Portable battery powered welder

• US 9,399,263 B2
• Filed: 08/31/2007
• Issued: 07/26/2016
• Est. Priority Date: 08/31/2007
• Status: Active Grant

• Current Assignee: Hobart Brothers Company (Illinois Tool Works Inc.)
• Original Assignee: Hobart Brothers Company (Illinois Tool Works Inc.)
• Inventors: Bashore, Brian S., Sickels, Darrell L., Vogel, Bernard J., Krisher, Caleb R.
• Primary Examiner(s): PAIK, SANG YEOP
• Application Number:
  US11/848,874
• Publication Number:
  US 20090057285A1
• Time in Patent Office: 3,252 Days
• Field of Search: 219/130.1, 219/137.2, 219/137.31, 219/137.7, 219/137.PS
• US Class Current: 1/1
• CPC Class Codes: B23K 9/1006 Power supply
• CPC Class Codes: B23K 9/32 Accessories earthing connections H01R

Abstract

A portable battery powered welder is disclosed that is configured to operate without an external power source. The portable battery powered welder may include a battery coupled to a welding circuit and a wire feeder. Further, the portable battery powered welder may include a suitcase to integrally support and completely enclose the welding circuit, the battery, and the wire feeder. The suitcase may include a lateral access door having a hinge and a latch. Additionally, the wire feeder and a wire spool may be disposed in a region accessible by the lateral access door. The suitcase may also include an access panel disposed over a region containing the battery. The access panel may be mounted to the case via a snap mount and/or secured via fasteners. Finally, the suitcase may include a top handle and may be made of a lightweight, impact resistant, and flame retardant material.

Claims

1. A battery powered welder, comprising:

a battery;

a welding circuit configured to output a welding power using power from the battery;

a wire feeder configured to feed a welding wire using power from the battery; and

a suitcase integrally supporting and completely enclosing the welding circuit, the battery, and the wire feeder, wherein the suitcase comprises;

a lateral access door comprising a first access panel over a first compartment supporting the wire feeder, and a second access panel over a second compartment supporting the battery, the first and second access panels are disposed along a common side of the suitcase, and the first and second access panels are coupled together at a hinge, wherein the hinge is configured to enable the lateral access door to be disengaged and removed from the suitcase, and wherein the lateral access door comprises a groove extending around a perimeter of the lateral access door and configured to engage a mating protrusion of a body of the suitcase; and

a side panel comprising a first structural rib defining a first protective recess, and an external control panel disposed within the first protective recess, such that one or more input devices disposed on the external control panel are enclosed within the first structural rib.

2. The battery powered welder of claim 1, wherein the first access panel comprises a latch configured to removably secure the first access panel in a closed position relative to the suitcase.

3. The battery powered welder of claim 1, wherein the second access panel comprises a snap-fit configured to removably secure the second access panel to the suitcase.

4. The battery powered welder of claim 1, wherein the suitcase is made of a flame retardant polymer.

5. The battery powered welder of claim 1, wherein the first and second access panels completely cover the common side of the suitcase.

6. The battery powered welder of claim 5, wherein the first access panel is substantially larger than the second access panel.

7. The battery powered welder of claim 1, comprising a power conversion and conditioning circuit and a battery charging circuit disposed in the suitcase and coupled to the battery.

8. The battery powered welder of claim 1, comprising a work clamp and a welding gun coupled to the wire feeder and the welding circuit.

9. The battery powered welder of claim 1, comprising a gas supply system disposed in the suitcase.

10. The battery powered welder of claim 1, comprising a voltage polarity unit configured to switch a positive and negative voltage potential in the battery powered welder, wherein the voltage polarity unit is disposed in the suitcase.

11. The battery powered welder of claim 1, wherein the second compartment is configured to receive the battery.

12. The battery powered welder of claim 11, wherein the second access panel is removable from the body of the suitcase to enable access to the battery.

13. The battery powered welder of claim 11, wherein the second access panel comprises a first set of snap-mounting features configured to engage with a second set of snap mounting features on the body of the suitcase to secure the second access panel to the body of the suitcase.

14. The battery powered welder of claim 1, wherein the external control panel comprises a work clamp connection, a welding wire outlet, a welding gun connection point, a welding output control, or a combination thereof.

15. The battery powered welder of claim 1, wherein the external control panel comprises a ready indicator, a low battery indicator, an over temperature indicator, a battery charge indicator, or a combination thereof.

16. A battery powered welder, comprising:

a battery;

a circuitry comprising a welding circuit and a power conversion circuit, wherein the circuitry is coupled to the battery, and the circuitry is configured to output a welding power using power from the battery;

a wire feeder configured to feed a welding wire using power from the battery; and

a suitcase supporting the circuitry, the wire feeder, and the battery, wherein the suitcase comprises;

at least one compartment supporting the wire feeder and the battery;

at least one access panel configured to open and close at least one opening into the at least one compartment, wherein the at least one compartment comprises a first compartment and a second compartment, the at least one access panel comprises a first access panel disposed over the first compartment and a second access panel disposed over the second compartment, the second access panel comprising a hinge and a first set of snap-mounting features that engage with a second set of snap mounting features on a body of the suitcase to removably couple the second access panel to the body of the suitcase, wherein the wire feeder is disposed in the first compartment, and the battery is disposed in the second compartment, wherein the first and second access panels are disposed on a common side of the suitcase, wherein the first access panel is coupled to the second access panel at the hinge; and

a side panel having a first structural rib defining a first protective recess, wherein a power switch and a power interface are disposed within the first protective recess, such that the power switch and the power interface are enclosed within the first structural rib.

17. The battery powered welder of claim 16, wherein the wire feeder and a wire spool mount are disposed inside the at least one compartment, and the wire spool mount is configured to support a wire spool inside the at least one compartment.

18. The battery powered welder of claim 16, wherein the circuitry comprises a battery charger circuit configured to recharge the battery.

19. The battery powered welder of claim 16, comprising a gas supply system disposed in the suitcase.

20. The battery powered welder of claim 16, comprising a voltage polarity unit configured to switch a positive and negative voltage potential in the battery powered welder, wherein the voltage polarity unit is disposed in the suitcase.

21. The battery powered welder of claim 16, wherein the first and second access panels substantially cover the common side of the suitcase.

22. The battery powered welder of claim 16, wherein the second access panel is removable from the body of the suitcase to enable access to the battery.

23. The battery powered welder of claim 16, wherein the at least one access panel comprises a groove extending around a perimeter of the at least one access panel configured to engage a mating protrusion of the body of the suitcase.

24. A battery powered welder, comprising:

a suitcase comprising;

at least one access panel disposed over at least one compartment, wherein the at least one access panel comprises a groove extending around a perimeter of the at least one access panel and configured to engage a mating protrusion of a body of the suitcase, wherein an interface between the groove and the mating protrusion comprises a seal, wherein the at least one access panel comprises first and second access panels disposed on a common side of the suitcase, the second access panel comprising a hinge and a first set of snap-mounting features that engage with a second set of snap mounting features on the body of the suitcase to removably couple the second access panel to the body of the suitcase, wherein the first and second access panels completely cover the common side of the suitcase, and the first and second access panels are coupled together at the hinge, wherein the hinge is configured to enable the at least one access panel to be disengaged and removed from the suitcase;

a first side panel having a first structural rib defining a first protective recess, and an external control panel disposed within the first protective recess, such that one or more input devices disposed on the external control panel are enclosed within the first structural rib; and

a second side panel having a second structural rib defining a second protective recess, wherein a power switch and a power interface are disposed within the second protective recess, such that the power switch and the power interface are enclosed within the second structural rib;

a battery disposed in the suitcase within the at least one compartment, wherein the battery may be accessed when the second access panel is removed; and

a welding circuit disposed in the suitcase, wherein the welding circuit is configured to output a welding power using power from the battery;

wherein the first access panel is disposed over the battery, and the second access panel is disposed over a welding component.

25. The battery powered welder of claim 24, wherein the at least one access panel comprises a tool-free fastener configured to mount the at least one access panel to the suitcase without use of a tool.

26. The battery powered welder of claim 24, wherein the first and second access panels, when coupled to the body of the suitcase, form a seal for the at least one compartment.