CA2021565A1 - Main and reserve battery construction - Google Patents

Abstract

ABSTRACT

A vehicle storage battery construction is provided wherein main and reserve battery units are provided in a single housing and are connected in parallel. A rotary switch is provided on the battery cover for movement between a normal position where the main and reserve units are simultaneously charged but only the main unit is permitted to discharge, and a backup position where the main and reserve units are charged and discharged in parallel. The reserve unit is comprised of a group of cells located between two groups of main unit cells in a sandwich arrangement which necessitates a unique cover assembly incorporating negative and positive terminal bushings with internal connections for making the appropriate connections between the main and reserve unit terminal pins and the rotary switch.

Description

2~12156~5 MAIN A~) RESE~VE BATTERY CONSTRUCTION

The invention relates to a storage battery construction and, more particularly, to a battery which includes both main and reserve units within a single casing.
There have been many attempts in the past to provide back-up electrical power for vehicles in the event of discharge of a main storage battery, or in the event of a desire or need for additional power for cold weather start-up. For the most part, these attempts have involved providing two separate batteries, and have often involved modifications of the vehicle electrical system. Complexity and user inconvenience have also been characteristic of the prior art arrangements. In some instances, a main and reserve battery are connected electrically in series. Example~ of such arrangements may be found in U.S. Patent Nos. 4,581,570; 3,105,909; and 1,924,949. ~n othor lnstances, the m~in and one or more reserve batteries are connected in parallel.
Examples may be found in U.S. Patent Nos. 4,004,208;

3,340,402; 2,730,630; 2,729,750; and 2,692,953. In stlll other instances, batteries may be connected in ~eries or parallel, depending on circumstances. See, for example, U.S. Patent No~. 4,412,137; 3,108,190;
and 2,335,526. It i9 also known to provide booster batteries which are intended to be kept warm (or at least at room temperature), with temporary installatlon in the vehicle when needed. See, for . . :

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example, U.S. Patent Nos. 4,321,522 and 4,684,580.
U.S. Patent Nos. 4,564,797 and 3,758,345 describe arrangements where main and reserve battery portions are located in a single casing.
More recently, other batteries have appeared on the market which also enclose reserve and main batteries within a single casing, with a switch provided on the battery cover, allowing a user to switch over to the reserve battery to start a vehicle when the main battery has been discharged.
The present invention seeks to improve on past and present battery designs by providing a uni~ue .
arrangement of main and reserve battery units in a single, standard size casing, with dual terminals to facilitate adaptability to a large segment of the vehicle population, and which requires no modification of the vehicle electrical system.
It is another feature of the present invention to provide increased cold-cranking current from both the main and reserve units.
It is another feature of the present invention to provide an easily accessible and convenient to use switch on the battery casing to facilitate utllization of the re8erve battery unit as needed, including isolating the switch to protect the switch contacts and electronics from exposure to the electrolyte and gases generated within the battery.
It iB another feature of the invention to locate the switch on the negative side of the battery circuit to reduce contact surface corrosion.
It iB still another feature of the invention to provide a unique battery cover construction including primary and secondary covers incorporating electrical 2021~

connectors for connecting ~he main and reserve units and the rotary switch, as well as means for venting gases generated within the battery cells.
Accordingly, in one exemplary embodiment of the invention, main and reserve batteries are hou~ed in a single standard size casing, with the batteries electrically connected in parallel. A rotary switch i8 provided which in a normal position permits simultaneous charging of the main and reserve units while preventing discharge of the reserve unit. When the switch is moved to a closed or back-up position, the main and reserve units are charged and discharged in parallel.
In a preferred construction, the cells of the main battery unit sandwich the cells of the reserve battery unit. Specifically, the six cell reserve battery unit is located intermediate the cells of the main battery unit, with four main battery cells on one side of the reserve battery unit, and two main battery cells on the other side of the reserve battery unit.
As in conventional battery con~truction, each cell i8 rated at two volts, 50 that both the main and reserve units are rated at 12 volts. It will be appreciated that the spacing between the cells of the reserve unit i 8 less than the spacing between the cells of the main unit. As a result, the main unit provide~ greater capacity and more power than the reserve unit, which i8 nevertheless capable of providing the power neces~ary for engine starting under adverse climatic conditions.
The cells of each unit are connected in series, utilizing conventional conductive strap connectors, , ~ , ,~
.
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and each unit has positive and negative terminal pins associated therewith. Because of the sandwich construction however, additional bridging terminal pins are provided for the main battery cells on either side of the reserve unit.
In this exemplary embodiment of the invention, a -unique battery cover is provided which is formed with lead connectors encased between upper and lower surfaces of the otherwise plastic cover. External dual terminals are provided at either end of the cover to accommodate most U.S. and imported vehicles without any need for terminal adaptors or other hardware kits. These terminals each include internal connecting portions which engage terminal pins of the main and reserve units. In addition, a bridge connector within the cover connects the additional main unit bridging terminal pins on either side of the reserve unit.
The cover also mounts a switch connected between the negative terminal pins of the main and reserve units. A shaft projects upwardly from the switch and mounts a selector knob for moving the sw~tch betw~en its open (normal) and closed (backup) positions.
Thus, except for the presence of the selector knob, the battery appeara externally like a standard 12 volt battery, with a standard size casing and with dual terminals in the usual locations.
As noted above, the arrangement is such that in a normal position, the vehicle electrical system is connected to the main battery unit, and the switch is open so that the electrical path to the reserve unit is broken against discharge currents. A second electrical path connects the two batteries at all 202~6~

times to the charging circuit, and a diode in that circuit prevents the resexve battery from discharging when the switch is closed. In other words, the main and reserve units are simultaneously charged at all times, but the reserve unit discharges only when the selector switch is rotated to the closed or back-up position when the reserve unit is needed to provide backup power.
Other features of the preferred construction include the isolation of the switch to protect the switch contacts and electronics against electrolyte and gas exposure. This is accomplished by intxoducing grease into the interior of the switch housing and by providing a chamber within the cover surrounding the switch which is also at least partially filled with grease.
In an exemplary embodirnent of the invention, therefore, a vehicle storage battery is provided which, in its broader aspects, comprises (a) a casing having a pair of opposed side walls, a pair of opposed end walls, a bottom wall, an upper peripheral edge, and a cover qealed to the peripheral edge; and (b) a plurality of main battery cells and a plurality of reserve battery cells, the plurality of main battery cells located on either side of the plurality of reserve battery cells, each of the plurality of main battery cells defined by an electrode stack and.
a pair of ad~acent partition walls extending vertically substantially between the bottom wall and the upper peripheral edge.
Other objects and advantages of the invention will become apparent from the detailed description which follows.

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2021~6~5 FIGURE 1 is a perspective view of a battery in accordance with an exemplary embodiment of the invention;

FIGURE 2 i 8 a perspective view taken from the rear of the battery a~ shown in Figure 1, with the battery cover removed;

FIGURE 3 i8 a plan view of the primary battery cover in accordance with the invention, with the secondary cover insert and the rotary switch removed;

FIGURE 4 is an underside view of the primary battery cover shown in Figure 3;

FIGURE 5 is a section view taken along the line 5-5 of Figure 4;

FIGURE 6 is a section view taken along the line 6~6 of Figure 4;

FIGURE 7 is a section view taken along the line 7-7 of Figure 3;

FIGURE 8 is a section view taken along the line 8-8 of Figure 3;

FIGURE 9 is a section view taken along the line 9-9 of Figure 3;

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FIGURE 10 is a section view taken along the line 10-10 of Figure 3;

FIGURE 11 is a partial schematic diagram illustrating the electrical connections and current paths in the battery;

FIGURE 12 is a circuit diagram of the main and reserve units and associated switch;

FIGURE 13 is a partial perspective of the primary battery cover with switch mounted therein, but with the top insert plate removed;

FIGURE 14 is a plan view of a vent baffle for use with the primary battery cover shown in Figure 3;

FIGURE 15 is a side view of the vent baffle shown in Figure 14;

FIGURE 16 is a bottom view of the vent baffle shown in Figure 14;

FIGURE 17 i8 an end view of the vent baffle taken along line 17-17 in Figure 15;

FIGURE 18 i8 a section view taken along the line 18-18 in Flgure 15;

FIGURE 19 i8 a partial side view taken along the line 19-19 of Figure 14;

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FIGURE 20 is a plan view of the secondary battery cover;

FIGURE 21 is a partial bottom view of the secondary battery cover shown in Figure 20;

FI~URE 22 is a section view taken along the line 22-22 in Figure 21;

FIGURE 23 is a partial side view taken along line 23-23 in Figure 20; and FI~URE 24 i6 a perspective view of a porous plastic disc for use with the secondary cover.

With reference now to Figures 1-3, a storage battery 10 in accordance with an exemplary embodiment of the invent:Lon includes a generally rectangular casing or hou~3ing 12, constructed preferably o A
molded thermopla~tic materlal. The casing 12 includes a pair of opposlte slde walls 14, 16, a pair of opposite end walls 18, 20 and a bottom wall 22. A
battery cover is provided which includes a primary cover 24 and an associated secondary cover 25 which are ~ealed to the ca~ing in a manner to be described in further detail below.
With specific reference to Figure 2, the interior of the casing 12 is divided into a plurality of cells by a plurality of parallel partition walls 2~2156~

26 extending between side walls 14, 16, parallel to end walls 18, 20.
A first group of cells 28 and a second group of cells 30 together comprise the main battery unit. An intermediate group of cells 32, sandwiched between the groups 28 and 30, comprise the reserve battery unit.
Each partition wall 26 extends vertically between the bottom wall 22 and an upper peripheral edge 34 of the casing 12. Within each cell, there is a conventional electrode stack 36 including negative and positive plate electrodes with a separator between each adjacent plate, as in conventional battery construction. The electrode stacks of each group of cells 28, 32 and 30 are connected in parallel by conductive strap connectors 38, 40, the negative plates of each group being connected to a first respective strap member 38, and the positive plates of each group being connected to a second respective strap member 40.
Specifically, the positive and negative plates include lugs (not shown) extending upward but offset laterally from their upper edge~. For the electrode stack in each cell of group 28, for example, the positive and negative lugs are grouped in two spaced parallel rows, as indicated by arrows A and B in Figure 2. The electrode stacks in adjacent cells are di~posed in opposite orientation so that each row of lugs along the row A in group 28 includes alternate cell groupC of positive and negative lug~. The lug~
of each cell group of common polarity are interconnected at their upper edges by one of the conductive straps 38 or 40. Thus, in rows A and B of ~ 1 5 6 A~

group 28, th~ nqgativ~ luga ln alt-rnAti~g e~ o~
Q~eh row are aonn~e~o~ ~y ~t~p- 3~ w~ h-po~ltlv- lugo ln alt-rn~tlng ~oll~ o~ ~aah row ~r~
eonn-ctod by ~ p~ 40 The loetrod- ~t~k~ ln th- eoll~ aro l-etrle~l~y eonn-ot-d ~n ~ri~ by ~nt~rcoll eonn~etion~ eh compri~lng a ~ortleally dl-~o~d eonn-~tor lu~ 42 ~tta~h-d to ~nd ~xt~nding upw~rd ~rom a atrap 38 or 40 ad~aeent ~ p~tltlon W-ll a6.
Ad~aeont lug~ aro w~ld-d throu~h tho partitlon w-ll to ~orm ~h~ etrleal eonnootion 31m~1ar eonn-et~on- a~- m~do ln ~ ~t~g-r~d ~rran~m~nt ln th- e-ll p~rtltion wall~ ln ~eh of cell groupfi 28, ~0 and 32 A~ not-d ~bov-, e-ll g~oup~ 28 ~nd 30 eomprl~-th~ m~ln battory unlt, ~nd tho out~r ond e~ of th~ ro~p~ ar- prov~d~d wlth v-rtically upwa~dly xt-ntln~ to~minal pln~ 44, 46, r--po~tlvoly, o oppo-lt- polarlty Th- inn-rmo~t eoll o~ gro~p 2a and th- lnn~rmo~t e-ll of ~roup 30 ~r- al~o provld-d wlth t-rmln~l brld~- pln~ 4~, 50, r~p~etivoly, ~l~o o~ oppo~lt- pol-rl~y, Whlch n~blo ~roup~ 20 ~nd 30 to b~ aonn-al;-d ~n c-rl-~ a~ oxpl~ d b-low Th~ lnt~rm-dl~tc coll group 32 ~ormlng th~
r--orv- bAtt~ry un~t 1~ provldod with tormln~l pin~
5~, 54 ln lt~ nd eoll~ o o~ oppo~lt~ pol~lty Wlth r-~or-ne- now to Fi~uro~ 3 thro~gh 6, tho prlm~ry ~ovor 24 or th~ c~ln~ 12 ~ d--ign-d to ~ ngly on~g~ th- ~pp-r p-riph~ral d~ 34 o~ th~
e~ In addltlon, th~ und-~ldo 56 o~ th~ cov~r 24 1- ~orm~d wlth ~ plur-lity o~ olonq~ted rlb~ 58 which xt-nd p~llol to ach oth~r, and p-r~ l to th~ nd w~ 19, 20 of th- a~ing 12, ln ~p~c-d ~021~6~

relationship corresponding to the lateral spacing between cell partitions 26. Each rib 58 is provided along its length by a plurality of guide gussets 60, (best seen in Figures 5 and 8-10) each of which includes oppositely extending members 60a, 60b which are provided with complementary inclined surfaces 60c, 60d which serve to guide the primary cover 24 into place so that the ribs 58 securely abut respective upper edges of the partition walls 26.
Additional guide gussets 62 (best seen in Figures 6 and 9) are provided at each corner of the underside of the cover, each provided with an inclined surface 62a which facilitates accurate and quick location of the flat peripheral surface 64 of the primary cover underside with the peripheral edge 34 of the casing 12. When in place, the cover is preferably heat sealed to the battery casing along the peripheral edge 34 and along each of the ribs 58, so that each cell of each unit 28, 30 and 32 is isolated from each other.
The primary cover 24 is also provided with a pair of integral, main dual terminal bushin~ 66 (positive), 6~ (negative), for accommodating top or side connection between vehicle battery cables (not shown) and the internal terminal pins 46 and 34, respectively.
With reference to Figure 7, the lead connector bushing 66 include~ a body portion 70, a top terminal post 72, and a side terminal connector 74. The post 70 and connector 74 are located on either side of the body portion 70, the latter being formed with a tapered but otherwise generally cylindrical hole 76 adapted to receive the te:rminal pin 46. The bushing 202~56~

66 is substantially encased within the thermoplastic primary cover 24, but the top post 72 and side connector 74 project through apertures formed in the plastic. The post 72 is adapted to receive a conventional cable connector (not shown) which is telescoped over the post and radially tightened in place. The side terminal connector 74 is adapted to receive a conventional screw-type connector (not shown) which is threadably received within a nut 78 encased in lead connector 34. As may be seen in Figure 1, the hole 76 is sealed shut by a cap 80 upon final assembly.
The bushing 68 is similar to bushing 66 insofar as it includes a similar body portion 82, top terminal post 84, side connector 86 and hole 88. The overall configuration, however, is somewhat different, as will be explained below.
With particular reference to Figures 10 and 11, the body portion 70 of the bushing 66 includes a laterally extended portion 90 which terminates at a hole 92 which is located to receive the positive terminal pin 54 of the reserve battery unit cell group 32. Thu13, the end portion of extended portion 90 surrounding the hole 92 may be regarded as a first reserve unit bushing. As best seen in Figure 10, the laterally extended portion 90 i~ also encased, and thereby insulated, within the plastic primary cover 24, with the exception, of course, of the interior surfaces of the hole 92 which must be in good electrical contact with the pin 54. This is achieved typically by fusing together the lead alloy pin and connector by the application or creation of sufficient heat to cause localized melting. As will 2a2l~6s further be appreciated from Figure 10, serrations 94, 96 provided between the plastic material of the primary cover 24 and the bushing 66 at hole 76 and at the lateral extension 90, respectively, extend the surface length of the face between plastic and the lead alloy component as a defense against electrolyte creepage to the exterior.
The body portion 82 of the bushing 68 includes a laterally extending portion 98 which terminates at an integral connector 100 for a switch 102 (not seen in Figure 10 but seen in Figures 11, 12 and 13). The extended portion 98 i5 also encased in plastic, with the copper-based connector 100 projecting therefrom.
A second reserve unit bushing 104 including a projecting switch connector 106, also copper-based, lies opposite the connector 100 and also encased within the primary cover 24. The reserve unit bushing 104 includes a hole 108 for receiving the negative terminal pin 52 of the reserve battery unit.
With specific reference to Figures 8, 10 and 13, the primary cover 24 is configured to provide a recessed area 110 defined in part by a flat surface 112 for enclosing the ~witch 102 80 that the cover presents a substantlally planar appearance as will be described in greater detail below.
A main battery unit bridge connector 114 is al~o encased within the primary cover 24, as best seen in Figures 9 and 11. Connector 114 comprises an elongated lead alloy strip which is provided with hole~ 116, 118 which receive the terminal bridge pins 4~, 50, respectively, for fuqing together to form an electrically conductive path. Alternatively, the connector 114 may comprise a copper link between lead 2Q215~

ends to reduce electrical resistance. As seen in Figure 11, the connector 114 is isolated from bushings 66 and 104 and serves to electrically connect the cell groups 28 and 30 of the main battery unit. Serrations 120 at opposite ends of the bushing insure a defense against electrolyte creepage between the terminal ends of connector 114.
With reference now to Figure 11, it will be apparent that an electrical path is established for the main battery unit from bushing 66 to bushing 68 via bridge connector 114, the appropriate connectors 42 (not shown in Figure 11) and the electrolyte of cell groups 28 and 30, as indicated by path 122. At the same time, an electrical path for the reserve battery unit is established from bushing 66 to bushing 68 via the appropriate connectors 42 and the electrolyte of cell group 32, the bushings 104, 98 and switch 102, as indicated by the path 124.
By the above described arrangement, and as further illustrated in the electrical circuit of Figure 11, when the switch 102 is in its normal or open position, a diode 126 in the swi.tch circuit permits charging current to flow to main unit M and reserve unit R, but prevents the reserve unit R from di~charging. This is a normal situation when the main battery M is fully charged.
When the need arises for reserve power, as when main unit M is di~charged or when additional powex i9 desired to effect cold start-up, switch 102 is rotated to its closed or backup position so that the batteries are discharged simultaneously.
With reference now to Figure 13, the rotary switch 102, which may be any conventional 202~56~

construction but which preferably includes positive open and close detents or click stops, has a shaft 128 projecting upwardly from the switch housing 130.
The shaft 128 passes through an aperture 132 in the secondary cover 25 (see Figure 14) and receives a manual turning knob or selector 134 (see Figure 1) for enabling the user to open and close the switch 102.
As shown in Figure 13, the switch includes connectors 100' and 106' for engaging connections 100, 106, respectively. The connections may be secured by screws, spot welding or any other suitable means. The interior of the switch housing 130 may be at least partially filled with an anti-oxidant grease 136 or other protective medium so as to inhibit sparks from switch operation and prevent exposure of the switch components and internal electronics to gas generated within the battery casing, electrolyte and/or other harmful substances. The surrounding recessed area 110 of the primary cover, which is essentially isolated upon application of the secondary cover 25, may also b~ at least partially filled with a similar anti-oxidant grease ~partially shown at 137 in Figure 13) or other protective medium to balance the pressure inside and outside the switch to thereby insure that the grease within the switch housing does not leak out. The additional greasé i~
area 110 will also protect the contacts 100, lO0' and 106, 106'.
Returning to Figure 3, and with further reference to Figure 7, the primary cover 24 is further provided with a series of vent apertures 138, one for each cell of the main and reserve battery 2021~

units. These apertures, which are located within a channel 140 in the primary cover, s0rve a double function of providing fill ports for adding electrolyte to the individual cells, and for venting gases generated within the cells. In accordance with one exemplary embodiment of the invention, these apertures may be covered by a vent baffle 142 as illustrated in Figures 14-19.
The vent baffle 142 comprises an elongated strip of plastic shaped to fit within the channel 40 formed in the primary cover 24. The baffle is formed with a vent plug 144 for each aperture 138. As will be appreclated from Figures 14-16, the centerline spacing between plugs 144 corresponds to the centerline spacing between apertures 138. Each plug 144 (only one need be described in detail) includes a relatively small aperture or slit 146 which opens into a triangular chamber formed by a pair of triangular side walls 148, 150 and an inclined connector wall 152 to thereby form a chamber 154 with three closed sides and one open side. A solid rib or boss 156 is formed where inclined wall 152 joins the underside of rjtrip 142 to facilitate a snug friction fit in the corresponding aperture 138.
With reference to Figure 7, it will be seen that each aperture 138 is surrounded by a depending skirt portion 158 which will partially cover the open énd of the chamber 154 when the vent baffle is in placé, thus providing a relatively ~3mall opening in a tortuous escape path for gases generated in the battery. Since the gases are generally accompanied by some liquid electrolyte, the inclined wall 152 2021~6.~

assists in catching and returning liquid into the interior of casing 12.
With vent baffle strip 142 mounted in place over the apertures 138, a small amount of clearance remains between the upper surface of the step 142 and the underside of the secondary cover 25, so that the channel 140, in effect, comprises a manifold for gases escaping the battery.
With reference again to Figure 3, the channel 140 is defined by a forward laterally extending rib 160, end rib~ 162, 164 and a rearward rib 166, all of which are sealed to the secondary cover 25 when the latter is heat sealed to the cover 24.
As best seen in Figure 3, the rearward rib 166 does not extend completely across the battery, so that passageways 168, 170 are established to lead the escaping gas to a pair of chambers or recesses 172, 174, the function of which will be described below.
With reference now to Figures 20-23, the secondary cover 25 has a peripheral shape including a front edge 176, rear edge 178 and stepped side edges 180, 182, resE~ectively, corresponding to a similarly shaped depresE~ion on the top or exterior side of cover 24. The underside secondary cover 25 is provided with a depending peripheral rib 186 which lie~ adjacent the edges 176, 178, 180 and 182, and which i8 received within the depression and heat sealed to form a permanent securement between the primary and secondary covers 24, 25, respectively.
It will be appreciated that the secondary cover 25 is also heat sealed along multiple rib~ which isolate areas of the cover such as ribs 160, 162, 164 and 166.

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A raised boss 188 is provided about the hole 132 to provide additional volume for the switch and to protect the switch cavity against ingress of liquids which might collect on the cover top surface. In addition, vents 190, 192 are provided at opposite end portions of the rear edge 178 and serve to vent gases from within the battery casing to atmosphere.
As illustrated in the enlarged detail drawings of Figures 21-23, the vent 190 (vent 192 is identical) includes a raised dome portion 194 and a radially extending portion 196 which has an interior pa~sageway 198 extending between an outer edge 200 and an interior chamber 202 defined by a depending annular skirt portion 204. Skirt portion 204 surrounds an annular inclined seating surface 206 which is adapted to fuse to and hold secure a porous plastic disk or frit 208 formed to fit snugly within the annular skirt 204. It will be appreciated that the disk or frit 208 permits gas to pass from within the chambers 172, 174 to pass therethrough into the passageway 198 and to the atmosphere. At the same time however, holes or passageways through the porous disk Z08 are ~30 small that any flame front exterior to the battery cannot pass through the disk into the interior of the cover and battery casing.
As already noted above, the storage battery in accordance with a preferred embodiment of this inventlon, ha# standard exterior dimensions for a 12 volt battery. Specifically, the exterior dimensions of the battery casing are approximately 10.6 inches in length, 6.75 inches in width, and about 7.8 inches in height. The width dimension between the main battery cells in groups 28 and 30 i3 approximately 2~21~6.~

one inch, while the width dimension between the cells of the reserve battery group 32 is approximately 1/2 inch.
The above described battery provides 60~ cold cranking amps from the main battery unit, and an additional 275 plus cold cranking amps of backup power from the reserve battery unit. These power specifications satisfy most O.E.M. manufacturers starting re~uirements. In addition, because of the standardized dimenæions, the battery is designed to provide over 50% market coverage.
The storage battery of this invention is mounted in a vehicle in a conventional way, with the positive cable fixed to the positive terminal 72, and the negative cable attached to the negative terminal post 84. In vehicles having screw-in type connectors adapted for side mounting, the positive connector is fastened to the side connector 74 and the negative screw-in type cable connector is attached to the side connector 86.
In use, a simple four-step procedure enables the user to engage the backup battery:
1) the vehicle'~ ignition and all accessories are turned off;
2) the selector knob 134 on the battery i8 rotated to the "backup battery" position clearly indicated on the battery cover;
3) the vehicle engine is started; and 4) the selector switch 134 i8 immediately returned to the "normal operation" position.
It will thus be appreciated that the vehicle storage battery of this invention provides a powerful, easy-to-use source of main and reserve .

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power for a vehicle with superior performance characteristics, corrosion resistance, and adaptability heretofore unavailable in the vehicle storage battery field.
While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment~ it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.

Claims (43)

WHAT IS CLAIMED IS:

1. A vehicle storage battery including main and reserve battery units comprising:
a) a casing having a pair of opposed side walls, a pair of opposed end walls, a bottom wall, and an upper peripheral edge and, a cover sealed to said peripheral edge;
b) a plurality of main battery cells and a plurality of reserve battery cells, the plurality of main battery cells located on either side of said plurality of reserve battery cells, each of said plurality of main battery cells and said plurality of reserve battery cells defined by an electrode stack and a pair of adjacent partition walls extending vertically substantially between said bottom wall and said upper peripheral edge.

2. A vehicle storage battery according to claim 1 and further including a rotary switch mounted within said cover for movement between open and closed positions; said switch connecting the main and reserve batteries electrically in parallel when rotated to the closed position.

3. A vehicle storage battery according to claim 2 wherein said main battery unit includes two pair of main terminal pins and said reserve unit includes a pair of reserve terminal pins, and wherein said cover includes first connection means for electrically connecting one of said two pair of main terminal pins and said one pair of reserve terminal pins, and second connection means for electrically connecting the other of said two pair of main terminal pins.

4. A vehicle storage battery according to claim 2 wherein said switch includes a diode to prevent the reserve battery unit from discharging when the switch is in the open position.

5. A vehicle storage battery according to claim 2 wherein said switch is mounted within the battery cover and includes a shaft projecting through said cover, and a selector knob mounted on said shaft exteriorly of said cover to enable a user to rotate the switch between said open and closed positions.

6. A vehicle storage battery according to claim 1 wherein said main battery unit includes two pair of main terminal pins and said reserve battery unit includes a third pair of reserve terminal pins; said battery further including a cover having positive and negative bushings connected to one of said two pair of main terminal pins and said third pair of reserve terminal pins, and a bridge connector connecting the other of said two pair of main terminal pins.

7. A vehicle storage battery according to claim 6 wherein said bridge connector comprises a copper link between lead ends to reduce electrical resistance.

8. A storage battery construction comprising:

a) an open top outer casing including a pair of opposite side walls, a pair of opposite end walls, a bottom wall and a cover;
b) a first plurality of substantially parallel, laterally spaced partition walls extending between said pair of opposite side walls to define a first plurality of cells;
c) a second plurality of substantially parallel, laterally spaced partition walls extending between said pair of opposite side walls to define a second plurality of cells, said second plurality of partition walls being substantially identical in size and shape to said first plurality of partition walls;
wherein said second plurality of partition walls are interposed between selected ones of said first plurality of partition walls, and further wherein lateral spacing between said second plurality of partition walls is less than lateral spacing between said first plurality of cells.

9. The battery according to claim 8 wherein said first plurality of cells define a main battery unit, and said second plurality of cells define a reserve battery unit.

10. The battery according to claim 9 wherein said first and second plurality of cells each comprise an identical number of cells.

11. The battery according to claim 10 wherein said number of cells comprises six.

12. The battery according to claim 8 wherein dual terminals are provided at either side of said cover for connection to power cables of a vehicle.

13. The battery according to claim 9 wherein said main unit includes two pair of terminal pins and said reserve unit includes a third pair of terminal pins.

14. The battery according to claim 9 wherein a switch is provided for connecting said main and reserve battery units in one position of said switch to permit charging but prevent discharging of said reserve unit, and in another position to permit charging and discharging of said reserve unit with said main unit.

15. A dual battery construction wherein main and reserve batteries are housed within a single battery case, the battery construction including a switch and associated circuit means for alternating between a first normal position wherein said reserve battery is connected for simultaneous charging with said main battery but prevented from discharging, and a second backup position wherein said main and reserve batteries are electrically connected in parallel for simultaneous charging and discharging, said switch located between negative terminals of the main and reserve batteries.

16. A dual battery construction according to claim 15 wherein said switch includes a diode to prevent discharging of said reserve battery when the switch is in the normal position.

17. A dual battery construction according to claim 15 wherein said switch is enclosed within a housing at least partially filled with a protective medium.

18. A dual battery construction according to claim 17 wherein said protective medium comprises an anti-oxidant grease.

19. A dual battery construction according to claim 17 wherein said battery includes a cover and said switch is located within an isolated recessed area of said cover, said isolated recessed area also at least partially filled with a protective medium.

20. A dual battery construction according to claim 19 wherein said protective medium in said isolated recessed area comprises an anti-oxidant grease.

21. A dual battery construction according to claim 15 wherein said battery case is provided with a primary cover and said switch is mounted on a supporting surface of said cover, said cover having a secondary cover sealed thereto to thereby enclose said switch between the primary and secondary covers.

22. A dual battery construction according to claim 21 wherein said switch includes a rotatable shaft adapted to project through an aperture in said secondary cover, and a rotatable selector knob mounted on said shaft above said secondary cover.

23. A storage battery construction comprising:
an open top outer casing including a pair of opposite side walls, a pair of opposite end walls and a bottom wall, said side and end walls including an upper peripheral edge;
a primary cover heat sealed to said casing about said upper peripheral edge;
a first plurality of substantially parallel, laterally spaced partition walls extending between said pair of opposite side walls to define a first plurality of cells forming a main battery unit;
a second plurality of substantially parallel, laterally spaced partition walls extending between said pair of opposite side walls to define a second plurality of cells forming a reserve battery unit, said second plurality of partition walls being substantially identical in size and shape to said first plurality of partition walls;
said main battery unit including two pair of main terminal pins and said reserve unit including a third pair of reserve terminal pins;
wherein said second plurality of partition walls are interposed between selected ones of said first plurality of partition walls, and further wherein lateral spacing between said second plurality of partition walls is less than lateral spacing between said first plurality of cells; and said cover having incorporated therein positive and negative bushings connected to one of said two pair of main terminal pins and said third pair of reserve terminal pins, and a bridge connector connecting the other of said two pair of main terminal pins.

24. A vehicle storage battery according to claim 23 wherein said positive and negative bushings each comprise dual terminal bushings, each of said dual terminal bushings having a post connector and a screw-in type connector.

25. A vehicle storage battery according to claim 24 wherein said positive and negative bushings and said bridge connector are substantially enclosed by said cover.

26. A vehicle storage battery according to claim 23 wherein said primary cover further includes a switch connected between said negative bushing and a negative terminal pin of said third pair of terminal pins, said switch operative in a normal position to permit charging of said main and reserve units and prevent discharging of said reserve unit;
and in a backup position to permit charging and discharging of said main and reserve units.

27. A vehicle storage battery according to claim 23 wherein said primary cover includes an access port to each of said first and second plurality of cells.

28. A vehicle storage battery according to claim 27 wherein said ports are formed in a recessed area of said primary cover, said primary cover further including a vent baffle strip for substantially but not completely plugging said ports.

29. A vehicle storage battery according to claim 28 wherein said secondary cover is mounted on said primary cover such that a chamber is formed between said primary and secondary cover in said recessed area.

30. A vehicle storage battery according to claim 29 wherein vent means are provided in said secondary cover to communicate each of said cells to atmosphere via said vent baffle strip and said chamber.

31. A vehicle storage battery according to claim 30 wherein said secondary cover vent means are provided with flame arrestor means.

32. A vehicle storage battery according to claim 31 wherein said flame arrestor means comprises a porous disk.

33. A cover assembly for a vehicle storage battery comprising a primary cover incorporating a pair of dual terminals, and having a recessed channel formed therein, a plurality of vent ports spaced along said channel; a secondary cover mounted on said primary cover such that a chamber is formed between said primary and secondary covers along said channel;
said secondary cover having formed therein at least one vent communicating with said chamber.

34. A cover assembly according to claim 33 wherein a vent baffle strip is fitted in said channel to substantially but not completely plug each of said vent ports.

35. A cover assembly according to claim 33 wherein said at least one vent in said secondary cover is provided with a porous plastic disk which permits gases formed in the vehicle storage battery to pass therethrough to atmosphere, but which prevents passage of flame therethrough from atmosphere to the interior of the battery.

36. A cover assembly for a vehicle storage battery which incorporates main and reserve units within a single housing, the cover comprising positive and negative dual terminal bushings incorporated therein, said positive bushing including first aperture adapted to receive a first main unit terminal pin and a second aperture adapted to receive a first reserve unit terminal pin; said negative bushing including a first aperture for receiving a second main unit terminal pin; said cover further incorporating a third bushing having a first aperture adapted to receive a second reserve unit terminal pin.

37. A cover assembly according to claim 36 wherein said cover incorporates a bridging connector adapted to electrically engage third and fourth main unit terminal pins.

38. A cover assembly according to claim 36 wherein said cover also incorporates a switch connected between said negative bushing and said second reserve unit terminal pin.

39. A cover assembly for a vehicle storage battery which incorporates main and reserve units within a single housing, said cover assembly including a primary cover having a recessed channel formed therein, a plurality of vent ports spaced along said channel; a secondary cover mounted on said primary cover such that a chamber is formed between said primary and secondary covers along said channel;
said secondary cover having formed therein at least one vent communicating with said chamber; said primary cover further comprising positive and negative dual terminal bushings incorporated therein, said positive bushing including a first aperture adapted to receive a first main unit terminal pin and a second aperture adapted to receive a first reserve unit terminal pin; said negative bushing including a first aperture for receiving a second main unit terminal pin; said cover further incorporating a third bushing having a first aperture adapted to receive a second reserve unit terminal pin.

40. A cover assembly according to claim 39 wherein said cover incorporates a bridging connector adapted to electrically engage third and fourth main unit terminal pins.

41. A cover assembly according to claim 39 wherein said cover also incorporates a switch connected between said negative bushing and said second reserve unit terminal pin.

42. A cover assembly according to claim 39 wherein a vent baffle strip is fitted in said channel to substantially but not completely plug each of said vent ports.

43. A cover assembly according to claim 36 wherein said at least one vent in said secondary cover is provided with a porous plastic disk which permits gases formed in the vehicle storage battery to pass therethrough to atmosphere, but which prevents passage of flame therethrough from atmosphere to the interior of the battery.