Battery clamp with endoskeleton design

Abstract

A clamp for coupling an electronic battery tester to a post of a storage battery. The clamp includes a first metal arm that extends from a first proximal end to a first distal end and a second metal arm that extends from a second proximal end to a second distal end. A first hinge portion on the first metal arm is positioned between the first proximal end and the first distal end. A second hinge portion is positioned on the second metal arm between the second proximal end and the second distal end. A pivot is configured to pivotally couple the first hinge portion to the second hinge portion. A first covering is overmolded on the first metal arm and a second covering is overmolded on the second metal arm.

Claims

1. A clamp for coupling battery maintenance equipment to a first post of a storage battery, comprising: a first metal arm extending from a first proximal end to a first distal end; a second metal arm extending from a second proximal end to a second distal end; a first hinge portion on the first metal arm positioned between the first proximal end and the first distal end; a second hinge portion positioned on the second metal arm between the second proximal end and the second distal end; a pivot configured to pivotally couple the first hinge portion to the second hinge portion; a first covering overmolded over the first metal arm using a coating applied to the first metal arm; a second covering overmolded over the second metal arm using a coating applied to the second metal arm; a first adhesive layer between the first covering and the first metal arm; and a second adhesive layer between the second covering and the second metal arm.

2. The clamp of claim 1 and further comprising a spring configured to urge the first distal end against the second distal end.

3. The clamp of claim 1 and wherein the first covering and the second covering comprise plastic.

4. The clamp of claim 1 and wherein the first covering and the second covering comprise 50% long fiber glass filled polypropylene.

5. The clamp of claim 1 and further comprising: a first post grasping element coupled to the first metal arm and positioned substantially at the first distal end of the clamp; and a second post grasping element coupled to the second metal arm and positioned substantially at the second distal end of the clamp.

6. The clamp of claim 5 and wherein the first post grasping portion comprises a first set of teeth, and wherein the second post grasping portion comprises a second set of teeth.

7. The clamp of claim 6 and wherein at least one of the first set of teeth or the second set of teeth is electrically coupled to at least one electrical wire.

8. The clamp of claim 6 and wherein the first set of teeth and the second set of teeth comprise at least one of copper or brass.

9. The clamp of claim 7 and wherein the at least one electrical wire comprises a first Kelvin conductor and a second Kelvin conductor, and wherein the first Kelvin conductor is electrically coupled to the first set of teeth, and wherein the second Kelvin conductor is electrically coupled to the second set of teeth.

10. The clamp of claim 9 and wherein: the first post grasping element further comprises a first base plate from which the first set of teeth extends, and wherein the first base plate is coupled to the first metal arm proximate to the first distal end such that the first covering is between the first base plate and the first metal arm; and the second post grasping element further comprises a second base plate from which the second set of teeth extends, and wherein the second base plate is coupled to the second metal arm proximate to the second distal end such that the second covering is between the second base plate and the second metal arm.

11. The clamp of claim 9 and wherein the first set of teeth is directly coupled to the first metal arm substantially at the first distal end, and wherein the second set of teeth is directly coupled to the second metal arm substantially at the second distal end.

12. The clamp of claim 10 and wherein the first Kelvin conductor is physically coupled to the first base plate, and wherein the second Kelvin conductor is physically coupled to the second base plate.

13. A battery tester, comprised in the maintenance equipment, attached to a first clamp and a second clamp, wherein each of the first clamp and the second clamp is a clamp as featured in claim 1.

14. The battery tester of claim 13 and wherein each of the first clamp and the second clamp comprises a first set of teeth and a second set of teeth, and when the battery tester is coupled to the first post of the storage battery via the first clamp and coupled to a second post of the storage battery via the second clamp, the battery tester is configured to: apply a forcing function to the battery between the first set of teeth of the first clamp and the first set of teeth of the second clamp, and sense a resulting response of the battery via the second set of teeth of the first clamp and the second set of teeth of the second clamp.

15. The battery tester of claim 14 and further comprising a microprocessor configured to calculate a dynamic parameter as a function of the sensed response of the battery to the applied forcing function.

16. A method of forming a clamp comprising: providing a first metal arm extending from a first proximal end to a first distal end and comprising a first hinge portion positioned between the first proximal end and the first distal end; overmolding a first covering over the first metal arm by applying a coating to the first metal arm adhered to the first metal arm by a first adhesive layer; providing a second metal arm extending from a second proximal end to a second distal end and comprising a second hinge portion positioned between the second proximal end and the second distal end; overmolding a second covering over the second metal arm by applying a routing to the second metal arm adhered to the second metal arm by a second adhesive layer; and pivotally coupling the first hinge portion to the second hinge portion.

17. The method of claim 16 and further comprising connecting a spring between the first metal arm and the second metal arm such that the spring urges the first distal end against the second distal end.

18. The method of claim 16 and wherein the first covering and the second covering comprise plastic.

19. The method of claim 16 and wherein the first covering and the second covering comprise 50% long fiber glass filled polypropylene.

20. The method of claim 16 and further comprising: coupling a first post grasping element substantially at the first distal end such that the first post grasping element is directly attached to the first metal arm; and coupling a second post grasping element substantially at the second distal end such that the second post grasping element is directly attached to the second metal arm.

21. The method of claim 16 and further comprising: coupling a first post grasping element substantially at the first distal end such that the first covering is positioned between the first post grasping element and the first metal arm; and coupling a second post grasping element substantially at the second distal end such that the second covering is positioned between the first post grasping element and the second metal arm.

22. A method of testing a storage battery having a first post and a second post, the method comprising: coupling a battery tester to the first post via a first clamp and coupling the battery tester to the second post via a second clamp, wherein the first clamp and the second clamp are formed by the method of claim 16; applying, by the battery tester, a forcing function to the battery between a first set of teeth of the first clamp and a first set of teeth of the second clamp; and sensing a response of the battery to the applied forcing function.

23. The method of claim 22 and wherein the sensing the response of the battery to the applied forcing function is carried out via a second set of teeth of the first clamp and a second set of teeth of the second clamp.

24. The method of claim 23 and further comprising calculating, by the battery tester, a dynamic parameter as a function of the sensed response of the battery to the applied forcing function.

25. A clamp for coupling to a battery contact, the clamp comprising: an interior skeleton comprising a first material; a covering overmolded over the interior skeleton with a coating applied to the interior skeleton which is adhered to the interior skeleton by an adhesive layer, wherein the covering comprises a second material, and wherein physical, chemical and mechanical properties of the first material differ substantially from physical, chemical and mechanical properties of the second material; and post grasping elements coupled to the interior skeleton such that the covering is between the post grasping elements and the interior skeleton.

26. The clamp of claim 25 and wherein the first material comprises steel and wherein the second material comprises a synthetic resin.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a diagrammatic view of a Kelvin clamp in accordance with one embodiment.

(2) FIGS. 2A through 2D are diagrammatic views that collectively illustrate a method of forming a Kelvin clamp in accordance with one embodiment.

(3) FIGS. 3A through 3D are diagrammatic views that collectively illustrate a method of forming a Kelvin clamp in accordance with another embodiment.

(4) FIGS. 4A through 4C are diagrammatic views that collectively illustrate a method of forming a Kelvin clamp in accordance with yet another embodiment.

(5) FIG. 5 is a simplified block diagram of a battery tester with which at least some of the present embodiments are useful.

(6) FIG. 6 is a simplified block diagram of a battery charger with which at least some of the present embodiments are useful.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

(7) Embodiments of the disclosure generally relate to clamps for coupling battery maintenance equipment such as battery chargers, battery testers, etc., to contacts of a storage battery. As will be described in detail further below, in different embodiments, each of the clamps includes an interior skeleton of a first material over-molded with a second material.

(8) In the discussion below, the term battery contact is used to define a portion of the battery onto which clamps of the present disclosure can be applied.

(9) FIG. 1 is a perspective view showing a Kelvin clamp 100 in accordance with one embodiment. The same reference numerals are used in the various figures to represent the same or similar elements. Kelvin clamp 100 is designed to electrically couple electrical conductors of a Kelvin connection to a battery contact. As will be described below, clamp 100 includes features that render it suitable for use in harsh environments to test and charge lead acid or other batteries.

(10) In the embodiment shown in FIG. 1, Kelvin clamp 100 includes a first metal arm 102 that extends from a first proximal end 104 to a first distal end 106. Clamp 100 also includes a second metal arm 108 that extends from a second proximal end 110 to a second distal end 112. First metal arm 102 and second metal arm 108 are pivotally coupled together. To enable the pivotal coupling, first metal arm 102 includes a first hinge portion 114 positioned between first proximal end 104 and first distal end 106. Similarly, second metal arm 108 includes a second hinge portion 116 that is positioned between second proximal end 110 and second distal end 112. First hinge portion 114 may include first aligned holes (not shown in FIG. 1) and second hinge portion 116 may include second aligned holes (not shown in FIG. 1). A pivot 122, which may comprise a suitable fastener that passes through the aligned holes, is configured to pivotally couple the first hinge portion 114 to the second hinge portion 116. A suitable spring 124 may be disposed on a portion of pivot 122. The spring urges distal ends 106 and 112 together.

(11) Is some embodiments, a first covering 126 is overmolded on the first metal arm 102 and a second covering 128 is overmolded on the second metal arm 108. The material used for the overmolding (i.e., for first covering 126 and second covering 128) may be chosen as desired. For example, a low cost resin or plastic based on chemical resistance can be selected because the temperature and dimensional properties of the overmolded material are enhanced due to the properties of the internal metal skeleton. One example overmolding material is a 50% long fiberglass-filled polypropylene. Such a material is preferably resistant to battery acid and other chemicals or materials which may be present in the testing environment. In one embodiment, the first metal arm 102 and the second metal arm 108 comprise steel. In general, the metal skeleton contributes substantially to a strength of clamp 100. There also may be a safety factor (i.e., a relatively higher degree of safety) due to the laminated plywood nature of the finished clamp 100.

(12) The distal ends 106 and 112 of the clamp 100 may include post grasping elements for proper coupling of the clamp 100 to a battery contact. Specifically, a first post grasping element 130 is coupled proximate to the first distal end 106 of first metal arm 102. Similarly, a second post grasping element 132 is coupled proximate to the second distal end 112 of second metal arm 108. Post grasping elements 130 and 132 may be formed of substantially highly electrically conductive metals such as copper or brass.

(13) In some embodiments, the first post grasping element 130 includes a first set of teeth 134 that extends from a first base plate 136. First base plate 136 may be coupled proximate to the first distal end 106 of first metal arm 102 such that the first base plate 136 is over the first covering 126 on the first metal arm 102. The second post grasping element 132 includes a second set of teeth 138 that extends from a second base plate 140. Second base plate 140 may be coupled proximate to the second distal end 112 of second metal arm 108 such that the second base plate 140 is over the second covering 128 on the second metal arm 108. In some such embodiments, suitable fasteners (for examples, screws) 142 and 144, respectively, are used to couple base plates 136 and 140 to first and second metal arms 102 and 108. Clearance holes in base plates 136 and 140 and in arms 102 and 108 that receive the fasteners 142 and 144 are not shown in FIG. 1 in the interest of simplification. In other such embodiments, instead of using fasteners such as screws 142 and 144, the base plates 136 and 140 may be bonded to coverings 126 and 128, respectively, using any suitable adhesive material 146. In the embodiments that employ base plates 136 and 140, respectively, for supporting teeth 134 and 138, individual Kelvin connectors or wires (not shown in FIG. 1) may be attached (for example, soldered) to base plates 138 and 140, respectively.

(14) In other embodiments, instead of employing base plates 136 and 140, first set of teeth 134 may be directly attached to, or integrally formed with, first metal arm 102 and second set of teeth 138 are directly attached to, or integrally formed with, second metal arm 108. In such embodiments, arms 102 and 108 and teeth 134 and 138 may be formed of one or more suitable electrically conductive metals. Here, coverings 126 and 128 may be formed such that they do not extend over teeth 134 and 138. Since, in such embodiments, teeth 134 and 138 extend directly from metal arms 102 and 108, respectively, Kelvin electrical connectors or wires may be coupled to any suitable portions of metal arms 102 and 108 that may be exposed (i.e., not covered by the resin). Direct coupling of Kelvin wires to arms 102 and 108 is described further below in connection with FIG. 4C.

(15) As indicated above, in some embodiments, arms 102 and 108 may be formed of a metal such as steel, which is a poor electrical conductor. Further, arms 102 and 108 may be electrically insulated from each other by coverings 126 and 128 or with the help of any additional insulating material (not shown) that may be included in suitable regions between the metal arms 102 and 108. In some embodiments, insulating grips (not shown) are provided over portions of each arm (102, 108), between each proximal end (104, 110) and each hinge portion (114, 116) for user protection.

(16) FIGS. 2A through 2D collectively illustrate a method of forming a Kelvin clamp in accordance with one embodiment. The method includes providing a first metal arm 102 and a second metal arm 108. As illustrated in FIG. 2A, the provided first and second metal arms 102 and 108 include hinge portions 114 and 116 that each include aligned holes 118, 120. First metal arm 102 and second metal arm 108 may include clearance holes 200 and 202, respectively, for receiving screws such as 142 and 144 shown in FIG. 1. First and second metal arms 102 and 108 are overmolded with a suitable material (for example, a synthetic resin) to form coverings 126 are 128 on arms 102 and 108, respectively, as shown in FIG. 2B. The overmolding may be carried out by placing the arms 102 and 108 on, for example, a conveyor mechanism that conveys the arms 102 and 108 through different zones in which different stages of an overmolding process are carried out. For example, arms 102 and 108 may be conveyed through a first zone where an adhesive layer may be applied (for example, sprayed) on the arms 102 and 108. Thereafter, the conveyor mechanism may move arms 102 and 108 through a second zone where a synthetic resin powder is applied using any suitable technique such that the resin powder sticks to the adhesive. The arms 102 and 108 may then be conveyed through a third zone in which the arms, coated with the resin powder, are heated to a suitable temperature. This heating causes the adhesive to evaporate, and causes the resin powder to melt and form a coating 126, 128 that is intimately coupled to the arms 102 and 108. Arms 102 and 108 may be passed through the different zones multiple times and may be positioned differently each time to ensure that the arms 102 and 108 are substantially completely coated with the resin.

(17) Instead of using the conveyor mechanism described above to apply coatings 126 and 128, arms 102 and 108 may be dipped into a container that includes a melted (i.e., liquid) resin that is at a relatively high temperature. When the arms are removed from the liquid, the resin dries to from the coatings 126 and 128. In general, any suitable technique, including any suitable injection molding technique, may be used to form coatings 126 and 128 on arms 102 and 108. As shown in FIG. 3C, remaining elements of clamp 100 such as post grasping elements 130 and 132 and a spring mechanism 206, which may include a fastener (for example, a bolt) 122 and a spring 124, are provided. As noted above, first post grasping element 130 includes a first set of teeth 134 that extends from a first base plate 136, and second post grasping element 132 includes a second set of teeth 138 that extends from a second base plate 140. Holes 208 and 210, which correspond to holes 200 and 202 in arms 102 and 104, are included in base plates 136 and 140, respectively. A first screw 142 is inserted in to into holes 200 and 208 and tightened to hold first post grasping element 130 in place. Similarly, a second screw 144 is inserted into holes 202 and 210 and tightened to hold second post grasping element 132 in place. Additional fasteners such as nuts and additional screws that may also be included are not shown in the interest of simplification. First arm 102 and second arm 108 are then pivotally connected together through aligned holes 118 and 120 with the help of a spring mechanism 206 that includes, for example, spring 124 and bolt 122 extending through aligned holes 120 and 122 to form Kelvin clamp 100 as shown in FIG. 2D. The spring 124 urges post grasping portions 130 and 132 together. Kelvin electrical connectors or wires 212 and 214 (shown in FIG. 2D) are attached (for example, soldered) to base plates 136 and 140, respectively.

(18) Although the above-included method steps are described in a particular order in connection with FIG. 2A thorough 2D, the method steps may be carried out in any suitable order. Also, in some embodiments, holes such as 200 and 202 may be formed in arms 102 and 108, respectively, after coverings 126 and 128 are applied.

(19) FIGS. 3A through 3D collectively illustrate a method of forming a Kelvin clamp in accordance with an embodiment in which post grasping elements 130 and 132 (shown in FIG. 3C) are attached to the clamp arms with an adhesive 146 (shown in FIG. 3C), thereby eliminating a need for holes 202, 204, 208 and 210, and screws 142 and 144. After the arms such as 102 and 108 shown in FIG. 3A are overmolded with coatings 126 and 128 using any suitable technique as shown 3B, base plates 136 and 140 may be bonded to coverings 126 and 128, respectively, using any suitable adhesive material 146 as shown in FIGS. 3C and 3D. First arm 102 and second arm 108 are pivotally connected together through aligned holes 118 and 120 with the help of a spring mechanism 206 in a manner described above in connection with FIGS. 2C and 2D. Also, Kelvin electrical connectors or wires 212 and 214 may be connected to base plates 136 and 140 in a manner described above in connection with FIG. 2D. It should be noted that, in some embodiments, both screws such as 142 and 144 (shown in FIG. 2D) and an adhesive 146 (shown in FIGS. 3C and 3D) may be used to attach post grasping elements 130 and 132 to the clamp arms.

(20) FIGS. 4A through 4C collectively illustrate a method of forming a Kelvin clamp in accordance with yet another embodiment. As illustrated in FIG. 4A, metal arms 102 and 108, which include attached teeth 134 and 138, are provided. Portions of arms 102 and 108 other than the teeth 134 and 138 are overmolded with a suitable resin to form coverings 126 and 128 as shown in FIG. 4B. In some embodiments, electrical connection areas 400 and 402 (shown in FIG. 4C) near proximal ends 104 and 110 are left exposed (i.e., not covered by the resin during the overmolding process). In other embodiments, areas 400 and 402 may be exposed by removing portions of coverings 126 and 128 after the overmolding is carried out. As shown in FIG. 4C, the spring mechanism 206 is connected in a manner described above in connection with FIGS. 2C and 2D to complete the clamp 100. Kelvin electrical connectors or wires 212 and 214 (shown in FIG. 4C) are attached (for example, soldered) to connection areas 400 and 402, respectively.

(21) Embodiments of Kelvin clamp 100, described above, are particularly useful with equipment for testing and charging storage batteries. Battery testers and chargers employing Kelvin clamps in accordance with the present embodiments are described below in connection with FIGS. 5 and 6.

(22) FIG. 5 is a simplified block diagram of electronic battery tester circuitry 500 with which at least some of the present embodiments are useful. A four point (or Kelvin connection) technique is used to couple system 500 to battery 502. Kelvin connections 508 and 510 are used to couple to battery contacts 504 and 506, respectively, of battery 502. Kelvin connection 508 includes two individual connections 508A and 508B. Similarly, Kelvin connection 510 includes two individual connections, 510A and 510B. Kelvin clamps such as 100, described above, grasp battery contacts 504 and 506 and couple them to electrical connections 508, 510. Specifically, a first set of teeth (such as 134 of FIG. 2D) of a first clamp such as 100 contacts battery post 504, and a corresponding first set of teeth (such as 134 of FIG. 2D) of a second clamp such as 100 contacts battery post 506. Similarly, a second set of teeth (such as 138 of FIG. 2D) of a first clamp such as 100 contacts battery post 504 and a corresponding second set of teeth (such as 138 of FIG. 2D) of a second clamp such as 100 contacts battery post 506. Also, in each of the first clamp and the second clamp, the first set of teeth (such as 134 of FIG. 2D) is coupled to a first Kelvin connector (for example, 212 of FIG. 2D, 508B, 510B) and the second set of teeth (such as 138 of FIG. 2D) is coupled to a second Kelvin connector (for example, 214 of FIG. 2D, 508A, 510A).

(23) Circuitry 500 includes a current source 512 and a differential amplifier 514. Current source (or forcing function source) 512 is coupled to connections 508B and 510B of Kelvin connections 508 and 510, respectively. Differential amplifier 514 is coupled to connection 508A and connection 510A of Kelvin connections 508 and 510, respectively. An output from differential amplifier 514 is provided to analog to digital converter 518 which itself provides a digitized output to microprocessor 520. Microprocessor 520 is connected to a system clock 522, a memory 524, and analog to digital converter 518. Microprocessor 520 is also capable of receiving an input from an input device 526 and providing an output of output device 528. The input can be, for example, a rating for the battery 502. Input device 526 can comprise any or multiple types of input devices. The result of a battery test, either qualitative or quantitative, can be an output of device 528. Device 528 can be a display or other output. The embodiments can operate with any technique for determining a voltage across battery 502 and a current through battery 502 and is not limited to the specific techniques set forth herein. The forcing function source or current source 512 can provide any signal having a time varying component, including a stepped pulse or a periodic signal, having any shape, applied to battery 502. The current source can be an active source in which the current source signal is injected into battery 502, or can be a passive source, such as a load, which is switched on under the control of microprocessor 520.

(24) In operation, under the control of microprocessor 520, forcing function source 512 applies a time varying forcing function (for example, a time varying current) to battery 502 through a first set of teeth (shown in FIG. 1) in each of clamps 100 coupled to first post 504 and second post 506, respectively, and coupled to connections 508B and 510B (in general, first Kelvin conductors). Differential amplifier (or any other suitable sensor) 514 senses a response of the storage battery 502 to the applied forcing function via a second set of teeth (shown in FIG. 1) in each of clamps 100 coupled to first post 504 and second post 506, respectively, and coupled to connections 508A and 510A (in general, second Kelvin conductors). Differential amplifier 514 provides a response signal to analog to digital converter 518. Analog to digital converter 518 digitizes the response signal and provides the digitized response signal to microprocessor 520. In one embodiment, microprocessor 520 determines a dynamic parameter, such as dynamic conductance, of battery 502 as a function of at least one of sensed voltage and current. The change in the one or more sensed values is used to determine the dynamic parameter. For example, the dynamic conductance (G) is determined as:
G=I/VEQ. 1
where I is the change in current flowing through battery 502 due to current source 512 and V is the change in battery voltage due to applied current I. A temperature sensor 530 can be thermally coupled to battery 502 and used to compensate battery measurements. Temperature readings can be stored in memory 524 for later retrieval.

(25) FIG. 6 is a simplified block diagram of a battery charging system 600 using one of the present embodiments. System 600 is shown coupled to battery 602. System 600 includes battery charging and testing circuitry 604 and microprocessor 606. System 600 couples to battery contacts 608 and 610 through Kelvin electrical connections 612 and 614 respectively. Electrical connection 612 includes a first connection 612A and second connection 612B and connection 614 includes a first connection 614A and a second connection 614B. Kelvin clamps such as 100, described above, provide coupling between battery contacts 608 and 610 and electrical connections 612 and 614. Battery charger 600 operates in a manner similar to the battery charger set forth in U.S. Pat. No. 6,104,167, issued Aug. 15, 2000, and entitled METHOD AND APPARATUS FOR CHARGING A BATTERY, which is incorporated herein by reference.

(26) Although the present disclosure has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the disclosure. Although the above clamp embodiments describe the interior skeleton as comprising a metal, and the covering comprising a synthetic resin, in general, the interior skeleton can comprise a first material that has physical, chemical and mechanical properties that differ substantially from physical, chemical and mechanical properties of the second material used for the covering. For example, the first material may contribute substantially to a strength of the clamp and the second material may render the clamp resistant to battery acid and other chemicals or materials which may be present in the testing environment. Further, although the above embodiments show Kelvin connections (i.e., two electrical wires) coupled to a clamp, in different embodiments, only one electrical wire may be coupled to a clamp.