Portable battery charger powered by internal combustion engine

• US 7,471,000 B1
• Filed: 04/25/2006
• Issued: 12/30/2008
• Est. Priority Date: 04/25/2006
• Status: Active Grant

• Current Assignee: Vanessa Marie Wheatley, Veronica Lynn Wheatley
• Original Assignee: Rafael J. Ruiz
• Inventors: Ruiz, Rafael J.
• Primary Examiner(s): Ponomarenko; Nicholas
• Application Number:
  US11/410,619
• Time in Patent Office: 980 Days
• Field of Search: 290/1.A, 290/7, 290/8, 290/41, 290/40.C, 290/50, 320/104, 320/105
• US Class Current: 290/1.00A
• CPC Class Codes: H02J 7/1415 with a generator driven by a prime mover other than the motor of a vehicle

Abstract

A portable battery charger that is powered by a gasoline, diesel, or propane engine. The portable device incorporates a recoil or electric starter and an engine throttle lever that can be used to vary the RPM of the engine and therefore the voltage/current output of the charger. The charger uses a permanent magnet alternator equipped with a belt tension adjustor arm and a heavy duty diode rectifier. The components of the charger (the engine and the alternator) are positioned on a wheeled, heavy-gauge steel, roll around cart that makes the charger easily portable. The two-wheeled cart includes an extended handle, allowing the user to move and steer the charger into position for use. Positioned on this handle is a control box with an anti-spark keyed switch that blocks any charging current from traveling through the charging cables until the switch is thrown. This control facilitates the safe hook-up of the charging clamps while the charger (engine) is running. The charger includes heavy duty cables between the alternator and the anti-spark control box, and additionally out from the control box to insulated clamps that are used to connect to the batteries. The control box additionally includes an ammeter and a voltmeter to indicate the charging current and voltage. The portable charger structured in this manner can be used to charge a non-specific number of batteries in parallel, typically in less than 2-4 hours depending on the size and state of the existing battery charge. The charger may also be used in the process of equalizing a bank of batteries to facilitate a reduction in stratification and sulfation.

Claims

1. A portable battery charger used to charge at least one lead-acid wet-cell battery, the portable battery charger comprising:

an internal combustion engine having an output drive shaft;

a generator comprising a permanent magnet alternator and a heavy-duty diode rectifier, the generator having an input drive shaft operably connected to the output drive shaft of the internal combustion engine;

a wheeled cart having a support frame and a handle for manipulation by the user;

an anti-spark control box positioned on the handle of the wheeled cart for controlling charging current flow, the control box electrically connected to an output of the generator; and

a pair of electrical connectors for conducting charging current from the control box to the at least one battery;

wherein the generator and the internal combustion engine are positioned on the support frame of the wheeled cart.

2. The portable battery charger of claim 1, wherein the engine further comprises an engine throttle adjustment to vary the RPM of the engine and thereby adjust the generator output voltage and current.

3. The portable battery charger of claim 1, wherein the internal combustion engine comprises a fuel tank and the engine operate on a fuel selected from the group of fuels that include gasoline, diesel, and propane fuel.

4. The portable battery charger of claim 1, wherein the output drive shaft of the engine further comprises an engine pulley and the input drive shaft of the alternator further comprises an alternator pulley, and wherein a V-belt connects the alternator pulley with the engine pulley.

5. The portable battery charger of claim 4, further comprising a belt tensioner for varying a transfer of torque between the engine and the alternator.

6. The portable battery charger of claim 1, wherein the alternator further comprises a permanent magnet rotor.

7. The portable battery charger of claim 1, wherein the handle of the wheeled cart comprises a rigid member extending to a height and at an angle appropriate for manipulation by a user of the portable battery charger.

8. The portable battery charger of claim 7, wherein the handle comprises a single rigid tube having a gooseneck shape.

9. The portable battery charger of claim 7, wherein the handle comprises a dual rigid tube having an inverted U-shape, and further comprising a cross-member element for positioning and supporting the control box.

10. The portable battery charger of claim 7, wherein the handle further comprises a cable hook affixed to said handle.

11. The portable battery charger of claim 1, wherein the wheeled cart comprises two rear wheels and a front support member, wherein the front support member facilitates the stationary placement of the portable battery charger when the charger is in use.

12. The portable battery charger of claim 11, wherein the front support member further comprises a support pad positioned beneath and affixed thereto, the support pad preventing easy movement of the wheeled cart on a flat support surface.

13. The portable battery charger of claim 1, wherein the control box further comprises a cut-off switch for interrupting a conductive path from the generator to the batteries.

14. The portable battery charger of claim 1, wherein the control box further comprises an ammeter for monitoring the charging current during the process of charging the batteries.

15. The portable battery charger of claim 1, wherein the control box further comprises a voltmeter for monitoring the charging voltage during the process of charging the batteries.

16. The portable battery charger of claim 1, wherein said pair of electrical connectors comprises a pair of heavy duty cable conductors, each of the conductors terminating with a spring biased battery clamp for attachment to terminal posts of the batteries to be charged.

17. The portable battery charger of claim 1, wherein said pair of electrical connectors comprise contact electrodes attached to said control box to which a standard set of jumper cables may be attached.