Portable alternating current inverter having reduced impedance losses

• US 8,994,336 B2
• Filed: 11/01/2010
• Issued: 03/31/2015
• Est. Priority Date: 02/26/2007
• Status: Active Grant

• Current Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Original Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Inventors: Brotto, Daniele C., Cruise, Nathan J., Ekstrom, Erik, Wang, Ren, Abolhassani, Mehdi T., Spencer, William D., Seman, Andrew E. Jr., Eshleman, Scott, Bailey, Rouse Roby Jr.
• Primary Examiner(s): Tso, Edward
• Assistant Examiner(s): PIGGUSH, AARON C
• Application Number:
  US12/917,128
• Publication Number:
  US 20110090726A1
• Time in Patent Office: 1,611 Days
• Field of Search: 320/107, 320/111, 320/113, 320/136, 320/141
• US Class Current: 320/136
• CPC Class Codes: H02J 2207/20 Charging or discharging characterised by the power electronics converter
• CPC Class Codes: H02J 3/00 Circuit arrangements for ac mains or ac distribution networks
• CPC Class Codes: H02J 7/0063 with circuits adapted for supplying loads from the battery
• CPC Class Codes: H02J 7/007182 in response to battery voltage
• CPC Class Codes: H02J 7/34 Parallel operation in networks using both storage and other dc sources, e.g. providing buffering H02J7/14 takes precedence
• CPC Class Codes: H02M 7/003 Constructional details, e.g. physical layout, assembly, wiring or busbar connections
• CPC Class Codes: H02M 7/04 by static converters
• CPC Class Codes: H02M 7/44 by static converters
• CPC Class Codes: H02M 7/49 Combination of the output voltage waveforms of a plurality of converters
• CPC Class Codes: H02M 7/537 using semiconductor devices only, e.g. single switched pulse inverters

Abstract

A portable power supply apparatus is provided having reduced impedance losses. The portable power supply apparatus is comprised of: a portable housing; a battery system residing in the housing; and an inverter circuit residing in the housing. The battery system generates a direct current (DC) voltage having a magnitude greater than or equal to a peak value of a desired alternating current (AC) voltage. The inverter circuit receives the DC voltage directly from the battery system, converts the DC voltage to an AC output voltage and outputs the AC output voltage to one or more outlets exposed on an exterior surface of the portable housing.

Claims

1. A portable power supply apparatus comprising:

a portable housing;

a battery system comprised of a plurality of batteries residing in the housing, the plurality of batteries generating a direct current (DC) voltage having a magnitude greater than or equal to a peak value of a desired alternating current (AC) voltage; and

an inverter circuit residing in the housing, the inverter circuit configured to receive the DC voltage directly from the plurality of batteries, convert the DC voltage generated by the plurality of batteries to an AC output voltage and output the AC output voltage to one or more outlets exposed on an exterior surface of the portable housing.

2. The portable power supply apparatus of claim 1 wherein the plurality of batteries generate a DC voltage having a magnitude greater than 150 volts (V).

3. The portable power supply apparatus of claim 1 wherein the inverter circuit modifies a waveform of the AC output voltage when the plurality of batteries generate a DC voltage having a magnitude less than the peak value of the desired AC voltage.

4. The portable power supply apparatus of claim 3 wherein the inverter circuit increases a duty cycle of pulse-width modulated (PWM) signals that control switching in the inverter circuit to maintain a root-mean-square (RMS) of the AC output voltage greater than or equal to an RMS of the desired AC voltage.

5. The portable power supply apparatus of claim 1 further comprises a power supply module residing in the housing and configured to receive an AC input signal from a power source external to the housing, the power supply module provides a charging current to the battery system.

6. The portable power supply apparatus of claim 5 wherein the power source is further defined as an internal combustion engine (ICE) generator.

7. The portable power supply apparatus of claim 5 further comprises a control module configured to monitor charge level of the plurality of batteries and selectively control the power supply module to charge the battery system.

8. The portable power supply apparatus of claim 5 wherein the power supply module includes a battery charge circuit electrically coupled to an AC power plug.

9. The portable power supply apparatus of claim 1 wherein the battery system includes one or more replaceable battery units, the replaceable battery units each having a storage capacity less than or equal to the storage capacity of the battery system.

10. A portable power supply apparatus comprising:

a portable housing, the housing having an exterior surface, the exterior surface having at least one outlet for providing an alternating current (AC) output voltage;

a battery system having a plurality of batteries housed in the housing, wherein the plurality of batteries generate a direct current (DC) voltage having a magnitude greater than or equal to a peak value of the AC output voltage; and

an inverter circuit housed in the housing, the inverter circuit configured to receive the DC voltage directly from the plurality of batteries and convert the DC voltage generated by the plurality of batteries to the AC output voltage.

11. A portable power supply apparatus, as recited in claim 10, wherein the portable power supply apparatus has a weight and outputs electrical power at a power-to-weight ratio greater than 50 watts (W) per pound.

12. The portable supply apparatus of claim 11 wherein the portable power supply apparatus weighs between 20 and 50 pounds.

13. The portable power supply apparatus of claim 11 wherein the portable power supply apparatus weighs approximately 35 pounds.

14. The portable power supply apparatus of claim 11 wherein the inverter circuit generates greater than or equal to 1500 W of continuous power.

15. The portable power supply apparatus of claim 11 wherein the inverter circuit generates greater than or equal to 3000 W of peak power.

16. The portable power supply apparatus of claim 11 wherein the inverter circuit receives the DC voltage directly from the plurality of batteries, the DC voltage having a magnitude greater than or equal to a peak value of a desired AC voltage output by the apparatus.

17. The portable power supply apparatus of claim 11 further comprises a power supply module residing in the housing, the power supply module configured to receive an AC input signal from a power source external to the housing and provide a charging current to the plurality of batteries.

18. The portable power supply apparatus of claim 17 further comprises a control module configured to monitor charge level of the plurality of batteries and selectively control the power supply module to charge the plurality of batteries.

19. The portable power supply apparatus of claim 11 wherein the inverter circuit modifies a waveform of the AC output voltage when the plurality of batteries generate a DC voltage having a magnitude less than a peak value of the desired AC voltage.

20. The portable power supply apparatus of claim 19 wherein the inverter circuit increases a duty cycle of pulse-width modulated (PWM) signals that control switching in the inverter circuit to maintain a root-mean-square (RMS) of the AC output voltage greater than or equal to an RMS of the desired AC voltage.