Battery connector

#The present invention relates generally to the field of batteries (e.g., lead-acid starting, lighting, and ignition batteries such as those used as automotive batteries) and the manufacturing of such batteries. More specifically, the present inventions relate to connectors for use in battery charging or formation operations with batteries having terminals provided on a side surface of such batteries.

#When batteries are initially charged in a manufacturing facility (referred to as battery “formation”), it is generally more efficient to simultaneously charge a number of batteries. Accordingly, a number of batteries are typically electrically connected together in series using wires that include contacts or leads on each end of the wire. The wires and contacts connect a positive terminal of a battery to a negative terminal of an adjacent battery. This process is repeated until all batteries are connected together. The first and last battery in the series have a terminal that is not connected to another battery, but rather to a charging or recharging device. For example, the negative terminal of the first battery and the positive terminal of the last battery in the series may be connected to the charging or recharging device. When the charging or recharging device subsequently provides a charge to the batteries, all connected batteries will be charged simultaneously.

#Certain batteries are manufactured such that they include side terminals or bushings. Such bushings may be configured such that the battery terminals may be connected to automobile battery cables by threading a portion of the leads of the battery cables into a threaded aperture provided in the terminals or bushings.

#FIG. 1 is a perspective view of a connector (e.g., a battery formation connector) according to an exemplary embodiment.

#FIG. 2 is a partially exploded perspective view of the connector shown in FIG. 1.

#FIG. 3 is an exploded plan view of a portion of the connector shown in FIG. 1.

#FIG. 1 shows a system 10 in the form of a battery formation connector that includes at least one member or clip for coupling to a battery. As shown in FIG. 1, two members or clips 20, 60 are shown, and are generally “U-shaped”. Member 20 includes a top portion 22 and two arms 24, 26 coupled to top portion 22. Similarly, member 60 includes a top portion 62 and two arms 64, 66 coupled to top portion 62. According to an exemplary embodiment (see e.g., FIG. 1), the arms are integrally formed with the top portion. According to another exemplary embodiment, the arms may be formed separately and coupled to the top portion (e.g., using adhesive, screws, or other fasteners).

#At least one of the top portion and the arms are made of a relatively resilient and/or flexible material. According to an exemplary embodiment, the arms and top portion comprise the same material. According to another exemplary embodiment, at least one of the arms and top portion comprise different materials (e.g., one or both of the arms comprise a relatively flexible material and the top portion comprise a relatively rigid and/or inflexible material).

#Arm 26 includes a contact or lead 40 (e.g., an electrical contact) for coupling or attaching (e.g., abutting, interfacing, etc.) to a terminal of a battery when the member is coupled thereto. Arm 60 includes a contact or lead 80 similar to that included with arm 26. According to an exemplary embodiment, contacts 40, 80 comprise elements that have generally cylindrical shapes (see, e.g., FIG. 2). For example, contact 40 includes a first portion 42 having a generally cylindrical shape and a smaller second portion 44 extending from first portion 42 having a generally cylindrical shape, and contact 80 includes a first portion 82 having a generally cylindrical shape and a smaller second portion 84 extending from first portion 82 having a generally cylindrical shape.