TECHNICAL FIELD

[0001] This invention generally relates to automotive lead-acid batteries incorporating embossed electrical contact sockets for the insertion of electrical connector prongs.

BACKGROUND ART

[0002] Automotive lead acid batteries are manufactured with a positive battery terminal and a negative battery terminal on a battery casing. A conventional booster cable typically includes battery terminal clamps having spring-loaded serrated jaws which cause indentations and scratches on lead alloy battery terminals and engine battery clamps. Over time, deterioration of these lead alloy surfaces results from repeated attachment of the booster cable clamps. What is needed is a battery charging apparatus that overcomes the limitations of the background art by:

(i) providing a method of electrically connecting automotive batteries without causing surface damage to battery terminals and engine battery clamps, (ii) assuring proper electrical polarity when connecting a source battery to a discharged battery, and (iii) reducing generation of electrical sparks that may result in hydrogen gas ignition.

INDUSTRIAL APPLICABILITY [0003] A novel method of establishing electrical connection between automotive batteries uses jumper plugs and embossed electrical contact sockets to replace conventional serrated-jaw booster cable battery terminal clamps.

DISCLOSURE OF INVENTION

[0004] The invention results from the observation that electrical connections to battery terminals on a battery housing can be made by inserting jumper cable electrical plugs into electrical contact sockets electrically connected to the battery terminals. These electrical contact sockets are attached to, or formed as part of, the surface of the battery housing. The present invention is an automotive battery with (i) a positive battery contact socket attached to a battery housing adjacent to the positive battery terminal, such that a positive electrical prong can be inserted into a positive socket shell slot and make electrical contact with the positive battery terminal; and, (ii) a negative battery contact socket attached to the battery housing surface adjacent to a negative battery terminal, such that a negative electrical prong can be inserted into a negative socket shell slot and make electrical contact with the negative battery terminal.

BRIEF DESCRIPTION OF DRAWINGS

[0005] Fig. 1 is a system for mobile battery charging using a novel battery jumper plug cable inserted into embossed battery contact sockets on source and load batteries;

[0006] Fig. 2 is an isometric detail sectional view of the positive source battery contact socket and the positive source battery terminal shown in Fig. 1 ;

[0007] Fig. 3 is an isometric sectional detail view of a battery dimple contact socket with a socket electrically conductive trace, a socket shell, and a socket shell sill;

[0008] Fig. 4 is an isometric view of a battery including a positive battery contact socket and a negative battery contact socket;

[0009] Fig. 5 is an exploded isometric view of the positive battery contact socket of Fig. 4, showing a positive battery socket shell, a positive prong retention insert, a socket shell sill, and a positive socket electrically conductive trace;

[0010] Fig. 6 is an isometric cross-sectional detail view of the positive battery contact socket and the positive battery terminal of Fig. 4;

[0011] Fig. 7 shows an insertion of a positive jumper electrical plug into a positive socket shell slot in the positive battery contact socket of Fig. 6; [0012] Fig. 8 is an isometric detail sectional view of a canted battery contact socket electrically connected to a battery terminal;

[0013] Fig. 9 is a cross-sectional isometric view of a battery contact socket;

[0014] Fig. 10 is a battery contact socket electrically connected to a battery terminal by an electrically conductive trace;

[0015] Fig. 11 is a battery with the contact socket of Fig. 10 at a positive battery terminal and the battery contact socket of Fig. 9 at a negative battery terminal;

[0016] Fig. 12 is an isometric detail sectional view of a battery contact socket electrically connected to a battery side terminal; [0017] Fig. 13 is a detail view of a battery contact socket and a modified battery side terminal;

[0018] Fig. 14 shows a side terminal battery with a positive battery contact socket and a negative battery contact socket;

[0019] Fig. 15 is a portable battery lug contact socket; [0020] Fig. 16 is a portable battery spade contact socket; and

[0021] Fig. 17 is a portable battery tab contact socket.

MODES FOR CARRYING OUT THE INVENTION

[0022] Figure 1 illustrates a system and method for mobile battery charging in accordance with aspects of the present invention. A novel battery jumper plug cable 100 is used to conduct an electrical charging current provided by a source battery 120 to a load battery 140. Both batteries 120, 140 are configured and manufactured in accordance with disclosed features of the present invention. The battery jumper plug cable 100 includes a positive insulated electrical conductor 106 and a negative insulated electrical conductor 108. The insulated electrical conductors 106, 108 each have sufficient cross-sectional areas when used to safely conduct high amperage engine starter current. Parallel lengths of the positive insulated electrical conductor 106 and the negative insulated electrical conductor 108 may be physically joined at a conductor pair section 110 for convenience in handling and storage of the battery jumper plug cable 100 with minimal tangling. One end of the positive insulated electrical conductor 106 is electrically connected to a source jumper plug 102. The other end is connected to a load jumper plug 112. One end of the negative insulated electrical conductor 108 is electrically connected to a source jumper plug 104. The other end is connected to a load jumper plug 114.

[0023] The source battery 120 includes a source battery contact socket 132 embossed, or otherwise attached, to the surface of a source battery housing 130 adjacent to a positive battery terminal 122. A source battery contact socket 134 is embossed adjacent to a negative battery terminal 124. The source battery contact sockets 132, 134 may be individual components formed from electrically nonconducting material, such as a plastic, and then attached to the source battery housing 130 during manufacture. The load battery 140 includes a load battery contact socket 152 on the surface of a load battery housing 150 adjacent to a positive battery terminal 142, and a load battery contact socket 154 adjacent to a negative battery terminal 144. The load battery contact sockets 152, 154 are formed from electrically insulating material, such as a plastic or other composite material, and may be bonded, thermally attached, or otherwise attached, to the load battery housing 150. The load battery contact sockets 152, 154 can alternatively be fabricated as embossed socket components, formed unitary with the load battery housing 150.

[0024] Figure 2 is an isometric detail sectional view 01-01 of the source battery contact socket 132 and the battery terminal 122. The source battery contact socket 132 includes an electrically conductive trace 160, a socket shell 162, and a socket shell sill 166 defining a socket shell slot 164. The socket shell slot 164 is substantially a rectangular parallelepiped slot opening extending through the socket shell 162. The source battery contact socket 132 may be fabricated from an electrically non-conductive material such as a plastic or a plastic composite. One end of the socket electrically conductive trace 160 includes a prong contact trace 161 , that is, a conductive trace segment lying at least partially within the socket shell 162. A second end of the socket electrically conductive trace 160 includes a terminal contact trace 163 electrically connected to the positive source battery terminal 122. The entire length of the metal or metal alloy strip forming the socket electrically conductive trace 160 has a sufficient cross-sectional area to safely conduct high amperage engine starter current. In an alternative embodiment, not shown, the socket shell slot 164 can be configured as an internal slot or closed cavity, open only at the socket shell sill 162, with the socket shell slot 164 extending to expose the prong contact trace 161 to an electrical plug prong.

[0025] The source battery contact socket 132 may be thermally bonded or chemically bonded to the surface of the source battery housing 130 of Figure 1 . The socket electrically conductive trace 160 extends from the socket shell sill 166 and is electrically connected to the positive battery terminal 122, such as by a conductive epoxy 123 or by a solder composition. The socket electrically conductive trace 160 can be fabricated from a copper alloy, or can be a lead alloy manufactured as a unitary element making up the battery terminal 122. The thickness of the socket electrically conductive trace 160 is preferably greater than the thickness of the socket shell sill 166, resulting in a relatively small trace sill offset 168. The source battery contact socket 134 of Figure 1 is similarly configured to the source battery contact socket 132.

[0026] The source jumper plug 102 includes a substantially rectangular parallelepiped plug prong 170 formed from a curved prong blade 172 and a substantially congruent prong blade 174, which may be curved or flat. Each prong blade 172, 174 is fabricated from an electrically conductive material, such as a copper alloy. The curved prong blade 172 provides a spring-like action against the adjacent prong blade 174. The plug prong 170 is electrically connected to the positive insulated electrical conductor 106 inside an electrically non-conductive jumper plug grip 176. The source jumper plug 104 of Figure 1 is similarly configured. [0027] Figure 3 is an isometric sectional detail view of an alternatively configured contact socket 180 that includes the electrically conductive trace 160, a socket shell 182, and a socket shell sill 186 defining a socket shell slot 184. The contact socket 180 includes a shell sill bevel 188 provided to facilitate insertion of the source jumper plug 102. The socket shell 182 includes a socket shell dimple 185 protruding into the socket shell slot 184 to increase the force of the plug prong 170 applied against the socket electrically conductive trace 160. A conventional engine battery clamp 129 may be on the battery terminal 122.

[0028] Figure 4 is an isometric view of the load battery 140 showing the positive battery terminal 142 and the negative battery terminal 144, with the load battery contact socket 152 and the load battery contact socket 154 attached near a front edge 149 of the load battery. The load battery contact socket 152 includes a battery socket shell 190, configured as an inverted U-shaped channel, enclosing a prong retention insert 192. A socket shell slot 194 is provided between the prong retention insert 192 and a socket shell sill 196. An electrically conductive trace 202 is attached to surface of the load battery housing 150 between the positive battery terminal 142 and the socket shell sill 196. The electrically conductive trace 202 may be fabricated from an electrically conductive material. The load battery contact socket 154 includes a battery socket shell 210, configured as an inverted U-shaped channel, enclosing a prong retention insert 212. A socket shell slot 214 is formed between the prong retention insert 212 and a socket shell sill 216. An electrically conductive trace 204 is attached to the surface of the load battery housing 150 between the negative battery terminal 144 and the socket shell sill 216. The load battery contact socket 154 is similar to the load battery contact socket 152.

[0029] Figure 5 is an exploded isometric view of the positive battery contact socket 152, which includes the battery socket shell 190, the prong retention insert 192, the socket shell sill 196, and the electrically conductive trace 202. The battery socket shell 190 is a plastic component configured as an essentially inverted U-shaped channel with a planar socket shell top 232, a first socket shell side 234, and a second socket shell side 236. The prong retention insert 192 is an elastic plastic or metal inverted U-shaped channel, sized and shaped to be attached to a shell insert support surface 233 of the battery socket shell 190. The prong retention insert 192 includes a substantially planar insert top cap 222 with a first insert flange 224 and a second insert flange 226. A side indent 228 may be provided in either or both insert flanges 224, 226. The electrically conductive trace 202 has a terminal contact end 242, which may be curved, and a socket sill end 244, which may be straight. The thickness of the socket shell sill 196 is smaller than the thickness of the socket electrically conductive trace 202 to form a trace sill offset 246. An insert cap dimple 198 in the insert top cap 222 functions to urge the inserted load jumper plug 112 of Figure 1 against an electrically conductive trace contact surface 248.

[0030] Figure 6 is an isometric cross-sectional detail view 02-02 of the positive battery contact socket 152 and the positive battery terminal 142. The socket shell sill 196 includes a socket sill bevel 195. The insert cap dimple 198 protrudes below an insert cap undersurface 199 of the prong retention insert 192 and into the socket shell slot 194. A trace sill offset 246 ensures that an inserted load jumper plug 112, of Figure 7, makes reliable contact with the electrically conductive trace 202. The electrically conductive trace 202 includes a prong contact trace 206 lying within the battery socket shell 190, and a terminal contact trace 208 electrically connected to the positive battery terminal 142.

[0031] Figure 7 shows an insertion of the load jumper plug 112 into the socket shell slot 194 in the load battery contact socket 152. The load jumper plug 112 includes an electrical prong 252 electrically connected to the positive insulated electrical conductor 106 inside an electrically nonconductive jumper plug grip 178. There may be a rounded prong corner 256 on a prong leading edge 258 to aid insertion of the electrical prong 252 into the socket shell slot 194. When inserted, an electrical prong contact surface 254 makes electrical contact with an electrically conductive trace contact surface 248 to complete an electrically conductive path between the positive insulated electrical conductor 106 and the positive battery terminal 142. A terminal contact end 249 is electrically connected to the positive battery terminal 142 at a terminal-trace interface 259. Alternatively, the electrically conductive trace 202 can be fabricated as part of the positive battery terminal 142.

[0032] Figure 8 is an isometric detail sectional view of a canted battery contact socket 260 configured for attachment to a surface of a battery housing and for electrical connection to a battery terminal 272. The canted battery contact socket 260 has a substantially wedge-shaped battery socket shell 262 with a beveled socket shell sill 264 defining a socket shell slot 266. A socket shell dimple 267 is provided to frictionally retain an inserted plug prong in the socket shell slot 266. The canted battery contact socket 260 is supported on a planar socket shell base 276. A socket longitudinal axis 268 is inclined with respect to the planar socket shell base 276, as indicated by an angle 273. The canted battery contact socket 260 includes an electrically conductive trace 270 that includes a planar terminal contact trace 274 extending from a planar prong contact trace 272. The terminal contact trace 274 forms an obtuse angle with the prong contact trace 272. The terminal contact trace 274 lies in the same plane as the planar socket shell base 276, and the prong contact trace 272 is parallel to the socket longitudinal axis 268.

[0033] Figure 9 is a cross-sectional isometric view of a compact battery contact socket 280 that includes a battery socket shell 282 with a socket inclined slot 286 adjacent a socket shell sill 284. One end of an electrically conductive trace 288 is electrically connected to a negative battery terminal 274. An electrical prong inserted into the socket inclined slot 286 will make electrical contact with a prong contact trace 287, a terminal contact trace 289, and the negative battery terminal 274.

[0034] Figure 10 shows a compact battery contact socket 290 connected to a positive battery terminal 276 by an electrically conductive trace 298. The electrically conductive trace 298 includes a prong contact trace 297, which is at a right angle to a terminal contact trace 299. A battery socket shell 292 includes a socket shell slot 296 adjacent a socket shell sill 294. The socket shell slot 296 forms a closed cavity.

[0035] Figure 11 shows a battery 300 with the compact battery contact socket 280 and the compact battery contact socket 290 on a battery housing 302. A jumper plug 304 is positioned for insertion into the socket shell slot 296 for connecting the positive insulated electrical conductor 106 to a positive battery terminal 276. A jumper plug 306 is positioned for insertion into the socket inclined slot 286 for connecting the negative insulated electrical conductor 108 to a negative battery terminal 274.

[0036] Figure 12 is an isometric detail sectional view of a battery contact socket 310 electrically connected to a positive battery side terminal 328. The battery contact socket 310 includes a wedge-shaped socket shell 312 with a socket shell sill 314 defining a socket inclined slot 316. The socket inclined slot 316 may extend through the battery socket shell 312 as shown, or alternatively, form a blind hole in the battery socket shell 312. The battery contact socket 310 has a planar socket shell base 318 and includes an electrically conductive trace 320 that is inclined at an angle 326 to the planar socket shell base 318. The electrically conductive trace 320 can be electrically connected to the positive battery side terminal 328 with a conductive epoxy 324 or a solder compound. [0037] Figure 13 is a detail view of a battery contact socket 330 and a modified battery side terminal 340. The battery contact socket 330 includes a battery socket shell 332 and a socket sill 334 defining a socket inclined slot 336. The socket sill 334 has a shell sill bevel 338 with a socket shell dimple 337 inside the socket inclined slot 336. A conductive trace 342 extends from the socket sill 334 and may be fabricated from the same material as the modified battery side terminal 340. The conductive trace 342 has a trace base 344 which lies in the same plane as a socket shell base 346.

[0038] Figure 14 shows a side terminal battery 350 that includes the positive battery side terminal 328 and a negative battery side terminal 362. The battery contact socket 310 is secured to a battery housing 352 near a battery corner 354. A negative battery contact socket 360 is formed as part of the battery housing 352 near a battery front edge 356. A positive jumper plug 367 is positioned for insertion into the socket inclined slot 316. A negative jumper plug 368 is positioned for insertion into a negative socket slot 366 to contact an electrically conductive trace 364.

[0039] It can be appreciated that conventional automotive batteries will remain commonplace and will require some time to be phased out in favor of batteries that incorporate the electrical connector battery contact sockets disclosed herein. To aid in this transition, portable battery lug contact sockets can be placed onto unmodified conventional automotive batteries to enable use of the battery jumper plug cable 100 of Figure 1 . Figure 15 shows a portable battery lug contact socket 370 placed on a battery terminal 380. The battery lug contact socket 370 can be removed from the enclosed battery terminal 380 and installed on another battery terminal, as desired. The battery lug contact socket 370 includes a cylindrical battery socket shell 374 made of an electrically insulating material. The battery socket shell 374 has a socket shell slot 376, rectangular in cross sectional shape, and extending through the battery socket shell 374 along a shell longitudinal axis 372. The socket shell slot 376 is sized and configured for insertion and retention of an electrical prong such as the electrical prong 112 of Figure 7. A conductive trace 386 is secured in the battery socket shell 374, parallel to the socket shell slot 376, and terminating at a socket shell sill 378. The conductive trace 386 includes a prong contact trace 384 secured within the battery socket shell 374, and a terminal contact trace 388 extending from the socket shell sill 378. The terminal contact trace 388 includes a planar terminal contact lug ring 382 placed over the battery terminal 380. [0040] Another portable battery contact socket is a battery spade contact socket 390, shown in Figure 16. The battery spade contact socket 390 includes a cylindrical battery socket shell 392 with a socket shell slot 396, rectangular in cross sectional shape, and extending through the battery socket shell 392. An electrically conductive trace 404 includes a prong contact trace 406 secured within the battery socket shell 392, and a terminal contact trace 408 extending from a socket shell sill 394 to the battery terminal 400. The prong contact trace 406 forms an obtuse angle with the terminal contact trace 408. The terminal contact trace 408 includes one or two terminal contact spade legs 402 partially enclosing the battery terminal 400. [0041] Figure 17 shows a portable battery contact socket 410 that includes a cylindrical battery socket shell 412 with a socket shell slot 414, rectangular in cross sectional shape, and extending into the positive battery socket shell 412. A conductive trace 424 includes a prong contact trace 426 secured within the battery socket shell 412 and extending from a socket shell sill 416, and a terminal contact trace 428 in electrical contact with a battery terminal 420. The prong contact trace 426 forms an obtuse angle with the terminal contact trace 428. The terminal contact trace 428 includes a terminal contact convex tab 422 partially enclosing the battery terminal 420.