JPH01281684A - Electrically actuated device having battery formed in one piece - Google Patents

Abstract

PURPOSE: To be able to recharge at a low cost by providing a device supported by a housing to perform predetermined function and connectable to batteries for selective energization. CONSTITUTION: A housing 12 is formed with a battery case, or a storage housing, in which the boundaries of batteries 42 are defined along four edges 44a, 44b, 44c, and a flange 50 and the bottom face. The batteries 42 are closed by an upper cover member 52 and the cover member 52 is given ultrasonic welding at the four battery storage sides formed by the housing 12. Electrodes 70 for the batteries 42 are folded or bent to form continuously curved members in an almost U-shaped cross section and separated from substantially flat positive electrode 74 on a separation layer 72. In this way, the need for a housing which is sealed to incorporate electrodes, electrolyte and a separator is eliminated, to ensure recharging at a low cost.

Description

DETAILED DESCRIPTION OF THE INVENTION Field of the Invention The present invention relates to an electrically powered unit that includes a rechargeable battery integrally formed therein. The present invention relates to an electrically energized unit having an electrically powered unit, a portion of which is used as part of a housing housing for a rechargeable battery.

BACKGROUND OF THE INVENTION Electrically energized units such as flash lights, emergency lights and the like have been known for a long time. These electrically powered units have in the past included individually replaceable batteries. Once the energy stored in the batteries was depleted, these batteries were replaced with new ones as needed.

More recently, electrically powered units containing rechargeable batteries have become available. Such units may be in the form of flashlights, portable radios or similar forms. Known electrically powered units incorporating rechargeable batteries are separate products, similar to disposable batteries, completely separate from the electrically powered units in question here. It uses a battery formed as However, these rechargeable batteries were not intended to be incorporated into the husband's electrically energized unit and easily removed during the subsequent manufacturing process.

Despite the convenience and usefulness of such rechargeable electrical units, the cost of such individually formed rechargeable batteries is a substantial portion of the cost of manufacturing the electrical unit. occupies the majority. Additionally, because rechargeable batteries are formed as individual units, each must typically have its own sealed housing to contain the electrodes, electrolyte, and separator. .

There is a need for a unit that provides the convenience of a rechargeable battery versus an electrically powered unit, yet at reduced cost.

OBJECTS OF THE INVENTION It is an object of the present invention to provide an electrically energized unit that satisfies the above-mentioned needs of the prior art.

SUMMARY OF THE INVENTION According to the present invention, an electrically energized unit having a housing is provided. The housing defines selectively projected areas within which components of the unit can be mounted or supported.

A rechargeable battery is provided. The rechargeable battery is integrally formed within at least a portion of the area bounded by the housing.

a battery is formed in part by the housing;
Partially contained within the volume formed by the cover member.

The housing also supports circuitry for recharging the battery and providing electrical energy to selected loads. The selected load may be one or more electric lights. The electrical unit is configured with a manually actuatable 111m member such as a three position switch. Rigid connecting conductors are provided adjacent the outer surface of the housing to facilitate connection of the unit to an external source of electrical energy. This electrical energy can be used for the purpose of recharging the integrally formed battery.

The electrical circuit also includes a photodetection device. This light detection device can be used to sense ambient light in the vicinity of the housing for the purpose of energizing one of the lights. The electrical circuit also includes a sensor that detects the absence of electrical energy from an external source. In response to detecting the absence of electrical energy supplied by an external source, the unit is adapted to energize a selected light bulb.

DESCRIPTION OF THE PREFERRED EMBODIMENTS Many other advantages and features of the present invention will be apparent from the following detailed description of the invention and embodiments thereof, the claims and the accompanying drawings, which are fully set forth as a part of the detailed written description. easily revealed.

Referring to FIG. 1, an electrical unit 10 according to a preferred embodiment of the present invention is a power outage night light (poverrail/
n1oht l1oht). The unit 1o includes a housing 12 molded from thermoplastic material.

The housing 12 includes an opening 16 through which a light sensor 16a senses ambient light and automatically opens and closes the switch when the night lighting mode is set. Housing 12 includes an opening 18;
A portion of the three position manually actuated switch 20 extends through this opening. This switch 2o can be used to shut off the unit 1o or to select a mode of operation.

The unit 10 is shown inserted into a standard AC receptacle, indicated generally at 22, in FIG.

When inserted into such a power socket, the unit 10
Not only is it capable of recharging the integrally formed battery contained within housing 12, but it is also capable of detecting the absence of power to socket 22. In response to detecting a lack of power to socket 22, unit 10 can automatically provide emergency lighting by switching to a higher illumination light.

In FIG. 2, the lens 14 is partially cut away to show a curved reflector 26 disposed between the housing 12 and the lens 14. A relatively large illumination light 28 is removably mounted within the socket 30. This socket 3o is a reflector 26
It is placed roughly in the center. Electric light 28 is used to provide a relatively large level of illumination when externally supplied electrical energy is exhausted. Such losses can occur when the unit 10 is removed from the socket 22, acting as a flashlight, or because the socket 22 is not receiving power.

A relatively low illumination, long life, non-replaceable electric current M32 extends through an aperture 34 in reflector 26. This light bulb 32 is intended to be used to provide a relatively low level of illumination when the unit 10 is used as a night light.

FIG. 3 further illustrates the interrelationship of the various components of unit 10. A set of extensions 36 extend outwardly from the outer surface of the molded housing 12. These extensions 36 are of conventional type and are intended to slidably engage the electrical conductors of the AC socket 22.

These extensions 36 are electrically connected to circuitry on a printed circuit board 38 supported by housing 12.

This printed circuit 138 also provides contact for the socket 30.

Housing 12 bounds an interior area 4o.

This section M40 includes a rechargeable, integrally formed battery 42.

As best shown in FIG.
are formed in the end area of the housing 12. The housing 12 has a boundary wall 44 which is connected to the battery 42 by wall members 44a, 44b and 44C.
is bounded by three sides. Housing 12 also has a bottom wall 46.

Within the area 48 this bottom wall 46 forms the lower boundary of the battery 42. A flange 50 molded into the housing 12 forms a slightly U-shaped interior wall for the battery 42 and extends between the two elongated sides 4 of the housing 12.
It extends between 4a and 44b.

The housing 12 includes the battery 42 at four edges 44a,
44b and 44C1 define a battery case or housing bounded along the bottom of flange 50 and area 48. The battery 42 is closed by an upper cover member 52. Top cover member 52 is a molded elongate plastic member that forms the cover for battery 42 .

This cover member 52 can be ultrasonically welded to the housing sides of the four batteries described above formed by the housing 12. Thus, battery 42 is formed within an area 54 defined by portions of housing 12 except for cover member 52 which is secured to housing 12.

Cover member 52 includes an integrally formed vent 56. The vent 56 includes a cylindrical boat 58 extending into the compartment 1154. This boat 58 is covered by a slide valve cap 60. This cap 60
is slidable along cylindrical bow 1-58 in response to pressure from gas generated within cavity or area 54. As cap 60 moves away from cylindrical boat 58 in response to pressure within cavity or area 54, the seal provided by cap 60 is broken and pressure is released from cavity or area 54. can be done.

Once the pressure is released, the cap 6o stops moving. In response to the subsequent falling pressure in zone 54, cap 60 is forced back toward battery 42 by atmospheric pressure, thereby resealing boat 58. A restraining member 62 integrally formed on the reflector 26 limits the range of motion of the absorbent plate or cap 6o.

The pressure relief valve or vent 56 has a pressure of 0.7 to 0.8.
It acts to relieve the pressure in area 54 when 4N9/a2 (10-12 pSl) is exceeded.

Battery 42 is provided with first and second external contacts or terminals 66a and 66b.

These contacts 66a and 66b are used to connect external circuitry on printed circuit board 38 to and recharge battery 42, or to extract electrical energy from the battery.

The battery 42 is of the recombinati type.
This is a sealed lead-acid battery. Such known batteries use spaced lead electrodes and an acidic electrolyte.

Referring to FIG. 5, taken in cross-section along plane 5-5 of FIG. 4, the structure of battery 42 includes an external negative electrode 70 that serves as an anode. This electrode 70 is a conventional negative fff rod formed by a lead grid. The grid spacing is filled with sponge lead.

Electrode 70 is folded or bent to form a continuously curved member having a generally U-shaped cross section. Although the sponge lead within the grid of electrode 70 will crack during bending operations, the grid members themselves are extremely tough and can be easily bent, thereby providing reliable electrical power within the cell. It provides continuity. Adjacent to this folded electrode 7o is placed a separate layer 72 formed by non-woven glass fibers of the type available on the market. This separation 1172, in addition to separating electrode 70 from a second, centrally located substantially planar electrode 74, is also adapted to absorb substantially any electrolyte present within the battery.

Electrode 74 forms the positive bridge of the battery. This electrode 74 is designed as a cast lead grid filled with lead dioxide.

The electrolyte used with the cells of battery 42 is 15.
It is diluted sulfuric acid with a specific gravity of about 1.32 at 56°C (below 60°C).

Electrodes 70 and 74 preferably used with battery 42 include a commonly available lead alloy with 1% calcium by weight. Electrodes 70 and 74 weigh 9
Contains less than 9.9% lead. Electrode 7o
As a result of the alloys used in and 74, these electrodes are substantially self-supporting.

FIG. 6, taken along plane 6--6 of FIG. 4, shows the dark interrelationship of negative electrode 70 and associated terminal 86a.

The tab 70a cast together with the grid of the electrode 7o is
170b and attached to terminal 66a. This terminal 66a can be formed from tin-plated copper or tin-plated brass. Alternatively, the terminal 88a can be made of brass or copper with a layer of tin plate. The thickness of this plating is 0.0076jIII (,3/1
It is desirable to have a thickness of about 1,000 inches). End 66b of terminal 66a is connected to area 7 of the end of lead tab 70a.
0b (best shown in FIG. 7). The end area 66t of the terminal 66a is re-flow soldered to the lead end area 70b.
w 5oldered).

Area 50a is filled with epoxy material to provide a seal and provide mechanical support between the inner section 1154 and the outer section.

FIG. 8 shows an electrical circuit 3 that can be used with this unit 10.
8a is shown. The circuit 38a includes an electrical connection extension 36 which extends from the bottom surface of the housing.
It extends from 2a. The circuit 38a is a printed circuit llA3
8 and can be supported by it.

Circuit 38a includes an automatic night light activation section 90. The circuit in this section 90 includes first, second and third resistors 9
2a, 92b and 92c. The night light activation circuit also includes a light sensor 16a and a silicon controlled rectifier (SCR) 94.

Optical sensor 16a is located at the rear of optical aperture 16 of housing 12. Light sensor-16a when there is ambient light
becomes conductive and a small voltage or no voltage appears on the gate input conductor 94a of the 5CR94.

Assuming that the three-position switch 20 is set to the upper or night light energized position, as the ambient light level decreases, the sensor 16a becomes less and less energized. This allows the voltage on conductor 94a to increase. When the voltage of gate input conductor 1!94a of 5CR94 becomes high enough, 5CR9
4 is conductive.

This causes current to flow through the night light 32 to provide continuous illumination until the light incident on the aperture 16 increases again. When the incident light increases, the light sensor 16a
becomes conductive again, thereby cutting off the conduction of 5CR94.

Capacitor 94b connects electric light 32 to sensor 16a.
This eliminates the flickering of the electric light 32 in response to the reflection from the lamp.

A second portion 96 of circuit 38a provides electrical energy from extension 36 for recharging battery 42. This recharging portion 96 of circuit 38a carries current i11
First and second rectifier diodes 98 along with limiting resistor 100
a and 98b. The recharging circuit portion 96 is configured to continuously recharge the battery 42 regardless of the toggle position of the switch 20 as long as the unit 10 is connected to the AC power socket 22 and the extension 36 is energized. Eggplant.

The fullest portion 102 of circuit 38a is supplied via extension 36 with 1'! f? It is designed to sense the absence of liE and voltage. In the absence of this supplied current and voltage, the power failure indicator light 28 will be illuminated when the switch 20 is in any position other than the 'mW;fi position.

The power failure detection circuit portion 102 includes resistors 106a and 106b.
and 106C as well as switching transistors 104a and 104b. ffi! to the circuit 38a via the extension section 36. As long as voltage is applied, transistor 104a is cut off.

When the transistor 104a is cut off, the transistor 104b is also cut off and the electric light 28 is turned off.

Transistor 1048 immediately begins conducting due to the potential and current from battery 42 in the absence of electrical energy supplied to extension 36 if switch 20 is not in the cut-off position. This causes current flowing through transistor 1048 through resistor 106C to cause transistor 104b to conduct. As a result, the emergency light 28
lights up. The lamp 28 remains conductive until the electrical energy supply through the extension 36 is restored, the switch 20 is turned to the shutoff position, or the battery 42 is discharged to approximately 6 volts.

FIG. 9 shows a modified structure 120 of a battery according to the invention. The battery 120 has a self-contained housing 122 that can be molded from a selected thermoplastic material.
Contains. Housing 122 has an elongated, generally rectangular shape (best shown in FIG. 12 in cross section). The housing 122 includes first and second elongate side members 12.
4a and 124b, which side members also have curved elongated end members 126 integrally formed therewith.
a and 126b.

The housing 122 has a bottom portion 12 integrally formed therein.
Closed by 8. Top member or cover member 1
30 is ultrasonically welded to the housing 122 at a joint 132.

The top or cover member 130 includes a vent 136 and spaced apart first and second positive and negative terminals 138.
a and 138b.

Cover member 130 includes an upper portion 132a that bounds an interior region 140. This area 140 can be filled with epoxy material 142. This epoxy material 142 provides a seal between the external environment of the battery 120 and the internal compartment 1iffi 132. Furthermore, this epoxy material 142 is applied to the terminal 138a.
and provides physical stability and strength to 138b.

12 to 15 show the internal structure of the battery 120. This structure is similar to the internal structure of the battery 42 described above. Battery 120 includes a folded or curved negative electrode 150 formed by a cast lead grid with sponge lead, as in battery 42. This negative electrode 150 forms the anode of battery 120 at terminal 138a. A second substantially planar positive electrode 152 is also provided. This electrode 1
52 forms a substantially flat cathode of battery 120. This electrode 152 is connected to terminal 138b and is formed as a cast lead grid. Electrode 152
is filled with lead dioxide.

Ti poles 150 and 152 are part of glass fiber separation device 154
separated by.

The vent 136 is formed into a cylindrical boat 136a whose inner surface 136b is connected to the interior area 13 of the battery 120.
2, forming a fluid flow path for communicating fluid flow. A slidable cap 136C reseals the vent 136 closed. This vent 136 operates similarly to the vent 56 of the battery 42.

Referring to FIGS. 14 and 15, electrode 152 supports an integrally cast contact tab 160. Referring to FIGS. The contact tab 160 is formed with a shaped end area 162 for the purpose of receiving a connecting end 164 of the terminal 138b. Both end 164 and section 162 are reflow brazed. This reflow brazing provides a physically strong bond between these items without the need for any other attachment materials.

Similarly, the electrode 150 has an integrally cast tab 17.
0, and the end section 14172 is the terminal 13
The adjacent end area 174 of 8a is reflow soldered.

These terminals 138a and 138b can be made of tinned brass or copper. Alternatively, terminals 138a and 138b can be made of tinned brass or copper.

Separator 154 and electrodes 150 and 152 are 15.56
It accepts an electrolyte such as sulfuric acid of the type described, which has a specific gravity of 1.32 at 60°C (below 60°C).

Although an elongated housing 122 of generally rectangular cross-section is illustrated above, batteries of the present invention may be constructed in a variety of configurations including substantially self-supporting lead electrodes having a purity of less than 99.9% lead by weight. It can be appreciated that the housing can be formed with a housing.

7.62αX4.45αXi, 274(3"×1-3/
An exemplary embodiment battery having physical dimensions on the order of 4" x 1/2"'j was capable of providing 1.6 amp hours of current at a nominal 2 volt rating.

8.89a+X3.81CmX1.59a1 (3-1
A battery 120 having physical dimensions on the order of /2"xl-1/2" x 5/8") was capable of providing 1.5 amp hours of current at a nominal 2 volt rating.

From the above description, it will be appreciated that various changes and modifications may be made without departing from the spirit and scope of the novel concept of the invention. It must be understood that nothing is intended or anticipated to limit the invention to the particular devices shown. It is, of course, intended that the invention, by virtue of the limitations of the claims, encompass all modifications that come within the scope of these claims.

[Effects of the Invention] Since the present invention is configured as described above, it is not necessary to have a housing sealed to contain the R electrode, electrolyte, and minute device, unlike the conventional ones, and it is easy to reuse. It is possible to provide an electrically powered unit that provides the convenience of a rechargeable battery, but with less cost.

[Brief explanation of the drawing]

FIG. 1 is a perspective view of a combined emergency light and night light electrically energized unit according to the present invention. FIG. 2 is a perspective view, partially cut away, showing the control switch and the relationship of the electric light to the flange of the unit of FIG. 1; FIG. 3 is a partially cutaway end view of FIG. 2; 4 is a top plan view of the housing of the unit of FIG. 1; FIG. FIG. 5 is a cross-sectional view taken along plane 5--5 of FIG. 4. FIG. 6 is a cross-sectional view taken along plane 6-6 of FIG. 4. FIG. 7 is a cross-sectional view taken along plane 7-7 of FIG. 4. 8 is a schematic diagram of an electrical control circuit usable with the unit of FIG. 1; FIG. FIG. 9 is a side view of the stand along the battery according to the present invention. FIG. 10 is an end view of the stand along the battery of FIG. 9. FIG. 11 is a top view of the stand along the battery of FIG. 9. FIG. 12 is a cross-sectional view taken along plane 12-12 of FIG. 9. FIG. 13 is a cross-sectional view taken along plane 13-13 of FIG. 9. FIG. 14 is a cross-sectional view taken along plane 14--14 of FIG. 9. 15 is a cross-sectional view taken along plane 15-15 of FIG. 9. FIG. 10...Electrical unit 12.122...Housing 14...Lens 16a...Light sensor 20...Manual operation switch 22. ...Standard AC power socket 26...
-Reflector 28...Light or electric light 32...Non-replaceable light bulb 36...Electrical connection extension 38...Printed circuit board 38a. ...Circuit 40.140 ...Internal area 42.120 ...Battery 50 ...Flange 52.130 ...Cover member 56.136. ... Ventilation section 5B, 138a ... Cylindrical boat 60 ...
...Cap 66a, 66b...Terminal 70.150.
...Negative electrode 72...Minimum layer 74.152...Positive electrode 90...Automatic night light energizing part 92a, 92t), 92C--・-Resistance 94・・・・
Silicon-controlled rectifier 94a...Gate input conductor 96...Second part 9 for recharging of circuit 38a
8a, 98b... Rectifier diode 100...
. . . Power limiting resistor 102 . . . Last portion 104a, 104b sensing the absence of power supply of circuit 38a . . . Switching transistor-1
06a, 106b, 106cm---Resistance 138
a, 138b...Terminal 142...
・Epoxy material 154--- Separation device

Claims (10)

[Claims] (1) a housing bounding a zone; a battery integrally formed in at least a portion of the zone; and a battery supported by the housing to perform a predetermined function; and a device connectable to selectively energize the battery. 2. The electrically energized unit of claim 1, wherein said battery has a case formed in part by said housing. 3. The electrically energized unit of claim 2, wherein said battery includes a folded electrode having a generally U-shaped cross section. 4. The electrically powered unit of claim 2, wherein said integrally formed battery is rechargeable. 5. The electrically powered unit of claim 4, including a device for selectively recharging said battery. (6) The unit is rechargeable from an external energy source, and the unit includes first and second rigid conductive members supported by the housing and for connecting to the external energy source. The electrically energized unit according to item 5. (7) the battery is partially surrounded by a portion of the housing and partially surrounded by a selectively shaped cover member secured to the portion, thereby defining a volume accommodating the battery; An electrically energized unit as claimed in claim 1, adapted to. (8) the battery is partially surrounded by a portion of the housing and partially surrounded by a selectively shaped cover member secured to the portion, thereby defining a volume accommodating the battery; 7. An electrically energized unit as claimed in claim 6, adapted to. 9. The electrically energized battery of claim 6, further comprising a device supported by the battery for venting the volume housing the battery in response to a sensed predetermined internal pressure. unit. 10. The electrically powered unit of claim 9, wherein said venting device is reclosable in response to a selected drop in pressure within said volume.