Jump starting apparatus

Abstract

A handheld device for jump starting a vehicle engine includes a rechargeable lithium ion battery pack and a microcontroller. The lithium ion battery is coupled to a power output port of the device through a FET smart switch actuated by the microcontroller. A vehicle battery isolation sensor connected in circuit with positive and negative polarity outputs detects the presence of a vehicle battery connected between the positive and negative polarity outputs. A reverse polarity sensor connected in circuit with the positive and negative polarity outputs detects the polarity of a vehicle battery connected between the positive and negative polarity outputs, such that the microcontroller will enable power to be delivered from the lithium ion power pack to the output port only when a good battery is connected to the output port and only when the battery is connected with proper polarity of positive and negative terminals.

Claims

1. A jump starting apparatus configured for boosting or charging a depleted or discharged battery having a positive polarity battery terminal and a negative polarity battery terminal, the jump starting apparatus comprising: at least one rechargeable battery comprising at least one battery cell having a positive tab and a negative tab; a positive battery cable having a positive polarity battery terminal connector for connecting the jump starting apparatus to the positive polarity battery terminal of the depleted or discharged battery; a negative battery cable having a negative polarity battery terminal connector for connecting the jump starting apparatus to the negative polarity battery terminal of the depleted or discharged battery; and a safety control system or circuit configured for detecting when the jump starting apparatus is properly connected to the depleted or discharged battery and then switching on power from the at least one rechargeable battery to the depleted or discharged battery only when the jump starting apparatus is properly connected to the depleted or discharged battery; wherein the positive battery cable has a conductor connected to the positive tab of the at least one battery cell of the rechargeable battery.

2. The apparatus according to claim 1, further comprising a USB output connector configured for electrically connecting the at least one rechargeable battery of the jump starting apparatus to one or more external electronic devices.

3. The apparatus according to claim 2, further comprising a USB output circuit electrically connecting the at least one rechargeable battery to the USB output connector.

4. The apparatus according to claim 3, wherein the USB output circuit is configured to down-convert a voltage of the at least one rechargeable battery to a voltage at the USB output connector.

5. The apparatus according to claim 4, wherein an output voltage of the at least one rechargeable battery is 12.4 VDC and the down-converted input and output voltage of the USB output connector is 5V.

6. The apparatus according to claim 2, further comprising a USB output control circuit connected to a microcontroller, the USB output control circuit is configured to allow the USB output to be turned on and off by software control to prevent the internal lithium battery from getting too low in capacity.

7. The apparatus according to claim 6, wherein the USB output connector includes a voltage divider for enabling charge to certain electronic devices.

8. The apparatus according to claim 1, wherein the safety control system or circuit signals to enable a power switch or circuit to turn on and connect power from the at least one rechargeable battery to the depleted or discharged battery.

9. The apparatus according to claim 1, wherein the jump starting apparatus is properly connected to the depleted or discharged battery when the positive and negative polarity battery terminal connectors are connected with proper polarity to the positive and negative polarity battery terminals of the depleted or discharged battery.

10. The apparatus according to claim 1, wherein the jump starting apparatus is properly connected to the positive and negative polarity battery terminals of the depleted or discharged battery when the positive and negative polarity battery terminal connectors are physically and electrically connected and connected with proper polarity to the positive and negative polarity battery terminals of the depleted or discharged battery.

11. The apparatus according to claim 1, wherein the at least one rechargeable battery is a single rechargeable battery.

12. The apparatus according to claim 1, wherein the safety control system or circuit comprises a microcontroller.

13. The apparatus according to claim 12, wherein the safety control system or circuit further comprises one or more sensors connected to the microcontroller configured for determining whether the depleted or discharged battery is properly connected to the jump starting apparatus prior to connecting power from the at least one rechargeable battery to the depleted or discharged battery.

14. The apparatus according to claim 13, wherein the one or more sensors connected to the microcontroller are configured to determine whether the depleted or discharged battery has a proper polarity connection with the jump starting apparatus prior to connecting power from the at least one rechargeable battery to the depleted or discharged battery.

15. The apparatus according to claim 14, wherein the one or more sensors is two or more separate sensors connected to the microcontroller.

16. The apparatus according to claim 15, wherein the two or more sensors comprises a presence sensor to determine whether the depleted or discharged battery is electrically connected between the positive and negative polarity battery terminal connectors and a reverse polarity sensor to determine whether the depleted or discharged battery has proper polarity connection with the positive and negative polarity battery terminal connectors.

17. The apparatus of claim 1, wherein the at least one rechargeable battery is at least one lithium ion battery or lithium ion battery cell.

18. The apparatus of claim 1, wherein the power switch comprises one or more FETs.

19. The apparatus of claim 1, further comprising a plurality of power diodes coupled between the positive or negative battery terminal connector and the at least one rechargeable battery to prevent back-charging of the power supply from the depleted or discharged battery or an electrical system connected to the depleted or discharged battery.

20. The apparatus of claim 1, further comprising a temperature sensor configured to detect temperature of the at least one battery and to provide a temperature signal to the safety control system or circuit.

21. The apparatus of claim 1, further comprising a voltage measurement circuit configured to measure output voltage of the at least one rechargeable battery and to provide a voltage measurement signal to the safety control system or circuit.

22. The apparatus of claim 1, further comprising a voltage regulator configured to convert output voltage of the at least one rechargeable battery to a voltage level appropriate to provide operating power internal components of the jump starting apparatus.

23. The apparatus of claim 1, further comprising a flashlight circuit configured to provide a source of light to a user.

24. The apparatus of claim 23, wherein the source of light is at least one LED.

25. The apparatus of claim 24, wherein the safety control system or circuit is configured to control the at least one LED to provide a visual alarm indicating an emergency situation.

26. The apparatus of claim 1, further comprising a plurality of visual indicators configured to display remaining capacity status of the at least one rechargeable battery.

27. The apparatus of claim 26, wherein the plurality of visual indicators comprises a plurality of LEDs providing output light of different colors.

28. The apparatus of claim 1, further comprising a visual indicator configured to warn a user when the depleted or discharged battery is connected to the jump starting apparatus with reverse polarity.

29. The apparatus of claim 1, further comprising separate visual indicators configured to display a power on status of the jump starting apparatus, and a jump start boost power status of power supplied to an output device.

30. The apparatus of claim 1, further comprising a manual override switch configured to activate a manual override mode to enable a user to connect jump start power to an output port when a vehicle battery isolation sensor is unable to detect presence of a vehicle battery.

31. The apparatus of claim 30, wherein the safety control system or circuit is configured to detect actuation of the manual override switch for at least a predetermined period of time before activation of the manual override mode.

32. The apparatus of claim 1, further comprising a jumper cable device, the jumper cable device comprising a plug configured to plug into an output port of the jump starting apparatus, a pair of battery cables integrated with the plug at one end of the pair of cables, and the positive and negative battery terminal connectors connected to an opposite end of the pair of battery cables.

33. The apparatus of claim 32, wherein the output port and the plug are dimensioned so that the plug will fit into the output port only in one specific orientation.

34. The apparatus of claim 1, wherein the jumper cable device further comprises a pair of ring terminals configured to respectively connect a pair of battery cables at the opposite end to the respective positive and negative battery terminals of the depleted or discharged battery, or connect to respective positive and negative battery clamps.

35. The apparatus according to claim 1, including an operation indicator LED to provide visual indication of the power supply capacity status.

36. The apparatus according to claim 1, including an operation indicator LED to provide visual indication of the switch activation status indicating power is being provided to the depleted or discharged battery.

37. The apparatus according to claim 1, wherein the at least one rechargeable battery is at least one lithium ion rechargeable battery having a positive tab and a negative tab.

38. The apparatus according to claim 37, further comprising a positive electrical conductor connecting the positive tab of the at least one lithium ion rechargeable battery to a positive battery cable and/or a negative electrical conductor connecting the negative tab of the at least one lithium ion rechargeable battery to a negative battery cable.

39. The apparatus according to claim 38, wherein the positive electrical conductor is a positive conductive bar, and the at least one negative electrical conductor is negative conductive bar.

40. The apparatus according to claim 38, wherein one end of the positive electrical connector at least partially wraps around and connected to an exposed end of a positive battery cable.

41. The apparatus according to claim 37, wherein the positive tab of the at least one lithium ion rechargeable battery is at least partially wrapped around and connected to a positive battery cable of the jump starting apparatus.

42. The apparatus according to claim 41, wherein a separate tab is connected to the positive tab to extend a length of the positive tab.

43. The apparatus according to claim 1, wherein the safety control system or circuit comprises a switch used for switching on the power from the at least one rechargeable battery.

44. The apparatus according to claim 43, wherein the switch is an electronic switch.

45. The apparatus according to claim 44, wherein the safety control system or circuit further comprises a microcontroller configured for controlling the electronic switch.

46. The apparatus according to claim 45, wherein the safety control system or circuit further comprises one or more electronic sensors configured for providing input signals to the microcontroller.

47. The apparatus according to claim 46, wherein the one or more electronic sensors comprising a battery presence sensor and a reverse polarity sensor.

48. The apparatus according to claim 1, wherein the safety control system or circuit comprises an output port and the positive polarity battery terminal connector and negative polarity battery terminal connector are defined by a battery cable assembly having a plug connector, a positive battery cable with a positive battery clamp, and a negative battery cable with a negative battery clamp, the plug connector being shaped to only fit into the output port in a single orientation.

49. The apparatus according to claim 1, wherein the negative tab of the at least one battery cell of the rechargeable battery is connected to a negative terminal conductor bar.

50. A jump starting apparatus configured for boosting or charging a depleted or discharged battery having a positive polarity battery terminal and a negative polarity battery terminal, the jump starting apparatus comprising: at least one rechargeable battery; a battery cable assembly comprising: a positive battery cable having a positive polarity battery terminal connector for connecting the jump starting apparatus to the positive polarity battery terminal of the depleted or discharged battery; a negative battery cable having a negative polarity battery terminal connector for connecting the jump starting apparatus to the negative polarity battery terminal of the depleted or discharged battery; and a plug connector coupled to the positive battery cable and the negative battery cable, the plug connector shaped to only fit into an output port in a single orientation; and a safety control system or circuit comprising the output port, the safety control system configured for detecting when the jump starting apparatus is properly connected to the depleted or discharged battery and then switching on power from the at least one rechargeable battery to the depleted or discharged battery only when the jump starting apparatus is properly connected to the depleted or discharged battery.

51. A jump starting apparatus configured for boosting or charging a depleted or discharged battery having a positive polarity battery terminal and a negative polarity battery terminal, the jump starting apparatus comprising: at least one rechargeable battery comprising at least one battery cell having a positive tab and a negative tab; a positive battery cable having a positive polarity battery terminal connector configured for connecting the jump starting apparatus to the positive polarity battery terminal of the depleted or discharged battery; a negative battery cable having a negative polarity battery terminal connector configured for connecting the jump starting apparatus to the negative polarity battery terminal of the depleted or discharged battery; a safety power switch or circuit configured for connecting power from the at least one rechargeable battery to the depleted or discharged battery when the jump starting apparatus is connected to the depleted or discharged battery; and a safety control system or circuit connected to and controlling the power switch or circuit, the safety control system or circuit configured to detect when the positive and negative polarity battery terminal connectors are properly connected to the positive and negative polarity battery terminals of the depleted or discharged battery and then control the power switch or circuit to turn on and connect power from the at least one rechargeable battery to the depleted or discharged battery; wherein the positive battery cable has a conductor connected to the positive tab of the at least one battery cell of the rechargeable battery.

52. A jump starting apparatus configured for boosting or charging a depleted or discharged battery having a positive polarity battery terminal and a negative polarity battery terminal, the jump starting apparatus comprising: at least one rechargeable battery comprising at least one battery cell having a positive tab and a negative tab; a positive battery cable having a positive polarity battery terminal connector for connecting the jump starting apparatus to the positive polarity battery terminal of the depleted or discharged battery; a negative battery cable having a negative polarity battery terminal connector for connecting the jump starting apparatus to the negative polarity battery terminal of the depleted or discharged battery; a safety control system or circuit configured for detecting when the jump starting apparatus is properly connected to the depleted or discharged battery and then switching on power from the at least one rechargeable battery to the depleted or discharged battery only when the jump starting apparatus is properly connected to the depleted or discharged battery; a USB output connector configured for electrically connecting the internal power supply of the jump starting apparatus to one or more external electronic devices; and a USB output circuit electrically connecting the at least one rechargeable battery to the USB output connector; wherein the positive battery cable has a conductor connected to the positive tab of the at least one battery cell of the rechargeable battery.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a functional block diagram of a handheld vehicle battery boost apparatus in accordance with one aspect of the present invention;

(2) FIGS. 2A-2C are schematic circuit diagrams of an example embodiment of a handheld vehicle battery boost apparatus in accordance with an aspect of the invention;

(3) FIG. 3 is a perspective view of a handheld jump starter booster device in accordance with one example embodiment of the invention; and

(4) FIG. 4 is a plan view of a jumper cable usable with the handheld jump starter booster device in accordance with another aspect of the invention.

(5) FIG. 5 is a front view of the battery jump starting device with the battery terminal clamps un-deployed.

(6) FIG. 6 is a rear perspective view of the battery jump starting device shown in FIG. 5.

(7) FIG. 7 is an end perspective view of the battery jump starting device shown in FIGS. 5 and 6.

(8) FIG. 8 is a front perspective view of the battery jump starting device shown in FIG. 5, however, with the battery terminal clamps deployed.

(9) FIG. 9 is a front perspective view of a battery connector device contained within the battery jump starting device shown in FIG. 5, however, with the negative cable not yet installed.

(10) FIG. 10 is a top planer view of the battery connector device shown in FIG. 9.

(11) FIG. 11 is a side elevational view of the battery connector device shown in FIG. 9.

(12) FIG. 12 is an end elevational view of the battery connector device shown in FIG. 9.

(13) FIG. 13 is a perspective view of the battery connector device shown in FIG. 9, however, the negative cable in now connected to the battery connector device.

(14) FIG. 14 is a view perspective view of the battery connector device shown in FIG. 9, however, with a diode connector installed on the positive cable.

(15) FIG. 15 is a perspective view of the battery connector device connected to other components or parts of the battery jump starting device.

(16) FIG. 16 is a perspective view of the battery assembly of the battery connector device shown in FIG. 9.

(17) FIG. 17 is a front perspective view of another battery connector device for the battery jump starting device.

(18) FIG. 18 is a detailed view of the positive cable connection with the relay printed circuit board prior to being soldered together.

(19) FIG. 19 is a detailed view of the positive cable connection with the relay printed circuit board after being soldered together.

(20) FIG. 20 is a front perspective view of the battery connector device shown in FIG. 17 prior to connection with the positive cable and negative cable.

(21) FIG. 21 is a partial top planar view of the battery assembly of the battery connector device shown in FIG. 20 showing the positive terminal conductor sheet in an unwound condition.

(22) FIG. 22 is an end perspective view showing the positive terminal conductor shown in FIG. 21 with the conductor end of the positive cable positioned on the positive terminal conductor just prior to winding the positive terminal conductor around the conductor end of the positive cable.

(23) FIG. 23 is an end perspective view showing the positive terminal conductor shown in FIG. 22 partially wound around the conductor end of the positive cable.

(24) FIG. 24 is an end perspective view of the positive terminal conductor shown in FIG. 22 fully wound around the conductor end of the positive cable.

(25) FIG. 25 is a side perspective view showing the positive terminal conductor fully wound around and soldered to the conductor end of the positive cable.

(26) FIG. 26 is an opposite end perspective view of the positive terminal conductor fully wound around and soldered to the end of the positive cable.

(27) FIG. 27 is a perspective view of the diode connector installed between overlapping sections of the positive cable.

(28) FIG. 28 is a perspective view of a Schottky diode used in the diode connector.

(29) FIG. 29 is a perspective view of the diode connector insulated with a shrink wrap sleeve.

(30) FIG. 30 is a graphical illustration showing a load test of the battery connection shown in FIGS. 9-14.

(31) FIG. 31 is a graphical illustration showing a load test of the battery connection shown in FIGS. 17-29.

(32) FIG. 32 is a front view of a further battery connector device for the battery jump starting device.

(33) FIG. 33 is a planar view of the battery connector device comprising a plurality of battery cells having separate tab and conductors (e.g. plate conductors) prior to assembly.

(34) FIG. 34 is a planar view of the battery connector device comprising battery cells being prepared with separate tabs for lengthening the tabs.

(35) FIG. 35 is a front view of the battery connector device comprising the plurality of battery cells having separate tab and conductors shown in FIG. 33, after assembly.

(36) FIG. 36 is a elevational view of the battery connector device comprising the battery cell assembly shown in FIG. 35, after folding the battery cells on top of each other.

(37) FIG. 37 is an end perspective view of the battery connector device showing the separate tab wrapped or wound around an exposed conductor end of the positive cable, and soldered together.

(38) FIG. 38 is an opposite end perspective view of the battery connector device showing a negative battery tab wrapped or wound around the negative terminal conductor plate and welded and/or soldered together.

(39) FIG. 39 is a perspective view of the battery connector device showing the flat separate tab connected to the positive battery tab and extending outwardly prior to connection with the conductive end of the positive cable.

(40) FIG. 40 is a side view of the temperature sensor assembly with wires and connector.

(41) FIG. 41 is a perspective view of the diode circuit board assembled or connected or spliced inline into the positive cable.

DETAILED DESCRIPTION

(42) FIG. 1 is a functional block diagram of a vehicle jump starting apparatus or a handheld battery booster according to one aspect of the invention. At the heart of the handheld battery booster is a lithium polymer battery pack 32, which stores sufficient energy to jump start a vehicle engine served by a conventional 12 volt lead-acid or valve regulated lead-acid battery. In one example embodiment, a high-surge lithium polymer battery pack includes three 3.7V, 2666 mAh lithium polymer batteries in a 351P configuration. The resulting battery pack provides 11.1V, 2666 Ah (8000 Ah at 3.7V, 29.6 Wh). Continuous discharge current is 25 C (or 200 amps), and burst discharge current is 50 C (or 400 amps). The maximum charging current of the battery pack is 8000 mA (8 amps).

(43) A programmable microcontroller unit (MCU) 1 receives various inputs and produces informational as well as control outputs. The programmable MCU 1 further provides flexibility to the system by allowing updates in functionality and system parameters, without requiring any change in hardware. According to one example embodiment, an 8 bit microcontroller with 2K×15 bits of flash memory is used to control the system. One such microcontroller is the HT67F30, which is commercially available from Holtek Semiconductor Inc.

(44) A car battery reverse sensor 10 monitors the polarity of the vehicle battery 72 when the handheld battery booster device is connected to the vehicle's electric system. As explained below, the booster device prevents the lithium battery pack from being connected to the vehicle battery 72 when the terminals of the battery 72 are connected to the wrong terminals of the booster device. A car battery isolation sensor 12 detects whether or not a vehicle battery 72 is connected to the booster device, and prevents the lithium battery pack from being connected to the output terminals of the booster device unless there is a good (e.g. chargeable) battery connected to the output terminals.

(45) A smart switch FET circuit 15 electrically switches the handheld battery booster lithium battery to the vehicle's electric system only when the vehicle battery is determined by the MCU 1 to be present (in response to a detection signal provided by isolation sensor 12) and connected with the correct polarity (in response to a detection signal provided by reverse sensor 10). A lithium battery temperature sensor 20 monitors the temperature of the lithium battery pack 32 to detect overheating due to high ambient temperature conditions and overextended current draw during jump starting. A lithium battery voltage measurement circuit 24 monitors the voltage of the lithium battery pack 32 to prevent the voltage potential from rising too high during a charging operation and from dropping too low during a discharge operation.

(46) Lithium battery back-charge protection diodes 28 prevent any charge current being delivered to the vehicle battery 72 from flowing back to the lithium battery pack 32 from the vehicle's electrical system. Flashlight LED circuit 36 is provided to furnish a flashlight function for enhancing light under a vehicle's hood in dark conditions, as well as providing SOS and strobe lighting functions for safety purposes when a vehicle may be disabled in a potentially dangerous location. Voltage regulator 42 provides regulation of internal operating voltage for the microcontroller and sensors. On/Off manual mode and flashlight switches 46 allow the user to control power-on for the handheld battery booster device, to control manual override operation if the vehicle has no battery, and to control the flashlight function. The manual button functions only when the booster device is powered on. This button allows the user to jump-start vehicles that have either a missing battery, or the battery voltage is so low that automatic detection by the MCU is not possible. When the user presses and holds the manual override button for a predetermined period time (such as three seconds) to prevent inadvertent actuation of the manual mode, the internal lithium ion battery power is switched to the vehicle battery connect port. The only exception to the manual override is if the car battery is connected in reverse. If the car battery is connected in reverse, the internal lithium battery power shall never be switched to the vehicle battery connect port.

(47) USB charge circuit 52 converts power from any USB charger power source, to charge voltage and current for charging the lithium battery pack 32. USB output 56 provides a USB portable charger for charging smartphones, tablets, and other rechargeable electronic devices. Operation indicator LEDs 60 provides visual indication of lithium battery capacity status as well as an indication of smart switch activation status (indicating that power is being provided to the vehicle's electrical system).

(48) Detailed operation of the handheld booster device will now be described with reference to the schematic diagrams of FIGS. 2A-2C. As shown in FIG. 2A, the microcontroller unit 1 is the center of all inputs and outputs. The reverse battery sensor 10 comprises an optically coupled isolator phototransistor (4N27) connected to the terminals of vehicle battery 72 at input pins 1 and 2 with a diode D8 in the lead conductor of pin 1 (associated with the negative terminal CB−), such that if the battery 72 is connected to the terminals of the booster device with the correct polarity, the optocoupler LED 11 will not conduct current, and is therefore turned off, providing a “1” or high output signal to the MCU 1. The car battery isolation sensor 12 comprises an optically coupled isolator phototransistor (4N27) connected to the terminals of vehicle battery 72 at input pins 1 and 2 with a diode D7 in the lead conductor of pin 1 (associated with the positive terminal CB+), such that if the battery 72 is connected to the terminals of the booster device with the correct polarity, the optocoupler LED 11A will conduct current, and is therefore turned on, providing a “0” or low output signal to the MCU, indicating the presence of a battery across the jumper output terminals of the handheld booster device.

(49) If the car battery 72 is connected to the handheld booster device with reverse polarity, the optocoupler LED 11 of the reverse sensor 10 will conduct current, providing a “0” or low signal to microcontroller unit 1. Further, if no battery is connected to the handheld booster device, the optocoupler LED 11A of the isolation sensor 12 will not conduct current, and is therefore turned off, providing a “1” or high output signal to the MCU, indicating the absence of any battery connected to the handheld booster device. Using these specific inputs, the microcontroller software of MCU 1 can determine when it is safe to turn on the smart switch FET 15, thereby connecting the lithium battery pack to the jumper terminals of the booster device. Consequently, if the car battery 72 either is not connected to the booster device at all, or is connected with reverse polarity, the MCU 1 can keep the smart switch FET 15 from being turned on, thus prevent sparking/short circuiting of the lithium battery pack.

(50) As shown in FIG. 2B, the FET smart switch 15 is driven by an output of the microcontroller 1. The FET smart switch 15 includes three FETs (Q15, Q18, and Q19) in parallel, which spreads the distribution of power from the lithium battery pack over the FETs. When that microcontroller output is driven to a logic low, FETs 16 are all in a high resistance state, therefore not allowing current to flow from the internal lithium Battery negative contact 17 to the car battery 72 negative contact. When the microcontroller output is driven to a logic high, the FETs 16 (Q15, Q18, and Q19) are in a low resistant state, allowing current to flow freely from the internal lithium battery pack negative contact 17 (LB−) to the car battery 72 negative contact (CB−). In this way, the microcontroller software controls the connection of the internal lithium battery pack 32 to the vehicle battery 72 for jumpstarting the car engine.

(51) Referring back to FIG. 2A, the internal lithium battery pack voltage can be accurately measured using circuit 24 and one of the analog-to-digital inputs of the microcontroller 1. Circuit 24 is designed to sense when the main 3.3V regulator 42 voltage is on, and to turn on transistor 23 when the voltage of regulator 42 is on. When transistor 23 is conducting, it turns on FET 22, thereby providing positive contact (LB+) of the internal lithium battery a conductive path to voltage divider 21 allowing a lower voltage range to be brought to the microcontroller to be read. Using this input, the microcontroller software can determine if the lithium battery voltage is too low during discharge operation or too high during charge operation, and take appropriate action to prevent damage to electronic components.

(52) Still referring to FIG. 2A, the temperature of the internal lithium battery pack 32 can be accurately measured by two negative temperature coefficient (NTC) devices 20. These are devices that reduce their resistance when their temperature rises. The circuit is a voltage divider that brings the result to two analog-to-digital (A/D) inputs on the microcontroller 1. The microcontroller software can then determine when the internal lithium battery is too hot to allow jumpstarting, adding safety to the design.

(53) The main voltage regulator circuit 42 is designed to convert internal lithium battery voltage to a regulated 3.3 volts that is utilized by the microcontroller 1 as well as by other components of the booster device for internal operating power. Three lithium battery back charge protection diodes 28 (see FIG. 2B) are in place to allow current to flow only from the internal lithium battery pack 32 to the car battery 72, and not from the car battery to the internal lithium battery. In this way, if the car electrical system is charging from its alternator, it cannot back-charge (and thereby damage) the internal lithium battery, providing another level of safety. The main power on switch 46 (FIG. 2A) is a combination that allows for double pole, double throw operation so that with one push, the product can be turned on if it is in the off state, or turned off if it is in the on state. This circuit also uses a microcontroller output 47 to “keep alive” the power when it is activated by the on switch. When the switch is pressed the microcontroller turns this output to a high logic level to keep power on when the switch is released. In this way, the microcontroller maintains control of when the power is turned off when the on/off switch is activated again or when the lithium battery voltage is getting too low. The microcontroller software also includes a timer that turns the power off after a predefined period of time, (such as, e.g. 8 hours) if not used.

(54) The flashlight LED circuit 45 shown in FIG. 2B controls the operation of flashlight LEDs. Two outputs from the microcontroller 1 are dedicated to two separate LEDs. Thus, the LEDs can be independently software-controlled for strobe and SOS patterns, providing yet another safety feature to the booster device. LED indicators provide the feedback the operator needs to understand what is happening with the product. Four separate LEDs 61 (FIG. 2A) are controlled by corresponding individual outputs of microcontroller 1 to provide indication of the remaining capacity of the internal lithium battery. These LEDs are controlled in a “fuel gauge” type format with 25%, 50% 75% and 100% (red, red, yellow, green) capacity indications. An LED indicator 63 (FIG. 2B) provides a visual warning to the user when the vehicle battery 72 has been connected in reverse polarity. “Boost” and on/off LEDs 62 provide visual indications when the booster device is provide jump-start power, and when the booster device is turned on, respectively.

(55) A USB output 56 circuit (FIG. 2C) is included to provide a USB output for charging portable electronic devices such as smartphones from the internal lithium battery pack 32. Control circuit 57 from the microcontroller 1 allows the USB output 56 to be turned on and off by software control to prevent the internal lithium battery getting too low in capacity. The USB output is brought to the outside of the device on a standard USB connector 58, which includes the standard voltage divider required for enabling charge to certain smartphones that require it. The USB charge circuit 52 allows the internal lithium battery pack 32 to be charged using a standard USB charger. This charge input uses a standard micro-USB connector 48 allowing standard cables to be used. The 5V potential provided from standard USB chargers is up-converted to the 12.4 VDC voltage required for charging the internal lithium battery pack using a DC-DC converter 49. The DC-DC converter 49 can be turned on and off via circuit 53 by an output from the microcontroller 1.

(56) In this way, the microcontroller software can turn the charge off if the battery voltage is measured to be too high by the ND input 22. Additional safety is provided for helping to eliminate overcharge to the internal lithium battery using a lithium battery charge controller 50 that provides charge balance to the internal lithium battery cells 51. This controller also provides safety redundancy for eliminating over discharge of the internal lithium battery.

(57) FIG. 3 is a perspective view of a handheld device 300 in accordance with an exemplary embodiment of the invention. 301 is a power on switch. 302 shows the LED “fuel gauge” indicators 61. 303 shows a 12 volt output port connectable to a cable device 400, described further below. 304 shows a flashlight control switch for activating flashlight LEDs 45. 305 is a USB input port for charging the internal lithium battery, and 306 is a USB output port for providing charge from the lithium battery to other portable devices such as smartphones, tablets, music players, etc. 307 is a “boost on” indicator showing that power is being provided to the 12V output port. 308 is a “reverse” indicator showing that the vehicle battery is improperly connected with respect to polarity. 309 is a “power on” indicator showing that the device is powered up for operation.

(58) FIG. 4 shows a jumper cable device 400 specifically designed for use with the handheld device 300. Device 400 has a plug 401 configured to plug into 12 volt output port 303 of the handheld device 300. A pair of cables 402a and 402b are integrated with the plug 401, and are respectively connected to vehicle battery terminal connectors, for example, battery terminal clamps 403a and 403b via ring terminals 404a and 404b. The port 303 and plug 401 may be dimensioned so that the plug 401 will only fit into the port 303 in a specific orientation, thus ensuring that clamp 403a will correspond to positive polarity, and clamp 403b will correspond to negative polarity, as indicated thereon.

(59) Additionally, the ring terminals 404a and 404b may be disconnected from the clamps and connected directly to the terminals of a vehicle battery. This feature may be useful, for example, to permanently attach the cables 302a-302b to the battery of a vehicle. In the event that the battery voltage becomes depleted, the handheld booster device 300 could be properly connected to the battery very simply by plugging in the plug 401 to the port 303.

Jump Starting Device with Battery Connection Device

(60) Another jump starting apparatus or device 510 is shown in FIGS. 5 and 6. The battery jump starting device 510 comprises the electronic components or parts of the handheld battery booster apparatus shown in FIGS. 1-3 and the handheld device 300 shown in FIG. 4, and described above, in combination with a battery connection device 600 according to the present invention.

(61) The jump starting apparatus 510 comprises a casing 512 having a display 514 provided with an arrangement of light emitting diodes (LEDs) 516a-d, as shown in FIG. 5.

(62) The jump starting device 510 further comprises a positive cable 518 having a positive clamp 520 and a negative cable 522 having a negative clamp 524. The positive cable 518 and negative cable 522 pass through openings 512a, 512b, respectively, in the casing 512.

(63) The clamps 520, 524 are stowed away or docked in an un-deployed mode by clamping each to a respective side posts 526 extending outwardly on opposite sides of the casing 512, as shown in FIGS. 5 and 6. The side posts 526 are shown in FIG. 8. The clamps 520, 524 are docked when the jump starting device 510 is in non-use, and then unclamped from the side post 526 during use.

(64) The jump starting device 510 is configured to jump start a vehicle battery. For example, the jump starting device 510 can be the PORTABLE VEHICLE JUMP START APPARATUS WITH SAFETY PROTECTION disclosed in U.S. Pat. No. 9,007,015, which is fully incorporated herein by reference, or a device or apparatus similar thereto.

(65) The jump starting device 510 comprises electrical components or parts located inside the casing 512. For example, the jump starting device 510 comprises a battery connector device 600 shown in FIGS. 7-13.

(66) The battery connector device 600 comprises a battery assembly 610 having a battery 612. For example, the battery 612 is a lithium-ion rechargeable type battery. The battery connector device 600 is configured to maximize conductivity from the battery 612 to the cables 518, 522 and clamps 520, 524 of the jump starting device 510. The battery 612 comprises a battery casing 612a, for example, a rectangular-shaped battery casing 612a.

(67) The battery 612 comprises a positive tab or terminal at one end (e.g. width) of the battery 612, and a negative terminal tab or terminal at an opposite end (e.g. width) of the battery 612. For example, the battery 612 comprises one or more battery cells each having a positive and negative tab. For example, the positive tab or terminal from the battery cell(s) is located at the one end of the battery 612 and the negative tab or terminal from the battery cell(s) is located at the opposite end of the battery 612. A positive terminal conductor plate 614 is connected (e.g. soldered, welded, or sonically welded) at the one end of the battery 612 to the positive tab (i.e. contact) or terminal of the battery 612. The positive terminal conductor plate 614 extends along the one end (e.g. width) of the battery 612.

(68) The positive cable 518 can be connected (e.g. directly connected by soldering) to the positive terminal conductor plate 614 and/or the positive tab of the battery 612. For example, the positive terminal conductor bar 614 can be provided with a conductive loop 616 wrapping around (e.g. entirely wrapping around) and connected (e.g. crimped and/or soldered) to an exposed conductor end 518a of the positive cable 518. For example, the positive terminal conductor plate 614 is made from heavy gauge copper or aluminum sheet (e.g. machined, cut, or stamped therefrom).

(69) As shown in FIGS. 9 and 10, the positive terminal conductor plate 614 can be configured (e.g. bent) to wrap around one of the square-shaped corners of the rectangular-shaped casing 612a of the battery 612 (e.g. L-shaped). The L-shaped positive terminal conductor plate 614 can extend along an end of the battery 612 and along at least a portion of the side of the battery 612, as shown in FIG. 9.

(70) The positive terminal conductor plate 614 can also be mechanically coupled and/or adhered to the outer surface of the battery casing 612a to provide additional support and stability thereof (e.g. assembled to survive mechanical shock when drop testing the battery jump starter device 510). For example, the positive terminal conductor bar 614 can be mechanically connected to the battery casing 612 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 612 can be formed (e.g. molded) to mechanically connect (e.g. snap fit or interference connection) with the positive terminal conductor plate 614.

(71) The positive cable 518 can be a single piece of wire or a cable (e.g. twisted or braided wires) extending from the battery 612 to the positive clamp 520. Specifically, one end of the positive cable 518 is connected to the positive terminal conductor plate 614 connected to the battery 612, and the opposite end of the positive cable 518 is connected to the positive clamp 520.

(72) More specifically, the positive cable 518 can comprise a flexible or bent cable portion 518 (FIG. 9) for changing the direction of the positive cable 518 within the device casing 512. The positive cable 518 can be fitted with a flexible outer sleeve portion 620 transitioning into a flexible inner sleeve portion 622 to flexibly accommodate the positive cable 518 passing through the device casing 512. The flexible outer sleeve portion 620 is externally located relative to the device casing 512 of the battery jump starter device 510, and the flexible inner sleeve portion 622 is internally located relative to the casing 512 of the battery jump starter device 510.

(73) The flexible outer sleeve portion 620 is configured to reinforce the connection between the positive cable 518 and the device casing 512 of the jump starting device 510 while remaining flexible. For example, the flexible outer sleeve portion 620 is provided with one or more grooves 618a (e.g. three (3) grooves 624 shown in FIG. 9) exposing portions 518a of the positive cable 518. The one or more grooves 624 act as hinges to ease bending of the positive cable 518 within the flexible outer sleeve portion 620.

(74) The flexible sleeve 620 comprises an outer flange 624 spaced apart (e.g. a small distance equal to about a wall thickness of the device casing 512 of the jump starting device 510) from an in inner flange 626. The flanges 624, 626 further anchor the positive cable 518 to the device casing 512 of the jump starting device 510.

(75) The flexible sleeve 620 comprises a sleeve portion 628 (FIG. 10) connecting together the outer flange 624 and inner flange 626. For example, the flexible outer sleeve portion 620 is molded or applied onto and around the positive cable 518 as a single unit (e.g. the flexible sleeve 620 is molded onto a portion of the positive cable 518 inserted within the mold during the molding process). Alternatively, the flexible sleeve 620 is made (e.g. molded) separately, and then installed or assembled onto a portion of the positive cable 518.

(76) The positive cable 518 comprises an inner conductor (e.g. single wire conductor, twisted wires, or braided wires) disposed within an outer insulating sheath (e.g. extruded plastic sheath). The inner conductor, for example, can be a solid wire conductor or a multi-strand metal wire conductor comprising bundle of wires. The inner conductor can be made of copper or aluminum. The flexible sleeve 620 can be applied (e.g. molded or installed or assembled) onto and surrounding the outer insulating sheath of the positive cable 518.

(77) The battery connector device 600 further comprises a negative terminal conductor plate 630 (FIG. 9) connected (e.g. soldered, welded, or sonically welded) at an opposite end of the battery 612 to the negative tab or terminal (i.e. contact) of the battery 612. The negative terminal conductor plate 630 can extend along the opposite end of the battery 612.

(78) The other end of the negative terminal conductor plate 630 is provided with a negative terminal conductor plate connector portion 632, as shown in FIGS. 9 and 10. The negative terminal conductor plate 630 can be configured to wrap around one of the corners of the rectangular-shaped battery 612 (e.g. L-shaped). The L-shaped negative terminal conductor plate 630 can extend along an end of the battery 612 and along at least a portion of the side of the battery 612, as shown in FIGS. 9 and 10.

(79) The negative terminal conductor bar 630 can also be mechanically coupled and/or adhered to the outer surface of the battery casing 612a to provide additional support and stability thereof (e.g. to survive mechanical shock when drop testing the battery jump starter device 510). For example, the negative terminal conductor bar 614 can be mechanically connected to the battery casing 612a 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 612 can be formed (e.g. molded) to mechanically connect (e.g. snap fit or interference connection) with the positive terminal conductor plate 614.

(80) The battery connector device 600 further comprises a smart switch battery interface 634. The smart switch battery interface 634 comprises a relay printed circuit board (PCB) 636 having a first circuit board conductor bar 638 spaced apart from a second circuit board conductor bar 640 located on one side of the circuit board 636, as shown in FIGS. 9 and 10.

(81) A pair of relays 642 are mounted on an opposite side of the circuit board 636. The relays 642 include relay anchoring pins 642a located in through holes 636a in the relay printed circuit board 636 (FIGS. 9 and 11). The relays 642 further comprise relay connector pins 642b extending through the through holes 636b provided in the circuit board 636 and slots 638a provided in the first conductor bar 638. The relays 642 even further comprise relay connector pins 642c located in the through holes 636c provided in the circuit board 636 and through holes 640a provided in the second conductor bar 640. The relay anchoring pins 636a are soldered in place to mechanically connect the relays 642 to the circuit board 636. The relay connecting pins 642b and 642c are soldered in place to mechanically and electrically connect the relays 642, respectively, to the circuit board conductor plates 638, 640.

(82) The through holes 636a in the circuit board 636 are rectangular-shaped (FIGS. 9 and 11) and accommodate the relay anchoring pins 642a. Specifically, a base portion of the relay anchoring pins 642a 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 636. When solder is applied to the exposed ends of the relay anchoring pins 642a, 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 636.

(83) The slots 632a provided in negative terminal conductor bar connector portion 632 are rectangular-shaped and the through holes 638a in the first circuit board conductor bar 638 (FIG. 7) are T-shaped to accommodate the three (3) horizontally oriented relay connector pins 642b, as shown in FIG. 7. The ends of the relay connector pins 642b are shown flush with the outer surface of the negative terminal conductor bar connector portion 632. When solder is applied to the exposed ends of the relay connector pins 642b, the solder fills in the slots 632a in the negative terminal conductor bar connector portion 632 and the through holes 638a of the first circuit board conductor bar 638, and connects the sides of the connector pins 642b with inner edges of the slots 632a and through holes 638a to anchoring the relays 642 to the circuit board 636 and negative terminal conductor bar connector portion 632. This applied solder also electrically connects the negative terminal conductor bar connector portion 632 to the first circuit board conductor bar 638.

(84) The through holes 640a provided in the second circuit board conductor bar 640 are T-shaped to accommodate the three (3) vertically oriented relay connecting pins 642b, as shown in FIG. 7. The relay connector prongs 640a extend outwardly from the outer surface of the circuit board 636 to connect with the exposed conductor end 644a of the negative cable 644, and shown in FIG. 11. When solder is applied to the exposed conductor end 644a and the ends of the relay connector prongs 640a, the solder fills in the T-shaped slot and electrically connects the relay connector prongs 640a, second circuit board conductor 640, and exposed conductor end 644a of the negative cable 644.

(85) The negative terminal conductor bar connector portion 632 of the negative terminal conductor bar 630 is connected (e.g. by soldering) to the first circuit board conductor bar 638 of the circuit board 636. The exposed conductor end 522a (i.e. with the insulating sheath removed) of the negative cable 522 is connected (e.g. by soldering) to the second circuit board conductor bar 640, as shown in FIG. 13.

(86) The battery connector device 600 can be modified by providing the positive cable 518 with a diode connection 650, as shown in FIG. 14. For example, a diode connection 650 is installed (e.g. spliced) into the positive cable 518. The diode connection 650 comprises a diode printed circuit board (PCB) 652 provided with a set of back-charge diodes 654 (e.g. Schottky diodes) located on one side thereof, and a conductor bar 656 provided on an opposite side of the circuit board 652.

Assembly

(87) The jump starting device 510 comprises the device casing 512 having an upper casing portion 512a and a lower casing portion 512b, as shown in FIG. 15. The upper casing portion 512a and the lower casing portion 512b are configured to be connected together when assembling the jump starting device 510.

(88) The jump starting device 510 further comprises the battery connection device 600 and controller assembly 710 both disposed within the casing 512. The controller assembly 710 comprises a circuit board 712 located adjacent to another circuit board 714.

(89) The positive terminal of the battery assembly 610 (FIG. 15) is connected to the circuit board 712 via a positive power wire 716. For example, one end of the positive power wire 716 is soldered to the positive terminal conductor bar 614 (FIG. 9) and the opposite end is soldered to the circuit board 712. The negative terminal of the battery assembly 610 is connected to the circuit board 714 via a negative power wire 718. For example, one end of the negative power wire 718 is soldered to the negative terminal conductor bar 630 (FIG. 9) and the opposite end is solder to the circuit board 714.

(90) The relay circuit board 636 is provided with a wire set 720 having a connector 722 (FIGS. 14 and 15). The connector 722 is configured to connect with the relay board connector 722 located on the circuit board 712 of the controller assembly 710 during assembly of the battery jump starting device 510.

(91) The battery assembly 610 further comprises a wire set 726 having a connector 728. The connector 728 is configured to connect with the battery cell charging/monitoring connector 728 located on the circuit board 712 of the controller assembly 710.

(92) The battery assembly 610 also comprises a battery temperature sensor having a wire set 732 (FIG. 16) having a connector 734. The connector 734 is configured to connect with the temperature sensor connector 736 located on the circuit board 712 of the controller assembly 720.

(93) The circuit board 712 is provided with in charge power resistors and an out relay. Further, the lower casing portion 512a is provided with a main user out connector 744 having a wire set 746 connected to the main circuit board 714, and a main user in connector 748 having a wire set 750 connected to the circuit board 714.

(94) The battery assembly 610 is connected to jump starting device 510, as shown in FIG. 15. The battery connector device 610 is installed within the device casing 512 of the jump starting device 510 when assembled.

Enhanced Conductivity Battery Connector Device

(95) An enhanced conductivity battery connector device 900 is shown in FIGS. 17-29. The enhanced conductivity battery connector device 900 provides a significantly increased conductivity compared to the battery connector device 600, as shown in FIGS. 9-16.

(96) The amount of power to be conducted from the battery 912 to the battery terminal clamps connected to a vehicle battery of a vehicle to be jump started can be enhanced as follows:

(97) 1) Increase Wire Gauge

(98) For example, change the 4 AWG (American Wire Gage) positive cable 518 and change the negative cable 522 (FIG. 13) to a 2 AWG positive cable 818 and negative cable 822 (FIG. 19).
2) Increase Conductivity of Negative Cable Connection For example, the negative cable conductor end 822a (FIGS. 18 and 19) connection to the relays is extended all the way across the connector pins 922c of the relays 922.
3) Increase Conductivity of Positive Cable Connection For example, the positive battery tab 914 is lengthened so that the inner conductor 818a of the positive cable 818 is rolled up (FIGS. 21-26) within the positive battery tab 914 and soldered together thoroughly;
4) Increase Conductivity of Diode Connection For example, the diode connection 650 (FIG. 14) is replaced with the diode connection 950 (FIG. 27);
5) Redesign Resistor/Diode Printed Circuit Board (PCB) For example, the diode printed circuit board (PCB) 652 (FIG. 14) is replaced with the diode printed circuit board (PCB) 952 (FIG. 27); and
6) Reconnect Resistors For example, the resistors R134A&B, R135A&B located on the diode printed circuit board (PCB) 652 (FIG. 14) is reconnected again.

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

(100) 1) Increase Wire Gauge

(101) The gauge of the positive cable 518 and negative cable 522 (FIG. 13), for example, can be increased from 4 AWG (American Wire Gage) cable to a 2 AWG cable for positive cable 818 and negative cable 822 (FIGS. 17-19). The comparative specifications of the 4 AWG cable and 2 AWG cable are as follows:

(102) TABLE-US-00001 2AWG 4AWG Diameter 0.2576 in 0.2294 in (6.544 mm) (5.189 mm) Turns of 3.88/in 4.89/in wire (1.53/cm) (1.93/cm) Area 66.4 kcmil 41.7 kcmil (33.6 mm.sup.2) (21.2 mm.sup.2) Resistance/ 0.5127 mQ/m 0.8152 mQ/m length (0.1563 mQ/ft) (0.2485 mQ/m) Ampacity  95 (60° C.) 70 (60° C.) 115 (75° C.) 85 (75° C.) 130 (90° C.) 95 (90° C.) Fusing 1.3 kA (10 s) 946 A (10 s) current 10.2 kA (1 s) 6.4 kA (1 s) 57 kA (32 ms)36 kA (32 ms)

(103) The 2 AWG cable provides a significant increase of conductivity (i.e. ampacity) compared to the 4 AWG cable (i.e. approximately 36% increase).

(104) 2) Increase Conductivity of Negative Cable Connection

(105) The negative cable 822 (FIG. 19) can be connected to the battery 912 (FIG. 17) in a manner to increase the conductivity (i.e. ampacity) between the battery 912 and negative cable 822. For example, the negative cable conductor end 822a can be directly connected (e.g. soldered) to the connector prongs 942c (FIG. 19) of the relays 942. Specifically, the negative cable conductor end 822a can extend across and directly connect to all relays 942 (e.g. like relays 642) of the smart switch battery interface 934 (FIGS. 18 and 19). Further, the negative cable conductor end 822a can be connected to the conductor loop 941 (FIG. 19) of the circuit board conductor bar 940.

(106) The negative cable 822, for example, can be made of stranded wire comprising an inner electrical wire conductor composed of an untwisted or twisted bundle of wires disposed within an outer electrical insulating sheath. The electrical insulating sheath of the negative cable 822 can be removed from the negative cable end exposing the inner conductor end 822a.

(107) The exposed bundle of wires 822d (FIG. 18) of the inner conductor 822a can be forced over the ends of the exposed connector pins 942c of the relays 942 so that strands of wires 822d are captured between the adjacent connector pins 942c. The exposed bundles of wires 832d can be further forced into contact with the conductor bar 940 (e.g. made of copper). Solder 923 is applied to this assembly so that the solder flows between the exposed bundles of wires 922d to the connector pins 942c and the conductor bar 940 to complete the electrical connection between the negative cable 322 and the smart switch battery interface 934 connected to the battery 912.

(108) The length of the exposed bundle of wires 822d is selected so that exposed bundle of wires 822d directly connects with each set of connector pins 942c of each and every relay 942 to provide the maximum electrical conductivity (i.e. maximum ampacity) between the negative cable 822 and the battery 912.

(109) 3) Increase Conductivity of Positive Cable Connection

(110) The positive cable 818 can be connected to the battery 912 in a manner to increase the conductivity (i.e. ampacity) between the battery 912 and positive cable 818. For example, the positive cable 818 can be rolled up in the positive battery tab 914 of the battery 912 and soldered together thoroughly. The steps for connection between the positive cable 818 and the positive battery tab 914 of the battery 912 is shown in FIGS. 22-26.

(111) The positive cable 818, for example, can be made of stranded wire comprising an inner electrical wire conductor composed of an untwisted or twisted bundle of wires disposed within an outer electrical insulating sheath. The electrical insulating sheath of the positive cable 818 can be removed from the positive cable conductor end 818a exposing the inner conductor end 818a.

(112) The battery 912 is provided with a positive battery tab 914. The positive battery tab 914 is a metal sheet (e.g. copper sheet) connected to the positive terminal tab 914 of the battery 912.

(113) The exposed bundle of wires 818d of the inner electrical conductor 818b can be soldered with tin, and then rolled up within the positive battery tab 812a. Solder 915 (FIG. 25) is applied to the exposed bundle of wires 818d and the positive battery tab 812a.

(114) The length of the exposed bundle of wires of the positive cable conductor end 818a is selected so that exposed bundle of wires directly connects with the full width of the positive battery tab 914 to provide the maximum electrical conductivity (i.e. maximum ampacity) between the battery 712 and the positive cable 718.

(115) 4) Increase Conductivity of Diode Connection

(116) The positive cable 818 can be provided with a diode connection 950 configured to increase the conductivity along the positive cable 818, as shown in FIGS. 27-29.

(117) The diode connection 950 comprises a plurality of diodes 954 connected between positive cable sections 818a and 818f (FIG. 29). For example, the diode connection 950 comprises six (6) back-charge type diodes (e.g. Schottky barrier diodes).

(118) The diodes 954 are soldered between the positive cable conductor ends 818b and 818b. Specifically, the diode conductor tabs 954a are soldered to the upper positive cable conductor end 818b and the diode conductor prongs 954b are soldered to the positive cable conductor end 818b. More specifically, the diode conductor prongs 954b of the diodes 954 extend through the diode circuit board 952, extend into the bundle of wires of the lower positive cable conductor end 818b, and then are soldered in place completing assembly of the diode connection 950.

(119) The diode connection 950 is then insulated, for example, using a shrink wrap insulator 955 (FIG. 29), which is applied around the diode connection 950, and then shrunk by applying heat (e.g. using heat gun).

(120) 5) Redesigned Resistor/Diode Printed Circuit Board (PCB)

(121) For example, the resistor/diode PCB are redesigned to eliminate the diodes extending therefrom;

(122) 6) Reconnected Resistors

(123) For example, the resistors R134A&B, R135A&B that are on the Resistor/Diode printed circuit board (PCB) 952 are reconnected to be connected again.

(124) Test #1

(125) The battery connection device 600 shown in FIG. 13 was subjected to a 1250A Load Test. The results are shown in FIG. 30, and as follows:

(126) TABLE-US-00002 Pulse #1 Average Power of 4799.01 W Pulse #2 Average Power of 5528.99 W Pulse #3 Average Power of 6101.63 W
Test #2

(127) The battery connection device 900 shown in FIG. 17 was subjected to a 1250A Load Test. The results are shown in FIG. 31, and as follows:

(128) TABLE-US-00003 Pulse #1 Average Power of 6584.61 W Pulse #2 Average Power of 7149.60 W Pulse #3 Average Power of 7325.91 W

(129) These test results show a significant increase of approximately twenty percent (20%) for peak power for TEST #2 compared to the results of TEST #1.

(130) Another enhanced conductivity battery conductor device 1000 is shown in FIGS. 32-41. The enhanced conductivity battery connector device 1000 provides a significantly increased conductivity compared to the battery connector device 600 shown in FIGS. 9-14.

(131) The battery conductor device 1000 comprises the battery assembly 1010, including the battery 1012 connected to the positive cable 1018 and the negative terminal conductor plate 1030. A positive wire 1019 is connected directly or indirectly to the positive tab or positive cable 1018 of the battery 1012, and a negative wire 1023 is connected directly or indirectly to the negative tab or negative terminal conductor plate 1030. The battery conductor device 1000 can further include a bundle of wires 1070 connected to or associated with the operation of the battery 1012 (e.g. battery temperature sensor, power supply, etc.).

(132) The battery 1012 can comprise a single battery cell 1012c (FIG. 34), or multiple battery cells 1012c connected end-to-end in series. For example, three (3) separate battery cells 1012c have respective tabs 512d to be connected together (FIG. 33).

(133) The battery cells 1012c each have respective positive and negative tabs 1012d located at opposite ends of each battery cell 1012c. The battery cells 1012c are connected together in series by welding (e.g. sonically and/or thermally welding) and/or soldering respective positive and negative tabs 1012d together. For example, the tabs 1012d are positioned so as to overlap each other (e.g. edges overlapping opposite tab 1012d, or edge-to-edge).

(134) The tabs 1012d are metal plates (e.g. relative thin metal foils) extending outwardly from the body and opposite edges of each battery cell 1012c. As shown in FIG. 34, the positive and negative tabs 1012d extend along opposite edges along the width dimension of each battery cell 1012c. The positive and negative tabs 1012d are each centered and extend most of the width dimension of each opposite edge of each battery cell 1012c.

(135) As shown in FIG. 33, a separate tab 1012e is added or connected to the right side of the battery cell 1012c (i.e. battery cell on right side in FIG. 33) to extend the length of the tab 1012d. The separate tab 1012e is shown as having the same width dimension as the tab 1012d; however, this width can be different. To assemble the separate tab 1012e to the tab 1012d, for example, the separate tab 1012e is positioned to overlap over the tab 1012d, and then welded (e.g. sonically and/or thermally welded) and/or soldered together.

(136) The exposed conductor end of the positive cable 1018 is then wound up inside the separate tab, as shown in FIGS. 35 and 37. For example, the initially flat separate tab 1012e is wrapped around the exposed conductor end of the positive cable 1018, 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 1012e, and then after wrapping the separate tab 1012e around the exposed end of the positive wire 1018, the assembly is heated to melt the layered solder and solder the assembly together.

(137) The three (3) battery cells 1012c once connected together are then folded over each other into the layered battery cell arrangement shown in FIG. 36. 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 1012, as shown in FIG. 38.

(138) As shown in FIG. 38, the negative tab 1012d can be attached to the negative terminal conductor plate 1030. For example, the negative tab 1012d can be wrapped partially or fully, as shown, around the negative terminal conductor plate 1030. The negative tab 1012d can be provided with a plurality of through holes 1012f to facilitate welding and/or soldering the negative tab 1012d to the negative terminal conductor plate 1030. For example, the through holes 1012f can be square-shaped through holes arranged into a matrix, as shown in FIG. 39. The negative wire 1023 is shown connected (e.g. soldered) to the negative tab 1012d.

(139) Another separate tab 1012e (see FIG. 33) can be connected to the negative tab 1012d to lengthen the negative tab 1012d, so that the lengthened negative tab can be wrapped or wound around the negative terminal conductor plate 1030 more than one time (e.g. 2, 3, 4, or more times). In this manner, the electrical connection between the negative tab 1012d and the negative terminal conductor plate 1030 can be enhanced. The separate tab 1012e can be provided with a layer of solder on one or both sides, so that after the separate tab 1012e is wrapped or wound around the negative terminal conductor plate 1030, this assembly can be heated up to solder the separate tab 1012e onto the negative terminal conductor plate 1030.

(140) The completed assembly of the battery conductor device 1000 with the connected separate positive tab 1012e ready to be wrapped or wound an exposed conductor end of the positive cable 1018 (FIG. 32) can be seen in FIG. 39. The bundle of wires 1070 shown in FIG. 39, includes wires 1072 for a temperature sensor embedded within the battery 1012 (e.g. temperature sensor located near battery tab or between battery cells.). The temperature sensor 1074 connected between two (2) wires 1072a and 1072b is shown in FIG. 40.

(141) The battery conductor device 1000 can be connected to the positive cable 1018 provided with a diode connector 1050 connected inline or splice into the positive cable 1018, as shown in FIG. 41.

(142) The diode connector 1050 comprises a diode circuit board 1052 having a plurality of diodes 1054 assembled thereon. The diodes 1054 each have a diode conductor tab 1054a connected (e.g. soldered) to an exposed conductor end of the positive cable 1018. The prongs of the diodes 1054 extend through holes in the diode circuit board 1052, and are soldered to both the conductive traces and the exposed conductor end of the positive cable 1018 along with a resistor 1076 to complete the assembly.

(143) The invention having been thus described, it will be apparent to those skilled in the art that the same may be varied in many ways without departing from the spirit or scope of the invention. Any and all such variations are intended to be encompassed within the scope of the following claims.