BATTERY CARRIER SYSTEM

• US 20190157881A1
• Filed: 01/17/2019
• Published: 05/23/2019
• Est. Priority Date: 10/06/2014
• Status: Active Grant

• Current Assignee: Stanley Black & Decker, Inc.
• Original Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Inventors: VELDERMAN, Matthew J., WHITE, Daniel J., SEMAN, Andrew E., MILLER, David A., CRUISE, Nathan J., HOWARD, Geoffrey S.
• Granted Patent: US 11,011,919 B2
• Time in Patent Office: Days
• CPC Class Codes: G07F 15/006 dispensed for the electrical charging of other devices than vehicles
• CPC Class Codes: G07F 7/06 by returnable containers , i.e. reverse vending systems in which a user is rewarded for returning a container that serves as a token of value, e.g. bottles
• CPC Class Codes: H02J 2207/40 adapted for charging from various sources, e.g. AC, DC or multivoltage
• CPC Class Codes: H02J 7/00 Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
• CPC Class Codes: H02J 7/00045 Authentication, i.e. circuits for checking compatibility between one component, e.g. a battery or a battery charger, and another component, e.g. a power source
• CPC Class Codes: H02J 7/0013 acting upon several batteries simultaneously or sequentially H02J7/1423 takes precedence
• CPC Class Codes: H02J 7/0045 concerning the insertion or the connection of the batteries

Abstract

A system including a carrier having a plurality of receptacles configured to receive rechargeable, removable battery packs, an AC power input connector for connecting to an AC power supply, a power output connector, a discharge/charge mode switch for switching between (1) a charging mode of operation that charges the battery packs using electrical power input through at least one of the power input connectors and (2) a discharging mode of operation that outputs electrical power from the battery packs through the power output connector, the charge/discharge control module controlling a plurality of charging switches to provide a charging current to the battery packs and an inverter electrically connected to the power output connector for providing an AC output signal at the power output connector.

Claims

1. A carrier comprising:

a housing, the carrier housing including;

a cover,

a plurality of receptacles, each receptacle configured to receive one rechargeable, removable battery pack, each receptacle including a terminal block for electrically coupling the battery pack to a plurality of electrical and electronic components for monitoring, managing and/or controlling the charging and discharging of the battery packs, the components including a system management unit (SMU), the SMU including a processor and a charge/discharge control module,

an AC power input connector for connecting to an AC power supply,

a power output connector;

a discharge/charge mode switch for switching between (1) a charging mode of operation that charges the battery packs using electrical power input through at least one of the power input connectors, and (2) a discharging mode of operation that outputs electrical power from the battery packs through the power output connector;

each battery pack including a terminal block, the charge/discharge control module electrically connected to the battery packs via the receptacle terminal block and the battery pack terminal block, the charge/discharge control module controlling a plurality of charging switches to provide a charging current to the battery packs through carrier power supply lines, the receptacle terminal block and the battery pack terminal block;

the SMU also communicates with a first power supply coupled to the AC power input connector, the first power supply, configured to provide a charging voltage equal to a rated charging voltage of the battery packs;

an inverter electrically connected to the power output connector for providing an AC output signal at the power output connector;

the SMU electrically connected to the discharge/charge mode switch, wherein (1) when the discharge/charge mode switch is in a charge position, a charge signal is sent to the SMU and the SMU sends a signal to the inverter to turn the inverter off, sends a signal to the first power supply to turn the first power supply on, and selectively sends a signal to the charging switches to close the charging switches to selectively connect the battery packs to the first power supply to charge the battery packs and (2) when the discharge/charge mode switch is in the discharge position, a discharge signal is sent to the SMU and the SMU sends a signal to the inverter to turn the inverter on, sends a signal to the first power supply to turn the first power supply off, and selectively sends a signal to the charging switches to selectively open the charging switches to disconnect the battery packs from the first power supply.

2. The carrier, as recited in claim 1, wherein the cover includes latching system configured to operate with a corresponding latching system on the carrier housing to fix the cover to the housing and to allow a user to open and close the cover.

3. The carrier, as recited in claim 1, wherein the power output connector is an AC power output connector.

4. The carrier, as recited in claim 1, wherein the power output connector is a DC power output connector.

5. The carrier, as recited in claim 1, wherein the discharge/charge mode switch is an automatic internal switch and further comprising a current sensor for the AC power input and the DC power input such that the internal switch switches to the charging mode when the current sensor senses an input current and switches to the discharge mode when the current sensor does not sense an input current.

6. The carrier, as recited in claim 1, wherein first power supply is a 120 VAC to 60 VDC power supply and the second power supply is a 12 VDC to 60 VDC power supply to supply power to the battery packs.

7. The carrier, as recited in claim 1, wherein when all of the battery packs are 60 V battery packs then the first and second power supplies are configured to provide a 60 VDC output.

8. The carrier, as recited in claim 1, wherein when all of the battery packs are 20 V battery packs, then the first and second power supplies will be configured to provide a 20 VDC output.

9. The carrier, as recited in claim 1, wherein the inverter is one of a pure sine wave inverter, a modified sign wave inverter, a pulse wave inverter or any other inverter capable of providing an AC output signal or an approximated AC output signal for providing power to AC electrical and electronic devices.

10. The carrier, as recited in claim 1, further comprising a plurality of cover switches coupling the plurality of carrier receptacles, wherein the plurality of cover switches are in an open state when the cover is open to provide an open circuit between carrier receptacle terminal.

11. The carrier, as recited in claim 10, wherein the battery pack may also be coupled to and discharged into an electrical device independent of the carrier by connecting the battery pack directly to the electrical device via the battery terminal block.

12. The carrier, as recited in claim 1, wherein a 60 volt battery pack is received in three of the receptacles and the carrier provides a 120V RMS AC, 15 A output waveform through the inverter 266.

13. The carrier, as recited in claim 1, further comprising a bypass switch that bypasses the internal power supply and the inverter to provide AC power directly from the AC input connector to the AC output connector.

14. A battery pack carrier, comprising a first set of battery packs and a second set of battery packs, a AC input connector and an AC output connector, wherein the first set of battery packs are charged from AC power provided to the AC input connector and the second set of battery packs provide AC power to the AC output connector.

15. A system comprising a battery pack;

a first electrical device;

a second electrical device; and

a charging and discharging container having a housing with a receptacle, the receptacle configured to removably receive and electrically connect to the battery pack, a power input connector configured to receive input power from an external power supply, a power output connector configured to deliver an output power from the battery pack, a charging circuit configured to control charging of the battery pack with the input power when the battery pack is received in the receptacle, and a discharging circuit configured to control discharging of output power from the battery pack to the power output connector, wherein the power output connector is electrically coupleable to the first electrical device to power the first electrical device when the battery pack is received in the receptacle, and wherein the battery pack is electrically coupleable to the second electrical device to power the second electrical device when the battery pack is removed from the receptacle.

16. The system, as recited in claim 17, wherein the power input connector may be configured to receive a source of AC input power or a source of DC input power.

17. The system, as recited in claim 15, wherein the power input connector comprises a first connector configured to receive a source of AC power and a second connector configured to receive a source of DC power.

18. The system, as recited in claim 15, wherein the power output connector comprises an AC connector or a DC connector.

19. The system, as recited in claim 15, further comprising a switching device that enables switching between a charging mode in which the charging circuit is active to charge the battery packs and a discharging mode in which the discharging circuit is active to enable discharge of the battery packs to the power output connector.

20. The system, as recited in claim 15, wherein the first electrical device comprises an AC power tool and the second electrical device comprises a DC power tool.