GB2592825A

GB2592825A - Battery connector device for a battery jump starting device

Info

Publication number: GB2592825A
Application number: GB2108126.0A
Authority: GB
Inventors: Lewis Nook Jonathan; Knight Nook William; Richard Stanfield James; Michael Underhill Derek
Original assignee: Noco Co
Current assignee: Noco Co
Priority date: 2017-02-10
Filing date: 2017-02-10
Publication date: 2021-09-08
Anticipated expiration: 2037-02-10
Also published as: GB202108126D0; GB2592825B

Abstract

A battery connector device 100 for a rechargeable battery jump starting device, has a smart switch interface comprising relays connected between two circuit board conductor bars 138 & 140, and a negative cable connected to second circuit board conductor bar 140. The smart switch interface comprises a circuit board 136 with first circuit board conductor bar spaced apart from second circuit board conductor bar, and the first circuit board conductor bar 138 is electrically connected to a negative terminal conductor bar of a battery. The smart switch interface comprises relays 142 connected between the first and second circuit board conductor bars for providing isolation between a negative terminal tab of the battery, and the battery is jump started. A negative cable is connected to the second circuit board conductor bar and can also connect to each of the relays. A diode may connect between sections of the positive cable 18.

Description

TITLE

BATTERY CONNECTOR DEVICE FOR A BATTERY JUMP STARTING DEVICE

FIELD

A portable battery connector device, for example, a battery connector arrangement or assembly for a battery jump starting device, in particular a portable vehicle jump starting apparatus, configured for enhancing the conductivity between the battery of the jump starting apparatus and a battery being charged.

BACKGROUND

The exists a portable vehicle battery jump start apparatus as disclosed in U.S. Patent No. 9,007,015 to Nook et al. The apparatus utilizes a lithium ion battery pack. In this type of apparatus, there exists a need to maximize conductivity from the battery pack to the vehicle battery of the vehicle being jump started.

For successful car jump-starts, there are two main factors dictating the results. The first factor is the amount of power provided by the lithium ion battery pack, and the second factor is the maximum conductivity. You need both factors to have the best chance to jump-start big engines. One factor without the other factor is not enough.

SUMMARY

The presently described subject matter is directed to a battery device, for example, a battery connector, battery connector arrangement, or battery conductor assembly for use in a device for jump starting a vehicle, and a device for jump starting a vehicle comprising the battery connector device.

The presently described subject matter is directed to a battery connector device comprising or consisting of a battery having at least one battery conductor connected to a terminal of the battery.

The presently described subject matter is directed to a battery connector device comprising or consisting of a battery having at least one battery conductor or cable connected to a battery tab of the battery.

The presently described subject matter is directed to a battery connector device comprising or consisting of a battery having a positive conductor and a negative conductor connected to the battery.

The presently described subject matter is directed to a battery connector device comprising or consisting of a battery having a positive conductor plate and/or a negative conductor plate connected to the battery.

The presently described subject matter is directed to a battery connector device comprising or consisting of a battery having a positive conductor plate and/or a negative conductor plate connected to the battery, and a positive cable connected to the positive conductor plate and/or a negative cable connected to the negative conductor plate.

The presently described subject matter is directed to a battery connector device comprising or consisting of a battery having a positive battery conductor connected to a positive terminal of the battery and/or a negative battery conductor connected to a negative terminal of the battery.

The presently described subject matter is directed to a battery connector device comprising or consisting of a battery having a positive battery conductor connected to a positive terminal contact of the battery and/or a negative battery conductor connected to a negative terminal contact of the battery, the battery conductors being soldered to the respective terminals of the battery.

The presently described subject matter is directed to a battery connector device comprising or consisting of a battery having a positive battery conductor connected to a positive terminal of the battery and/or a negative battery conductor connected to a negative terminal contact of the battery, and a relay connected to one of the battery conductors of the battery.

The presently described subject matter is directed to a battery connector device comprising or consisting of a battery having a positive battery conductor connected to a positive terminal contact of the battery and/or a negative battery conductor connected to a negative terminal contact of the battery, and a relay connected to the negative battery conductor.

The presently described subject matter is directed to a battery connector device comprising or consisting of a battery having a positive battery conductor connected to a positive terminal contact of the battery and/or a negative battery conductor connected to a negative terminal contact of the battery, and multiple relays connected to the negative battery conductor.

The presently described subject matter is directed to a battery connector device comprising or consisting of a battery having a positive battery conductor connected to a positive terminal contact of the battery and/or a negative battery conductor connected to a negative terminal contact of the battery, and a positive cable connected to the positive battery conductor.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a front view of the battery jump starting device with the clamps undeployed.

FIG. 2 is a rear perspective view of the battery jump starting device shown in FIG. 1.

FIG. 3 is an end perspective view of the battery jump starting device shown in FIGS. 1 and 2.

FIG. 4 is a front perspective view of the battery jump starting device shown in FIG. 1, however, with the clamps deployed.

FIG. 5 is a front perspective view of a battery connector device contained within the battery jump starting device shown in FIG. 1, however, with the negative cable not yet installed.

FIG. 6 is a top planer view of the battery connector device shown in FIG. 5. FIG. 7 is a side elevational view of the battery connector device shown in FIG. 5. FIG. 8 is an end elevational view of the battery connector device shown in FIG. 5. FIG. 9 is a perspective view of the battery connector device shown in FIG. 5, however, with the negative cable connected to the battery connector device.

FIG. 10 is a view perspective view of the battery connector device shown in FIG. 5, however, with a diode connector installed on the positive cable.

FIG. 11 is a perspective view of the battery connector device connected to other components or parts of the battery jump starting device.

FIG. 12 is a perspective view of the battery assembly of the battery connector device shown in FIG. 5.

FIG. 13 is a front perspective view of another battery connector device for the battery jump starting device.

FIG. 14 is a detailed view of the positive cable connection with the relay printed circuit board prior to being soldered thereto.

FIG. 15 is a detailed view of the positive cable connection with the relay printed circuit board after being soldered thereto.

FIG. 16 is a front perspective view of the battery assembly of the battery connector device shown in FIG. 13.

FIG. 17 is a partial top planar view of the battery assembly shown in FIG. 16, however, with the positive terminal conductor sheet in an unwound condition.

FIG. 18 is a partial top planer view of the positive terminal conductor of the battery assembly shown in FIG. 16.

FIG. 19 is an end perspective view of the positive terminal conductor partially wound around the end of the positive cable.

FIG. 20 is an end perspective view of the positive terminal conductor fully wound around the end of the positive cable.

FIG. 21 is a side perspective view of the positive terminal conductor fully wound around and soldered to the end of the positive cable.

FIG. 22 is an opposite end perspective view of the positive terminal conductor fully wound around and soldered to the end of the positive cable.

FIG. 23 is a perspective view of the diode connector between sections of the positive cable.

FIG. 24 is a perspective view of a Schottky Diode used in the diode connector. FIG. 25 is a perspective view of the diode connector insulated with a shrink wrap sleeve.

FIG. 27 is a graphical illustration showing a load test of the battery connection shown in FIGS. 5-10.

FIG. 28 is a graphical illustration showing a load test of the battery connection shown in FIGS. 13-25 FIG. 29 is a front view of a further battery connector device for the battery jump starting device.

FIG. 30 is a front view of the battery connector device comprising a plurality of battery cells, separate tab, and conductors (e.g. plate conductors) prior to assembly.

FIG. 31 is a front view of the battery connector device comprising battery cells being prepared with separate tabs for lengthening the tabs.

FIG. 32 is a front view of the battery connector device comprising the plurality of battery cells, separate tab, and conductors shown in FIG. 30, after assembly.

FIG. 33 is a perspective view showing the battery connector device comprising the battery cell assembly shown in FIG. 32, after folding the battery cells FIG. 34 is an end perspective view of the battery connector device showing the separate tab being wrapped or wound around an exposed end of the positive cable, and soldered together.

FIG. 35 is an opposite end perspective view of the battery connector device showing a negative battery tab wrapped around the negative terminal conductor plate and welded and/or soldered together.

FIG. 36 is a perspective view of the battery connector device showing the flat separate tab connected to the battery and extending outwardly prior to connection to the positive cable.

FIG. 37 is a side view of the temperature sensor assembly with wires and connector.

FIG. 38 is a perspective view of the diode circuit board assembled connected inline or spliced into the positive cable.

DETAILED DESCRIPTION

A battery jump starter device 10 is shown in FIGS. 1 and 2. The battery jump starting device 10 comprises a casing 12 having a display 14 provided with an arrangement of light emitting diodes (LEDs) 16.

The battery jump starting device 10 further comprises a positive cable 18 having a positive clamp 20 and a negative cable 22 having a negative clamp 24. The positive cable 18 and negative cable 22 pass through openings 12a, 12b, respectively, in the casing 12.

The clamps 20, 24 are stowed away or docked in an un-deployed mode by clamping each to a respective side posts 26 extending outwardly on opposite sides of the casing 12, as shown in FIG. 1. The side posts 26 are shown in FIG. 2. The clamps 20, 24 are docked when the battery jump starter device 10 is in non-use, and then unclamped from the side post 26 during use.

The battery jump starting device 10 is configured to jump start a vehicle battery. For example, the battery jump starting device 10 can be the PORTABLE VEHICLE JUMP START APPARATUS WITH SAFETY PROTECTION disclosed in U.S. Patent No. 9,007,015, which is fully incorporated herein by reference, or a device or apparatus similar thereto.

The battery jump starting device 10 comprises electrical components or parts located inside the casing 12. For example, the battery jump starting device 10 comprises a battery connector device 100 shown in FIGS. 3 -9.

The battery connector device 100 comprises a battery assembly 110 having a battery 112. For example, the battery 112 is a lithium ion rechargeable type battery. The battery connector device 100 is configured to maximize conductivity from the battery 112 to the cables 18, 22 and clamps 20, 24 of the battery jump starter device 10. The battery 112 comprises a battery casing 112a, for example, a rectangular-shaped battery casing 112a.

The battery 112 comprises a positive tab at one end (e.g. width) of the battery 112, and a negative terminal tab at an opposite end (e.g. width) of the battery 112. For example, the battery 112 comprises one or more battery cells each having a positive and negative tab. For example, the positive tab from one battery cell is located at the one end of the battery 112 and the negative tab from one battery cell is located at the opposite end of the battery 112. A positive terminal conductor plate 114 is connected (e.g. soldered, welded, or sonically welded) at the one end of the battery 112 to the positive tab (i.e. contact) of the battery 112. The positive terminal conductor plate 114 extends along the one end (e.g. width) of the battery 112.

The positive cable 18 can be connected (e.g. directly connected by soldering) to the positive terminal conductor plate 114 and/or the positive tab of the battery 112. For example, the positive terminal conductor bar 114 can be provided with a conductive loop 116 wrapping around (e.g. entirely wrapping around) and connected (e.g. crimped and/or soldered) to an exposed end 18a of the positive cable 18. For example, the positive terminal conductor plate 114 is made from heavy gauge copper sheet (e.g. machined, cut, or stamped therefrom).

As shown in FIGS. 5 and 6, the positive terminal conductor sheet 114 can be configured (e.g. bent) to wrap around one of the square-shaped corners of the rectangular-shaped casing 112a of the battery 112 (e.g. L-shaped). The L-shaped positive terminal conductor sheet 114 can extend along an end of the battery 112 and along at least a portion of the side of the battery 112, as shown in FIG. 5.

The positive terminal conductor plate 114 can also be mechanically coupled and/or adhered to the outer surface of the battery casing 112a to provide additional support and stability thereof (e.g. assembled to survive mechanical shock when drop testing the battery jump starter device 10). For example, the positive terminal conductor bar 114 can be mechanically connected to the battery casing 112 by adhesive (e.g. silicon adhesive), double sided tape, double sided foam tape, insulated plastic or ceramic connector with snap fit connection and/or adhesive connection, and/or the battery casing 112 can be formed (e.g. molded) to mechanically connect (e.g. snap fit or interference connection) with the positive terminal conductor plate 114.

The positive cable 18 can be a single piece of wire or a cable (e.g. twisted or braided wires) extending from the battery 110 to the positive clamp 20. Specifically, one end of the positive cable 18 is connected to the positive terminal conductor plate 114 connected to the battery 18, and the opposite end of the positive cable 18 is connected to the positive clamp 20.

More specifically, the positive cable 18 can comprise a flexible or bent cable portion 118 for changing the direction of the positive cable 18 within the casing 12. The positive cable 18 can be fitted with a flexible outer sleeve portion 120 transitioning into a flexible inner sleeve portion 122 to flexibly accommodate the positive cable 18 passing through the casing 12. The flexible outer sleeve portion 120 is externally located relative to the casing 12 of the battery jump starter device 10, and the flexible inner sleeve portion 122 is internally located relative to the casing 12 of the battery jump starter device 10.

The flexible outer sleeve portion 120 Is configured to reinforce the connection between the positive cable 18 and the casing 12 of the battery jump starter device while remaining flexible. For example, the flexible outer sleeve portion 120 is provided with one or more grooves 124 (e.g. three (3) shown in FIG. 5) exposing portions of the positive cable 18. The one or more grooves 124 act as hinges to ease bending of the positive cable 18 within the flexible outer sleeve portion 120.

The flexible sleeve 120 comprises an outer flange 124 spaced apart (e.g. a small distance equal to about a wall thickness of the casing 12 of the battery jump starter device 10) from an in inner flange 126. The flanges 124, 126 further anchor the positive cable 18 to the casing 12 of the battery jump starter device 10.

The flexible sleeve 120 comprises a sleeve portion 128 (FIG. 6) connecting together the outer flange 124 and inner flange 126. For example, the flexible outer sleeve portion 120 is molded or applied onto and around the positive cable 18 as a single unit (e.g. the flexible sleeve 120 is molded onto a portion of the positive cable 18 inserted within the mold during the molding process). Alternatively, the flexible sleeve 120 is made (e.g. molded) separately, and then installed or assembled onto a portion of the positive cable 18.

The positive cable 18 comprises an inner conductor 18b (e.g. single wire conductor, twisted wires, or braided wires) disposed within an outer insulating sheath 18c (e.g. extruded plastic sheath). The inner conductor 18b, for example, can be a solid wire conductor or a multi strand metal wire conductor comprising bundle of wires 18d.

The inner wire can be made of copper or aluminum. The flexible sleeve 120 can be applied (e.g. molded or installed or assembled) onto and surrounding the outer insulating sheath 18c of the positive cable 18.

The battery connector device 100 further comprises a negative terminal conductor plate 130 connected (e.g. soldered, welded, or sonically welded) at an opposite end of the battery 112 to the negative tab (i.e. contact) of the battery 112 The negative terminal conductor plate 130 can extend along the opposite end of the battery 112 The other end of the negative terminal conductor plate 130 is provided with a negative terminal conductor plate connector portion 132, as shown in FIGS. 5 and 6.

The negative terminal conductor plate 130 can be configured to wrap around one of the corners of the rectangular-shaped battery 112 (e.g. L-shaped). The L-shaped negative terminal conductor plate 130 can extend along an end of the battery 112 and along at least a portion of the side of the battery 112, as shown in FIGS. 5 and 6.

The negative terminal conductor bar 130 can also be mechanically coupled and/or adhered to the outer surface of the battery casing 112a to provide additional support and stability thereof (e.g. to survive mechanical shock when drop testing the battery jump starter device 10). For example, the negative terminal conductor bar 114 can be mechanically connected to the battery casing 112a by adhesive (e.g. silicon adhesive), double sided tape, double sided foam tape, insulating plastic or ceramic connector with snap fit connection and/or adhesive connection, and/or the battery casing 112 can be formed (e.g. molded) to mechanically connect (e.g. snap fit or interference connection) with the positive terminal conductor plate 114.

The battery connector device 100 further comprises a smart switch battery interface 134. The smart switch battery interface 134 comprises a relay printed circuit board (PCB) 136 having a first circuit board conductor bar 138 spaced apart from a second circuit board conductor bar 140 located on one side of the circuit board 136, as shown in FIGS. 5 and 6.

A pair of relays 142 are mounted on an opposite side of the circuit board 136. The relays 142 include relay anchoring pins 142a located in through holes 136a in the relay printed circuit board 136 (FIGS. 5 and 7). The relays 142 further comprise relay connector pins 142b extending through the through holes 136b provided in the circuit board 136 and slots 138a provided in the first conductor bar 138. The relays 142 even further comprise relay connector pins 142c located in the through holes 136c provided in the circuit board 136 and through holes 140a provided in the second conductor bar 140. The relay anchoring pins 136a are soldered in place to mechanically connect the relays 142 to the circuit board 136. The relay connecting pins 142b and 142c are soldered in place to mechanically and electrically connect the relays 142, respectively, to the circuit board conductor plates 138, 140.

The through holes 136a in the circuit board 136 are rectangular-shaped (FIGS. 5 and 7) and accommodate the relay anchoring pins 142a. Specifically, a base portion of the relay anchoring pins 142a are rectangular-shaped with square-shaped ends. The square-shaped ends are dimensionally less wide verses the base portions creating transverse edges oriented flush with the outer surface of the circuit board 136. When solder is applied to the exposed ends of the relay anchoring pins 142a, the solder connects to the sides of the square-shaped ends and transverse edges to anchor and lock the relay anchoring pins to the circuit board 136.

The slots 132a provided in negative terminal conductor bar connector portion 132 are rectangular-shaped and the through holes138a in the first circuit board conductor bar 138 (FIG. 3) are T-shaped to accommodate the three (3) horizontally oriented relay connector pins 142b, as shown in FIG. 3. The ends of the relay connector pins 142b are shown flush with the outer surface of the negative terminal conductor bar connector portion 132. When solder is applied to the exposed ends of the relay connector pins 142b, the solder fills in the slots 132a in the negative terminal conductor bar connector portion 132 and the through holes 138a of the first circuit board conductor bar 138, and connects the sides of the connector pins 142b with inner edges of the slots 132a and through holes 138a to anchoring the relays 142 to the circuit board 136 and negative terminal conductor bar connector portion 132. This applied solder also electrically connects the negative terminal conductor bar connector portion 132 to the first circuit board conductor bar 138 The through holes 140a provided in the second circuit board conductor bar 140 are T-shaped to accommodate the three (3) vertically oriented relay connecting pins 142c, as shown in FIG. 3. The relay connector prongs 140a extend outwardly from the outer surface of the circuit board 136 to connect with the exposed conductor end 144a of the negative cable 144, and shown in FIG. 7. When solder is applied to the exposed conductor end 144a and the ends of the relay connector prongs 140a, the solder fills in the T-shaped slot and electrically connects the relay connector prongs 140a, second circuit board conductor 140, and exposed conductor end 144a of the negative cable 144.

The negative terminal conductor bar connector portion 132 of the negative terminal conductor bar 130 is connected (e.g. by soldering) to the first circuit board conductor bar 138 of the circuit board 136. The exposed conductor end 22a (i.e. with the insulating sheath removed) of the negative cable 22 is connected (e.g. by soldering) to the second circuit board conductor bar 140, as shown in FIG. 9.

The battery connector device 100 can be modified by providing the positive cable 18 with a diode connection 150, as shown in FIG. 10. For example, a diode connection is installed (e.g. spliced) into the positive cable 18. The diode connection 150 comprises a diode printed circuit board (PCB) 152 provided with a set of back-charge diodes 154 (e.g. Schottky Diodes) located on one side thereof, and a conductor bar 156 provided on an opposite side of the circuit board 152.

ASSEMBLY

The battery jump starting device 10 comprises the casing 12 having an upper casing portion 12a and a lower casing portion 12b, as shown in FIG. 11. The upper casing portion 12a and the lower casing portion 12b are configured to be connected together when assembling the battery jump starting device 10.

The battery jump starting device 10 further comprises the battery connection device 100 and controller assembly 210 both disposed within the casing 12. The controller assembly 210 comprises a circuit board 212 located adjacent to another circuit board 214.

The positive terminal of the battery assembly 110 (FIG. 12) is connected to the circuit board 212 via a positive power wire 216. For example, the positive power wire 216 is soldered to the positive conductor bar 114 (FIG. 5). The negative terminal of the battery assembly 110 is connected to the circuit board 214 via a negative power wire 218 The relay circuit board 136 is provided with a wire set 220 having a connector 222. The connector 222 is configured to connect with the relay board connector 224 located on the circuit board 212 of the controller assembly 210 during assembly of the battery jump starting device 10.

The battery assembly 110 further comprises a wire set 226 having a connector 228. The connector 228 is configured to connect with the battery cell charging/monitoring connector 230 located on the circuit board 212 of the controller assembly 220.

The battery assembly 110 also comprises a battery temperature sensor having a wire set 232 having a connector 234. The connector 234 is configured to connect with the temperature sensor connector 236 located on the circuit board 212 of the controller assembly 220.

The circuit board 212 is provided with in charge power resistors 240 and an out relay 242, as shown in FIG. 11. Further, the lower casing portion 12a is provided with a main user out connector 244 having a wire set 246 connected to the circuit board 214, and a main user in connector 248 having a wire set 250 connected to the circuit board 214.

The battery assembly 110 is connected to battery jump starting device 10, as shown in FIG. 11. The battery connector device 110 is installed within the casing 12 of the battery jump starting device 10 when assembled.

ENHANCED CONDUCTIVITY

An enhanced conductivity battery connector device 400 is shown in FIGS. 13 -25. The enhanced conductivity battery connector device 400 provides a significantly increased conductivity compared to the battery connector device 100, as shown in FIGS. 5 -10.

The amount of power to be conducted from the battery 412 to the clamps can be enhanced as follows: 1) Increase Wire Gauge e.g. change 4AWG (American Wire Gage) positive cable 18 and negative cable 22 (FIG. 9) to a 2AWG positive cable 318 and negative cable 322 (FIGS. 13 and 15) 2) Increase Conductivity of Negative Cable Connection e.g. negative cable end 322a (FIG. 15) connection to the relays will extend all the way across the connector pins 422c of the relays 422.

3) Increase Conductivity of Positive Cable Connection e.g. the positive battery tab 414 is lengthened so that the positive cable 318 can be rolled up (FIGS. 17-22) in the positive battery tab 414 and soldered together thoroughly; 4) Increase Conductivity of Diode Connection e.g. replace the diode connection 150 (FIG. 5) with the diode connection 450 (FIG. 23).

5) Redesign Resistor/Diode Printed Circuit Board (PCB) e.g. replace the diode printed circuit board (PCB) 152 (FIG. 10) with the diode printed circuit board (PCB) 452 (FIG. 23).

6) Reconnect Resistors e.g. reconnect resistors R134A&B, R135A&B located on the diode printed circuit board (PCB) 152 (FIG. 10) to be connected again.

A detailed description of each of these enhanced conductivity features or arrangement is set forth below.

1) Increase Wire Gauge The gauge of the positive cable 18 and negative cable 22 (FIG. 9), for example, can be increased from 4AWG (American Wire Gage) cable to a 2AWG cable for positive cable 318 and negative cable 322 (FIGS. 13 and 15). The comparative specifications of the 4AWG cable and 2AWG cable are as follows: 2AWG 4AWG Diameter 0.2576 in 0.2294 in (6.544 mm) (5.189 mm) Turns of wire 3.88/in 4.89/in (1.53/cm) (1.93/cm) Area 66.4 kcmil 41.7 kcmil (33.6 mm2) (21.2 mm2) Resistance/length 0.5127 mf2/m 0.8152 mf2/rn (0.1563 mO/ft) (0.2485 mG/m) Ampacity 95 (60° C) 70 (60° C) 115(75° C) 85 (75° C) (90° C) 95 (90° C) Fusing current 1.3 kA (10 s) 946 A (10 s) 10.2 kA (1s) 6.4 kA (1 s) 57kA (32 ms) 36 kA (32 ms) The 2AWG cable provides a significant increase of conductivity (i.e. ampacity) compared to the 4AWG cable (i.e. approximately 36%).

2) Increase Conductivity of Negative Cable Connection The negative cable 322 (FIG. 15) can be connected to the battery 412 (FIG. 13) in a manner to increase the conductivity (i.e. ampacity) between the battery 412 and negative cable 322. For example, the negative cable end 322a can be directly connected (e.g. soldered) to the connector prongs 442c (FIG. 15) of the relays 442. Specifically, the negative cable end 322a can extend across and directly connect to all relays 342 of the smart switch battery interface 434, as shown in FIGS. 14 and 15. Further, the negative cable end 322a can be connected to a conductor loop 441 of the circuit board conductor bar 440.

The negative cable 322, for example, can be stranded wire comprising an inner electrical wire conductor 322b composed of an untwisted or twisted bundle of wires 322d disposed within an outer electrical insulating sheath 322c. The electrical insulating sheath 322c of the negative cable 322 can be removed from the negative cable end 322a exposing the inner electrical conductor 322b at the negative cable end 322a.

The exposed bundle of wires 322d of the electrical conductor 322b can be forced over the ends of the exposed connector pins 442c of the relays 442 so that strands of wires 322d are captured between the adjacent connector pins 442c. The exposed bundles of wires 332d can be further forced into contact with the conductor bar 440 (e.g. made of copper). Solder 423 is applied to ths assembly so that the solder flows between the exposed bundles of wires 422d to the connector pins 442c and the conductor bar 440 to complete the electrical connection between the negative cable 322 and the smart switch battery interface 434 connected to the battery 412.

The length of the exposed bundle of wires 322d is selected so that exposed bundle of wires 322d directly connects with each set of connector pins 442c of each and every relay 442 to provide the maximum electrical conductivity (i.e. maximum am pacity) between the negative cable 322 and the battery 412.

3) Increase Conductivity of Positive Cable Connection The positive cable 318 can be connected to the battery 412 in a manner to increase the conductivity (i.e. ampacity) between the battery 412 and positive cable 318. For example, the positive cable 318 can be rolled up in the positive battery tab 414 and soldered together thoroughly. The connection between the positive cable 318 and battery 412 is shown in FIGS. 16-22.

The positive cable 318, for example, can be stranded wire comprising an inner electrical wire conductor 318b composed of an untwisted or twisted bundle of wires 318d disposed within an outer electrical insulating sheath 318c. The electrical insulating sheath 318c of the positive cable 318 can be removed from the positive cable end 318a exposing the inner electrical conductor 318b at the positive cable end 318a.

The battery 412 is provided with a positive battery tab 414. The positive battery tab 414 is a metal sheet (e.g. copper sheet) connected to the positive terminal tab 414 of the battery 412.

The exposed bundle of wires 318d of the inner electrical conductor 318b can be soldered with tin, and then rolled up within the positive battery tab 312a. Solder 415 (FIG. 21) is applied to the exposed bundle of wires 318d and the positive battery tab 312a.

The length of the exposed bundle of wires 318d is selected so that exposed bundle of wires 318d directly connects with the full width of the positive battery tab 414 to provide the maximum electrical conductivIty (i.e. maximum ampacity) between the battery 312 and the positive cable 318.

4) Increase Conductivity of Diode Connection The positive cable 318 can be provided with a diode connection 450 configured to increase the conductivity along the positive cable 318, as shown in FIGS. 23 -25.

The diode connection 450 comprises a plurality of diodes 454 connected between positive cable sections 318e and 318f (FIG. 25). For example, the diode connection 450 comprises six (6) back-charge type diodes (e.g. Schottky barrier diodes).

The diodes 454 are soldered between the positive cable sections 318e and 318f. Specifically. the diode conductor tabs 454a are soldered to the positive cable section 318e and the diode conductor prongs 454b are soldered to the positive cable section 318f. More specifically, the diode conductor prongs 454b of the diodes 354 extend through the diode circuit board 452, extend into the bundle of wires 318b, and then are soldered in place completing assembly of the diode connection 450.

The diode connection 450 is then insulated, for example, using a shrink wrap insulator 455 (FIG. 25), which is applied around the diode connection 450, and then shrunk by applying heat (e.g. using heat gun).

5) Redesign Resistor/Diode Printed Circuit Board (PCB) e.g. redesign of resistor/diode PCB to eliminate the diodes extending therefrom; 6) Reconnect Resistors e.g. reconnect resistors R134A&B, R135A&B that are on the Resistor/Diode PCB to be connected again.

TEST #1 The battery connection device 100 shown in FIG. 5 was subjected to a 1250A Load Test. The results are shown in FIG. 27, and as follows: Pulse #1 Average Power of 4799.01W Pulse #2 Average Power of 5528.99W Pulse #3 Average Power of 6101.63W TEST #2 The battery connection device 400 shown in FIG. 13 was subjected to a 1250A Load Test. The results are shown in FIG. 28, and as follows: Pulse #1 Average Power of 6584.61W Pulse #2 Average Power of 7149.60W Pulse #3 Average Power of 7325.91W This results in a significant increase of approximately twenty percent (20%) for peak power compared to the results of TEST #1.

Another enhanced conductivity battery conductor device 500 is shown in FIGS. 29 -37. The enhanced conductivity battery connector device 500 provides a significantly increased conductivity compared to the battery connector device 100, as shown in FIGS. 5-10.

The battery conductor device 500 comprises the battery assembly 410, including the battery 512 connected to the positive cable 518 and the negative terminal conductor plate 530. A positive wire 519 is connected directly or indirectly to the positive tab or positive cable 518 of the battery 530, and a negative wire 523 is connected directly or indirectly to the negative tab or negative terminal conductor plate 530. The battery conductor device 500 can further include a bundle of wires 570 connected to or associated with the operation of the battery 512 (e.g. battery temperature sensor, power supply, etc.).

The battery 512 can comprise a single battery cell 512c (FIG. 30), or multiple battery cells 512C connected end-to-end in series. Three (3) separate battery cells 512c are shown in FIG 30 The battery cells 512c each have positive and negative tabs 512d located at opposite ends of each battery cell 512c. The battery cells 512c are connected together in series by welding (e.g. sonically and/or thermally welding) and/or soldering respective positive and negative tabs 512d together. For example, the tabs 512d are positioned so as to overlap each other (e.g. edges overlapping opposite tab 512d, or edge-to-edge).

The tabs 512d are metal plates (e.g. relative thin metal foils) extending outwardly from the body and opposite edges of each battery cell 512c. As shown in FIG. 30, the tabs 512d extend along opposite edges at the width of each battery cell 512c. The tabs 512d are each centered and extend most of the width of each opposite edge of each battery cell 512c As shown in FIGS. 30 and 31, a separate tab 512e is added or connected to the right side of the battery cell 512c to extend the length of the tab 512d. The separate tab 512e is shown as having the same width as the tab 512d; however, this width can be different. To assemble the separate tab 512e to the tab 512d, for example, the separate tab 512e is positioned to overlap over the tab 512d, and then welded (e.g. sonically and/or thermally welded) and/or soldered together. The exposed end of the positive cable 518 is then wound up inside the separate tab, as shown in FIGS. 32 and 34. For example, the initially flat separate tab 512e is wrapped around the exposed end of the positive cable 518, and then connected to the exposed end by welding (e.g. sonically and/or thermally welding) and/or soldering. For example, a layer of solder is applied to one or both sides of the separate tab 512e, and then after wrapping the separate tab 512e around the exposed end of the positive wire 518, the assembly is heated to melt the layered solder and solder the assembly together.

The three (3) battery cells 512c once connected together, as shown in FIG. 32, are then folded over each other into the layered battery cell arrangement shown in FIG. 33. The layered battery cell arrangement can be packaged (e.g. the three (3) battery cells can be taped or shrink wrapped together). or placed within a battery cover or casing, as shown in FIG. 34.

As shown in FIG. 35, the negative tab 512d can be attached to the negative terminal conductor plate 530. For example, the negative tab 512d can be wrapped partially or fully, as shown, around the negative terminal conductor plate 530. The negative tab 512d can be provided with a plurality of through holes 512f to facilitate welding and/or soldering the negative tab 512d to the negative terminal conductor plate 530. For example, the through holes 512f can be square-shaped through holes arranged into a matrix, as shown in FIG. 35. The negative wire 523 is shown connected (e.g. soldered) to the negative tab 512d.

A separate tab 512e (see FIG. 30) can be connected to the negative tab 512d to lengthen same, so that the lengthened negative tab can be wrapped or wound around the negative terminal conductor plate 530 more than one time (e.g. 2, 3, 4, or more times). In this manner, the electrical connection between the negative tab 512d and the negative terminal conductor plate 530 can be enhanced. The separate tab 512e can be provided with a layer of solder on one or both sides, so that after the separate tab 512e is wrapped or wound around the negative terminal conductor plate 530, this assembly can be heated up to solder the separate tab 512e onto the negative terminal conductor plate 530.

The completed assembly of the battery conductor device 500 with the connected separate positive tab 512d ready to be wrapped or wound an exposed end of the positive cable 518 (FIG. 29) can be seen in FIG. 36. The bundle of wires 570 shown in FIG. 36, includes wires 572 for a temperature sensor embedded within the battery 512 (e.g. temperature sensor located near battery tab or between battery cells. The temperature sensor 574 having two (2) wires 572a. 572b is shown in FIG. 37.

The battery conductor device 500 can comprise a diode connector 550 connected inline or splice into the positive cable 518, as shown in FIG 38.

The battery conductor device 500 comprises a diode circuit board 552 having a plurality of diodes 454 assembled thereon. The diodes 454 each have a diode conductor tab 454a connected (e.g. soldered) to an exposed end of the positive cable 518. The prongs of the diodes 454 extend through holes in the diode circuit board 552, and are soldered to both the conductive traces and exposed end of the positive cable 518 along with a resistor 576 to complete the assembly.

Claims

CLAIMS1. A battery connector device for a battery jump starting device having a smart switch, the device comprising: a battery comprising a positive terminal tab and a negative terminal tab; a positive terminal conductor sheet connected to the positive terminal tab of the battery; a negative terminal conductor bar connected to the negative terminal tab of the battery; a positive cable connected to the positive terminal conductor sheet of the battery; a smart switch interface connectable to the smart switch of the jump starting device, the smart switch interface comprising a circuit board having a first circuit board conductor bar spaced apart from a second circuit board conductor bar, the first circuit board conductor bar electrically connected to the negative terminal conductor bar of the battery, the smart switch interface further comprising one or more relays connected between the first circuit board conductor bar and the second circuit board conductor bar for providing isolation between the negative terminal tab of the battery and a battery being jump started; and a negative cable connected to the second circuit board conductor bar.
2. A battery connector device for a battery jump starting device having a smart switch, the device comprising: a rechargeable battery comprising a positive terminal tab and a negative terminal tab, a positive terminal conductor sheet connected to the positive terminal tab of the battery; a negative terminal conductor bar connected to the negative terminal tab of the battery; a positive cable connected to the positive terminal conductor sheet of the battery; a smart switch interface connectable to the smart switch of the jump starting device, the smart switch interface comprising a circuit board having a first circuit board conductor bar spaced apart from a second circuit board conductor bar, the first circuit board conductor bar electrically connected to the negative terminal conductor bar of the battery, the smart switch interface further comprising a plurality of relays each connected between the first circuit board conductor bar and the second circuit board conductor bar for providing isolation between the negative terminal tab of the battery and a battery being jump started; and a negative cable connected to the second circuit board conductor bar, the negative cable directly electrically connecting to each of the plurality of relays.
3. A battery connector device for a battery jump starting device having a smart switch, the device comprising: a rechargeable battery comprising a positive terminal tab and a negative terminal tab, a positive terminal conductor sheet connected to the positive terminal tab of the battery; a negative terminal conductor bar connected to the negative terminal tab of the battery; a positive cable connected to the positive terminal conductor sheet of the battery; a smart switch interface connectable to the smart switch of the jump starting device, the smart switch interface comprising a circuit board having a first circuit board conductor bar spaced apart from a second circuit board conductor bar, the first circuit board conductor bar electrically connected to the negative terminal conductor bar of the battery, the smart switch interface further comprising multiple relays each connected between the first circuit board conductor bar and the second circuit board conductor bar for providing isolation between the negative terminal tab of the battery and a battery being jump started; a negative cable connected to the second circuit board conductor bar, the negative cable directly electrically connecting to each of the plurality of relays; and a diode connection provided between a first section of the positive cable and a second section of the positive cable.
4. The device according to claim 1, wherein the one or more relays is multiple relays connected in parallel between the first circuit board conductor bar and the second circuit board conductor bar.
5. The device according to claim 1, wherein the negative terminal conductor bar is configured to mechanically and electrically connect the battery to the smart switch battery interface.
6. The device according to claim 5, wherein the negative terminal conductor bar is configured to position the smart switch battery above and adjacent to the battery.
7. The device according to claim 1, wherein the positive terminal conductor sheet wraps around one end of the positive cable to electrically connect the battery to the positive cable.
8. The device according to claim 1, wherein the positive terminal conductor bar is ultrasonically welded to the positive terminal tab of the battery and the negative terminal conductor bar is ultrasonically welded to the negative terminal tab of the battery.
9. The device according to claim 1, wherein the battery is rectangular-shaped and a width of the positive terminal conductor sheet of the battery is equal to the width of the battery, and the negative terminal conductor bar is L-shaped and configured to wrap around a respective corner of the battery.
10. The device according to claim 9, wherein the battery tabs are mounted flush with a casing of the battery.
11. The device according to claim 1, wherein a diode connection is provided between a first section of the positive cable and a second section of the positive cable
12. The device according to claim 11, wherein the diode connection comprises one or more diodes connected between the first section of the positive cable and the second section of the positive cable.
13. The device according to claim 12, wherein the diode connection comprises multiple diodes each connected between the first section of the positive cable and the second section of the positive cable.
14. The device according to claim 13, wherein conductor tabs of the multiple diodes are connected to the first section of the positive cable and the conductor prongs of the multiple diodes are connected to the second section of the positive cable.
15. The device according to claim 14, wherein the multiple diodes are connected to a printed circuit board.
16. The device according to claim 15, wherein the conductor prongs of the multiple diodes extend through the printed circuit board and electrically connect with the second section of the conductor prongs.
17. The device according to claim 16, wherein the multiple diodes are arranged abutting each other along a single axis.
18. The device according to claim 13, wherein the diode connector is insulated with a heat shrink insulator.