Battery charger with high frequency transformer
First Claim
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1. A daisy chained battery charging system for charging a plurality of vehicle batteries, the charging system comprising:
- a plurality of power supplies, each power supply electrically coupled in a daisy chain configuration and each power supply sharing a common input power, each power supply including a high-frequency transformer, and each power supply configured to deliver a DC battery charging power to charge at least one vehicle battery;
each power supply including a wind tunnel, the wind tunnel formed by a first end and a second end coupled to a base, an L-shaped assembly coupled to at least one of the first end, the second end, and the base, and a side coupled to at least one of the first end, the second end, and the base;
the high-frequency transformer positioned within the wind tunnel of each power supply including;
a bobbin including an elongated top and bottom surfaces and first and second substantially semi-circular end surfaces connecting the top surface with the bottom surface to form an elongated first coil winding surface having a central axis;
a first coil wound around the first coil winding surface; and
a second coil magnetically coupled to the first coil and wound thereto.
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Abstract
A battery-charging system includes a power supply having a high-frequency transformer and is configured to deliver a battery charging power to charge at least one battery. The high-frequency transformer has a bobbin including an elongated top and bottom surfaces and first and second substantially semi-circular end surfaces connecting the top surface with the bottom surface to form an elongated first coil winding surface having a central axis. A first coil is wound around the first coil winding surface, and a second coil is magnetically coupled to the first coil and wound thereto.
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Citations
20 Claims
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1. A daisy chained battery charging system for charging a plurality of vehicle batteries, the charging system comprising:
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a plurality of power supplies, each power supply electrically coupled in a daisy chain configuration and each power supply sharing a common input power, each power supply including a high-frequency transformer, and each power supply configured to deliver a DC battery charging power to charge at least one vehicle battery; each power supply including a wind tunnel, the wind tunnel formed by a first end and a second end coupled to a base, an L-shaped assembly coupled to at least one of the first end, the second end, and the base, and a side coupled to at least one of the first end, the second end, and the base; the high-frequency transformer positioned within the wind tunnel of each power supply including; a bobbin including an elongated top and bottom surfaces and first and second substantially semi-circular end surfaces connecting the top surface with the bottom surface to form an elongated first coil winding surface having a central axis; a first coil wound around the first coil winding surface; and a second coil magnetically coupled to the first coil and wound thereto. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 20)
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10. A vehicle battery charging and monitoring system, comprising:
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a power supply including a high-frequency transformer and configured to deliver a direct current battery charging power to charge a vehicle battery; a battery module simultaneously carried by and connected to the vehicle battery, the battery module to provide control and monitoring of the vehicle battery to assess the vehicle battery health, the charging process, charging and discharging history, and fleet operations data; a wind tunnel, the wind tunnel formed by a first end and a second end coupled to a base, an L-shaped assembly coupled to at least one of the first end, the second end, and the base, and a side coupled to at least one of the first end, the second end, and the base; the high-frequency transformer positioned within the wind tunnel and having; a bobbin having a first coil winding surface; a first coil wound around the first coil winding surface; a second coil wound concentric to the first coil; and a cover, wherein the first coil and the second coil are compressed between the first coil winding surface and the cover. - View Dependent Claims (11, 12, 13, 14)
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15. A daisy chained battery charging system for charging at least one vehicle battery, the system comprising:
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a plurality of power supplies, each of the plurality of power supplies being electrically coupled in a daisy chain configuration and each of the plurality of power supplies sharing a common input power, each of the plurality of power supplies including a high-frequency transformer, each of the plurality of power supplies configured to deliver a DC battery charging power to charge the at least one vehicle battery; a battery module carried by and connected to at least one of the at least one vehicle battery, the battery module to provide control and monitoring of the at least one vehicle battery to assess vehicle fleet operations data; each of the plurality of power supplies including a wind tunnel, the wind tunnel formed by a first end and a second end coupled to a base, an L-shaped assembly coupled to at least one of the first end, the second end, and the base, and a side coupled to at least one of the first end, the second end, and the base; the high frequency transformer positioned within the wind tunnel and having; a first coil; a second coil magnetically coupled to the first coil, the second coil including a plurality of second coil turns; and a plurality of locating spacers disposed to maintain a desired spacing between each of the plurality of second coil turns; and at least one battery charging cable extending from the power supply, the at least one battery charging cable including a connector for coupling to the battery within the vehicle. - View Dependent Claims (16, 17)
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18. A method of manufacturing a vehicle battery charging system, the method comprising the steps of:
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constructing a vehicle battery charging power supply including electrical connections for receiving a high-frequency transformer; forming a wind tunnel, the wind tunnel formed by coupling a first end and a second end to a base, coupling an L-shaped assembly to at least one of the first end, the second end, and the base, and coupling a side to at least one of the first end, the second end, and the base; forming the high-frequency transformer by; providing a first coil; winding a second coil concentric to the first coil; compressing the first coil and the second coil together to reduce the leakage inductance between the first coil and the second coil to a desired value; mounting the high-frequency transformer within the wind tunnel and to the vehicle battery charging power supply through the electrical connections, such that the vehicle battery charging power supply is configured to deliver a DC battery charging power to charge at least one vehicle battery; and providing a battery module to be simultaneously carried by and connected to the vehicle battery, the battery module providing control and monitoring of the vehicle battery and assessing the vehicle battery health, the charging process, charging and discharging history, and vehicle fleet operations data. - View Dependent Claims (19)
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Specification