US5466545A — Compact, shock resistant battery pack

Claim 1

Independent Claim 201 words

A battery pack comprising: (a) a case comprising a generally rectangular enclosure, said enclosure formed by a bottom wall and a generally planar top wall, said top and bottom walls being separated by a pair of parallel side walls that are normal to said top and bottom walls, and first and second parallel end walls that are normal to said top, bottom, and side walls, said top wall being longer than said bottom wall at said first end wall, and a portion of said first end wall that intersects said top wall being positioned farther from said second end wall than a portion of said first end wall that intersects said bottom wall; (b) a battery assembly comprising a plurality of battery cells housed in said case; and (c) two or more generally planar electrical contacts, the plane of each of said electrical contacts generally parallel to the plane of said top wall, each of said electrical contacts being positioned in a notch in a portion of said top wall extending past said bottom wall and recessed under an outer surface of said top wall, each of said electrical contacts functioning as positive and negative terminals connected to said battery assembly.

Claim 2

Dependent Claim 201 words

A battery pack comprising: (a) a case comprising a generally rectangular enclosure, said enclosure formed by a bottom wall and a generally planar top wall, said top and bottom walls being separated by a pair of parallel side walls that are normal to said top and bottom walls, and first and second parallel end walls that are normal to said top, bottom, and side walls, said top wall being longer than said bottom wall at said first end wall, and a portion of said first end wall that intersects said top wall being positioned farther from said second end wall than a portion of said first end wall that intersects said bottom wall; (b) a battery assembly comprising a plurality of battery cells housed in said case; and (c) two or more generally planar electrical contacts, the plane of each of said electrical contacts generally parallel to the plane of said top wall, each of said electrical contacts being positioned in a notch in a portion of said top wall extending past said bottom wall and recessed under an outer surface of said top wall, each of said electrical contacts functioning as positive and negative terminals connected to said battery assembly.

Claim 3

Dependent Claim 52 words

The battery pack of claim 1, further comprising a generally rectangular hollow chamber formed by a portion of said side walls extending past said bottom wall to said portion of said first end wall that intersects said top wall, said top wall, and said first end wall that intersects said top wall.

Claim 4

Dependent Claim 34 words

The battery pack of claim 2, further comprising reinforcing members in said hollow chamber, said reinforcing strength members being parallel to said side walls and normal to said top wall and first end wall.

Claim 5

Dependent Claim 34 words

The battery pack of claim 1 wherein said battery pack further includes vents extending through said case to allow cases generated by said battery cells during charging to be vented to the external environment.

Claim 6

Dependent Claim 37 words

The battery pack of claim 1 wherein said electrical contacts for said positive and negative terminals are spaced at opposite edges of said top wall adjacent respective side walls to substantially maximize the spacing between said contacts.

Claim 7

Dependent Claim 30 words

The battery pack of claim 1 wherein said electrical contacts are electrically connected to a circuit board electrically connected to said battery cells, said circuit board housed in said case.

Claim 8

Dependent Claim 23 words

The battery pack of claim 6 wherein said circuit board further includes at least one integrated circuit electrically coupled to said battery cells.

Claim 9

Dependent Claim 23 words

The battery pack of claim 7 wherein said integrated circuit capable of maintaining a record of the available charge of said battery cells.

Claim 10

Dependent Claim 28 words

The battery pack of claim 1 wherein a top surface of said top wall further comprises rails along the entirety of said top surface adjacent said side walls.

Claim 11

Dependent Claim 30 words

The battery pack of claim 1, further comprising ribs in said bottom wall, said ribs comprising longitudinal troughs generally conforming to the length, shape, and orientation of said battery cells.

Claim 12

Dependent Claim 39 words

The battery pack of claim 1 wherein said case comprises a chamfer in said portion of each of said side walls extending past said bottom wall to said portion of said first end wall that intersects said top wall.

Claim 13

Dependent Claim 39 words

The battery pack of claim 1 wherein said case further comprises a chamfer from said portion of said first end wall that intersects said top wall to said portion of said first end wall that intersects said bottom wall.

Claim 14

Dependent Claim 21 words

The battery pack of claim 1 wherein said top wall comprises a chamfer from said notch toward said second end wall.

Claim 15

Independent Claim 132 words

A method for housing a circuit structure in a battery pack of the type having a plurality of cylindrical battery cells, electrical contacts, intercell connections, and leaded electronic components enclosed in a case, said method comprising: (a) binding together adjacent cylindrical battery cells longitudinally to form a composite unit of said cells, said composite unit comprising grooves at longitudinal junctions of said adjacent battery cells; (b) electrically interconnecting said battery cells with said plurality of intercell connections and said plurality of leaded electronic components; (c) placing said plurality of leaded electronic components into said longitudinal grooves; (d) placing said composite unit of battery cells with said plurality of leaded electronic components located in said longitudinal grooves into said case; and (e) electrically connecting said battery cells to said plurality of electrical contacts.

Claim 16

Independent Claim 132 words

A method for housing a circuit structure in a battery pack of the type having a plurality of cylindrical battery cells, electrical contacts, intercell connections, and leaded electronic components enclosed in a case, said method comprising: (a) binding together adjacent cylindrical battery cells longitudinally to form a composite unit of said cells, said composite unit comprising grooves at longitudinal junctions of said adjacent battery cells; (b) electrically interconnecting said battery cells with said plurality of intercell connections and said plurality of leaded electronic components; (c) placing said plurality of leaded electronic components into said longitudinal grooves; (d) placing said composite unit of battery cells with said plurality of leaded electronic components located in said longitudinal grooves into said case; and (e) electrically connecting said battery cells to said plurality of electrical contacts.

Claim 17

Dependent Claim 17 words

A method of claim 14, further comprising binding together said adjacent cylindrical battery cells longitudinally with adhesive.

Claim 18

Dependent Claim 24 words

A method of claim 14, further comprising placing double-back tape between said composite unit of said cells and an inner surface of said case.

Claim 19

Dependent Claim 24 words

A method of claim 14, further comprising electrically connecting said battery cells to a circuit board electrically connected to said plurality of electrical contacts.

Claim 20

Dependent Claim 25 words

A method of claim 17, further comprising mounting an integrated circuit on said circuit board and electrically connecting said circuit board to said integrated circuit.

Claim 21

Dependent Claim 18 words

A method of claim 14, further comprising electrically interconnecting said battery cells with a circuit breaker connection tab.

Claim 22

Dependent Claim 25 words

A method of claim 14, further comprising electrically interconnecting said battery cells with a thermal switch and placing said thermal switch into said longitudinal grooves.

Claim 23

Dependent Claim 23 words

A method of claim 14, further comprising electrically interconnecting said battery cells with a thermistor and placing said thermistor into said longitudinal grooves.

Claim 24

Dependent Claim 27 words

A method of claim 14, further comprising electrically interconnecting said battery cells with a non-resettable thermal fuse and placing said non-resettable thermal fuse into said longitudinal grooves.

Claim 25

Dependent Claim 14 words

A method of claim 14, further comprising performing step (e) before performing step (d).

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1998-11-13	1999-05-15	1999-11-14	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	2002-11-13	2003-05-15	2003-11-14	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2006-11-13	2007-05-15	2007-11-14	$7700.00	Window Closed / Lapsed

Compact, shock resistant battery pack

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