MULTI-BAY BATTERY CHARGER

• US 20130044002A1
• Filed: 07/20/2012
• Published: 02/21/2013
• Est. Priority Date: 07/20/2011
• Status: Active Grant

• Current Assignee: Milwaukee Electric Tool Corporation (Techtronic Industries Company Limited)
• Original Assignee: Milwaukee Electric Tool Corporation (Techtronic Industries Company Limited)
• Inventors: Schneider, Scott, Rosenbecker, Jay, Bublitz, Scott D., Coulis, Christian, Hull, James S.
• Granted Patent: US 9,077,053 B2
• Time in Patent Office: Days
• US Class Current: 340/636.2
• CPC Class Codes: H01M 10/441 for several batteries or cells simultaneously or sequentially
• CPC Class Codes: H02J 7/0013 acting upon several batteries simultaneously or sequentially H02J7/1423 takes precedence
• CPC Class Codes: H02J 7/0042 characterised by the mechanical construction
• CPC Class Codes: H02J 7/0045 concerning the insertion or the connection of the batteries
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

A battery charger for charging a first battery pack and a second battery pack includes a housing, a charging circuit positioned within the housing, and a first charging port coupled to the housing and electrically coupled to the charging circuit. The first charging port is configured to support the first battery pack and defines a first connection axis along which the first battery pack is movable to connect with the charging circuit. The battery charger also includes a second charging port coupled to the housing and electrically coupled to the charging circuit. The second charging port is configured to support the second battery pack while the first charging port supports the first battery pack. The second charging port defines a second connection axis along which the second battery pack is movable to connect with the charging circuit. The first connection axis is angled relative to the second connection axis.

Claims

1. A battery charger for charging a first battery pack and a second battery pack, the battery charger comprising:

a housing;

a charging circuit positioned within the housing;

a first charging port coupled to the housing and electrically coupled to the charging circuit, the first charging port configured to support the first battery pack, the first charging port defining a first connection axis along which the first battery pack is movable to connect with the charging circuit; and

a second charging port coupled to the housing and electrically coupled to the charging circuit, the second charging port configured to support the second battery pack while the first charging port supports the first battery pack, the second charging port defining a second connection axis along which the second battery pack is movable to connect with the charging circuit;

wherein the first connection axis is angled relative to the second connection axis.

2. The battery charger of claim 1, wherein the housing includes a first surface and a second surface that is spaced apart from the first surface, and wherein the first charging port is positioned on the first surface and the second charging port is positioned on the second surface such that the first and second battery packs do not interfere with each other when being connected to and removed from the first and second charging ports.

3. The battery charger of claim 2, wherein the first surface is angled relative to the second surface.

4. The battery charger of claim 3, wherein the first surface and the second surface connect together to form an apex of the housing, and wherein the housing defines a plurality of vents adjacent the apex.

5. The battery charger of claim 1, wherein the first charging port includes a first connecting structure and the second charging port includes a second connecting structure that is different than the first connecting structure.

6. The battery charger of claim 5, wherein the first connecting structure includes guide rails configured to engage corresponding guide rails of a slide-on style battery pack, and wherein the second connecting structure includes a recess configured to receive a portion of a tower style battery pack.

7. The battery charger of claim 1, wherein the first charging port is configured to support and charge a battery pack having a first voltage, and wherein the second charging port is configured to support and charge a battery pack having a second voltage that is different than the first voltage.

8. The battery charger of claim 7, wherein the first charging port is configured to support and charge an 18 volt battery pack, and wherein the second charging port is configured to support and charge a 12 volt battery pack.

9. The battery charger of claim 1, wherein the charging circuit is configured to charge the first and second battery packs in series.

10. The battery charger of claim 9, wherein the charging circuit is a single charging circuit positioned within the housing.

11. A battery charging system comprising:

a first battery pack having a first set of battery cells operable to store a first amount of energy;

a second battery pack having a second set of battery cells operable to store a second amount of energy; and

a battery charger for charging the first and second battery packs, the battery charger including

a housing having an outer perimeter that defines a footprint area of the battery charger,

a charging circuit positioned within the housing,

a first charging port coupled to the housing and electrically coupled to the charging circuit, the first charging port supports the first battery pack, and

a second charging port coupled to the housing and electrically coupled to the charging circuit, the second charging port supports the second battery pack while the first charging port supports the first battery pack;

wherein a ratio of a sum of the first and second amounts of energy in Watt-hours to the footprint area in square-inches is at least about 1.2.

12. The battery charging system of claim 11, wherein the ratio of the sum of the first and second amounts of energy in Watt-hours to the footprint area in square-inches is between about 1.2 and about 3.2.

13. The battery charging system of claim 11, wherein the sum of the first and second amounts of energy is at least about 43 Watt-hours.

14. The battery charging system of claim 13, wherein the sum of the first and second amounts of energy is between about 43 Watt-hours and about 115 Watt-hours.

15. The battery charging system of claim 14, wherein the sum of the first and second amounts of energy is about 86 Watt-hours.

16. The battery charging system of claim 11, wherein the footprint area is about 36 square-inches.

17. The battery charging system of claim 11, wherein a ratio of the number of cells in the first and second sets of battery cells to the footprint area in square-inches is at least about 0.4.

18. The battery charging system of claim 17, wherein the first battery pack includes at least ten battery cells and the second battery pack includes at least six battery cells.

19. The battery charging system of claim 11, wherein the first battery pack is an 18 volt battery pack and the second battery pack is a 12 volt battery pack.

20. A battery charging system comprising:

a first battery pack having a first set of battery cells operable to store a first amount of energy;

a second battery pack having a second set of battery cells operable to store a second amount of energy; and

a battery charger for charging the first and second battery packs, the battery charger including

a housing having an outer surface that defines a volume of the battery charger,

a charging circuit positioned within the housing,

a first charging port coupled to the housing and electrically coupled to the charging circuit, the first charging port supports the first battery pack, and

a second charging port coupled to the housing and electrically coupled to the charging circuit, the second charging port supports the second battery pack while the first charging port supports the first battery pack;

wherein a ratio of a sum of the first and second amounts of energy in Watt-hours to the volume in cubic-inches is at least about 0.5.

21. The battery charging system of claim 20, wherein the ratio of the sum of the first and second amounts of energy in Watt-hours to the volume in cubic-inches is between about 0.5 and about 1.3.

22. The battery charging system of claim 20, wherein the sum of the first and second amounts of energy is at least about 43 Watt-hours.

23. The battery charging system of claim 22, wherein the sum of the first and second amounts of energy is between about 43 Watt-hours and about 115 Watt-hours.

24. The battery charging system of claim 23, wherein the sum of the first and second amounts of energy is about 86 Watt-hours.

25. The battery charging system of claim 20, wherein the volume is about 86 cubic-inches.

26. The battery charging system of claim 20, wherein the first battery pack is an 18 volt battery pack and the second battery pack is a 12 volt battery pack.

27. A battery charger for charging a first battery pack and a second battery pack, the battery charger comprising:

a housing;

a charging circuit positioned within the housing, the charging circuit configured to charge the first and second battery packs in series;

a first charging port coupled to the housing and electrically coupled to the charging circuit, the first charging port configured to support the first battery pack;

a second charging port coupled to the housing and electrically coupled to the charging circuit, the second charging port configured to support the second battery pack while the first charging port supports the first battery pack; and

an indicator light associated with the first charging port and supported by the housing, the indicator light operable to blink at a first speed when charging of the first battery pack connected to the first charging port is pending and operable to blink at a second speed that is different than the first speed when the first charging port detects a fault in the first battery pack.

28. The battery charger of claim 27, wherein the indicator light is operable to blink at the second speed when a temperature of the first battery pack connected to the first charging port is outside of a predetermined range.

29. The battery charger of claim 27, wherein the indicator light is continuously on when the first battery pack connected to the first charging port is charging.

30. The battery charger of claim 29, wherein the indicator light is a first indicator light, and further comprising a second indicator light associated with the first charging port and supported by the housing, wherein the second indicator light is continuously on when charging of the first battery pack connected to the first charging port is complete.

31. The battery charger of claim 30, wherein both the first indicator light and the second indicator light blink when the first charging port detects a fault in the first battery pack.

32. The battery charger of claim 27, wherein the indicator light is a first indicator light, and further comprising a second indicator light associated with the second charging port and supported by the housing, wherein the second indicator light is operable to blink at a first speed when charging of the second battery pack connected to the second charging port is pending and is operable to blink at a second speed that is different than the first speed when the second charging port detects a fault in the second battery pack.

33. The battery charger of claim 32, wherein the first indicator light is continuously on when the first battery pack connected to the first charging port is charging, and wherein the second indicator light is continuously on when the second battery pack connected to the second charging port is charging.

34. The battery charger of claim 33, further comprising:

a third indicator light associated with the first charging port and supported by the housing, the third indicator light being continuously on when charging of the first battery pack connected to the first charging port is complete; and

a fourth indicator light associated with the second charging port and supported by the housing, the fourth indicator light being continuously on when charging of the second battery pack connected to the second charging port is complete.

35. The battery charger of claim 27, wherein the housing includes a first surface and a second surface, wherein the first surface is angled relative to the second surface, and wherein the indicator light includes a lens that extends over a portion of the first surface and a portion of the second surface.

36. The battery charger of claim 35, wherein the housing defines a plurality of vents, and wherein at least some of the plurality of vents extend over a portion of the first surface and a portion of the second surface of the housing.