Filling pod for a battery, vehicle and method of supplying...

Fluid handling – Processes

Reexamination Certificate

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Details

C137S260000, C429S063000, C429S073000, C429S074000

Reexamination Certificate

active

06622744

ABSTRACT:

FIELD OF THE INVENTION
The present invention relates to liquid electrolyte batteries and, more particularly, to a filling pod and a method for supplying fluid to such a battery.
BACKGROUND OF THE INVENTION
A typical liquid electrolyte battery, such as a lead acid battery, includes a plurality of battery cells, each cell including at least one electrode submergible in the liquid electrolyte fluid. For example, a conventional 12-volt battery includes six 2-volt cells. Different battery applications may require different battery configurations. The battery also includes a battery housing having a cover portion substantially enclosing the battery cells and defining a cell port communicating with each of the cells and through which liquid electrolyte fluid is suppliable to the cell.
For optimal battery performance, each electrode is preferably completely submerged in the liquid electrolyte fluid, promoting a maximum degree of electricity-generating electrochemical reaction within each cell of the battery. However, electrolyte fluid is lost from each cell due to outgassing, which occurs during charging of the battery. To maintain the optimal level of battery performance and to maximize the service life of the battery, the electrolyte level in the battery must be regularly checked, and, if the electrolyte level is below the desired level, water must be added to replenish the electrolyte fluid. Accordingly, the electrolyte level in the battery is monitored and adjusted after charging of the battery.
In some constructions, the battery includes a vent cap member to close each cell port. To replenish the electrolyte fluid in the battery, the vent cap is removed from each cell, and electrolyte fluid is supplied to each cell separately through the individual cell ports. The vent caps are then replaced.
In some other constructions, a separate filling device is provided for each cell in the battery. A filling device may replace each conventional vent cap, and the separate filling devices are connected by flexible conduits to a fluid source so that fluid may be supplied to each filling device and to the corresponding cell. Such filling devices are disclosed in U.S. Pat. Nos. 1,791,152; 1,878,223; 4,353,968; 4,424,263; and 4,522,896 and in published PCT Application No. WO 98/40653.
In yet other constructions, a series of filling devices are constructed integrally with the battery or with the battery cover. Such constructions are illustrated in U.S. Pat. No. 3,722,087 and in published PCT Application No. WO 98/40653.
Battery-powered vehicles, such as for example, golf carts and utility vehicles, require periodic charging and replenishment of liquid electrolyte in the batteries. In most cases, the individual cells are replenished one at a time, for example, by an operator using a “watering gun”, a water hose or a cup. In typical filling circuits, the filling circuits and procedures require connection of the circuit to a fluid source, either pressurized or in a vacuum arrangement, the source being located off board the vehicle. Flow of fluid through the circuit is caused by pressurized supply fluid or a vacuum applied to the filling circuit.
SUMMARY OF THE INVENTION
One problem with the above-described battery including conventional vent cap members is that, because the battery is typically supported on a battery-powered vehicle or device in a position which does not permit easy access to the battery, it is difficult to monitor the electrolyte level and to replenish the electrolyte fluid in each cell of the battery. Also, for a multiple cell battery, it is inconvenient and time consuming to remove each vent cap, check the electrolyte level in the cell, replenish the electrolyte fluid in the cell, as necessary, and replace the vent cap. Because these replenishment operations are difficult and time consuming, an operator may not replenish the electrolyte level as often as necessary, reducing the performance and service life of the battery.
One problem with the above-described separate filling devices is that the junction between the separate filling devices and the separate conduits provide areas in which leaks or blockages may occur. Also, the flexible conduit used to connect such separate filling devices is subject to being damaged or pinched, possibly preventing the flow of electrolyte to the separate filling devices and to the associated battery cell. In addition, installation of the separate filling devices and proper connection of the flexible conduits between the separate filling devices is inconvenient and time consuming. Further, because of the difficult-to-access position of these filling devices on the vehicle, an operator may not conduct the necessary maintenance to ensure proper operation of the filling devices and of the connecting conduits.
One problem with the above-described filling devices which are constructed integrally with the battery and/or with the battery cover is that such devices are not usable with existing batteries as a substitute for the separate vent caps or for the separate filling devices. Instead, a new battery including such integral filling devices is required to implement such a fluid replenishment system.
The present invention provides a filling pod, a vehicle and a method of supplying fluid to a battery which substantially alleviate the problems with the above-described batteries and filling devices. More particularly, the present invention provides a filling pod for supplying fluid to a battery and having a fluid supply member for each cell and a channel in fluid communication between each fluid supply member and a fluid source. In some constructions, the filling pod is configured to be removably mounted on the cover portion of an existing battery.
In particular, the present invention provides a filling pod including a filling pod housing having a filling pod port fluidly connectable to a fluid source for receiving fluid from the fluid source, a first fluid supply member fluidly connectable to a first cell, a second fluid supply member fluidly connectable to a second cell, and an integral channel in fluid communication between the filling pod port, the first fluid supply member and the second fluid supply member. The channel includes a first channel portion in fluid communication between the filling pod port and the first fluid supply member and a second channel portion in fluid communication between the filling pod port and the second fluid supply member. When fluid is supplied to the filling pod through the filling pod port, a first amount of fluid flows through the first channel portion to the first fluid supply member and to the first cell, and a second amount of fluid flows through the second channel portion to the second fluid supply member and to the second cell.
Preferably, the channel fluidly connects the filling pod port, the first fluid supply member and the second fluid supply member in series. The first channel portion may extend between the filling pod port and the first fluid supply member, and the second channel member may extend between the first fluid supply member and the second fluid supply member and fluidly connect the filling pod port to the second fluid supply member. Also, the channel may fluidly connect the filling pod port, the first fluid supply member and the second fluid supply member such that, when fluid is supplied through the filling pod port, the first amount of fluid flows through the first fluid supply member and to the first cell before the second amount of fluid flows to the second fluid supply member and to the second cell.
Preferably, the filling pod housing further defines a second filling pod port through which fluid flows from the filling pod. The channel may fluidly connect the first filling pod port, the first fluid supply member, the second fluid supply member and the second filling pod port in series, and the second filling pod port may be fluidly connected to the fluid source to supply any excess amount of fluid from the filling pod to the fluid source.
Preferably, the first filling pod port and the second fi

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