Direct current power supply

• US 20060208695A1
• Filed: 03/21/2006
• Published: 09/21/2006
• Est. Priority Date: 03/21/2005
• Status: Active Grant

• Current Assignee: Energizer Brands, LLC (Energizer Holdings, Inc.)
• Original Assignee: Eveready Battery Company Incorporated (Energizer Holdings, Inc.)
• Inventors: Gaber, Benny, Weinstein, Nir
• Granted Patent: US 7,489,105 B2
• Time in Patent Office: Days
• US Class Current: 320/110
• CPC Class Codes: H01M 10/425 Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing printed circuits H05K1/00
• CPC Class Codes: H01M 50/202 Casings or frames around the primary casing of a single cell or a single battery
• CPC Class Codes: H01M 50/247 specially adapted for portable devices, e.g. mobile phones, computers, hand tools or pacemakers
• CPC Class Codes: H01M 50/284 with incorporated circuit boards, e.g. printed circuit boards [PCB]
• CPC Class Codes: H01M 50/296 characterised by terminals of battery packs terminals of batteries H01M50/543
• CPC Class Codes: H02J 7/0044 specially adapted for holding portable devices containing batteries H02J7/0045 takes precedence
• CPC Class Codes: H02J 7/342 The other DC source being a battery actively interacting with the first one, i.e. battery to battery charging with circuits for polarity protection H02J7/0034
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y10T 29/49895 Associating parts by use of aligning means [e.g., use of a drift pin or a "fixture"]

Abstract

A portable electrochemical power supply for handheld electronic devices, such as cellular telephones, is disclosed. The power supply includes a housing with an electrical connector, a circuit board, and a removable electrochemical cell disposed therein. The circuit board carries power supply circuitry which receives electrical energy from the electrochemical cell and provides a power supply output for powering an external device.

Claims

1. A portable electrochemical power supply, comprising:

(a) a housing having an interior surface and an exterior surface, wherein said housing comprises at least two sections joined to one another, and wherein the housing includes a cavity adapted to removably receive an electrochemical cell;

(b) an electrical connector disposed through said housing, said connector having a first end accessible from said exterior surface;

(c) a circuit board disposed within said housing, said circuit board in electrical connection with both the electrochemical cell and the connector, said circuit board receiving an input voltage from said cell less than 1.90V and providing an output voltage through said connector greater than 3.00V.

2. The portable electrochemical power supply of claim 1 wherein said two sections comprise a first section and a second section, wherein said first section comprises said connector and defines a first end of said housing, wherein said second section is tubularly shaped and includes an open end and a closed end, and wherein said first section is removably joined to the open end of said second section.

3. The portable electrochemical power supply of claim 2 wherein said first section is electrically nonconductive and said second section is electrically conductive.

4. The portable electrochemical power supply of claim 2 wherein said first section is optically transparent.

5. The portable electrochemical power supply of claim 2 wherein said second section comprises a first subsection and a second subsection, said first subsection comprising a leading end and a trailing end, said second subsection secured to said first subsection'"'"'s trailing end.

6. The portable electrochemical power supply of claim 5 wherein said first and second subsections form at least a portion of an electrically conductive path between said cell and said circuit board.

7. The portable electrochemical power supply of claim 5 wherein said circuit board comprises an electrically conductive member, and wherein said electrically conductive member contacts the leading end of said first subsection.

8. The portable electrochemical power supply of claim 5 wherein at least a portion of the exterior surface of said subsections is textured to facilitate manual counter rotation of said first and second subsections thereby enabling said first and second subsections to be readily secured to or separated from one another.

9. The portable electrochemical power supply of claim 5 wherein said second subsection is removably secured to the trailing end of said first subsection.

10. The portable electrochemical power supply of claim 5 wherein said electrochemical cell has a first terminal having a first polarity and a second terminal having a second polarity.

11. The portable electrochemical power supply of claim 10 wherein said second subsection comprises a resilient electrically conductive contact that abuts and establishes electrical contact between the second subsection and the electrochemical cell'"'"'s second terminal.

12. The portable electrochemical power supply of claim 2 wherein said the first end of said connector is recessed below the first end of said housing.

13. The portable electrochemical power supply of claim 12 wherein the first end of said connector is located at the center of said housing'"'"'s first end.

14. The portable electrochemical power supply of claim 2 including an electrically nonconductive member, wherein said nonconductive member is disposed within said housing between said cell and said circuit board, and wherein said nonconductive member comprises an opening through which said cell contacts said circuit board.

15. The portable electrochemical power supply of claim 2 wherein said electrochemical cell includes an exterior circumferential surface and wherein the circumferential surface is substantially thermally insulated from said housing'"'"'s second section.

16. The portable electrochemical power supply of claim 2 wherein said connector extends through the first end of said housing.

17. The portable electrochemical power supply of claim 1 wherein said cell has a theoretical electrochemical capacity and at least 20% of said cell'"'"'s theoretical electrochemical capacity is discharged at 1.40V or higher.

18. The portable electrochemical power supply of claim 1 wherein said housing comprises an opening therethrough.

19. The portable electrochemical power supply of claim 18 wherein said opening allows gas in the cavity to pass therethrough.

20. The portable electrochemical power supply of claim 1 wherein said housing is cylindrically shaped, said cavity is cylindrically shaped and said electrochemical cell is cylindrically shaped, said cavity has an inside diameter that is at least 5% larger than the outer diameter of said cell thereby creating an air gap between the interior surface of said housing, and wherein at least 95% of the exterior circumferential surface area of said cell does not contact an interior circumferential surface of the cavity.

21. The portable electrochemical power supply of claim 20 comprising means for centering said electrochemical cell within said cavity.

23. The portable electrochemical power supply of claim 1 wherein said electrochemical cell comprises a single anode and a single cathode.

24. The portable electrochemical power supply of claim 1, wherein said cell has an initial unaltered open circuit voltage between 1.50V and 1.90V.

25. The portable electrochemical power supply of claim 24, wherein said cell comprises an alkaline electrolyte, zinc and at least one of the electrochemically active materials selected from the group consisting of manganese dioxide, nickel oxyhydroxide and silver oxide.

26. The portable electrochemical power supply of claim 24, wherein said cell comprises lithium.

27. The portable electrochemical power supply of claim 26, wherein said cell comprises iron disulfide.

28. The portable electrochemical power supply of claim 1 wherein said electrochemical cell occupies at least 85% of the electrochemical power supply'"'"'s total volume.

29. The portable electrochemical power supply of claim 1 wherein said electrochemical cell occupies at least 90% of the electrochemical power supply'"'"'s total volume.

22. The portable electrochemical power supply of claim 22 wherein said cavity and said housing are concentric.

30. A process for providing an electric current to a battery powered device, comprising;

(a) providing a battery powered device having at least one port physically and electrically configured to receive an electric current from an external power supply;

(b) selecting an electrochemical cell having a first terminal, a second terminal and an initial unaltered open circuit voltage less than 1.90 V;

(c) providing a housing for at least one circuit board and said electrochemical cell, said housing comprising an open end, a sidewall and a closed end, said circuit board capable of transforming an the electrochemical cell'"'"'s voltage from a first voltage to a second higher voltage, said housing comprising an electrically nonconductive first section defining the closed end of the housing and through which said electrical connector is disposed and an electrically conductive second section comprising said sidewall;

(d) disposing said cell inside said housing;

(e) securing a cover over the open end of the housing;

(f) providing an elongated electrically conductive connector;

(g) securing said elongated connector to said housing and to said device'"'"'s port thereby establishing an electrical connection between said housing and said device; and

(h) allowing the assembled housing, elongated connector and device to remain connected while said circuit board receives an input voltage from said cell and provides an output voltage to said device, wherein said input voltage is less than 1.90V and said output voltage is greater than 3.00V.

31. The process of claim 30 wherein said housing comprises an electrically nonconductive first section defining the closed end of the housing and an electrically conductive second section comprising said sidewall.

32. The process of claim 31 wherein said cover and said housing each comprise threaded surfaces and said step of securing a cover over the open end of said housing comprises rotating said cover and said housing in opposite directions to mutually engage the threaded surface on said cover with the threaded surface on said housing.

33. The process of claim 31 wherein said electrochemical cell comprises a single anode and a single cathode.

34. The process of claim 31 wherein said cell comprises an alkaline electrolyte, zinc and at least one of the electrochemically active materials selected from the group consisting of manganese dioxide, nickel oxyhydroxide and silver oxide.

35. The process of claim 35 wherein said cell comprises lithium.

36. The process of claim 36 wherein said cell comprises iron disulfide.

37. A portable battery powered power supply comprising:

(a) a first housing portion having a first end which includes a first opening and a second end;

(b) a second housing portion having third and fourth ends and a battery receiving region disposed therebetween;

(c) a circuit board;

(d) a power supply circuit carried by the circuit board and including an input which receives electrical energy from a first battery and an output which provides electrical energy to a battery powered device;

(e) a first battery contact carried by the circuit board and in electrical communication with the input of the power supply circuit, wherein the first battery contact is adapted to make electrical contact with a terminal located at a first end of a battery received in the battery receiving region;

(f) an electrical connector carried by the circuit board and in electrical communication with the power supply output, wherein the electrical connector is accessible to an exterior of the power supply through the first opening;

(g) a second battery contact adapted to make electrical contact with a terminal located at a second end of the battery.

38. The power supply of claim 37 wherein the second housing portion forms at least a portion of an electrically conductive path between the second battery contact and the input of the power supply circuit.

39. The power supply of claim 38 wherein the second housing portion is fabricated from an electrically conductive material.

40. The power supply of claim 39 wherein the first housing portion is fabricated from an electrically insulative material.

41. The power supply of claim 37 wherein the power supply includes an electrically insulating member, the third end includes a recess, the electrically insulating member is disposed in the recess, the circuit board is in electrical contact with the third end, and the insulating member allows the positive terminal of a battery received in the battery receiving region to contact the first battery contact but prevents the negative terminal of the battery from contacting the first battery contact.

42. The power supply of claim 37 wherein the circuit board includes an electrically conductive member in electrical communication with the input of the power supply circuit, the second housing portion includes an electrical conductor, the electrically conductive member is in electrical contact with the electrical conductor, and the electrical conductor is in electrical communication with the second battery contact.

43. The apparatus of claim 42 wherein the second housing portion is fabricated from an electrically conductive material.

44. The apparatus of claim 37 including a cover threadedly joined to the fourth end.

45. The apparatus of claim 44 wherein the first and second housing portions are threadedly joined.

46. The apparatus of claim 37 wherein the second housing portion includes a first cover portion and a second cover portion snappingly connected to the first cover portion, and wherein the first housing portion is snappingly connected to the second housing portion.

47. The apparatus of claim 37 including a light pipe disposed in the first housing portion, and wherein the circuit board carries a first light emitting diode, a first light receiving portion of the light pipe is in optical communication with the light emitting diode, and light emitted by the light pipe is visible through the first housing portion.

48. The apparatus of claim 47 wherein light emitted by the light pipe is visible through first and second sides of the first housing portion.

49. The apparatus of claim 48 wherein light emitted by the light pipe is visible through a third side of the first housing portion.

50. The apparatus of claim 48 wherein the circuit board carries a second light emitting diode and wherein a second light receiving portion of the light pipe is in optical communication with the second light emitting diode.

51. The apparatus of claim 37 including a third battery contact carried by the circuit board and in electrical communication with the input of the power supply circuit, and wherein the battery receiving region is adapted to receive a second battery.

52. The apparatus of claim 51 including a cover latchedly attached to the fourth end, and wherein the second battery contact is carried by the cover.

53. The apparatus of claim 52 including a mechanically resilient, electrically conductive member and a user operable latch member operable through the cover, wherein the conductive member and the latch member are carried by the cover, the electrically conductive member is adapted to make electrical contact with terminals of the first and second batteries, and the electrically conductive member urges the latch member toward an exterior of the cover.

54. The apparatus of claim 51 including a cover and an electrically conductive member carried by the cover, wherein the conductive member is adapted to make electrical contact with terminals of the first and second batteries, and wherein the cover may be latchedly joined to the fourth end in first and second 180°

rotationally opposed positions.

55. The apparatus of claim 37 including a cover and first and second user operable latch members, wherein the first latch member is operable through a first material free region disposed on a first side of the cover and the second latch member is operable through a second material free region disposed on a second side of the cover which is opposite the first side, whereby a user may selectively attach the cover to and remove the cover from the fourth end.

56. The apparatus of claim 37 wherein a first angular portion of the first opening has a first diameter and second angular portion of the first opening has a second diameter, whereby the opening is adapted to selectively receive a corresponding external electrical connector for rotational locking engagement therewith.

57. A portable battery powered power supply, wherein the power supply is adapted to selectively receive first and second generally cylindrical batteries and supply electrical energy to an external portable battery powered device through an electrical connector, the power supply consisting essentially of:

(a) first, second, and third cover portions which lockingly engage so as to form a unitary assembly having a battery receiving region;

(b) a circuit board, wherein the circuit board carries power supply circuitry, the electrical connector, a first battery contact adapted to make electrical contact with a terminal located at a first end of the first battery, and a second battery contact adapted to make electrical contact with a terminal located at a first end of the second battery,

(c) a fourth cover portion;

(d) first and second user operable attachment members carried by the fourth cover portion and adapted to removably attach the fourth cover portion to the unitary assembly;

(e) a mechanically resilient, electrically conductive member carried by the fourth cover portion, wherein the mechanically resilient, conductive member is adapted to provide an electrical connection between terminals located at a second end of the respective first and second batteries, and wherein the mechanically resilient, conductive member is in operative mechanical communication with the latch members.

58. The power supply of claim 57 including a light source carried by the circuit board.

59. The power supply of claim 58 including a light pipe in operative communication with the light source.

60. A portable battery powered power supply comprising:

(a) a first polymeric cover portion;

(b) a second polymeric cover portion which lockingly engages the second cover portion so as to form a unitary assembly which includes a cavity adapted to receive a battery;

(c) a circuit board;

(d) power supply circuitry carried by the circuit board and having an input which receives electrical energy from a battery and an output for providing electrical energy to an external device;

(e) a first electrical connector carried by the circuit board and in electrical communication with the output of the power supply circuitry, wherein the first electrical connector is adapted to provide a removable electrical connection to a corresponding external connector;

(f) a first battery contact carried by the circuit board and in electrical communication with the input of the power supply circuitry, wherein the first battery contact is adapted to provide an electrical contact with a terminal located at a first end a battery received in the cavity;

(g) a third polymeric cover portion which latchingly engages the unitary assembly so as to allow a user to selectively access the cavity;

(h) a second battery contact carried by the third cover portion, wherein the second battery contact is adapted to provide an electrical contact with a terminal located at a second end of the battery.

61. A method of assembling a battery powered power supply, the method including:

(a) installing first and second human operable attaching members and a mechanically resilient, electrically conductive member in a first cover portion so that the conductive member urges the attaching members toward an interior surface of the first cover and provides a first battery contact;

(b) snappingly attaching a second cover portion to a third cover portion to form a housing having first and second ends and a battery receiving region disposed therebetween;

(c) inserting a circuit board which carries an electrical connector, a second battery contact, and electrical circuitry which receives electrical energy from a battery and generates a power supply output for providing electrical energy to an external device in a fourth cover portion so that the electrical connector aligns with a first opening in the fourth cover portion;

(d) snappingly attaching the fourth cover portion to the first end of the housing;

(e) using the attaching members to removably attach the first cover portion to the second end of the housing.

62. The method of claim 61 including inserting a light pipe in the fourth cover portion.

63. A method of assembling a portable battery powered power supply comprising:

(a) placing a circuit board which carries an electrically conductive member, an electrical connector, a first battery contact, and electrical circuitry which receives electrical energy from a battery and generates a power supply output for providing electrical energy to an external device in a first cover portion so that the electrical connector aligns with a first opening in the first cover portion;

(b) attaching the first cover portion to a second cover portion having first and second ends and a battery receiving region disposed therebetween so that the electrically conductive member makes an electrical contact with the first end of the first housing;

(c) removably attaching a third cover portion which carries a second battery contact to the second end of the housing.

64. The method of claim 63 wherein the third cover portion is threadedly attached to the second cover portion.

65. The method of claim 64 wherein the first cover portion is threadedly attached to the second cover portion;

66. The method of claim 63 including installing, prior to the step of attaching, an insulating member including a material free region which aligns with the first battery contact in a recess disposed in the first end of the second member.