(19) United States
`(12) Patent Application Publication (10) Pub. No.: US 2010/0173182 A1
`(43) Pub. Date:
`Jul. 8, 2010
`Baxter et al.
`
`US 20100173182A1
`
`(54) LOW-VOLTAGE CONNECTION WITH
`SAFETY CIRCUIT AND METHOD FOR
`DETERMINING PROPER CONNECTION
`POLARITY
`
`(76) Inventors:
`
`Michael Baxter, Hillsboro, OR
`(US); Mark Walker, Hillsboro, OR
`(US)
`Correspondence Address:
`Michael F. Krieger
`Kirton & McConkie
`60 East South Temple, Suite 1800
`Salt Lake City, UT 84111 (US)
`
`(21) Appl. No.:
`
`12/731,041
`
`(22) Filed:
`
`Mar. 24, 2010
`
`Related U.S. Application Data
`(63) Continuation-in-part of application No. 12/559,357,
`filed on Sep. 14, 2009.
`(60) Provisional application No. 61/175,696, filed on May
`5, 2009, provisional application No. 61/118,511, filed
`on Nov. 28, 2008.
`
`Publication Classification
`
`(51) Int. Cl.
`(2006.01)
`HO2H 7/8
`(2006.01)
`HO2H 9/02
`(2006.01)
`HO2H 3/04
`(2006.01)
`HOLM 2/00
`(52) U.S. Cl. ........................... 429/61; 361/101: 361/93.9
`(57)
`ABSTRACT
`A safety circuit for use in low-voltage systems improves
`safety of and additional features to low-voltage connections.
`When incorporated into a battery, the circuit leaves the battery
`disconnected from the low-voltage system until it determines
`that it is safe to make a connection. When the safety circuit
`determines that no unsafe conditions exist and that it is safe to
`connect the battery, the safety circuit may connect the battery
`by way of a “soft start” that provides a connection over a
`period of time that reduces or prevents inductive Voltage
`spikes on the low-voltage system. A method is used for detec
`tion of properpolarity of the connections between the battery
`and the low-voltage system. When incorporated into a jumper
`cable, the safety circuit provides communication abilities,
`can provide testabilities, and improves connection safety and
`functionality, such as allowing transfer of power between
`low-voltage systems having different Voltages.
`
`S.
`S V S Š
`
`SS SS
`
`
`
`10
`
`
`
`
`
`S&
`
`Š sy
`
`16
`
`NOCO Ex. 1006
`Page 1
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`

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`Patent Application Publication
`
`Jul. 8, 2010 Sheet 1 of 27
`
`US 2010/0173182 A1
`
`
`
`& Š Š SS Š
`
`s Š
`
`Nses - 4
`. an S
`
`
`
`
`
`16
`
`FIG. 1
`
`NOCO Ex. 1006
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`Patent Application Publication
`
`Jul. 8, 2010 Sheet 2 of 27
`
`US 2010/0173182 A1
`
`
`
`Detection Circuitry &
`Power Supply
`
`24
`
`POWer
`TransistOr
`
`LOgic Or
`miCrOCOntroller
`
`FIG 2
`
`NOCO Ex. 1006
`Page 3
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`Jul. 8, 2010 Sheet 3 of 27
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`US 2010/0173182 A1
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`NOCO Ex. 1006
`Page 4
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`

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`Patent Application Publication
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`Jul. 8, 2010 Sheet 4 of 27
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`US 2010/0173182 A1
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`40
`
`38
`
`36
`
`FIG. 4
`
`NOCO Ex. 1006
`Page 5
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`Patent Application Publication
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`Jul. 8, 2010 Sheet 5 of 27
`
`US 2010/0173182 A1
`
`46 1
`
`
`
`
`
`
`
`42
`
`
`
`(A test
`NL/ current
`
`SOUECS
`
`- - - Dead
`- Battery
`
`Other electrical
`loads
`
`Single test current direction
`
`FIG. 5
`
`NOCO Ex. 1006
`Page 6
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`

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`Patent Application Publication
`
`Jul. 8, 2010 Sheet 6 of 27
`
`US 2010/0173182 A1
`
`bi-
`| directional
`current
`& Ksource
`
`
`
`
`
`
`
`48
`
`44
`
`- E - Dead
`Battery
`
`~.
`| Other system
`loads
`
`Bi-directional test citient direction
`
`FIG. 6
`
`NOCO Ex. 1006
`Page 7
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`Patent Application Publication
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`Jul. 8, 2010 Sheet 7 of 27
`
`US 2010/0173182 A1
`
`
`
`
`
`
`
`
`
`– – – – – – – – – – – – – + – – – i
`
`- - - - - - - - - - - - -
`
`*** • • • •
`
`TTTT
`
`
`
`
`
`
`
`
`
`NOCO Ex. 1006
`Page 8
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`

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`Patent Application Publication
`
`Jul. 8, 2010 Sheet 8 of 27
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`US 2010/0173182 A1
`
`
`
`Negative Cable A
`
`FIG. 8
`
`9
`g
`
`5
`
`GND SOkder Pa
`
`NOCO Ex. 1006
`Page 9
`
`

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`Patent Application Publication
`
`Jul. 8, 2010 Sheet 9 of 27
`
`US 2010/0173182 A1
`
`CABLE A
`
`WOO
`
`WSS
`
`RAAN
`RA1AN
`RA2AN2
`RC5 FRCOAN4
`RC4
`RC 8
`RC3
`RC2
`PC6F676
`
`
`
`FIG. 9
`
`
`
`NOCO Ex. 1006
`Page 10
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`

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`Patent Application Publication
`
`Jul. 8, 2010 Sheet 10 of 27
`
`US 2010/0173182 A1
`
`
`
`sfet TurnON
`
`PC87D
`
`FIG 10
`
`NOCO Ex. 1006
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`

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`Patent Application Publication
`
`Jul. 8, 2010 Sheet 11 of 27
`
`US 2010/0173182 A1
`
`2
`
`
`
`s
`
`U
`
`Positive Cable B
`
`Negative Cable B
`
`FIG 11
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`NOCO Ex. 1006
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`Patent Application Publication
`
`Jul. 8, 2010 Sheet 12 of 27
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`US 2010/0173182 A1
`
`
`
`
`
`s
`s
`i
`
`Y
`
`ei
`3
`
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`3.
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`ONEOES
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`- R
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`
`VN
`
`3
`CD
`N |
`
`55g
`
`NOCO Ex. 1006
`Page 13
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`

`

`Patent Application Publication
`
`Jul. 8, 2010 Sheet 13 of 27
`
`US 2010/0173182 A1
`
`Start-Attach at least one pair of clamps at +6V
`Or Ore
`
`62
`
`64
`
`Return LOCation
`13A
`
`66
`
`yes
`
`GO to
`Fig. 16
`
`?
`
`O
`
`yeS
`
`e yeS
`
`7O
`
`Batteries Connected to both ends?
`
`O
`
`Connect power systems
`
`
`
`TOO much Current flow?
`
`
`
`
`
`
`
`GO to
`Fig. 15
`
`Return LOCation
`13B
`72
`
`74
`
`76
`
`78
`
`At least 10A flowing?
`
`8O
`
`Disconnect power systems
`
`FIG. 13
`
`NOCO Ex. 1006
`Page 14
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`

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`Patent Application Publication
`
`Jul. 8, 2010 Sheet 14 of 27
`
`US 2010/0173182 A1
`
`82
`
`84
`
`88
`
`
`
`
`
`90
`
`92
`
`98
`
`From
`Fig. 13
`
`Which cable is low voltage?
`86
`Cable A
`Turn on Cable A's red LEDS
`
`Cable B
`
`Turn on Cable B's red LEDS
`
`Slower voltage clamp below -2.5V:
`
`yes
`
`Go to Fig. 13,
`LOCation 13A
`
`O
`FOW 5A
`
`Any noise associated with short?
`
`yes
`
`Turn Off 5A
`
`O
`
`96
`
`Turn Off all red LEDS
`
`94
`
`Both pairs of clamps above 2.5V?
`
`O
`
`102
`
`Go to Fig. 13,
`Location 13A
`
`Turn Off 5A
`
`100
`yeS
`
`Turn Off all red LEDS
`
`Go to Fig. 13,
`LOCation 13B
`
`FIG. 14
`
`NOCO Ex. 1006
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`

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`Patent Application Publication
`
`Jul. 8, 2010 Sheet 15 of 27
`
`US 2010/0173182 A1
`
`Fig. 13
`
`104
`
`Turn off logo LED
`
`106
`
`Turn On all red LEDS
`
`108
`
`Disconnect power systems
`
`110
`
`Reset power connect
`
`112
`
`114
`
`Wait for Several Seconds to COO
`transistors
`
`Turn on logo LED
`
`116
`
`Turn Off all red LEDS
`
`Go to Fig. 13,
`LOCation 13A
`
`FIG. 15
`
`NOCO Ex. 1006
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`

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`Patent Application Publication
`
`Jul. 8, 2010 Sheet 16 of 27
`
`US 2010/0173182 A1
`
`From
`Fig. 13
`
`118
`
`Wait
`
`120
`
`Cables A and B ClOSe to 13V?
`
`122
`
`124
`
`yes
`
`Store Channel A and B
`difference Offset
`
`Turn on logo LED
`
`126
`
`Turn On all red LEDS
`
`Go to Fig. 13,
`LOCation 13A
`
`FIG. 16
`
`NOCO Ex. 1006
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`Patent Application Publication
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`Jul. 8, 2010 Sheet 17 of 27
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`US 2010/0173182 A1
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`Interrupt
`
`Demand for LED lights?
`
`yes
`ls the Blight on?
`
`Turn Blight off
`
`ls the A light on?
`
`1 28
`O
`
`30
`
`32
`1
`
`13 6
`
`
`
`8 13
`
`
`
`
`
`Turn Blight on
`
`Turn Alight off
`
`Turn A light on
`
`O
`
`Demand for 5 amps?
`
`yeS
`S 5A transistor Over
`power dissipation limit2
`yes
`Turn 5A transistor Off
`
`O
`
`Demand for main transistors?
`
`yeS
`Are main transistorS OWe
`OWer dissipation limits 2
`
`Turn main transistOrS Off
`
`142
`
`144
`
`148
`
`Leave 5A transistor On
`
`150
`
`152
`
`O
`
`Return from interrupt
`
`FIG. 1 7
`
`NOCO Ex. 1006
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`Patent Application Publication
`
`Jul. 8, 2010 Sheet 18 of 27
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`US 2010/0173182 A1
`
`
`
`FIG. 18
`
`NOCO Ex. 1006
`Page 19
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`Patent Application Publication
`
`Jul. 8, 2010 Sheet 19 of 27
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`US 2010/0173182 A1
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`
`
`NOCO Ex. 1006
`Page 20
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`

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`Patent Application Publication
`
`Jul. 8, 2010 Sheet 20 of 27
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`US 2010/0173182 A1
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`NOCO Ex. 1006
`Page 21
`
`

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`Patent Application Publication
`
`Jul. 8, 2010 Sheet 21 of 27
`
`US 2010/0173182 A1
`
`
`
`
`
`WIKIŠ?III, ?I?
`
`NOCO Ex. 1006
`Page 22
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`

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`Patent Application Publication
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`US 2010/0173182 A1
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`
`
`NOCO Ex. 1006
`Page 23
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`

`

`Patent Application Publication
`
`Jul. 8, 2010 Sheet 23 of 27
`
`US 2010/0173182 A1
`
`SSSS
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`
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`EFS
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`
`rii
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`NS
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`SS
`
`FIG. 23
`
`NOCO Ex. 1006
`Page 24
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`

`

`Patent Application Publication
`
`Jul. 8, 2010 Sheet 24 of 27
`
`US 2010/0173182 A1
`
`site:ASDM
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`E.
`N is
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`p5A
`six as Sist3ASEs
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`WUD
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`FIG. 24
`
`NOCO Ex. 1006
`Page 25
`
`

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`Patent Application Publication
`
`Jul. 8, 2010 Sheet 25 of 27
`
`US 2010/0173182 A1
`
`
`
`.
`
`f
`
`Rat
`R
`
`ft3.
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`
`FIG. 25
`
`NOCO Ex. 1006
`Page 26
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`

`

`Patent Application Publication
`
`Jul. 8, 2010 Sheet 26 of 27
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`US 2010/0173182 A1
`
`
`
`WN
`
`-ve
`
`LVEN.
`
`i
`
`.
`
`fia
`SS
`
`NOCO Ex. 1006
`Page 27
`
`

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`Patent Application Publication
`
`Jul. 8, 2010 Sheet 27 of 27
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`US 2010/0173182 A1
`
`
`
`FIG. 27
`
`NOCO Ex. 1006
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`US 2010/01 73182 A1
`
`Jul. 8, 2010
`
`LOW-VOLTAGE CONNECTION WITH
`SAFETY CIRCUIT AND METHOD FOR
`DETERMINING PROPER CONNECTION
`POLARITY
`
`CROSS-REFERENCE TO RELATED
`APPLICATIONS
`0001. This application is a continuation-in-part of prior
`application Ser. No. 12/559,357, filed Sep. 14, 2009, which
`claims the benefit of U.S. Provisional Application No.
`61/175,696, filed May 5, 2009, and U.S. Provisional Appli
`cation No. 61/118,511, filed Nov. 28, 2008, which applica
`tions are incorporated herein by reference in their entireties
`for all purposes.
`
`BACKGROUND OF THE INVENTION
`
`0002 1. Field of the Invention
`0003. The present invention relates to batteries and, more
`particularly, to batteries providing certain safety features.
`0004 2. Background and Related Art
`0005 Cables such as jumper cables are commonly used to
`connect two low-voltage (e.g. battery-powered) systems tem
`porarily. However, the use of such cables can result in per
`Sonal injury and equipment damage. For example, one
`instance where equipment damage or personal injury occurs
`is in the case of jump starting a car with a "dead' (i.e. par
`tially- or totally-discharged) battery using a car with a good
`battery. During connection of jumper cables to jump start the
`car with the discharged battery, a spark may be created, and if
`the spark is in the vicinity of hydrogen gas commonly gener
`ated by car batteries, the spark can ignite the hydrogen gas to
`explosive effect. Additionally, as the connection is made
`between vehicles, inductive Voltage spikes may be formed,
`and the Voltage spikes can damage sensitive automotive elec
`tronics, including expensive computer-controlled engine
`control components and the like. Additionally, connecting a
`jumper cable set backward (i.e. with polarity of one of the
`battery connections reversed) can also cause injury or dam
`age.
`0006 Similar problems can be encountered when replac
`ing a battery in a battery-containing low-voltage system. For
`example, a battery that is improperly connected (e.g. a battery
`connected with reverse polarity, a battery connected to a
`system having an intermittent or long-term short circuit, etc.)
`can cause equipment damage or injury.
`
`BRIEF SUMMARY OF THE INVENTION
`0007 Implementation of the invention provides a safety
`circuit for use in low-voltage systems that improves safety of
`and provides additional features to low-voltage connections.
`When incorporated into a battery, the circuit leaves the battery
`disconnected from the low-voltage system until it determines
`that it is safe to make a connection. When the safety circuit
`determines that no unsafe conditions exist and that it is safe to
`connect the battery, the safety circuit may connect the battery
`by way of a “soft start” that provides a connection over a
`period of time that reduces or prevents inductive Voltage
`spikes on the low-voltage system. A method is used for detec
`tion of properpolarity of the connections between the battery
`and the low-voltage system. When incorporated into a jumper
`cable, the safety circuit provides communication abilities,
`can provide testabilities, and improves connection safety and
`
`functionality, such as allowing transfer of power between
`low-voltage systems having different Voltages.
`0008 Implementation of the invention provides a battery
`integrated connection between a battery and a low-voltage
`system that includes a safety circuit. The safety circuit leaves
`the low-voltage system disconnected until it determines that it
`is safe to make a connection. If the safety circuit detects an
`unsafe condition, it responds to the unsafe condition in one or
`more of several fashions. In some instances, the safety circuit
`can internally reverse connection polarity to correct for incor
`rect connections to the low-voltage system of a reversed
`polarity type. In some instances, the safety circuit provides an
`audible and/or visible alarm identifying a potential problem.
`In some instances, the safety circuit refuses to make a con
`nection to the low-voltage system while an unsafe condition
`exists.
`0009. When the safety circuit determines that no unsafe
`conditions exist and that it is safe to connect or power the
`low-voltage system, the safety circuit may connect the system
`by way of a “soft start.” The soft start provides a connection
`between the two systems that is not instantaneous, but is
`instead provided over a period of time. Such as approximately
`a millisecond to tens of milliseconds, that reduces or prevents
`inductive Voltage spikes on the low-voltage system. The soft
`start procedure reduces and/or prevents damage to sensitive
`low-voltage electronics forming a part of the low-voltage
`system.
`0010 Some implementations of the invention utilize one
`or more high-current transistors as a Switch to connect the two
`low-voltage systems. The one or more transistors are con
`trolled by the safety circuit or control circuit that detects the
`condition at each end of the connection cable or cables. In
`other implementations providing automatic correction of
`attempted reversed-polarity connections, additional compo
`nents are used to provide additional convenience. While such
`implementations provide no additional safety benefit over
`implementations not providing automatic polarity reversal as
`the connection is not completed when a reversed polarity is
`detected, the added convenience of not requiring manual
`polarity correction may justify the added component cost in
`Some instances.
`
`BRIEF DESCRIPTION OF THE SEVERAL
`VIEWS OF THE DRAWINGS
`0011. The objects and features of the present invention
`will become more fully apparent from the following descrip
`tion and appended claims, taken in conjunction with the
`accompanying drawings. Understanding that these drawings
`depict only typical embodiments of the invention and are,
`therefore, not to be considered limiting of its scope, the inven
`tion will be described and explained with additional specific
`ity and detail through the use of the accompanying drawings
`in which:
`0012 FIG. 1 shows a perspective view of a jumper cable
`embodiment;
`0013 FIG. 2 shows a schematic illustrating concepts in
`accordance with embodiments of the invention;
`0014 FIG. 3 shows a perspective view of a representative
`circuit board in accordance with embodiments of the inven
`tion;
`0015 FIG. 4 shows a generalized circuit schematic repre
`sentative of a discharged car battery in a car;
`0016 FIG. 5 shows a representative schematic showing
`one method for testing a battery for proper polarity;
`
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`US 2010/01 73182 A1
`
`Jul. 8, 2010
`
`0017 FIG. 6 shows a representative schematic showing
`another method for testing a battery for proper polarity;
`0018 FIG. 7 shows a representative circuit diagram for
`use in embodiments of the invention;
`0019 FIGS. 8-12 show expanded views of portions of the
`circuit diagram shown in FIG. 7:
`0020 FIGS. 9-17 show flow charts illustrating processes
`that may be implemented in the circuit of FIGS. 7-12;
`0021
`FIG. 18 shows one example of a battery incorporat
`ing protection circuitry;
`0022 FIGS. 19-20 show overview views of a representa
`tive circuit diagram for use in embodiments of the invention;
`and
`0023 FIGS. 21-27 show expanded views of portions of the
`representative circuit of FIGS. 19-20 with representative
`component values added for clarity.
`
`DETAILED DESCRIPTION OF THE INVENTION
`0024. A description of embodiments of the present inven
`tion will now be given with reference to the Figures. It is
`expected that the present invention may take many other
`forms and shapes, hence the following disclosure is intended
`to be illustrative and not limiting, and the scope of the inven
`tion should be determined by reference to the appended
`claims.
`0025 Embodiments of the invention provide a safety cir
`cuit for use in low-voltage systems that improves safety of
`and provides additional features to low-voltage connections.
`When incorporated into a battery, the circuit leaves the battery
`disconnected from the low-voltage system until it determines
`that it is safe to make a connection. When the safety circuit
`determines that no unsafe conditions exist and that it is safe to
`connect the battery, the safety circuit may connect the battery
`by way of a “soft start” that provides a connection over a
`period of time that reduces or prevents inductive Voltage
`spikes on the low-voltage system. A method is used for detec
`tion of properpolarity of the connections between the battery
`and the low-voltage system. When incorporated into a jumper
`cable, the safety circuit provides communication abilities,
`can provide testabilities, and improves connection safety and
`functionality, Such as allowing transfer of power between
`low-voltage systems having different Voltages.
`0026. Embodiments of the invention provide a battery
`integrated connection between a battery and a low-voltage
`system that includes a safety circuit. The safety circuit leaves
`the low-voltage system disconnected until it determines that it
`is safe to make a connection. If the safety circuit detects an
`unsafe condition, it responds to the unsafe condition in one or
`more of several fashions. In some instances, the safety circuit
`can internally reverse connection polarity to correct for incor
`rect connections to the low-voltage system of a reversed
`polarity type. In some instances, the safety circuit provides an
`audible and/or visible alarm identifying a potential problem.
`In some instances, the safety circuit refuses to make a con
`nection to the low-voltage system while an unsafe condition
`exists.
`0027. When the safety circuit determines that no unsafe
`conditions exist and that it is safe to connect or power the
`low-voltage system, the safety circuit may connect the system
`by way of a “soft start.” The soft start provides a connection
`between the two systems that is not instantaneous, but is
`instead provided over a period of time. Such as approximately
`a millisecond to tens of milliseconds, that reduces or prevents
`inductive Voltage spikes on the low-voltage system. The soft
`
`start procedure reduces and/or prevents damage to sensitive
`low-voltage electronics forming a part of the low-voltage
`system.
`0028. Some embodiments of the invention utilize one or
`more high-current transistors as a Switch to connect the two
`low-voltage systems. The one or more transistors are con
`trolled by the safety circuit or control circuit that detects the
`condition at each end of the connection cable or cables. In
`other embodiments providing automatic correction of
`attempted reversed-polarity connections, additional compo
`nents are used to provide additional convenience. While such
`embodiments provide no additional safety benefit over
`embodiments not providing automatic polarity reversal as the
`connection is not completed when a reversed polarity is
`detected, the added convenience of not requiring manual
`polarity correction may justify the added component cost in
`Some instances.
`0029. An embodiment of the invention includes a battery
`integrated safety circuit for use in establishing that a low
`Voltage system is safely and properly connected to a battery.
`The safety circuit includes a pair of output terminals, a detec
`tion circuit operatively connected to the output terminals and
`configured to detect whether the output terminals are properly
`connected to a low-voltage system with a correct polarity, and
`a power-controlling circuit configured to provide electrical
`power to the output terminals only when a proper connection
`of correct polarity has been detected.
`0030. In some embodiments, the power-controlling circuit
`provides electrical power to the output terminals using a soft
`start procedure that reduces inductive Voltage spikes. As one
`example, the power-controlling circuit may control one or
`more power transistors that are used to provide electrical
`power to the output terminals using the Soft start procedure.
`The soft start procedure provides electrical power to the out
`put terminal over a period of approximately a millisecond to
`tens of milliseconds.
`0031. A battery-integrated safety circuit may also include
`a polarity test circuit configured to Supply a test current to the
`output terminals and measure a resulting Voltage to determine
`a proper polarity of a low-voltage system connected to the
`output terminals. The polarity test circuit may be configured
`to Supply test currents of different directions and to compare
`the Voltages caused by the test currents.
`0032. Another embodiment of the invention provides a
`battery containing a battery-integrated safety circuit, the bat
`tery having a positive terminal, a negative terminal, and a
`safety circuit operatively connected to the positive terminal
`and the negative terminal and configured to Supply power
`through the positive and negative terminals only when a con
`nection between the terminals and a low-voltage system has
`been properly made with a correct polarity. The battery may
`prevent the Supply of power to the positive and negative
`terminals when a short circuit exists between the positive and
`negative terminals. The safety circuit may include a polarity
`test circuit configured to Supply a test current to the terminals
`and measure a resulting Voltage to determine a properpolarity
`of a low-voltage system connected to the battery. The safety
`circuit may also include a detection circuit operatively con
`nected to the terminals and configured to detect whether the
`terminals are connected to the low-voltage system with the
`correct polarity, and a power-controlling circuit configured to
`provide electrical power to the terminals.
`0033. Another embodiment encompasses a battery having
`an energy storage cell, a pair of output terminals, and a safety
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`circuit electrically connected to the energy storage cell. The
`safety circuit includes a detection circuit operatively con
`nected to the output terminals for detecting whether the out
`put terminals are properly connected to a low-voltage system
`with a correct polarity of connection, and a power-controlling
`circuit configured to Supply power from the energy storage
`cell to the output terminals only when a proper connection of
`correct polarity has been detected.
`0034. Other embodiments of the invention illustrating fea
`tures of the battery-incorporated safety circuits provide a
`connecting cable or cables (such as jumper cables) between
`two low-voltage systems (such as batteries, battery-powered
`systems, or low-voltage systems incorporating one or more
`batteries) that includes a safety circuit. The safety circuit
`leaves the two low-voltage systems disconnected until it
`determines that it is safe to make a connection. If the safety
`circuit detects an unsafe condition, it responds to the unsafe
`condition in one or more of several fashions. In some
`instances, the safety circuit can internally reverse connection
`polarity to correct for incorrect connections between low
`Voltage systems of a reversed-polarity type. In some
`instances, the safety circuit provides an audible and/or visible
`alarm identifying a potential problem. In some instances, the
`safety circuit refuses to make a connection between the two
`low-voltage systems while an unsafe condition exists.
`0035. When the safety circuit determines that no unsafe
`conditions exist and that it is safe to connect the two low
`Voltage systems, the safety circuit may connect the two sys
`tems by way of a “soft start.” The soft start provides a con
`nection between the two systems that is not instantaneous, but
`is instead provided over a period of time, such as approxi
`mately a millisecond to tens of milliseconds, that reduces or
`prevents inductive Voltage spikes on one or more of the low
`Voltage systems. The Soft start procedure reduces and/or pre
`vents damage to sensitive low-voltage electronics forming a
`part of one or more of the low-voltage systems.
`0.036 Some embodiments of the invention utilize two
`high-current transistors as a Switch to connect the two low
`Voltage systems. The transistors are controlled by the safety
`circuit or control circuit that detects the condition at each end
`of the connection cable or cables. In other embodiments
`providing automatic correction of attempted reversed-polar
`ity connections, additional components are used to provide
`additional convenience. While such embodiments provide no
`additional safety benefit over embodiments not providing
`automatic polarity reversal as the connection is not completed
`when a reversed polarity is detected, the added convenience
`of not requiring manual polarity correction may justify the
`added component cost in Some instances.
`0037. In some embodiments, inexpensive transistors may
`be used, and the safety circuit or control circuit incorporates
`features to protect the transistors from potential damage. For
`example, the safety or control circuit may maintain a thermal
`model of the transistors and may turn the transistors off and
`on to protect the transistors against failure. Additionally, the
`safety or control circuit may monitor for over-current condi
`tions that could destroy the transistors in short periods of
`time, and could turn off the transistors when Such conditions
`are detected. Such types of protection/detection also may
`serve to protect components of one or more of the connected
`low-voltage systems, such as by preventing a starter motor
`from overheating due to excessive cranking. The safety or
`control circuit may also monitor for under-Voltage conditions
`on the transistor Supply side, to prevent the transistors from
`
`entering a non-fully-on state that would cause increased heat
`ing and damage to the transistors.
`0038. As it may be desirable to connect two low-voltage
`systems in an instance where one of the low-voltage systems
`has a completely-discharged battery incorporated into it,
`embodiments of the invention may utilize a method for detec
`tion of proper polarity of the connections between the low
`Voltage systems. Such a method is particularly useful when a
`voltage of one of the low-voltage systems is below a reliable
`detection threshold. The method may rely on nonlinear
`behavior of any discharged batteries in the low-voltage sys
`tem. The polarity of the discharged battery (and thus whether
`the connected cable is connected correctly) is determined by
`passing a small amount of current through it and determining
`whether a corresponding Voltage rise is observed (indicating
`a correct polarity connection) or not (indicating an incorrect
`polarity connection). In some embodiments, test currents can
`be applied in opposite polarities and the resulting measured
`Voltages compared to more reliably detect incorrect polarity
`connection and additional potential problem causes.
`0039 Similar methods may be used to discriminate
`between a short circuit condition (e.g. clamps touching) and a
`completely-discharged battery, and at least Some embodi
`ments may incorporate Such features. Embodiments may also
`be able to detect whether there are batteries connected to both
`ends of the circuit by biasing the Voltage at each connection to
`a Voltage unlikely to occur in the low-voltage systems, such as
`6.5 volts for a typical car battery system. If the voltage then
`varies from this value by a small amount in either direction, a
`battery is determined to be connected.
`0040 FIG. 1 provides a perspective view of a jumper cable
`set 10 incorporating features in accordance with embodi
`ments of the invention. The jumper cable set 10 includes a first
`pair of contact clamps 12 and a second pair of contact clamps
`14. When two low-voltage systems (e.g. systems commonly
`including one or more batteries) are to be connected, the first
`pair of contact clamps 12 and the second pair of contact
`clamps 14 are used to connect to high and low (e.g. high and
`ground) terminals of the two low-voltage systems, similar to
`the manner in which Such connections are commonly made
`with existing jumper cables. In automotive systems and other
`vehicles (boats, motorcycles, all-terrain vehicles (ATVs),
`etc.), the final connection is commonly made to a ground
`location away from any battery to minimize the risk of any
`spark igniting hydrogen gas off-gassed by the battery. While
`this final connection is used or recommended with embodi
`ments of the invention for maximum safety, such sparking is
`greatly reduced using embodiments of the invention, as no
`electrical connection is provided between the first pair of
`contact clamps 12 and the second pair of contact clamps 14
`until it has been determined that it is safe to do so.
`0041. The jumper cable set 10 includes a control box 16
`that provides one or more features including the features of
`testing the connections and of preventing any electrical con
`nection until it has been determined that it is safe to provide
`the electrical connection. Although the control box 16 is
`illustrated as being physically close to the first pair of contact
`clamps 12 in FIG. 1, it should be understood that the control
`box 16 can be located at any physical position along the
`jumper cable set 10 where it can control the electrical con
`nection between the two pairs of contact clamps 12, 14.
`Placing the control box 16 near one of the ends of the jumper
`cable set 10 may provide some benefits to a user of the jumper
`cable set 10, such as making it more intuitive to know which
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`end of the jumper cable set 10 has a problem by lighting an
`indicator on one side of the control box 16. It may also make
`it easier to see when the unit is powered (such as by a power
`on LED). It also keeps the control box 16 in a location less
`likely to be stepped on, tripped over, etc. Such a location
`makes it less likely for one of the two pairs of contact clamps
`12, 14 to be disturbed from their attachments to the battery by
`a user seeking to view the control box 16, and may assist in
`keeping the control box 16 out of water that may be on an
`underlying Surface.
`0042. The control box 16 includes a safety circuit that
`leaves the two low-voltage systems disconnected until the
`safety circuit determines that it is safe to make the connection.
`If the safety circuit determines that it is unsafe to proceed, it
`may sound an audible alarm or illuminate one or more warn
`ing lights on the control box 16 to identify any detected
`potential problem before the problem can cause damage or
`injury. In some embodiments, the selection of lights illumi
`nated or a physical and/or timed pattern of lights illuminated
`may indicate the type of problem detected. In other embodi
`ments, no alarm (visual or auditory) is provided; instead, the
`connection is simply not made.
`0043. When the safety circuit determines that it is safe to
`proceed, the safety circuit completes the connection between
`the two low-voltage systems smoothly in a soft start. The soft
`start prevents or minimizes inductive Voltage spikes that
`could damage sensitive electronics of the low-voltage sys
`tems (such as an automobile computer component). In some
`embodiments, as a connection is made, and audible and/or
`visual notification may be provided so the user becomes
`aware that the connection has been made. In the case of a
`vehicle having a discharged battery, the user can thus be
`notified that the vehicle can then be started.
`0044 FIG. 2 provides a diagram illustrating the concepts
`incorporated into one embodiment of a safety circuit 18 such
`as housed within the control box 16. The safety circuit 18
`includes input terminals 20 and output terminals 22 that are
`electrically connected to the first and second pairs of contact
`clamps 12, 14. The input terminals 20 and the output termi
`nals 22 are connected in this embodiment by way of one or
`more power transistors 24. The power transistor 24 (or tran
`sistors) are controlled by a logic circuit or mic