FIELD OF DISCLOSURE
The present disclosure relates to a battery disconnect switch for a vehicle. More specifically, the present disclosure relates to a rotary switch to turn ON/OFF a high ampere battery power from the vehicle electrical system.
BACKGROUND OF THE DISCLOSURE
The existing electrical system of a vehicle are in form of a closed circuit with an independent power source. A battery or a battery bank is utilised as the independent power source. These closed circuits may have their own switches, circuit breakers and fuses to ensure it is electrically safe and to protected major equipment from short circuits, overloading, mismatched loads, or device failure. Various types of battery disconnect switches are known to be used.
In the existing switches, if the vehicle is not in use for a couple of weeks or if any equipment of the vehicle for example a light is unintentionally remained ON when the engine is OFF, causes a potential battery drain. Therefore, the problem of avoiding draining of battery in the vehicle is a major issue in existing switches.
Further, the existing battery disconnect switches do not address the problem of protection of vehicle against theft. Since, the switch unveiled in the present disclosure is installed near the engine of the vehicle under the bonnet, it provides protection from theft as well. Therefore, to overcome the above problems, a battery disconnect switch is disclosed which addresses one or more problems associated with the existing switches.
SUMMARY
The one or more shortcomings of the prior art are overcome by a mechanism as claimed and additional advantages are provided through the provision of mechanism as claimed in the present disclosure. Additional features and advantages are realized through the techniques of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered a part of the claimed disclosure.
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A battery disconnection switch comprising a rotatable knob; a first carrier, said first carrier having a proximal end connected to the said knob; a cam, said cam includes a cam profile and the said cam is coupled with a distal end of the said first carrier; an upper body, said upper body having a cavity therebetween for encapsulating the said first carrier and the said cam follower; a plurality of torsion springs, said torsion springs are secured at one end to the said first carrier, and non-rotatably secured at its other end to the said upper body to enable first carrier to attain one of the circuit ON or circuit OFF position; a lower body, including a socket to rotatably dispose the said cam over the said lower body and the said upper body is mounted over the said lower body; a secondary carrier, said secondary carrier disposed inside the said lower body such that the upper end of the said secondary carrier functions as a follower by abutting the said cam and reciprocates within the said lower body following the cam profile; a movable contact, including at least two contact arms, such that the said moving contact is slide-ably disposed within a slot of the said secondary carrier; a first spring , said first spring is disposed inside the slot of the said secondary carrier and positioned above the said movable contact; a second spring, said second spring is disposed inside the slot of the said secondary carrier and positioned below the said movable ; a base, defining a chamber having an open upper end and the said base is disposed inside the said lower body; and a plurality of terminals including a first terminal, a second terminal and a third terminal, fixed in the said base so as to be exposed inside the said base chamber.
BRIEF DESCRIPTION OF FIGURES
The novel features and characteristics of the disclosure are set forth in the description. The disclosure itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will best be understood by reference to the following description of an illustrative embodiment when read in conjunction with the accompanying drawings. One or more embodiments are now described, by way of example only, with reference to the accompanying drawings wherein like reference numerals represent like elements and in which:
Figure 1 illustrates an isometric view of the complete assembly of the battery disconnect switch assembly according to the present disclosure.
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Figure 2 illustrates an exploded view of the battery disconnect switch assembly according to the present disclosure.
Figure 3a-3b illustrates the sectional views of the battery disconnect switch assembly according to the present disclosure.
Figure 4a-4b illustrates the plurality of torsion springs accommodated in the upper body of the battery disconnect switch assembly according to the present invention.
Figure 5 illustrates the sectional view of the battery disconnect switch assembly along with details A and B according to the present disclosure
Figure 6 illustrates the sectional view of the battery disconnect switch assembly along with detail C according to the present disclosure.
Figure 7 illustrates the bottom view of the battery disconnect switch assembly according to an embodiment of the present disclosure.
DESCRIPTION OF PRESENT DISCLOSURE
While the invention is susceptible to various modifications and alternative forms, specific embodiment thereof has been shown by way of example in the figures and will be described in detail below. It should be understood, however that it is not intended to limit the invention to the particular forms disclosed, but on the contrary, the invention is to cover all modifications, equivalents, and alternative falling within the spirit and the scope of the invention as defined by the appended claims.
Before describing in detail embodiments, it may be observed that the novelty and inventive step that are in accordance with the present invention resides in battery disconnect switch assembly for vehicles. It is to be noted that a person skilled in the art can be motivated from the present invention and modify the various constructions of assembly, which are varying from vehicle to vehicle. However, such modification should be construed within the scope and spirit of the invention. Accordingly, the drawings are showing only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having benefit of the description herein.
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The terms “comprises”, “comprising”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a setup, device that comprises a list of components does not include only those components but may include other components not expressly listed or inherent to such setup or device. In other words, one or more elements in a system or apparatus proceeded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or apparatus.
Accordingly, the main aim of the present invention is to provide battery disconnect switch assembly which can make and break electrical contacts at higher velocities which overcome at least one of the problems of the existing switch assembly.
The present battery disconnect switch (interchangeably referred as to switch) is a high ampere switch which operates at applications of up to 200 amperes. The mechanism in the switch assembly enables making and breaking of electrical contacts at higher velocities which results in lesser time for arcing in the switch. Lesser arcing results in switching of high ampere current. Also, the switch works on a single pole double throw mechanism i.e. a butt type contact system with larger contact gaps and therefore it provides more di-electric strength and withstands high voltage surges.
Reference will now be made to the exemplary embodiments of the disclosure, as illustrated in the accompanying drawings. Where ever possible same numerals will be used to refer to the same or like parts.
Figure 1 illustrates a battery disconnect switch (100) for vehicle according to an embodiment of the present disclosure. Referring to Figure 2 the switch comprises a knob (1) upper body (2), a lower body (3), a base (4) and a plurality of electrical terminals.
Referring to figure 4a and 4b the upper body (2) is characterized as a housing for a first carrier (8), said upper body having a cavity therebetween for the said first carrier and the said cam follower; A first carrier (8), comprises a proximal end (8a), a distal end (8b) and a flange (8c). The proximal end (8a) is connected to the knob (1) and the distal end (8b) is coupled to a cam (9). The cam (9) includes a cam profile on the
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surface opposite to the surface where the distal end 8b is coupled. The cam profile includes at least one peak surface (9a), at least one inclined surface (9b) and a flat surface (9c) diametrically positioned on the surface. A quartet of torsion springs (18) are secured at one end to flange (8c) of the first carrier (8), and non-rotatably secured at its other end to the interior of the upper body (2) to enable first carrier to attain one of the circuit ON or circuit OFF position.
The quartet of torsion springs (18) get energized during the first 45 degrees of knob (1) rotation by the user and release energy during the next 45 degrees of knob (1) rotation. Due to such swift contact making and breaking mechanism, the switch (100) can be operate at higher velocities.
Referring to figures 3a and 3b, the lower body (3) is characterised to encapsulate a secondary carrier 11 and opened at the bottom to accommodate a base (4). The lower body 3 is made of insulator material, and the upper body can be mounted over the upper surface by fastening elements such as a plurality of screws (14). The upper surface of the lower body (3) includes a socket to rotatably dispose the shaft portion (9d) projecting from the centre of the said cam (9).
The lower body (3) further includes a provision in the internal and external construction to allow the secondary carrier (11) to functions as a follower by abutting the cam profile and to reciprocate within the lower body (3) following the cam profile. The secondary carrier (11) has a rectangular slot (11a) to accommodate a moving contact (13) such that the moving contact (13) can slide within a rectangular slot (11a). The moving contact (13) is a rectangular block made of electrically conductive material and is positioned centrally with the vertical central axis of the secondary carrier (11). The moving contact (13) may further includes two contact rivets (13a ,13b) disposed at lower side of two extreme arms of the moving contact (13). The secondary carrier (11) carries a first spring (10) in compression that presses the moving contact (13) towards and a second spring (12) mounted over the bottom of the secondary carrier (11).
The base (4) is a rectangular box with open upper end made of insulator material positioned inside the lower body (3) of the switch (100). A first terminal (5) further comprise of nuts and bolts (5b), a spring washers (5c), and a contact rivet (5a).
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Similarly, a second terminal (6) further comprise of nuts and bolts (6b), a spring washers (6c), and a contact rivets (6a). A third terminal (7) comprising of a Lucar terminal (7c), an intermediate plate(7b) and a contact rivet (7a). The first and the second terminals (5, 6) forms an electrical circuit with a battery source or power source and vehicle electrical system, whereas the third terminal (7) is connected to an auxiliary indicating device to indicate the circuit open or close condition. The base (4) comprises multiple pockets to accommodate and to plurality of terminals (5, 6, 7) such that the contact rivets (5a, 6a, 7a) are exposed towards the inside of the chamber.
According to an embodiment of the present disclosure, as shown in Detail A of Figure 5, an O-ring (17) is compressed between the upper body (2) and the proximal end (8a) of the first carrier (8) of the switch (100). The O-ring (17) restricts the entry of dust and water from the upper side of the switch (100). As shown in Detail B of Figure 5, a first gasket (15) is inserted between the upper body (2) and the lower body (3) of the switch (100) by means of plurality of screws (14). The first gasket (15) provides sealing from the sides of the switch (100).
Referring to Detail C of Figure 6, the second gasket (16) is inserted between lower body (3) and the base (4) of the switch (100) by means of snap locks to provide sealing from dust and water from the bottom side of the switch (100).
As shown in Figure 7 the Lucar terminal (7c) is connected to an intermediate plate(7b) by means of a contact rivet (7a) or caulking. The contact rivet (7a) is directly engaged to the second spring (12). A epoxy (E) bonding between the components of the third terminal (7) and the base (4) ensures prevention of entry of dust and water in the switch (100).
The working of the switch (100) according to an embodiment of the present disclosure is as following.
The switch (100) has the first terminal (5) and the second terminal (6) coupled to forms an electrical circuit with a battery source or power source and vehicle electrical system, whereas the third terminal (7) is connected to an auxiliary indicating device to indicate the circuit open or close condition.
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The working of the switch (100) according to an embodiment of the present disclosure is as following. When the switch (100) is in circuit ON condition, the peak surface (9a) of the cam (9) effectuates the secondary carrier (11) to a lowest position and, in consequence, the contact rivets (13a ,13b) of movable contact forms a closed circuit with the contact rivets (5a, 6a, 7a) of first terminal, second terminal and third terminal. When a user requires to disconnect the battery source from the vehicles electrical system, the user must rotate the knob in anti-clockwise direction.
The 45-degree anti-clockwise rotation of the knob (1), causes the flat (9c) or the inclined surface (9b) of the cam (9) to come in contact with the secondary carrier (11). The remaining 45-degree rotation is caused by the charged torsion spring (9) and thereby, the cam (9) effectuates the secondary carrier (11) to a highest position and, in consequence, the movable contact forms an open circuit with the contact rivets (5a, 6a) of first terminal and second terminal.
ADVANTAGES OF THE PRESENT DISCLOSURE
 The primary advantage of the present switch assembly is to provide a water, dust and other contamination proof structure of the switch assembly with improved operability.
 Another advantage of the switch assembly is that it operates at high ampere applications (i.e. up to 200 Amperes at 12 Volts).
 Another advantage of the present switch assembly is that it protects vehicles from theft and battery drain.
 Another advantage of the present switch is that it provides an emergency cut-off in the battery circuit of the vehicle.
 The switch according to the invention equips a better operational reliability, and is easy to manufacture.
Further, various modifications and variations may be made without departing from the scope of the present invention. Therefore, it is intended that the present disclosure covers such modifications and variations provided they come within the ambit of the appended claims and their equivalents.
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EQUIVALENTS:
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.
The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.
Any discussion of documents, acts, materials, devices, articles and the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters
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form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.
While considerable emphasis has been placed herein on the particular features of this disclosure, it will be appreciated that various modifications can be made, and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other modifications in the nature of the disclosure or the preferred embodiments will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.
LIST OF REFERNCE NUMERALS
Description
Reference Number
Battery disconnect switch
100
Knob
1
Upper body
2
Lower body
3
Socket
3a
Base
4
First terminal
5
Second terminal
6
Third terminal
7
11
Intermediate plate
7b
Lucar Terminal
7c
Nut and Bolt
5b, 6b
Spring Washers
5c, 6c
Contact Rivet
5a, 6a, 7a
First Carrier
8
Proximal end of first carrier
8a
Distal end of first carrier
8b
Flange
8c
Cam
9
Peak surface of cam profile
9a
Inclined surface of cam profile
9b
Flat surface of cam profile
9c
Shaft portion of cam
9d
First Spring
10
Second Carrier
11
Rectangular slot
11a
Second Spring
12

We claim:
1. A battery disconnection switch (100) comprising:
a rotatable knob (1),
a first carrier (8), said first carrier (8) having a proximal end (8a) connected to the said knob (1);
a cam (9), said cam (9) includes a cam profile and the said cam is coupled with a distal end (8b) of the said first carrier (8);
an upper body (2), said upper body (2) having a cavity therebetween for encapsulating the said first carrier (8) and the said cam (9);
a plurality of torsion springs (18), said torsion springs (18) are secured at one end to the said first carrier (8), and non-rotatably secured at its other end to the said upper body (2) to enable first carrier (8) to attain one of the circuit ON or circuit OFF position;
a lower body (3), including a socket (3a) to rotatable dispose a shaft portion (9d) of the said cam (9) over the said lower body (3) and the said upper body (2) is mounted over the said lower body (3);
a secondary carrier (11), said secondary carrier (11) disposed inside the said lower body (3) such that the upper end of the said secondary carrier (11) functions as a follower by abutting the said cam (9) and reciprocates within the said lower body (3) following the cam profile;
a movable contact (13), including at least two contact arms, such that the said moving contact (13) is slide-ably disposed within a slot of the said secondary carrier (11);
a first spring (10), said first spring is disposed inside the slot of the said secondary carrier (11) and positioned above the said movable contact (13);
a second spring (12), said second spring (12) is disposed inside the slot of the said secondary carrier (11) and positioned below the said movable contact (13);
a base (4), defining a chamber having an open upper end and the said base is disposed inside the said lower body (3); and
a plurality of terminals including a first terminal (5), a second terminal (6) and a third terminal (7), fixed in the said base (4) so as to be exposed inside the said base chamber.
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2. The battery disconnection switch as claimed in claim 1, wherein the said first and terminal (5, 6) forms an electrical circuit with a battery source or power source and vehicle electrical system, whereas the remaining third terminal (7) is connected to an auxiliary indicating device to indicate the circuit open or close condition.
3. The battery disconnection switch as claimed in claim 1, wherein the said cam (9) profile includes at least one peak surface (9a), at least one inclined surface (9b) and a flat surface (9c).
4. The battery disconnection switch as claimed in claim 1, wherein the peak surface (9a) of the said cam (9) effectuates the said secondary carrier (11) to a lowest position and, in consequence, the movable contact (13) forms a closed circuit with the said first terminal (5), second terminal (6) and third terminal (7).
5. The battery disconnection switch as claimed in claim 1, wherein the inclined or the flat surface of the said cam (9) effectuates the said secondary carrier (11) to a highest position and, in consequence, the movable contact (13) forms an open circuit with the said first terminal (5) and second terminal (6).6. The battery disconnection switch as claimed in claim 1, wherein the said second spring (12) engages with the said third terminal (7) and the movable contact (13) in both closed circuit condition and open circuit condition.
7. The battery disconnection switch as claimed in claim 1, wherein the said normal condition has the said secondary carrier (11) at the lowest position and the movable contact (13) forms a closed circuit with the said first terminal (5), second terminal (6) and third terminal (7).
8. The battery disconnection switch as claimed in claim 1, wherein upon 45-degree clockwise rotation of said knob (1) from the said normal condition to charges the torsion spring and release charge in next 45-degree clockwise rotation of man independent operation, considering either of the case On to OFF or OFF to ON…. open circuit condition and on upon further rotation of said knob (1) causes the said knob to return to the said normal condition due to the resilient action of the said plurality of torsion spring (18).