Battery cooling system

• US 6,949,309 B2
• Filed: 08/20/2002
• Issued: 09/27/2005
• Est. Priority Date: 03/05/1998
• Status: Expired due to Fees

• Current Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Original Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Inventors: Brotto, Daniele C., Bradus, Robert, White, Paul S., Watts, Fred S., Cochran, John R., Embrey, Janet M., Bailey, Rouse R. Jr., Ramstrom, Lee W., Moores, Robert G. Jr.
• Primary Examiner(s): Kalafut, Stephen J.
• Application Number:
  US10/223,964
• Publication Number:
  US 20030027037A1
• Time in Patent Office: 1,134 Days
• Field of Search: 320/107, 320/110, 320/111, 320/112, 320/113, 320/150, 320/151, 320/152, 320/153, 320/154, 429/50, 429/71, 429/83, 429/120, 429/148
• US Class Current: 429/50
• CPC Class Codes: B25F 5/008 Cooling means
• CPC Class Codes: H01M 10/46 Accumulators structurally combined with charging apparatus circuits for charging H02J7/00
• CPC Class Codes: H01M 10/482 for several batteries or cells simultaneously or sequentially
• CPC Class Codes: H01M 10/486 for measuring temperature
• CPC Class Codes: H01M 10/613 Cooling or keeping cold
• CPC Class Codes: H01M 10/615 Heating or keeping warm
• CPC Class Codes: H01M 10/617 for achieving uniformity or desired distribution of temperature
• CPC Class Codes: H01M 10/623 Portable devices, e.g. mobile telephones, cameras or pacemakers
• CPC Class Codes: H01M 10/6235 Power tools
• CPC Class Codes: H01M 10/63 Control systems charging or discharging in response to temperature H01M10/44 , H01M10/443; measurement of temperature H01M10/48 , H01M10/486
• CPC Class Codes: H01M 10/643 Cylindrical cells
• CPC Class Codes: H01M 10/652 characterised by gradients for achieving a desired temperature gradient H01M10/617
• CPC Class Codes: H01M 10/653 characterised by electrically insulating or thermally conductive materials
• CPC Class Codes: H01M 10/6551 Surfaces specially adapted for heat dissipation or radiation, e.g. fins or coatings
• CPC Class Codes: H01M 10/6554 Rods or plates
• CPC Class Codes: H01M 10/6555 arranged between the cells
• CPC Class Codes: H01M 10/6556 Solid parts with flow channel passages or pipes for heat exchange closed pipes H01M10/6552
• CPC Class Codes: H01M 10/6557 arranged between the cells
• CPC Class Codes: H01M 10/6563 with forced flow, e.g. by blowers
• CPC Class Codes: H01M 10/6566 Means within the gas flow to guide the flow around one or more cells, e.g. manifolds, baffles or other barriers H01M10/6565 takes precedence
• CPC Class Codes: H01M 10/6572 : Peltier elements or thermoelectric devices
• CPC Class Codes: H01M 10/66 : Heat-exchange relationships between the cells and other systems, e.g. central heating systems or fuel cells
• CPC Class Codes: H01M 10/667 : the system being an electronic component, e.g. a CPU, an inverter or a capacitor
• CPC Class Codes: H01M 50/204 : Racks, modules or packs for multiple batteries or multiple cells
• CPC Class Codes: H01M 50/213 : adapted for cells having curved cross-section, e.g. round or elliptic H01M50/209, H01M50/216 take precedence
• CPC Class Codes: H01M 50/247 : specially adapted for portable devices, e.g. mobile phones, computers, hand tools or pacemakers
• CPC Class Codes: H01M 50/30 : Arrangements for facilitating escape of gases
• CPC Class Codes: H02J 7/0042 : characterised by the mechanical construction
• CPC Class Codes: H02J 7/0044 : specially adapted for holding portable devices containing batteries H02J7/0045 takes precedence
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries
• CPC Class Codes: Y02P 70/50 : Manufacturing or production processes characterised by the final manufactured product
• CPC Class Codes: Y10T 29/49108 : Electric battery cell making

Abstract

A cordless power tool has a housing which includes a mechanism to couple with a removable battery pack. The battery pack includes one or more battery cells as well as a vent system in the battery pack housing which enables fluid to move through the housing. A mechanism is associated with the battery pack to dissipate heat from the battery pack.

Claims

1. A charger and battery pack combination, comprising:

a battery pack comprising a housing having top, bottom and side walls, a terminal tower disposed on the top wall, an air inlet disposed on at least one of the terminal tower and the top wall, and an air outlet for allowing air to exit from the housing, a plurality of cells disposed in the housing, and

a charger comprising;

a charger housing for supporting the battery pack, the charger housing having a first duct opposite of the air inlet of the battery pack;

charging circuitry provided within the charger housing; and

a fan disposed within the charger housing for blowing air through the first duct and into the battery pack via the air inlet, and for blowing air through a second duct directing cooling air to the charging circuitry.

2. The charger and battery pack combination of claim 1, wherein the first duct and the air inlet of the battery pack are axially aligned.

3. The charger and battery pack combination of claim 1, where the first duct and the air inlet of the battery pack are axially misaligned.

4. The charger and battery pack combination of claim 1, further comprising a chamber disposed between the first duct and the air inlet of the battery pack.

5. A charger and battery pack combination, comprising:

a battery pack comprising a housing having top, bottom and side walls, a terminal tower disposed on the top wall, an air inlet disposed on at least one of the terminal tower and the top wall, and an air outlet for allowing air to exit from the housing, a plurality of cells disposed in the housing, and

a charger comprising;

a charger housing for supporting the battery pack, the charger housing having a first duct opposite of the air inlet of the battery pack and vents disposed near the air exiting from the battery pack housing;

a fan disposed within the charger housing for blowing air through the first duct and into the battery pack via the air inlet;

wherein air exiting from the battery pack housing creates a low pressure region near the vents.

6. The charger and battery pack combination of claim 5, wherein the first duct and the air inlet of the battery pack are axially aligned.

7. The charger and battery pack combination of claim 5, wherein the first duct and the air inlet of the battery pack are axially misaligned.

8. The charger and battery pack combination of claim 5, further comprising a chamber disposed between the first duct and the air inlet of the battery pack.

9. A method for controlling a charger for charging a battery, wherein the charger comprises a fan for cooling the battery, the method comprising:

providing power to the fan so that it rotates at a first speed prior to battery insertion.

10. The method of claim 9, wherein the power is provided when the charger is connected to a power supply source.

11. The method of claim 9, wherein the power is provided when the charger is turned on.

12. The method of claim 9, wherein the power is provided when a button disposed on the charger is activated.

13. The method of claim 9, wherein the power is provided for a predetermined period of time.

14. The method of claim 9, further comprising providing power to the fan so that it rotates at a second speed lower than the first speed.

15. The method of claim 14, wherein the second speed is equal to zero revolutions per minute.

16. A method for controlling a charger for charging a battery usable with an electric device separate from the charger, wherein the charger comprises a housing, and a fan mounted in the housing for cooling the battery, the method comprising:

disposing the battery on the housing and electrically connecting the battery to the charger;

determining battery temperature;

providing power to the fan so that it rotates at a first speed if the battery temperature is above a predetermined temperature;

providing power to the fan so that it rotates at a second speed lower than the first speed if the battery temperature is equal to or below a predetermined temperature; and

removing the battery from the charger for use with the electric device.

17. The method of claim 16, wherein the predetermined temperature is about 20°

C.

18. The method of claim 16, wherein the second speed is equal to zero revolutions per minute.

19. A method for controlling a charger for charging a battery usable with an electric device separate from the charger, wherein the charger comprises a housing, and a fan mounted in the housing for cooling the battery, the method comprising:

disposing the battery on the housing and electrically connecting the battery to the charger;

providing power to the fan so that it rotates at a first speed;

providing power to the fan so that it rotates at a second speed lower than the first speed

determining battery temperature;

providing power to the fan so that it rotates at a third speed; and

removing the battery from the charger for use with the electric device.

20. The method of claim 19, wherein the second speed is equal to zero revolutions per minute.

21. The method of claim 19, wherein the third speed is selected so as to maintain battery temperature at a predetermined temperature.

22. The method of claim 21, where the predetermined temperature is about 30°

C.

23. The method of claim 19, wherein the third speed is about equal to the first speed.

24. A method for cooling a battery disposed on a charger, the method comprising:

providing a fan in the charger;

providing an air inlet in the battery for allowing air to enter the batter;

providing an air outlet in the battery for allowing air to exit the battery;

providing power to the fan to force air to enter the battery through the air inlet, to exit the battery through the air outlet and to enter the charger, in that order.