FIELD OF DISCLOSURE

[0001] The present disclosure relates to the field of automotive electrical systems. More particularly, the present disclosure relates to a protective device in automotive electrical systems.

BACKGROUND OF THE DISCLOSURE

[0002] The background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.

[0003] Battery Fuse Terminals (BFTs) are used as protection devices for protection and safety in accident against over current due to various faults (for instance short circuits). A BFT forms an electrical connection between an electrical power source (for instance battery post of a battery) and an electrical component or a combination of components arranged in one or more electrical circuits. Each electrical circuit is protected by a fusible element of the BFT so that when electrical current passing through the fusible element exceeds a preset limit the fusible element melts thereby avoiding any damage to components of the electrical circuit and other serious damage such as fire etc.

[0004] Due to increasing and more sophisticated electrical and electronic circuits in 4- wheeler models being introduced in the market, wiring harness and its components are becoming bigger and complex, and there is a concomitant increasing demand for cost, weight and size reduction in wiring harness components while making the various circuits easier to maintain. Presently high current carrying fuses of various circuits of a vehicle are carried in the BFT in an attempt to reduce the fuse box size and standardize the power circuits. However, this makes for a bulkier BFT with greater heat generation as well as greater risk of fire and damage to associated components when any such fuse blows/melts due to any fault such as short circuit in the circuit being served by it. Further, a battery terminal (interchangeably termed as battery post terminal) mounted on the appropriate battery post (usually the positive battery post) connects present BFTs to the battery wherein the battery post terminal is mounted on the battery post and other end of the battery post terminal connects to the BFT. In this manner current from the battery is distributed to various fuses in the BFT, including the high current carrying fuses.

[0005] Having a separate battery post terminal and the BFT results in higher costs on account of each having separate tools, molds and associated processes for their production. Besides having a separate battery post terminal and the BFT also results in additional cost in respect of wiring harness connecting the battery post terminal to the BFT, cost of mounting arrangement and additional assembly cost.

[0006] There is therefore a need in the art for a device that incorporates functions of the battery post as well as of a fuse box fulfilling all the current requirements while reducing cost, number of components and provides ease of maintenance.

[0007] All publications herein are incorporated by reference to the same extent as if each individual publication or patent application were specifically and individually indicated to be incorporated by reference. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.

[0008] In some embodiments, the numbers expressing quantities or dimensions of items, and so forth, used to describe and claim certain embodiments of the invention are to be understood as being modified in some instances by the term“about.” Accordingly, in some embodiments, the numerical parameters set forth in the written description and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by a particular embodiment. In some embodiments, the numerical parameters should be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of some embodiments of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as practicable. The numerical values presented in some embodiments of the invention may contain certain errors necessarily resulting from the standard deviation found in their respective testing measurements.

[0009] The recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g.“such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.

[00010] Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description of all groups used in the appended claims.

OBJECTS OF THE DISCLOSURE

[00011] Some of the objects of the present disclosure, which at least one embodiment herein satisfies are as listed herein below.

[00012] It is an object of the present disclosure to provide for an integrated battery post terminal and battery fuse terminal (interchangeably termed as battery fuse terminal assembly or BFT assembly herein).

[00013] It is another object of the present disclosure to provide for a BFT assembly that avoids a wiring harness between itself and a battery post terminal.

[00014] It is yet another object of the present disclosure to provide for a compact BFT assembly that reduces the risk of fire and associated damage due to a fuse blowout.

SUMMARY

[00015] The present disclosure relates to electrical systems and protective devices in various vehicles. More particularly, it relates to an integrated battery post terminal and battery fuse terminal (interchangeably termed as BFT assembly herein). [00016] In an aspect, present disclosure elaborates upon a battery fuse terminal (BFT) assembly for a vehicle, the BFT assembly comprising a current carrying element formed of a single metal piece, the current carrying element comprising: a battery post mounting portion for directly affixing the BFT assembly to a battery post and thereby receive electric current from the battery post, a bus bar portion connecting the battery post mounting portion to proximal end of at least one fusible element portion to provide the electric current to the at least one fusible portion; and a connection terminal portion formed at distal end of the at least one fusible element portion to provide the electric current to an external electric circuit, the at least one fusible link portion designed to protect the external electric circuit.

[00017] In another aspect, the battery post mounting portion can be adapted to have a clamping mechanism portion to clamp the battery post mounting portion to the battery post.

[00018] In yet another aspect, the assembly can further include a body part configured to provide electric insulation as required to any or a combination of the battery post mounting portion, the busbar portion, the at least one fusible element portion, the connection terminal portion and the clamping mechanism portion.

[00019] In an aspect, the body part can provide the electric insulation by embedding any or a combination of the battery post mounting portion, the busbar portion, the at least one fusible element portion, the connection terminal portion and the clamping mechanism portion within itself.

[00020] In another aspect, the body part can be configured to enclose any or a combination of the battery post mounting portion, the busbar portion, the at least one fusible element portion, the connection terminal portion and the clamping mechanism portion.

[00021] In yet another aspect, the body part can have fins for dissipating heat.

[00022] In an aspect, the body part can be lockable.

[00023] In another aspect, the body part can have a transparent cover configured to make visible any or a combination of the battery post mounting portion, the busbar portion, the at least one fusible element portion, the connection terminal portion and the clamping mechanism portion.

[00024] In an aspect, present disclosure elaborates upon a battery configured to hold a battery fuse terminal (BFT) assembly, the BFT assembly comprising a current carrying element formed of a single metal piece, the current carrying element comprising: a battery post mounting portion for directly affixing the BFT assembly to a battery post of the battery and thereby receive electric current from the battery post, a busbar portion connecting the battery post mounting portion to proximal end of at least one fusible element portion to provide the electric current to the at least one fusible portion; and a connection terminal portion formed at distal end of the at least one fusible element portion to provide the electric current to an external electric circuit, the at least one fusible link portion designed to protect the external electric circuit.

[00025] In another aspect, present disclosure elaborates upon a vehicle having at least one battery, the battery having at least one battery post configured to hold a battery fuse terminal (BFT) assembly, the BFT assembly comprising a current carrying element formed of a single metal piece, the current carrying element comprising: a battery post mounting portion for directly affixing the BFT assembly to the at least one battery post of the battery and thereby receive electric current from the battery post, a busbar portion connecting the battery post mounting portion to proximal end of at least one fusible element portion to provide the electric current to the at least one fusible portion; and a connection terminal portion formed at distal end of the at least one fusible element portion to provide the electric current to an external electric circuit, the at least one fusible link portion designed to protect the external electric circuit.

[00026] Various objects, features, aspects and advantages of the present disclosure will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like features.

[00027] Within the scope of this application it is expressly envisaged that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments, unless such features are incompatible.

BRIEF DESCRIPTION OF DRAWINGS

[00028] The accompanying drawings are included to provide a further understanding of the present disclosure, and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure. The diagrams are for illustration only, which thus is not a limitation of the present disclosure, and wherein:

[00029] FIG. 1 illustrates a conventional battery fuse terminal (BFT) and its connection to a battery post.

[00030] FIGs. 2A and 2B illustrate exemplary views of the proposed integrated battery post terminal and battery fuse terminal (BFT assembly) in accordance with embodiments of the present disclosure.

DETAILED DESCRIPTION

[00031] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.

[00032] In the following description, numerous specific details are set forth in order to provide a thorough understanding of embodiments of the present invention. It will be apparent to one skilled in the art that embodiments of the present invention may be practiced without some of these specific details.

[00033] If the specification states a component or feature“may”, “can”, “could”, or “might” be included or have a characteristic, that particular component or feature is not required to be included or have the characteristic.

[00034] As used in the description herein and throughout the claims that follow, the meaning of “a,”“an,” and“the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of“in” includes“in” and“on” unless the context clearly dictates otherwise.

[00035] Exemplary embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which exemplary embodiments are shown. These exemplary embodiments are provided only for illustrative purposes and so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those of ordinary skill in the art. The invention disclosed may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Various modifications will be readily apparent to persons skilled in the art. The general principles defined herein may be applied to other embodiments and applications without departing from the spirit and scope of the invention. Moreover, all statements herein reciting embodiments of the invention, as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently known equivalents as well as equivalents developed in the future (i.e., any elements developed that perform the same function, regardless of structure). Also, the terminology and phraseology used is for the purpose of describing exemplary embodiments and should not be considered limiting. Thus, the present invention is to be accorded the widest scope encompassing numerous alternatives, modifications and equivalents consistent with the principles and features disclosed. For purpose of clarity, details relating to technical material that is known in the technical fields related to the invention have not been described in detail so as not to unnecessarily obscure the present invention.

[00036] Thus, for example, it will be appreciated by those of ordinary skill in the art that the diagrams, schematics, illustrations, and the like represent conceptual views or processes illustrating systems and methods embodying this invention. The functions of the various elements shown in the figures may be provided through the use of dedicated hardware as well as hardware capable of executing associated software. Similarly, any switches shown in the figures are conceptual only. Their function may be carried out through the operation of program logic, through dedicated logic, through the interaction of program control and dedicated logic, or even manually, the particular technique being selectable by the entity implementing this invention. Those of ordinary skill in the art further understand that the exemplary hardware, software, processes, methods, and/or operating systems described herein are for illustrative purposes and, thus, are not intended to be limited to any particular named element.

[00037] Each of the appended claims defines a separate invention, which for infringement purposes is recognized as including equivalents to the various elements or limitations specified in the claims. Depending on the context, all references below to the "invention" may in some cases refer to certain specific embodiments only. In other cases it will be recognized that references to the "invention" will refer to subject matter recited in one or more, but not necessarily all, of the claims.

[00038] Various terms as used herein are shown below. To the extent a term used in a claim is not defined below, it should be given the broadest definition persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing.

[00039] In an aspect, present disclosure elaborates upon an integrated battery post terminal and battery fuse terminal (interchangeably termed as BFT assembly herein) for a vehicle, the BFT assembly comprising a current carrying element formed of a single metal piece, the current carrying element comprising: a battery post mounting portion for directly affixing the BFT assembly to a battery post and thereby receive electric current from the battery post, a busbar portion connecting the battery post mounting portion to proximal end of at least one fusible element portion to provide the electric current to the at least one fusible portion; and a connection terminal portion formed at distal end of the at least one fusible element portion to provide the electric current to an external electric circuit, the at least one fusible link portion designed to protect the external electric circuit.

[00040] In another aspect, the battery post mounting portion can be adapted to have a clamping mechanism portion to clamp the battery post mounting portion to the battery post.

[00041] In yet another aspect, the assembly can further include a body part configured to provide electric insulation as required to any or a combination of the battery post mounting portion, the busbar portion, the at least one fusible element portion, the connection terminal portion and the clamping mechanism portion.

[00042] In an aspect, the body part can provide the electric insulation by embedding any or a combination of the battery post mounting portion, the busbar portion, the at least one fusible element portion, the connection terminal portion and the clamping mechanism portion within itself.

[00043] In another aspect, the body part can be configured to enclose any or a combination of the battery post mounting portion, the busbar portion, the at least one fusible element portion, the connection terminal portion and the clamping mechanism portion.

[00044] In yet another aspect, the body part can have fins for dissipating heat.

[00045] In an aspect, the body part can be lockable. [00046] In another aspect, the body part can have a transparent cover configured to make visible any or a combination of the battery post mounting portion, the busbar portion, the at least one fusible element portion, the connection terminal portion and the clamping mechanism portion.

[00047] In an aspect, present disclosure elaborates upon a battery configured to hold a battery fuse terminal (BFT) assembly, the BFT assembly comprising a current carrying element formed of a single metal piece, the current carrying element comprising: a battery post mounting portion for directly affixing the BFT assembly to a battery post of the battery and thereby receive electric current from the battery post, a busbar portion connecting the battery post mounting portion to proximal end of at least one fusible element portion to provide the electric current to the at least one fusible portion; and a connection terminal portion formed at distal end of the at least one fusible element portion to provide the electric current to an external electric circuit, the at least one fusible link portion designed to protect the external electric circuit.

[00048] In another aspect, present disclosure elaborates upon a vehicle having at least one battery, the battery having at least one battery post configured to hold a battery fuse terminal (BFT) assembly, the BFT assembly comprising a current carrying element formed of a single metal piece, the current carrying element comprising: a battery post mounting portion for directly affixing the BFT assembly to the at least one battery post of the battery and thereby receive electric current from the battery post, a busbar portion connecting the battery post mounting portion to proximal end of at least one fusible element portion to provide the electric current to the at least one fusible portion; and a connection terminal portion formed at distal end of the at least one fusible element portion to provide the electric current to an external electric circuit, the at least one fusible link portion designed to protect the external electric circuit.

[00049] The present disclosure relates to electrical systems and protective devices in various vehicles. More particularly, it relates to a Battery Fuse Terminal that has an integrated battery post terminal.

[00050] FIG. 1 illustrates a conventional battery fuse terminal (BFT) and its connection to a battery post. As shown therein, conventionally a BFT 102 is connected to a corresponding battery post (104) of a battery 106 using a battery post terminal 108. Due to design and shape of battery post 104 and battery post terminal 108, packaging constraints of present BFT design, and material difference between battery post terminal 108 and present BFT 102 it is not possible to integrate the battery post terminal within the present BFT.

[00051] FIGs. 2A and 2B illustrate exemplary views of the proposed integrated battery post terminal and battery fuse terminal (BFT assembly) in accordance with embodiments of the present disclosure. In an aspect, the disclosed battery fuse terminal (BFT) assembly seeks to integrate battery post terminal within itself. Due to this integration and other aspects as elaborated herein, the proposed BFT assembly can be made in a very compact form. Further, it can directly be mounted on positive post of the battery. Such a construction serves to eliminate enumerated disadvantages associated with the conventional arrangement.

[00052] FIG. 2A illustrates construction of current carrying elements of the proposed BFT assembly in accordance with an exemplary embodiment of the present disclosure. In an aspect, current carrying element of the proposed BFT assembly can be fabricated as an integrated, single metal element 202.1n another aspect, element 202 can consist of four distinct parts/portions shown as 204, 206, 208 and 210, but fabricated as an integrated, single metal piece. In an exemplary embodiment, the single metal piece can be formed using techniques such as sheet metal punching and pressing. Part 204 can be termed as battery post mounting member (since it mounts on a battery post, thereby affixing/connecting the disclosed BFT assembly to the battery post without a battery post terminal being required). Part 206 can be termed as a busbar since it serves to direct current received by mounting member 204 to various fusible elements 208 as shown. The other end of the fusible elements 208 can be formed into connection terminals shown as 210 that can be adapted for connection with different electric circuits. A fusible element 208 can be designed for rated current capacity of the circuit that the corresponding connection terminal 210 is configured to be connected to. A connection terminal 210 can be connected to its corresponding circuit using any of the means well known in the art.

[00053] In yet another aspect, mounting member 204 can be mounted on a battery post, for instance on the post 104 as illustrate in FIG. 1 using appropriate means. In an exemplary embodiment, mounting member 204 can be affixed to battery post 104 using a clamping mechanism 212. Any other method that securely mounts mounting member 202 on battery post providing for strong electrical as well as mechanical connection can be used without any limitation whatsoever. For instance, mounting member 204 can have a hole through which a self- tapping screw/bolt can be passed that can drill its own threaded hole in the battery post as it is screwed into the battery post and thereby can affix/mount mounting member 204 over the battery post.

[00054] FIG.2B illustrates embedding of the element 202 into an appropriate material, in accordance with an exemplary embodiment of the present disclosure. The element 202 can be completely embedded into an appropriate material (for instance, a suitable resin) that can provide strength, insulation and fire resistance to the part. Only such portions that require electrical connectivity, or need to be visible for inspection/maintenance purpose may be left exposed. For instance, clamping mechanism 212 used for mounting on the battery post can be left exposed. Likewise, connection terminals 210 can be left exposed in order to allow their connection to corresponding electric circuits. Other parts such as busbar 206, fusible elements 208 can be embedded in resin. Any intervening spaces, such as those between two fusible elements 208, can be filled with resin in order to provide additional strength and insulation/fire resistance properties. Such an embedment can be achieved by using appropriate processes such as insert molding, and is termed as a body part 214 (refer to FIG.2B) for further references.

[00055] It can readily be appreciated that using insertion molding the body part 214 can be configured/profiled in various different ways. For instance, fusible elements 208/ busbar 206 can be embedded in such a manner that their top surfaces remain visible. This can enable any damage therein to be quickly spotted visually without needing to dismount the BFT assembly proposed from the battery post. Any fusible element that has melted due to any electric fault can be quickly spotted leading to quick and easy maintenance. Flanges can be provided around each connection terminal 210 for increased strength as well as to segregate wires being connected. Fusible elements 208 can be enclosed in a box that can be configured with a transparent cover on top so that the elements 208 can be visually inspected. The box can have a finned construction for dissipation of heat generated by fusible elements, particularly in the event of a fusible element blowout.

[00056] Further, insert molding can provide excellent strength, rigidity, electric insulation and fire resistance properties to the proposed BFT assembly. In case of heat/spark/flame due to a fusible element meltdown, the fire can be prevented from spreading to other areas and causing more serious damage. [00057] In this manner, battery post terminal 108 (refer to FIG.l) can be eliminated / integrated within the proposed integrated battery post terminal and battery fuse terminal (BFT assembly). Consequently, the proposed BFT assembly can be made in very compact shape and can be mounted directly over the battery positive post. The compact BFT assembly reduces space requirement, number of parts and manufacturing costs. Embedding using insert molding enables the BFT assembly to have excellent electrical, mechanical and fire resistance properties.

[00058] As used herein, and unless the context dictates otherwise, the term“coupled to” is intended to include both direct coupling (in which two elements that are coupled to each other or in contact each other) and indirect coupling (in which at least one additional element is located between the two elements). Therefore, the terms“coupled to” and“coupled with” are used synonymously. Within the context of this document terms“coupled to” and“coupled with” are also used euphemistically to mean“communicatively coupled with” over a network, where two or more devices are able to exchange data with each other over the network, possibly via one or more intermediary device.

[00059] Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms“comprises” and“comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refers to at least one of something selected from the group consisting of A, B, C ... .and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc.

[00060] While some embodiments of the present disclosure have been illustrated and described, those are completely exemplary in nature. The disclosure is not limited to the embodiments as elaborated herein only and it would be apparent to those skilled in the art that numerous modifications besides those already described are possible without departing from the inventive concepts herein. All such modifications, changes, variations, substitutions, and equivalents are completely within the scope of the present disclosure. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims. ADVANTAGES OF THE INVENTION

[00061] The present disclosure provides for an integrated battery post terminal and battery fuse terminal (BFT assembly).

[00062] The present disclosure provides for a BFT assembly that avoids a wiring harness between itself and a battery post terminal.

[00063] The present disclosure provides for a BFT assembly that is compact and reduces the risk of fire and associated damage due to a fuse blowout.