1. Field of the Invention
This invention relates to battery receptacles or battery packs that can be used with batteries, especially dry cell batteries. More specifically this invention relates to a modular battery pack that can be reconfigured, using the same components, to connect dry cell batteries in series and parallel, in different arrangements, to provide a DC voltage and/or amperage suitable for almost any desired application.
2. Description of the Prior Art
Battery packs or receptacles are employed in a number of configurations for use with stand alone or portable devices requiring a DC power supply. For devices suited for mass production, batteries are normally inserted into the body of the device. For other applications, a separate battery pack is employed and a cable is used to connect the battery pack to the device. Normally these battery packs employ four batteries, and they are typically arranged to receive the batteries either in side by side configuration or in two rows of two batteries each. However, this arrangement is not suited for ganging multiple battery packs when more than four batteries are required for a specific device.
Although not as common, batteries can also be aligned end to end. No matter what configuration is employed to position the batteries in a battery receptacle housing, it is still desirable to provide an arrangement in which the user cannot incorrectly position batteries so that proper polarity is not maintained. There have been suggestions to use contact arrangements between batteries in which electrical continuity will not be established unless the batteries are inserted in the proper orientation.
U.S. Pat. No. 6,238,818 discloses a housing in which two or more dry cell batteries are positioned end to end so that the batteries in the housing can be inserted into appliances that use dry cells, such as flashlights. The shape of the housing will conform to cylindrical appliance cavities in which dry cell batteries to be inserted. One purpose of this housing is to insure that the polarity of all of the dry cell batteries is properly aligned. The housing has intermediate walls between positions in which individual dry cells are positioned, and contacts are mounted on these intermediate walls. On one side of the wall, the terminal is recessed so that the terminal cannot make contact with the flat negative terminal of a dry cell battery. Therefore if only one of the batteries is not properly inserted, electrical continuity cannot be established between opposite ends of the housing.
U.S. Pat. No. 4,265,984 is another example of a battery housing in which multiple dry cell batteries are aligned end to end. Terminals of opposite polarity are located at the same end of a housing and an elongate conductive element, with a fuse connected thereto, extends from a terminal on a dry cell battery at one end of the housing to the opposite end. Two semi-cylindrical housings are ultrasonically welded or glued together, with the elongate conductive element extending through the housing. The individual dry cells are properly aligned in the housing during manufacture of the housing, so it is not necessary to properly align the dry cell batteries in the field, where improper insertion can be a problem.
U.S. Pat. No. 4,595,641 shows an appliance with a battery compartment in which the positive and negative terminals of four dry cell batteries must all be properly oriented in order to make contact with terminal at opposite end of the battery compartment, and a terminal between the two middle batteries.
Prior art battery packs or receptacles are generally dedicated devices in that they are specifically designed for or incorporated into one device. The instant invention is intended to be used with various electrical or electronic devices that can have different voltage and/or amperage requirements. The same modular components are employed, but the batteries can be wired in different ways to provide the operating voltage and amperage required by any number of different device. Therefore, the battery packs of this invention are especially suited for devices that are never intended to be used in the quantities required for efficient mass production and assembly. This battery pack or receptacle is fabricated from modular components that can be wired in different ways to supply different voltage and amperage depending upon the apparatus with which they are to be used. By wiring the receptacle in different ways, the batteries will be combined to supply different voltage and amperage levels. Multiple batteries can be wired in series to provide a voltage in excess of that generated by the individual batteries and different groups of series wired batteries can be wired in parallel to provide greater amperage or current levels.
To provide the different voltage and amperage levels, a battery receptacle in accordance with one aspect of this invention would be used to house multiple dry cell batteries. This battery receptacle would include a housing having a plurality of battery compartments extending end to end between opposite first and second end walls of the housing. Each battery compartment would receive a single dry cell battery, and the intermediate walls would extend between adjacent battery compartments. This battery receptacle would also employ a plurality of contacts. One contact would be mounted in each end wall and in each intermediate wall. Each contact would have a first contact surface, such as an embossment that would engage a positive electrode of a dry cell battery and a second contact surface, such as a spring, that would engage a negative electrode of a dry cell battery. Each contact mounted in an intermediate wall is narrower than the intermediate wall in which the contact is mounted. The intermediate wall has an opening positioned beside the contact mounted therein. A first elongate electrical conductor, typically a wire, would be electrically connected to a contact mounted in the first end wall and would extend through openings in the intermediate walls to the second end wall. A second elongate electrical conductor or wire, would be electrically connected to a contact in the second end wall on an opposite end of the housing from the first end wall, so that dry cell batteries mounted in the battery compartment can be connected in series to an electrical component.
A modular apparatus, in accordance with this invention would be used to mount and connect a sufficient number of batteries to generate a voltage and amperage equal to an operating voltage and amperage for different electrical assemblies with which the modular assembly is used. This modular apparatus would include at least one housing having a plurality of battery compartments with contacts mounted on each end of the housing and between each battery compartment. Each contact includes contact surfaces for engaging positive and negative battery electrodes, to connect batteries, positioned in the battery compartments, in series. Each contact would also include a conductor coupling part where a wire or conductor could be terminated to the contact. A first conductor would be connected to a conductor coupling part of a first contact, and a second conductor would be connected to a conductor coupling part of a second contact so that batteries positioned in battery compartments between the first and second contacts will be connected in series, while multiple modular assemblies can be connected in parallel, so that the operating voltage and amperage for different electrical assemblies can be provided. The contacts are mountable in the housing after being connected to the first and second conductors with the second conductor extending at least partially through multiple battery compartments in the housing. Identical housing components and contacts can be employed with different electrical assemblies having different operating voltage and amperage.
One specific use of a modular battery pack or receptacle in accordance with this invention would be in a retail point of sale device. A method of powering point of sale displays of this type, having electrical components, such as light emitting diodes, audio components and video components, would employ this battery pack assembly including modular components configurable to deliver different output voltages. At least one housing having a plurality of battery compartments would be mounted on the point of sale display. A first contact would be attached or terminated to a first conductor and a second contact to a second conductor. These contacts would be mounted in the housing between each battery compartment. Each contact would include contact surfaces for engaging positive and negative battery electrodes, to connect batteries, positioned in the battery compartments, in series. Each contact would also include a conductor coupling part. The contacts would be positioned with first and second conductors attached thereto so that batteries positioned in battery compartments between the contacts with first and second conductors attached thereto will be connected so that the operating voltage and amperage required for the point of sale display will be provided. Identical housing components and contacts can thus be employed with different electrical components or assemblies having different operating voltages.
The modular battery pack or receptacle 2 according to this invention can be configured to wire multiple batteries in different ways so that voltage and amperage supplied by the batteries in battery pack 2 will correspond to the voltage and amperage requirements for the electrical or electronic device with which the battery pack 2 and the batteries are to be used. The same components of battery pack 2 can be employed for electrical and electronic devices having different voltage and amperage requirements. The battery pack or receptacle 2 according to this invention is modular in form and is to be used with a wide variety of electronic or electrical devices that require electrical power from DC batteries. This battery pack 2 is especially suited for use in retail point of display devices that employ electrical components such as LED's, LCD, lamps, audio annunciators or other components. However, this battery pack 2 is not limited to use with such devices.
Not only is this battery pack 2 intended for use in different applications, it is especially suited for use, sometimes alone or sometimes in combination with one or more other identical battery packs 2, for supplying different voltages in different applications. Battery packs 2 can be ganged, and batteries in the battery pack can be wired in series, to deliver the needed voltage, as well as amperage, for a particular situation. For example, three D-cell batteries mounted in a single battery pack 2 can be wired in series to deliver 4.5VDC. Four identical battery packs 2 can be connected so that 16 batteries are mounted therein to provide two 12VDC power supplies wired in parallel to deliver sufficient amperage to a load and to be capable of having a relatively long battery life required for certain situations.
In the preferred embodiment of this invention, each battery pack or receptacle 2 includes a housing 10 with four battery compartments 12. Three contacts 50 are located in intermediate walls 18 to connect the positive electrode of each battery to a negative electrode of an adjacent battery. The same contacts 50 are mounted in a first end wall 14 at one end of the housing 10 and in a second end wall 16 at the opposite end of the housing 10. In the embodiment of
Four battery compartments 12 are located in end to end alignment between the first end 14 and the second end 16. Four 1.5 VDC, preferably in the form of conventional D-cell batteries, positioned in these compartments 12 will be connected in series to deliver 6VDC. Each battery compartment is defined by at least one intermediate wall 18 and by a portion of the first and second side walls 32, 34. The battery compartments 12, on the opposite ends of the housing 10, are also formed by the first and second end walls 14 and 16. The two central battery compartments 12 are flanked by intermediate walls 18 on opposite ends of the compartments. A bottom wall 46 extends between opposite end walls 14, 16 and the top of each battery compartment 12 is open so that a single battery can be inserted into each battery compartment in a conventional manner. A cover 40 can be attached to the housing by mounting screws 42 to close the battery compartments 12 after insertion of batteries therein.
In order to permit passage of an elongate conductor or wire 60 from first end 14 to second end 16 and beyond, each of the intermediate walls 18 has an intermediate wall opening 20 located beside the contact 50 mounted in that intermediate wall 18, which is wider than the contact 50. Opening 22 at the base of the first end wall 14 and an opening 24 at the base of the second end wall 16 are aligned with the three openings 20 on one side and adjacent to the base of the intermediate walls 18, so that five aligned openings are formed through the housing 10. This will permit any of the contacts 50 to be connected to any other contact 50 in the same housing by conductor 60, although normally the conductor 60 will only be terminated to one of the contacts 50. Conductor 62 will typically be terminated to another contact 50, so that the batteries between the two terminated contacts 50 will be connected in series.
Individual stamped and formed contacts 50 are mounted in each intermediate wall 18 as well as in the first and second end walls 14, 16. The intermediate walls 18 each have a slot 26 extending inwardly from the top of each wall 18. Contacts 50 are inserted into the intermediate wall slots 26 from above. Contacts 50 are also inserted into the first end wall slot 28 and second end wall slot 30. The end wall slots 28 and 30 have a width that is greater than the intermediate wall slots 26. The intermediate wall slots 26 extend from the top of each intermediate wall 18 to the housing bottom wall 46. The intermediate walls 18 can therefore are formed by two separate wall sections on opposite sides of its intermediate wall slot 26. As best seen in
The greater width of the end wall slots 28, 30, especially the slot 28 in end wall 14, allows insertion of the contacts 50, and the contact spring 54 into the end wall slots 28, 30. The significance of this slot width will also be more apparent after a discussion of the contact geometry.
Each contact 50 comprises a U-shaped stamped and formed member fabricated from an electrically conductive metal. The one piece contact 50 has a first plate 51 joined to a second parallel plate 53 by a bend or curved middle section 58 at the top of the two plates 51, 53. A first contact surface 52 in the form or an embossment or generally conical protrusion extends from the first plate 51. In the preferred embodiment, the size and shape of this embossment 52 allows this contact surface to engage a protruding positive electrode on a standard D-cell, dry cell battery. The second plate 53 includes a second contact surface 54 in the form of a coil spring extending therefrom. In the representative embodiment depicted herein, the spring 54 has a size and shape that will allow it to make electrical contact with a generally flat negative electrode on a standard D-cell, dry cell battery. Of course it should be understood that the contact surfaces 52 and 54 can have a different size and shape for embodiments that are employed with other battery sizes or types.
The first contact plate 51 is taller than the second contact plate 53. In the preferred embodiment depicted herein, three conductor coupling parts in the form of three holes 56A, 56B and 56C are located on the first contact plate 51. Two of these conductor coupling holes 56A and 56B are located near the protruding lower edge of the first contact plate, and the third conductor coupling hole 56C is located near the bend 58 at the upper end of the contact plate. Wires can be inserted through these holes 56A, 56B and 56C to couple or electrically connect the wire to the contact 50. In the preferred embodiment, the striped end of a 22 AWG wire can be inserted through any of these holes and soldered to the contact 50. Two holes or coupling parts 56A and 56B are provided so that two wires, one of which may be a jumper wire, can be electrically connected to the same contact 50, as will be subsequently discussed in more detail. It should be understood that other coupling configurations can be employed with these contacts. For example, solderless connections, such as crimped or insulation displacement contacts can be substituted for the solder connection employed in this representative embodiment. A resilient male contact can also be crimped to the wire and inserted into engagement with a coupling part, which can have the same configuration as the holes 56A, 56B or 56C. The contacts 50 can also be plated in a conventional manner.
Each contact 50 will be inserted in one of the slots 26, 28 or 30. A wire or wires can be terminated to each contact 50 before the contact is inserted into its appropriate housing or housing wall slot or after the contact 50 is positioned in the appropriate slot. Retention tabs 57 are struck from the lower edge of the first plate 51, and these retention tabs will engage the interior sides of the intermediate wall along the grooves 21 to secure the contact 50 into an intermediate wall 18.
The configuration of the contacts 50 and the intermediate wall slots 26 insure that the batteries can only be inserted into the battery compartments 12 in the proper orientation if there is to be continuity between the batteries. The relatively wider yoke 19 on the intermediate walls 18 is located adjacent slots 26 and yoke 19 is wider than other portions of the intermediate walls 18 so that the yoke 19 extends beyond the embossment 52 on the contact 50 positioned in the intermediate wall slot 26. In other words the contact embossment 52 is recessed relative to the insulating intermediate wall 18. If a battery is inserted into a battery compartment 12, with the generally flat negative electrode positioned adjacent to a contact embossment 52, there will be a gap between the battery electrode and the contact surface formed by the contact embossment 52. Thus there will be a open condition in which current will not flow and in which the batteries will not be connected in series. There will then be no potential difference between the conductors 60 and 62 at the output connector 68 attached thereto. Thus one improperly oriented battery means that the batteries will not drain. If a battery is properly positioned in its battery compartment 12, the protruding positive battery electrode will extend into the gap formed by the intermediate wall slot 26 for a sufficient distance to engage the embossment 52 forming the first contact surface. With all of the batteries properly aligned, a potential difference will be present across the contacts in the electrical connector 58.
An important feature of the battery receptacle or pack 2 according to this invention is that the housing 10 and the contacts 50 can be assembled with wires that have been cut to length to fabricate different assemblies that provide different voltage levels. In other words the receptacle 2 is modular and can be employed as a single component or multiple battery receptacles can be ganged for voltage levels that are greater than the sum of the voltages of batteries that can be inserted into a single battery housing 10. The manner in which different voltages can be delivered will be apparent by comparing the configuration shown in
Since each of the receptacles 2 are configured to accept four batteries aligned end to end, two or more battery receptacle housings 10 can be positioned side by side when multiple receptacles 2 are ganged. One side wall 32 has a series of protruding male profiles 36 and the other side wall 34 has a series of cooperating female profiles 38. The male profiles 36 can be inserted into the female profiles 38 to secure adjacent housings together. A solvent weld of these male and female or dovetail profiles can be formed to insure that the individual housings are held together and the array can be handled as a single part. Handles 44 at one end, serve not only to help manipulate the receptacles 2 to assemble them to a device, but also provide a readily observable indication of polarity.
Although more that four batteries can be connected in series by ganging multiple receptacles 2, it should be understood that the same components can be employed if fewer than four batteries need to be connected in series. For example, if a 4.5 VDC supply is required, three 1.5 VDC batteries can be connected in series in one battery receptacle or battery pack 2. All of the contacts 50 are identical and each can be terminated to a wire. Thus instead of terminating wire 60 in
The preferred embodiment of this invention may employ a housing 10 in which all of the batteries will be inserted in end to end alignment. However, it should be understood that alternate embodiments are also possible. For example, the alternate embodiment of a battery receptacle 202, shown in
Although battery receptacles or battery packs employing the principles of this invention can be employed in any number of applications, one typical application is shown with reference to a retail point of sale device 300 shown in