Title: Rotatable connector for a battery cable clamp
Abstract: An improved rotatable battery cable clamp connector is designed for use with applying pressure to legs of the clamp intermediate the cable section and post section of the clamp. Self-lubricating and non-corrosive materials are also used to advantage in the manufacture of the connector.
Patent Number: 6,971,925 Issued on 12/06/2005 to Orange
| Inventors:
|
Orange; Charles M. (Nashville, TN)
|
| Assignee:
|
Batlock, LLC (Nashville, TN)
|
| Appl. No.:
|
894606 |
| Filed:
|
July 20, 2004 |
| Current U.S. Class: |
439/773; 439/757; 439/769 |
| Intern'l Class: |
H01R 004/50 |
| Field of Search: |
439/754,773,772,726,757,761,769
|
References Cited [Referenced By]
U.S. Patent Documents
| 1696531 | Dec., 1928 | Eaton.
| |
| 1814156 | Jul., 1931 | Hedges.
| |
| 1873775 | Aug., 1932 | McMaster et al.
| |
| 1941773 | Jan., 1934 | Wright.
| |
| 1977179 | Oct., 1934 | Fisch.
| |
| 2878460 | Mar., 1959 | Coleman.
| |
| 3084306 | Apr., 1963 | Cribbs.
| |
| 3521223 | Jul., 1970 | Martinez.
| |
| 3838386 | Sep., 1974 | Chartrain et al.
| |
| 4385796 | May., 1983 | Eriksson.
| |
| 4537460 | Aug., 1985 | McCaig.
| |
| 4555159 | Nov., 1985 | Chartrain et al.
| |
| 5269709 | Dec., 1993 | Eriksson.
| |
| 5389466 | Feb., 1995 | Inoue et al.
| |
| D363699 | Oct., 1995 | Mountfort.
| |
| 6773310 | Aug., 2004 | Davis.
| |
| 6802747 | Oct., 2004 | Orange.
| |
| Foreign Patent Documents |
| WO 97/0348/0 | Jan., 1997 | WO.
| |
Primary Examiner: Hyeon; Hae Moon
Attorney, Agent or Firm: Miller & Martin PLLC
Claims
1. An improved connector for a battery cable clamp of the type having a first
end connected to a battery cable and first leg with a first aperture therein extending
to an arcuate post section and thence to a second leg with a second aperture therein
extending roughly parallel to the first leg section comprising:
(a) a handle having a first end with two parallel wings having aperatures therein
and being separated by a channel, and a second opposite end;
(b) a pivot pin received within the aperatures of the parallel wings, and spanning
the channel between said wings;
(c) a connecting pin having a proximal end connected through a hole of the pivot
pin in the channel between the wings, said connecting pin extending through said
channel away from the handle to a threaded distal end;
(d) a seat having an aperature upon which the connecting pin is received, and
a cam surface which is adjacent to the parallel wings;
(e) a fastener having a threaded aperture being received on the threaded distal
end of the connecting pin;
wherein the connecting pin passes through the first aperture and the second aperture
intermediate the first end and the arcuate post section of the battery clamp.
2. The improved connector for a battery cable clamp of claim 1 wherein the handle
has a concave side and a convex side and when lying in the plane of the post section,
the concave side encircles a substantial portion of the arcuate post section of
the clamp.
3. The improved connector for a battery cable clamp of claim 1 wherein at least
one of the handles, the fastener and the seat is manufactured from a non-corrosive material.
4. The improved connector for a battery cable clamp of claim 3 wherein the non-corrosive
material is glass-filled nylon.
5. The improved connector for a battery cable clamp of claim 1 wherein the connecting
pin has an intermediate section between the proximal end and the distal end, and
said intermediate section is smooth.
6. The improved connector for a battery cable clamp of claim 1 wherein the handle
is rotatable axially to position a boss intermediate the pivot pin and the seat.
7. The improved connector for a battery cable clamp of claim 1 wherein the diameter
of the connecting pin is at least 0.05 inches less than the diameter of the first
and second apertures in the first and second legs.
8. The improved connector for a battery cable clamp of claim 2 wherein the handle
is rotatable laterally to a position normal to the plane of the post section.
9. An improved battery cable clamp comprising:
(a) a first end having a cable section with cable connectors to secure a battery cable;
(b) a first leg section extending therefrom and having a first aperture therein;
(c) a post section connected to said first leg section and defining a cavity
to receive a battery post;
(d) a second leg section extending from the post section and having a second
aperture therein such that the first and second apertures are axially aligned;
(e) a connecting pin passing through the axially aligned aperatures in the legs,
having a proximal end and a distal end;
(f) a handle having first end with a pair of parallel wings having apertures
therein which receive a pivot pin, said wings being separated by a channel and
said handle having a second opposite end;
(g) the pivot pin having a hole and being connected to the proximal end of the
connecting pin through the channel;
(h) a seat having a cam surface and an aperature receiving the connecting pin,
and being positioned between the pair of legs and the pivot pin; and
(i) a fastener connected to the distal end of the connecting pin.
10. The improved battery cable clamp of claim 9 wherein at least one of the handles,
the fastener and the seat is manufactured from a non-corrosive material.
11. The improved battery cable clamp of claim 9 wherein the handle has a concave
side and a convex side and when lying in the plane of the post section, the concave
side encircles a substantial portion of the arcuate post section of the clamp.
12. The improved battery cable clamp of claim 11 wherein at least one of the
handles, the fastener and the seat is manufactured from a non-corrosive material.
13. The improved battery cable clamp of claim 12 wherein the non-corrosive material
is glass-filled nylon.
14. The improved battery cable clamp of claim 9 wherein the connecting pin has
an intermediate section between the proximal end and the distal end, and said intermediate
section is smooth.
15. The improved battery cable clamp of claim 9 wherein the handle is rotatable
axially to position a boss intermediate the pivot pin and the seat.
16. The improved battery cable clamp of claim 9 wherein the diameter of the connecting
pin is at least 0.05 inches less than the diameter of the first and second apertures
in the first and second legs.
17. The improved battery cable clamp of claim 9 wherein the handle is rotatable
laterally to a position normal to the plane of the post section.
18. A method for connecting a battery cable clamp of the type having a first
end having a cable section with a cable connector to secure a battery cable; a
first leg section extending therefrom and having a first aperture therein; a post
section connected to said first leg section and defining a cavity to receive a
battery post; a second leg section extending from the post section and having a
second aperture therein such that the first and second apertures are axially aligned;
using a rotatable connecting pin and cammed handle assembly and comprising the
steps of:
(a) placing a pivot pin through an aperture in a base end of a handle;
(b) attaching a first proximate end of a connecting pin to a hole in the pivot
pin through a channel formed between two parallel wings in the base so that said
connecting pin extends from the base of the handle;
(c) placing a seat with a concave surface facing the base end of the handle on
the connecting pin and passing the connecting pin through the first and second
apertures of the first and second legs;
(d) fastening an end nut on a distal end of the connecting pin; and
(e) rotating the handle axially so that a boss section of the base is interposed
between the pivot pin and the concave surface of the seat, thereby compressing
the first and second legs.
19. The method of claim 18 further comprising the steps of rotating the handle
laterally so that a concave surface of the handle substantially encircles the post section.
Description
The present invention relates generally to battery cable clamps and more particularly
to an improvement to existing battery cable clamps which facilitates the breaking
of corroded connections and the removal of battery cable clamps from the battery post.
BACKGROUND ART
It will be appreciated by those skilled in the art that most automobiles, motorized
vehicles and inboard boats are started via battery power and that the standardized
modern battery is the 12-volt battery having metal posts for the opposing polarities
of the battery to which connector cables are attached. The standard battery cable
connector is a yoke-type structure. The typical battery cable is connected to one
end of the connector by either crimping or bolt and nut, and the yoke portion of
the connector is fitted over the battery post and clamped down onto the battery
post by tightening a nut onto a bolt passing through the two ends of the yoke.
The yokes are usually made of steel or lead.
Many standard 12-volt batteries will last for several years, especially when
used sparingly, as in some recreational boats. During the course of the life of
a battery, corrosion buildup may occur and may cause the battery clamp to attach
by corrosion to the battery post. Corrosion also tends to build up between the
bolt and the nut threaded on the bolt and used to tighten the yoke about the battery
post. Corrosion may impair the proper transmission of battery power from the battery
post through the battery cable clamp to the battery cable thereby diminishing the
electrical power available. To remedy the diminished transmission of power, the
battery cable clamp has to be removed, corrosion brushed away and the clamp reamed
out so that a solid connection between the clamp and the post can be re-established.
This process generally requires loosening of the nut on the bolt clamping the yoke
about the post and "breaking" the corrosive seal between the clamp and the post
to remove the clamp. In addition, if the battery is spent, the old battery must
be removed and replaced with a new one. In these circumstances, once again, the
battery cable clamp must be loosened and the seal of the corrosion broken to remove
the clamp from the post. Because of the corrosion of the nut to the bolt clamping
the yoke to the battery post, either the process of cleaning the battery post and
battery cable clamp or replacing the battery can be time consuming and difficult.
What is needed, then, is a battery cable clamp that will overcome the problems
with prior art devices. Prior efforts in this regard include those in WO 97/03480
and commonly owned U.S. Ser. No. 10/237,341, and especially the latter design has
proved useful in the after market, on yokes with clamping bolts opposite the terminal
post from the cable. However, original equipment manufacturers and others utilizing
yokes with clamping bolts intermediate the post and the cable and particularly
those utilizing steel yokes, may advantageously use an improved design.
SUMMARY OF THE INVENTION
Instead of the standard bolt which passes through the ends of the yoke and
nut that is tightened to secure the clamp about the battery post, the battery cable
clamp of the invention utilizes a bolt with a clamping handle. The connection between
the bolt head and the attached handle includes a boss or camming structure that
increases or decreases the clamping pressure of the bolt based on a small rotation
of the handle. Thus, the nut on the bolt connecting the two legs of the yoke can
be tightened finger tight and the handle rotated approximately half of a turn to
substantially increase the clamping pressure of the bolt. When it is desired to
remove the battery cable clamp, the handle can be released and a substantial decrease
in the clamping pressure of the bolt results. The nut on the bolt can then be easily
loosened to relieve additional pressure on the battery cable clamp. The handle
may be rotated into an upper locking and unlocking position, and downward to lay
upon the surface of the battery. Preferably at least the handle, nut and seat interfacing
with the boss on the handle are made of non-corrosive and even non-metallic materials.
In this fashion, preferably the entire operation of the invention is possible without
the need for using any additional tools.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the battery cable clamp of the present invention
in locked position.
FIG. 2 is a perspective view of the battery cable clamp of FIG. 1 in locked
position with the handle rotated upward.
FIG. 3 is a perspective view of the battery cable claim of FIG. 1 in unlocked position.
FIG. 4
a is a side sectional view of a seat according to the present invention.
FIG. 4
b is a front sectional view of the seat of FIG. 4
a.
FIG. 4
c is a top plan view of the seat of FIG. 4
a.
FIG. 5
a is a partial sectional view of a handle according to the present invention.
FIG. 5
b is a top plan view of the handle of FIG. 5
a.
FIG. 5
c is a side plan view of the handle of FIG. 5
a.
FIG. 6
a is a sectional view of a knurled nut that may be used in the
present invention.
FIG. 6
b is a top plan view of the knurled nut of FIG. 6
a.
FIG. 7
a is a side plan view of a connecting pin according to the present invention.
FIG. 7
b is an end plan view of the connecting pin of FIG. 7
a.
FIG. 8
a is a sectional view of a pivot pin that may be used in the present invention.
FIG. 8
b is a top plan view of the pivot pin of FIG. 8
a.
FIG. 8
c is an end plan view of the pivot pin of FIG. 8
a.
FIG. 9
a is a prior art battery clamp having a steel connecting yoke and
crimped to the battery cable.
FIG. 9
b is a prior art lead battery clamp bolted to the battery cable.
DETAILED DESCRIPTION OF THE INVENTION
A description of the preferred embodiment of the present invention will be best
understood by referring to FIGS. 1-9 of the accompanying drawings wherein like
reference numerals refer to like parts.
Referring first to FIG. 9
a, prior art steel battery clamp
110
is shown having a first end with crimping section
111 to connect with battery
cable C and post section
112 encompassing the battery terminal T and legs
118,
118′ extending from each side of the post section of
the yoke and having apertures therein to receive a bolt B that is tighten nut N
to securely clamp the post section
112 about terminal T. It is to be noted
that the nut N and bolt B are at the opposite end of the clamp from the crimping
section
111 that connects with cable C.
Similarly, prior art battery clamp
210 shown in FIG. 9
b is
of a thicker construction typical of battery clamps made from lead rather than
steel. This clamp
210 also has a first end
211 that receives bolt
201 passing through the first end
211 and through connector plate
203 attached to battery cable and secured thereto by wing nut
202.
Then, a post section
212 substantially encompasses the terminal T of the
battery and ends in legs
218,
218′ each having an aperture
to receive bolt B that is secured thereon by nut N. Nut N is tightened to bring
legs
218,
218′ closer together and thereby securely fix post
section
212 to the terminal T. Most prior art battery cable clamps have
utilized this structure with the first end of the clamp being connected to the
battery cable and the opposite end of the clamp applying the pressure to secure
the post section of the yoke about the terminal T. Particularly as use of steel
to manufacture battery cable clamps became more prevalent and the need for thick
post section and legs was greatly reduced, it became possible to design battery
cable clamps that had a first end connected to the battery cable, a leg section
extending to the distal post section and with a returning second leg oriented between
the post section and the connection to the cable so that the clamping action was
applied by a bolt extending between leg sections intermediate the post section
and the cable connecting section of the clamp.
Shown in FIG. 1, is battery clamp
10 of such configuration having a
rotatable quick release connector in place of the usual nut and bolt connector.
Specifically, battery clamp connector
10 has a first end
11 with
a cable joining section. In this case, cable joining section
14 is a threaded
post on which cable end plate having an aperture may be mounted and secured with
a nut or wing nut. First end
11 extends to first leg section
18 then
to post section
12 and back to second leg section
18′. The
post section
12 encircles the terminal post of battery and is securely held
in place thereon by clamping action applied to legs
18,
18′
by a fastener connecting the two through apertures
22,
22′
therein. The usual connector is a simple nut and bolt construction that may require
a wrench to remove in the ordinary case and in the event of corrosion may be difficult
or practically impossible to remove. In FIG. 1, the usual nut and bolt fastener
has been replaced with a quick release rotatable connector having a handle
50
with boss
58 resting on seat
40 in locked position to apply pressure
via connecting pin
28 to end nut
36 and sandwich legs
18,
18′ between the seat
40 and end nut
36. The interior
or concave side of handle
50 encircles a substantial portion of the post
section
12 in this position.
In FIG. 2, the battery clamp is still shown in closed position, however, the
handle
50 has been rotated laterally approximately 90° upward from its prior
position where it was parallel to the plane of the post section
12 and would
be generally laying upon the surface of the battery. In this position, the boss
on handle
50 is still exerting pressure against the seat and compressing
legs
18,
18′ to secure post section
12 of the yoke
about the terminal. The battery clamp
10 in FIG. 2 is slightly modified
in that the cable connector is a simple aperture
14′ to which a cable
end may be bolted. It will be understood that a cable end may be attached to a
battery clamps in many different ways.
In FIG. 3, the handle
50 has been rotated axially so that boss
58
no longer rests upon seat
40 and pressure applied by connecting pin
28
to end nut
36 is reduced, allowing legs
18,
18′ to
separate and the post section to be loosened from the battery terminal. This permits
the battery clamp to be loosened from the terminal. It will be seen in FIGS. 1-3
that the legs
18,
18′ each having holes
22,
22′
therein in registry, facilitate the placement of a connecting pin
28 therein.
It will be understood that electrical power generated by the battery is transferred
from battery terminals to post section
12 of battery clamp
10 and
through the battery connector to the cable connecting end
11 and cable connector
14,
14′ whereby power may continue on to the battery cables
(not shown). Thus, the power generated by the battery is transmitted through the
battery clamp
10 to the battery cable which is in turn connected to a solenoid,
a starter motor, or other electrical devices.
Because the battery clamp may remain in static contact, in its tightened
position, with the battery post for many years, corrosion often binds clamps to
the associated battery posts and an ordinary nut and bolt securing legs
18,
18′ may also rust or corrode so that it is difficult to remove the
battery clamp from the battery post. The rotatable battery clamp connector of the
present invention is installed by removing the standard nut and bolt connection
extending between apertures
22,
22′ and replacing it with
a connecting pin
28 and cammed handled
50 assembly as illustrated.
The connecting pin
28 has a threaded distal end
30 upon which is
secured end nut
36. Spacers may be fitted about the connecting pin
28
when it is installed in order to properly position the handle structure for adequate
leverage when operated, although the spacers are preferably integrally formed with
other components of the assembly.
The fastener
36 may be knurled, as illustrated, or may comprise another
preferably manually operable connector. The end nut
36 illustrated in FIGS.
6
a and
6b has a threaded aperture
37, to be received
on the threaded end
30 of connecting pin
28 and knurled surface
38
for easy gripping. The length of nut
36 is designed both to provide adequate
threading for secure mounting to the connecting pin
28 and to provide proper
spacing so that there is appropriate leverage exerted when the cammed handle
50
is operated. Preferably connecting pin
28 is threaded at each end and has
a smooth central section that will not bind with legs
18,
18′
of the yoke. Furthermore, the diameter of the pin
28 is preferably smaller
than customary to further safeguard against binding. For instance, according to
the present invention it is desirable to replace a standard 6 mm×|mm bolt
with a 12/24 connecting pin. The size 12 machine screw provides nearly 0.06 inches
additional clearance in the aperture in comparison to the 6 mm diameter bolt. A
total clearance of 0.05 inches or more is preferred. The other components of the
connecting pin
28 and cammed handle
50 assembly include the seat
40 and pin
45. The pin
45 is mounted in the base of handle
50 and has a threaded aperture
46 into which proximal end
32
of connecting pin
28 is secured. The seat
40 has an aperture
43
extending from a curved upper surface
42 to a substantially flat lower surface
41. After the proximal end
32 of connecting pin
28 is secured
to pin
45 mounted in the base of cammed handle
50, the aperture
43
of seat
40 may be received over the connecting pin
28 with curved
surface
42 of seat oriented toward the handle
50. The flat surface
41 of the seat is positioned against leg
18 of battery cable clamp
and connecting pin passed through apertures
22,
22′ of legs
18,
18′ of battery cable clamp and then the end nut
36
is attached to the threaded end
30 of connecting pin.
The handle
50 has a base
55 with aperture
52 therein to
receive pivot pin
45 and an opposite distal end
51. Intermediate
the base
55 and distal end
51 is a curving handle with concave side
57 and opposite convex side
56. Convex side
56 may have a
recess
59 to facilitate gripping of handle
50. The base
55
of handle
50 has a wall extending from opening
52 with boss
58
on the interior side and thinner wall
53. In addition, the base
55
has wing sections
60,
61 separated by channel
54 that permits
connecting pin
28 to remain in fixed orientation while handle
50
is rotated axially about pivot pin
45 with respect to seat
40.
Thus, it may be seen that in order to assemble the rotatable connecting pin
and cammed handle assembly, the pivot pin
45 is placed through aperture
52 of the base end
55 of handle
50. The first threaded end
32 of connecting pin
28 is passed through channel
54 and threaded
into aperture
46 of pivot pin
45. Then, the aperture
43 of
seat
40 is placed over the connecting pin
28 and connecting pin
28
is passed through apertures
22,
22′ of legs
18,
18′
of the battery clamp, and end nut
36 is secured to second threaded end
30
of connecting pin
28.
When end nut
36 is tightened by hand, the cammed handle
50 is
preferably in its unlocked position with relatively thin walls
53 intermediate
the pivot pin
45 and seat
40. In order to securely lock the post
section
12 of battery clamp
10 about the terminal, the cammed handle
50 is rotated axially on pivot pin
45 so that the boss section
58
is intermediate the seat
40 and pivot pin
45 thereby exerting additional
pressure on legs
18,
18′ and securing the post section
12
about the terminal. This axial rotation to place the boss section
58 intermediate
the pivot pin
45 and seat
40 preferably occurs in a direction normal
to the surface of the battery from which the terminal post extends. The handle
50 is then in its locked position and may be rotated approximately 90°
so that the concave side
57 of handle
50 at least partially encircles
post section
12 of battery clamp
10 providing a compact connecting
pin assembly.
Because the principal purpose of the improved connector is to address difficulties
that arise due to corrosion binding parts together and other fastening issues,
the design of the components should resist corrosion, and permit the fastening
and unfastening of battery cables from battery terminals without the need for tools.
Specifically, at least fastener
36 and seat
40 are preferably injection
molded from glass-filled nylon. This material is corrosion-resistant like nylon,
but has superior tensile strength and stiffness, even when subjected to high temperatures
and also enjoys low thermal expansion similar to metals. The handle
58 may
also be manufactured from glass-filled nylon. The use of glass-filled nylon to
mold these parts not only prevents corrosion between seat
40, fastener
36
and legs
18,
18′ and threads
32 of connecting pin
28,
but also provides self-lubricating properties to help prevent binding of parts.
In addition, connecting pin
28 preferably has a noticeably smaller diameter
than apertures
22,
22′ at least over its central portion
20
and passes through the apertures
22,
22′ and legs
18,
18′. The connector is designed for use replacing a connecting bolt
positioned intermediate the battery cable and the battery terminal post.
While the invention has been described in terms of its preferred embodiments,
numerous alterations of the products and methods herein described will suggest
themselves to those skilled in the art. It will be understood that the details
and arrangements of the embodiments that have been described and illustrated in
order to explain the nature of the invention are not to be construed as any limitation
of the invention, and all such alterations which do not depart from the spirit
of invention are intended to be included within the scope of the appended claims.
*
