Power supply system comprising rechargeable battery pack and attachment apparatus

• US 7,656,120 B2
• Filed: 09/15/2005
• Issued: 02/02/2010
• Est. Priority Date: 09/15/2004
• Status: Expired due to Fees

• Current Assignee: Belkin International Incorporated (Hon Hai Precision Industry Co., Ltd.)
• Original Assignee: Belkin International Incorporated (Hon Hai Precision Industry Co., Ltd.)
• Inventors: Neu, Thorben, Seil, Oliver Duncan, Sinclair, Ian, Wadsworth, John, Sween, Barry P., Meyers, Jeff
• Primary Examiner(s): Vu; Bao Q
• Assistant Examiner(s): Tran; Nguyen
• Application Number:
  US11/228,666
• Publication Number:
  US 20060061332A1
• Time in Patent Office: 1,601 Days
• Field of Search: 320/114, 320/122, 320/125, 320/128, 320/135, 320/115, 363/143, 363/56
• US Class Current: 320/112
• CPC Class Codes: G06F 1/1632 External expansion units, e.g. docking stations
• 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 10/4257 Smart batteries, e.g. electronic circuits inside the housing of the cells or batteries
• CPC Class Codes: H01M 10/488 Cells or batteries combined with indicating means for external visualization of the condition, e.g. by change of colour or of light density
• 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 29/49108 Electric battery cell making

Abstract

A power supply system capable of providing electric power to an electronic device having a first battery includes a battery pack (100) and an attachment apparatus (300). The battery pack includes a body (110) having at least a first recess (221), a second battery inside the body, and at least one of a first circuit (500) capable of dynamically changing a charge current supplied to the second battery based on a power consumption level of the electronic device, and a second circuit (600) capable of dynamically switching the electronic device between a recharging state and a non-recharging state depending on a status of the battery pack. The attachment apparatus includes a frame (310), an extension (350) protruding from the frame, and attachment features (461) suitable for working with the recess to attach the battery pack and the attachment apparatus to each other and to the electronic device.

Claims

1. A rechargeable battery pack capable of providing electric power to an electronic device having a first battery, the rechargeable battery pack comprising:

a body;

a second battery inside the body and supplemental to the first battery inside the electronic device; and

a first circuit inside the body and configured to dynamically change a charge current supplied from an external power source to the second battery based on a power consumption level of the electronic device;

wherein;

the first circuit comprises;

a current sense subcircuit;

a power limiting switch having a first terminal electronically coupled to an output of the current sense subcircuit; and

a first resistor with a first end electronically coupled to a second terminal of the power limiting switch;

the charge current comprises a first magnitude and a second magnitude less than the first magnitude;

the power consumption level of the electronic device comprises a first level and a second level greater than the first level;

the power consumption level of the electronic device is measured via the current sense subcircuit of the first circuit;

when the power consumption level is less than the first level, the first circuit turns on the power limiting switch, via the output of the current sense subcircuit, to allow a flow of the charge current through the first resistor and to transmit the first magnitude of the charge current to the second battery; and

when the power consumption level is greater than the second level, the first circuit turns off the power limiting switch, via the output of the current sense subcircuit, to inhibit the flow of the charge current through the first resistor and to transmit only the second magnitude of the charge current to the second battery.

2. The rechargeable battery pack of claim 1, wherein:

the current sense subcircuit of the first circuit comprises;

an operational amplifier having an inverting input, a non-inverting input, and an output; and

an inverter having a first terminal electrically coupled to the output of the operational amplifier.

3. The rechargeable battery pack of claim 2, wherein:

the first circuit further comprises;

a second resistor and comprising a first end electrically coupled to a third terminal of the power limiting switch and a second end electrically coupled to a second end of the first resistor.

4. The rechargeable battery pack of claim 3, wherein:

the first circuit further comprises;

a first end of a third resistor and a first end of a fourth resistor electrically coupled to the inverting input of the operational amplifier;

a first end of a fifth resistor and a first end of a sixth resistor electrically coupled to the non-inverting input of the operational amplifier;

a second end of the fourth resistor electrically coupled to the output of the operational amplifier;

a second end of the sixth resistor electrically coupled to a ground; and

a seventh resistor electrically coupling together a second end of the third resistor and a second end of the fifth resistor;

the inverter is a first transistor;

the power limiting switch is a second transistor; and

a magnitude of a voltage drop across the seventh resistor corresponds to the power consumption level of the electronic device.

5. The rechargeable battery pack of claim 3, wherein:

the first circuit further comprises;

a first end of a third resistor electrically coupled to the output of the operational amplifier;

a first end of a capacitor electrically coupled to a second end of the third resistor and to the first terminal of the inverter;

a second end of the capacitor electrically coupled to the ground;

a first end of a fourth resistor electrically coupled to the first terminal of the power limiting switch; and

a second end of the fourth resistor electrically coupled to the third terminal of the power limiting switch.

6. The rechargeable battery pack of claim 1, wherein:

the first circuit'"'"'s ability to dynamically change the charge current supply permits a charging of the first battery of the electronic device to be unaffected by power fluctuations from the external power source.

7. The rechargeable battery pack of claim 1, wherein:

the first circuit further comprises;

a charge management subcircuit configured to adjust a charge rate for the second battery between a fast charge mode and a slow charge mode, the charge management sub circuit comprising;

a first terminal coupled to the second terminal of the first resistor; and

a second terminal coupled to the second battery.

8. The rechargeable battery pack of claim 1, further comprising:

a second circuit inside the body and configured to;

power the electronic device with the second battery when the rechargeable battery pack is electrically decoupled from the external power source; and

power the electronic device with the external power source when the rechargeable battery pack is electrically coupled to the external power source.

9. The rechargeable battery pack of claim 8, wherein:

the second circuit is configured to signal the electronic device that the rechargeable battery pack is electrically coupled to the electronic device.

10. The rechargeable battery pack of claim 1, further comprising:

a charge level indicator comprising;

an actuator button;

a third circuit inside the body;

a first light source; and

a second light source;

wherein;

the actuator button, when actuated, turns on the third circuit for a predetermined period of time to measure a remaining charge level of the second battery;

when the third circuit measures the remaining charge level of the second battery to be greater than a first charge level, the third circuit turns on the first light source and not the second light source; and

when the third circuit measures the remaining charge level of the second battery to be less than a second charge level, the third circuit turns on the second light source and not the first light source.

11. The rechargeable battery pack of claim 10, wherein:

when the third circuit measures the remaining charge level of the second battery to be less than the first charge level and greater than the second charge level, the third circuit turns on the first light source and the second light source such that the first light source and the second light source emit light at the same time.

12. The rechargeable battery pack of claim 10, wherein:

the actuator button comprises a light pipe; and

light emitted by the first light source and light emitted by the second light source are visible through the light pipe.

13. The rechargeable battery pack of claim 1, further comprising:

an attachment apparatus configured to at least partially surround and attach to the battery pack and the electronic device;

an electrical connector configured to electrically connect the battery pack and the electronic device; and

an extension projecting from the attachment apparatus and configured to at least partially surround and protect the electrical connector.

14. The rechargeable battery pack of claim 1, wherein:

the first circuit is configured to toggle the charge current supplied to the second battery between at least two non-zero rates of charge based on the power consumption level of the electronic device.

15. The rechargeable battery pack of claim 1 configured for use with a digital music player.

16. A method of manufacturing a power supply system capable of providing electric power to an electronic device having a first battery, the method comprising in any order at least the steps of:

providing a battery pack having a body configured to contain a second battery;

providing a first circuit within the body and configured to dynamically change a charge current supplied from an external power source to the second battery based on a power consumption level of the electronic device;

wherein;

providing the first circuit comprises;

providing a current sense subcircuit to measure the power consumption level of the electronic device;

coupling a first terminal of a power limiting switch to an output of the current sense subcircuit; and

coupling a first end of a first resistor to a second terminal of the power limiting switch;

providing the current sense subcircuit further comprises;

providing the current sense sub circuit to;

enable the power limiting switch, via the output of the current sense subcircuit, to allow a flow of the charge current through the first resistor and to transmit a first magnitude of the charge current to the second battery when a power consumption level of the electronic device is less than a first level; and

disable the power limiting switch, via the output of the current sense subcircuit, to inhibit the flow of the charge current through the first resistor and to transmit a second magnitude of the charge current to the second battery when the power consumption level of the electronic device is greater than a second level;

the first magnitude of the charge current is greater than the second magnitude of the charge current; and

the second level of the power consumption of the electronic device is greater than the first level of the power consumption of the electronic device.

17. The method of claim 16, wherein:

providing the first circuit further comprises;

providing a charge management subcircuit configured to adjust a charge rate for the second battery between a fast charge mode and a slow charge mode;

coupling a first terminal of the charge management subcircuit to the second terminal of the first resistor; and

coupling a second terminal of the charge management subcircuit to the second battery.

18. The method of claim 16, wherein:

providing the first circuit further comprises;

coupling a first end of a second resistor to a third terminal of the power limiting switch; and

coupling a second end of the second resistor to a second end of the first resistor;

providing the current sense subcircuit comprises;

at least one of;

providing an operational amplifier having an inverting input, a non-inverting input, and an output;

or

providing an inverter having a first terminal electrically coupled to the output of the operational amplifier;

and

routing the output of the current sense subcircuit via at least one of;

the output of the operational amplifier;

or

a second terminal of the inverter.

19. The method of claim 16, further comprising:

providing a second circuit configured to;

power the electronic device from the second battery when the battery pack is connected to the electronic device and no external power source is connected to the battery pack; and

power the electronic device and charge both the first battery and the second battery from an external power source when the battery pack is connected to the electronic device and the external power source is connected to the battery pack.

20. The method of claim 16, further comprising:

providing an electrical connector configured to electrically connect the battery pack and the electronic device; and

providing an attachment apparatus configured to at least partially surround and attach to the body of the battery pack and to the electronic device.

21. The method of claim 16, further comprising:

providing a charge level indicator at the body to comprise;

a first light source;

a second light source; and

a charge level circuit inside the body and configured for;

illuminating the first light source and not the second light source when the charge level circuit measures a charge level of the second battery to be greater than a first charge level;

illuminating the second light source and not the first light source when the charge level circuit measures the charge level of the second battery to be less than a second charge level.

22. The method of claim 16, further comprising:

configuring the rechargeable battery pack for use with a digital music player.

23. A rechargeable battery pack capable of providing electric power to an electronic device having internally a first battery, the rechargeable battery pack comprising:

a body;

a second battery inside the body and supplemental to the first battery inside the electronic device; and

a first circuit inside the body and comprising a power switch set;

wherein;

when an external power source is decoupled from an external power input of the rechargeable battery pack, the power switch set is configured to couple a first power path from the second battery to the electronic device;

when the external power source is coupled to the external power input of the rechargeable battery pack, the power switch set is configured to;

decouple the first power path from second battery from the electronic device; and

couple a second power path from the external power source to the electronic device;

and

the first circuit comprises;

a first transistor having a first terminal electrically coupled to an input of the first battery;

a second transistor having a first terminal electrically coupled to an output of the second battery;

a third transistor having a first terminal electrically coupled to the external power source;

a first resistor electrically coupled to a second terminal of the third transistor;

a first diode electrically coupled to a second terminal of the second transistor;

a first capacitor and a second resistor electrically coupled to the first diode;

a second capacitor and a third resistor electrically coupled to a second terminal of the first transistor; and

a second diode electrically coupled to a third terminal of the first transistor.