood from this FIG. 1, each battery  204  includes a negative tab type terminal  200  and a positive tab type terminal  202 . These tab connectors  200 ,  202  are positioned near the outer peripheral edges of the battery  204 , one on either side as illustrated. To form the battery stack  22 , a user merely places the batteries side by side on a rack or in a housing. The series connection between each of the adjacent batteries is then made by the battery terminal jumper clip  20  of the invention as illustrated in this FIG.  1 . Specifically, the battery terminal jumper clip  20  makes electrical connection from the positive tab type terminal connector  202  of one battery to the negative tab type terminal connector  200  of the battery directly adjacent thereto to form the series connection. Once these series connections between the batteries have been made, the battery bank may be coupled in circuit with the UPS by providing connection to the tab connectors on the outside edges of the two end batteries ( 204 A,  204 E) in the battery stack  22 . The UPS voltage requirements and the individual power output voltage level determines how many batteries are placed in series to form the complete battery stack  22 . 
     FIG. 2 provides a rear view illustration of the battery stack  22  illustrated in FIG.  1 . This rear view illustration allows a clearer view of each of the tab type terminal connectors  200 ,  202  for each of the series connected batteries  204 . The battery terminal jumper clip  20  provides this series connection in a very low profile manner as may be seen from this FIG.  2 . Specifically, there are no wire loops or other structures that may protrude or otherwise extend vertically from the planar surface of the tab type terminals  200 ,  202  that could catch on other equipment such as the wire loops discussed in the background section above. Indeed, the battery terminal jumper clip  20  provides a unitary single piece construction whose reliability greatly exceeds the multi-piece assembly utilized to provide the series coupling in the past. 
     FIG. 3 illustrates an expanded perspective view of the battery terminal jumper clip  20 , as installed to provide a series coupling between two adjacent batteries  204   a ,  204   b , as taken along section  24  of FIG.  1 . As may be seen from this sectional illustration, the front edge surface  26  of the battery terminal jumper clip  20  provides a relatively smooth rounded surface on which assembly personnel may press to install the clip  20  on the adjacent batteries to complete the series coupling therebetween. Since this clip  20  is a unitary, single piece construction, the rigidity of the top bus surface  28  allows both connections to the tab type terminals of the adjacent batteries in a single operation. This greatly reduces the assembly time, labor costs, and discomfort as compared to the prior methods of making this series coupling. 
     Also as may be seen from this expanded view, the clip  20  includes axial retention surfaces  30 ,  32  that prevent the clip  20  from working off of one of the tab type connectors in a lateral manner. That is, any lateral motion of the batteries that would tend to cause the clip  20  to creep in one lateral direction or the other will only be able to cause movement of the clip  20  to the point where the axial retention surface  30  or  32  contacts the edge of one of the tab connectors or the other. In addition to providing the retention function as just discussed, it should be noted that some relative movement is allowed between the two adjacent batteries without resulting in fatiguing of the tab terminal connectors due to the placement of the axial retention surfaces  30 ,  32 . 
     Specifically, these surfaces  30 ,  32  are positioned in such a manner and with such a dimension so that preferably neither surface  30 ,  32  is in contact with the edge of either of the tab type terminal connectors when the batteries  204   a ,  204   b  are properly placed and the clip  20  is centered about the adjacent edges of the battery. In this way, either battery may move in a lateral side-to-side fashion toward or away from the other without fatiguing the tab connectors. This is accomplished by allowing the tab terminal connectors to freely move in a lateral side-to-side direction without encountering a constraining vertical surface until the outer axial retention surface  30 ,  32  is contacted. Even at this point, however, damage causing fatigue will still not occur on the tab terminal connector as the entire clip  20  will then slide laterally until the tab terminal connector on the other battery contacts the other axial retention surface  32 . However, while slight vibration and some small lateral misalignments are common in UPS assembly operation, such larger scale movement is typically not encountered. 
     In addition to allowing relatively substantial lateral movement between adjacent batteries  204   a  and  204   b , the battery terminal jumper clip  20  also allows relative vertical movement between the two batteries without unduly stressing the tab type terminal connectors  200 ,  202  and without breaking electrical or mechanical contact therewith. Specifically, the surface  26  is bent under the bus surface  28  forming two tab retention clips  42 ,  44 . These two retention clips independently clamp onto its associated tab terminal connector  202 ,  204  respectively. As one battery moves in a vertical direction relative to the placement of the other battery, the tab retention clips  42 ,  44  will individually flex to accommodate the relative vertical movement. 
     Depending on the severity of the vertical relative movement, the bus surface  28  may be angled between the two tab terminal connectors. However, each of the two tab retention clips  42 ,  44  will flex to maintain a relatively uniform mechanical contact with the undersurface  36  of its respective tab terminal connector. This relatively uniform mechanical connection provides both mechanical stability as well as electrical continuity to maintain the series connection between the batteries under such conditions. 
     As may be seen from the rear view of the battery terminal jumper clip  20  as illustrated in FIG. 4, lateral movement of the clip  20  in a direction along the junction between the two batteries  204   a ,  204   b  is inhibited by the snap-on locking mechanism or surface  34  formed on the rear edge of the bus surface  28 . As may be seen from this FIG. 4, this snap-on retention surface  34  drops down over the rear of the horizontal surface  36  of the tab type terminal connector  200 ,  202  thereby inhibiting the clip&#39;s inadvertent removal. As will be recognized by one skilled in the art, movement in the opposite lateral direction is inhibited by the front surface  26 . Alternatively, this movement will be inhibited by the contacting of the vertical surface  38  of the tab type terminal connectors  200 ,  202  by the guided insertion surface  40  of the clip  20  (as will be described in greater detail below). The particular mechanism which will prevent movement in this direction is dependent somewhat on the length of the horizontal surface  36  of the tab type terminal connector in relation to a similar dimension of the bus surface  28 . 
     FIG. 5 illustrates a top view of the installed battery terminal jumper clip  20  on batteries  204   a  and  204   b . As this top view illustration of FIG. 5 demonstrates, the clip  20  may be positioned off center without stressing the tab type connectors. This is evident from the position of the tab connector  202  in proximity to the axial retention surface  30 , but without the tab connector  200  being visible in a similar position with respect to surface  32 . As such, battery  204   a  could move away from battery  204   b  quite a distance before both tab terminals  200 ,  202  would begin to contact surfaces  30  and  32 . 
     A cross-sectional view of the battery terminal jumper clip  20  is illustrated in FIG. 6 to which specific reference is made. This cross-sectional view clearly illustrates the interaction between the clip  20  and the battery&#39;s tab type terminal connector  202 . Specifically, it may be seen that the snap-on locking mechanism or surface  34  extends beyond and over the ninety-degree bend of the tab terminal connector  202 . This, in conjunction with the force applied by the tab retention clip  42  inhibits the clip  20  from being inadvertently removed from its installed position. It may also be seen from this cross-sectional illustration that the bus surface  28  provides approximately uniform electrical contact across the surface of the horizontal surface  36  of the tab terminal connector  202 . As discussed above, this electrical connection is facilitated by the mechanical force applied by the tab retention clip  42 . This retention clip  42  also provides an electrical contact point on the lower surface of the horizontal tab terminal connector surface  36 . Both of these electrical connections may be facilitated in a preferred embodiment by applying a tin surface coating to the clip  20 . This reduces the dissimilar metal contact problem that often results for batteries which utilize tin-plated tab terminal connectors. 
     While most batteries manufactured for inclusion in battery banks for uninterruptible power supplies utilize similar external physical construction, batteries from different manufacturers are not held to an industry standard for the physical placement and size of the tab terminal connectors included thereon. As such, the sizing and dimensioning of the battery terminal jumper clip  20  preferably allows for such physical deviation between manufacturers so that its applicability to battery banks constructed from batteries supplied from different manufacturers may be preserved. As illustrated in FIG. 6, this universal applicability may be accomplished by controlling the distance from the snap-on locking surface  34  to the mechanical contact point of the tab retention clip  42 . This distance is illustrated in FIG. 6 as L′. By controlling this length to be less than the shortest length of the horizontal surface  36  of any tab terminal connector utilized in the industry, solid electrical and mechanical contact with the smallest connectors  202  may be ensured. 
     To accommodate larger tab terminal connectors, the distance L from the snap-on locking surface  34  to the surface  26  is controlled to be at least as long as the largest tab type terminal connector utilized in the industry in such applications. In this way the snap-on locking retention surface  34  will always be able to be properly seated to inhibit the inadvertent removal of clip  20 . Also, the possible different placement of the tab type terminal connectors on the top surface of the batteries is accommodated by the distance W between the axial retention surfaces  30 ,  32  as illustrated in the above-described FIG.  5 . Once again, if it is desired to construct a single clip  20  which will accommodate any battery manufactured for such an application, this distance W is controlled to be, preferably, slightly longer than the distance between the outer relative edges of the two tab terminal connectors required to make the series electrical connection. 
     In an alternate embodiment of the battery terminal jumper clip  20 ′ illustrated in FIG. 7, a auxiliary connection terminal  46  is formed in the horizontal bus surface  28 . This auxiliary connection terminal  46  may also preferably include an aperture  48 . The size of the auxiliary connection terminal  46  may be as desired, and is preferably sized to accommodate tab type terminal connections for conventional battery monitoring and utilization equipment. A rear view of this alternate embodiment  20 ′ is illustrated in FIG.  8 . 
     A further embodiment of the battery terminal jumper clip  20 ″ having a battery auxiliary connection terminal  50  included therewith is illustrated in FIG.  9 . As may be seen from this illustration, the auxiliary connection terminal  50  is formed as part of one of the axial retention surfaces  30 . In this alternate configuration, the axial retention surface  30  includes an additional bend to the horizontal and a ninety-degree turn to allow the auxiliary connection terminal  50  to extend in a forward direction. This forward facing auxiliary connection terminal  50  is preferable to allow the most unobstructed access thereto. While the invention contemplates a battery auxiliary connection terminal which extends to the side, such configuration may not be desired in applications where the individual batteries and the battery stack are relatively thin and their tab terminal connectors  200 ,  202  are in close proximity to one another. With the configuration illustrated in FIG. 9, even in such situations the monitoring may be accomplished via tab  50  without interference between or the chance of a short across the tab terminal connectors  200 ,  202  of the same battery. 
     FIG. 10 illustrates a rear view of the battery terminal jumper clip  20 ″ of FIG.  9 . As may be more clearly visualized from this FIG. 10, the battery auxiliary connection terminal  50  is maintained at a sufficient vertical distance above the top of the battery to allow monitoring equipment to properly attached thereto. 
     Turning now to the bottom view illustration of the battery terminal retention clip  20  of the invention, the tab retention clips  42 ,  44  may be examined in closer detail. In a preferred embodiment as illustrated in FIG. 11, the battery terminal retention clip  20  includes two tab retention clips  42 ,  44  configured to individually contact one of the two tab terminal connectors  200 ,  202  required to make the series connection between adjacent batteries. The distance D between these two retention clips  42 ,  44  is sized to preferably preclude the contact of one retention clip  42 ,  44  with both tab terminal connectors  200 ,  202  at the same time. This distance D takes into account the condition where the clip  20  has slid its maximum distance to one side so that one of the tab terminal connectors is contacting one of the axial retention surfaces  30  or  32 . 
     By providing two independently flexible retention clips  42 ,  44 , any relative vertical movement between adjacent batteries may be fully accommodated by the individual flexure of the retention clips  42 ,  44  with the vertical position of its associated tab type terminal connector. As may be seen in this FIG. 11, each of the tab retention clips  42 ,  44  terminates in a guided insertion surface  40  that significantly aids in the installation of the clip  20 . 
     An alternate embodiment of the battery terminal jumper clip  20  is illustrated in FIG.  12 . As may be seen from this alternate embodiment, a single tab retention clip  54  is formed. This single retention clip  54  contacts both tab type terminal connectors. While relative vertical motion between adjacent batteries is not individually accommodated as in the case of the embodiment in FIG. 11, adequate electrical and mechanical contact is still maintained to each of the tab type terminal connectors by the clip  20  to maintain a reliable series coupling therebetween. 
     Yet a further embodiment of the battery terminal retention clip  20  is illustrated in FIG.  13 . As may be seen from this bottom view illustration, two bifurcated tab retention clips  56 ,  58  are provided. Each of these two bifurcated retention clips  56 ,  58  provide two independently flexible clips  60 ,  62  and  64 ,  66 . In such a configuration, the battery terminal jumper clip  20  may accommodate even greater relative vertical movement between the adjacent batteries without stressing the tab type terminal connectors. Additionally, by maintaining multiple points of electrical contact during such relative vertical motion between adjacent batteries, this embodiment also provides improved electrical connection to the bottom surface of each of the tab terminal connectors. Of course from an electrical standpoint, while two individual retention clips  60 ,  62  are illustrated to make up the retention clip  56 , the number of individual sections may be increased significantly. However, from a mechanical stability and manufacturability standpoint, a limit on the number of individual constituent retention clip segments to make up the overall retention clip  56 ,  58  will reach a practical limit. While more than two may be applicable and are clearly within the scope of the invention, physical practicalities and system requirements and constraints may well limit the number of these constituent clip segments. 
     An alternate embodiment of a battery terminal clip  70  constructed in accordance with the teachings of the invention is illustrated in FIG.  14 . In this embodiment, the clip  70  includes two battery terminal retention clips  72 ,  74  coupled one to another by a flexible bus  76 . The flexibility of the bus  76  allows for relative movement between the batteries without unduly stressing the tab type terminal connectors thereon. Unlike the prior coupling apparatus illustrated in FIG. 16, the clip  70  of FIG. 14 is a unitary component. This greatly simplifies the manufacture of this clip  70 , while increasing the reliability and reducing the cost thereof. 
     The foregoing description of various preferred embodiments of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiments discussed were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally, and equitably entitled.

Technology Category: h