Battery post connector
View Patent ↗A battery monitoring system that may be used to measure/monitor any number of battery operating conditions, including those associated with a vehicle battery. The system may be configured to interconnect a battery post that receives energy from the battery and a cable that electrically connects the battery to a vehicle.
1. A battery monitoring system for use with a battery used to power electronic devices within a vehicle, the battery having a ledge proximate a battery post, the system comprising:
a terminal adapter having a first compressively tightened connection at one end to electrically connect to the battery post and a second compressively tightened connection at another end to connect to a non-conducting portion of a cable, the cable being used to carry energy between the battery and the vehicle;
a shunt attached at one end to the terminal adapter and at another end to a conducting portion of the cable;
a battery monitoring circuit configured to measure a voltage drop between at least two separate portions of the shunt; and
wherein the first compressively tightened connection at the one end and the second compressively tightened connection at the another end are sized and shaped to fit entirely within the ledge.
2. The system of claim 1 wherein the terminal adapter is more rigid than the cable.
3. The system of claim 1 wherein the second compressively tightened connection includes fingers that are compressed around an outside of a non-conducting portion of the cable.
4. The system of claim 1 further comprising s-shaped flexible connection pins soldered to the at least two separate portions of the shunt, the flexible connection pins providing a flexible electrical connection between the battery monitoring circuit and the shunt.
5. The system of claim 1 wherein the battery monitoring circuit is positioned below a portion of the terminal adapter extending between the one and the another ends, wherein the portion including a leg that extends down to support an offset between the battery monitoring circuit and the terminal adapter.
6. The system of claim 5 wherein the leg is soldered to the battery monitoring circuit and is one of the at least two separate portions used by the battery monitoring circuit to measure the voltage drop.
7. The system of claim 1 wherein a portion of the conducting portion that extends beyond the non-conducting portion is soldered to shunt.
8. The system of claim 1 wherein a portion of the conducting portion of the cable is bent at an angle relative to the non-conducting portion.
9. A battery monitoring system for use between a vehicle battery and a vehicle cable, the cable being used for transferring energy between the vehicle battery and one or more electronic devices included within a vehicle, the battery monitoring system comprising:
a shunt having a first end connected to an electrically conducting portion of the cable;
a terminal adapter composed of a continuous piece of material, the terminal adapter having:
(i) a first cylindrically shaped, compressively tightened portion to electrically connect to a post of the battery;
(ii) a second, shunt connecting portion at a first quadrant of the first portion, the second portion being electrically connected to the shunt; and
(iii) a third, cable connecting portion proximate a boundary defined by a second and a third quadrant of the first portion, the third portion connecting to a non-conducting portion of the cable; and
a battery monitoring circuit having first and second pins respectively connected to first and second points of the shunt, the battery monitoring circuit measuring a voltage drop between the pins.
10. The battery monitoring system of claim 9 wherein:
the shunt is rectangular and extends lengthwise beyond both of the first and second quadrants of the first portion; and
wherein an axis of the third portion corresponds with a center axis of the cable and is perpendicular to an axis of the second portion corresponding with a center axis of the post.
11. The battery monitoring system of claim 10 wherein the conducting portion of the cable is bent at an angle of approximately 90°.
12. The battery monitoring system of claim 11 wherein the non-conducting portion of the cable is not bent at the angle of approximately 90°.
13. The battery monitoring system of claim 10 wherein the cable extends beyond both of the second and third quadrants of the first portion.
14. The battery monitoring system of claim 13 wherein the cable and shunt are connected at an angle of approximately 90°.
15. The battery monitoring system of claim 9 wherein the first portion includes a tightening fastener extending from a fourth quadrant of the first portion such that the second portion, third portion, and tightening fastener each extend from different quadrants of the first portion, the tightening fastener being operable to tighten the first portion to the post of the battery.
16. A battery monitoring system for between a battery having a battery post and a cable used to carry energy exchanged with the battery, the battery monitoring system comprising:
a shunt having a first end and a second end, the shunt extending lengthwise between the first and second ends;
a first electrically conducting portion connected between the first end of the shunt and the battery post, the first electrically conducting portion having a fastener to attach to the battery post, the first electrically conducting portion including a first leg extending below a first main body portion, the first main body portion being generally rectangular and extending lengthwise beyond both sides of the first leg and both sides of the first end of the shunt;
a second electrically conducting portion connected between the second end of the shunt and the cable, the second electrically conducting portion being separate from the first electrically conducting portion and including a second leg extending below a second main body portion, the second main body portion extending above and beyond both sides of the second end of the shunt; and
a battery monitoring circuit in contact with both of the first and second legs, the battery monitoring circuit having electrical connections with the shunt at two separate locations, the battery monitoring circuit measuring a voltage drop between the two separate locations of the shunt.
17. The battery monitoring system of claim 16 wherein the first and second electrically conducting portions are separately stamped components.
18. The battery monitoring system of claim 16 wherein the first and second main body portions are even with a top side of the fastener, and wherein the battery includes a ledge proximate the battery post and the first and second electrically conducting portions are sized and shaped to fit entirely within the ledge.
19. The battery monitoring system of claim 16 further comprising a clip configured to removably attach the cable to the second electrically conducting portion, the clip being soldered to the cable.
20. The battery monitoring system of claim 16 wherein the first and second legs are the two separate locations used to electrically connect the battery monitoring circuit to the shunt.