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Patent 2021565 Summary

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Claims and Abstract availability

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(12) Patent Application: (11) CA 2021565
(54) English Title: MAIN AND RESERVE BATTERY CONSTRUCTION
(54) French Title: STRUCTURE RECEVANT DES BATTERIES D'ALIMENTATION ET DE SECOURS
Status: Deemed Abandoned and Beyond the Period of Reinstatement - Pending Response to Notice of Disregarded Communication
Bibliographic Data
(51) International Patent Classification (IPC):
  • H01M 10/14 (2006.01)
  • H01M 10/02 (2006.01)
  • H01M 10/44 (2006.01)
(72) Inventors :
  • MUSGROVE, EDWARD R. (United States of America)
(73) Owners :
  • EXIDE CORPORATION
(71) Applicants :
  • EXIDE CORPORATION (United States of America)
(74) Agent: MCCARTHY TETRAULT LLP
(74) Associate agent:
(45) Issued:
(22) Filed Date: 1990-07-19
(41) Open to Public Inspection: 1991-10-17
Availability of licence: N/A
Dedicated to the Public: N/A
(25) Language of filing: English

Patent Cooperation Treaty (PCT): No

(30) Application Priority Data:
Application No. Country/Territory Date
07/508,714 (United States of America) 1990-04-16

Abstracts

English 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.


Claims

Note: Claims are shown in the official language in which they were submitted.


21
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

22
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:

23
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.

24
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

26
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

28
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.

29
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.

31
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.

Description

Note: Descriptions are shown in the official language in which they were submitted.


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
. . :

2~21~6~
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,
, ~ ,
,~
.
: .

2021~
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.
' ,
: "

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;

202156~
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;
.~ - ................................. .
. ,
- : :
:

202~56~
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~
11
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~
12
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
13
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~
14
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~
16
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.

2n2l~6~
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
.

` 2021~6~
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.

Representative Drawing
A single figure which represents the drawing illustrating the invention.
Administrative Status

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Event History

Description Date
Time Limit for Reversal Expired 1995-01-19
Application Not Reinstated by Deadline 1995-01-19
Deemed Abandoned - Failure to Respond to Maintenance Fee Notice 1994-07-19
Inactive: Adhoc Request Documented 1994-07-19
Application Published (Open to Public Inspection) 1991-10-17

Abandonment History

Abandonment Date Reason Reinstatement Date
1994-07-19
Owners on Record

Note: Records showing the ownership history in alphabetical order.

Current Owners on Record
EXIDE CORPORATION
Past Owners on Record
EDWARD R. MUSGROVE
Past Owners that do not appear in the "Owners on Record" listing will appear in other documentation within the application.
Documents

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Document
Description 
Date
(yyyy-mm-dd) 
Number of pages   Size of Image (KB) 
Drawings 1991-10-16 9 225
Abstract 1991-10-16 1 19
Claims 1991-10-16 11 299
Descriptions 1991-10-16 20 619
Representative drawing 1999-07-15 1 31
Fees 1993-07-14 1 37
Fees 1992-07-09 1 32
Courtesy - Office Letter 1995-02-01 1 13