Battery with integrated power inverter

• US 9,461,488 B2
• Filed: 06/07/2012
• Issued: 10/04/2016
• Est. Priority Date: 06/09/2011
• Status: Active Grant

• Current Assignee: Vector Products Incorporated (Stanley Black & Decker, Inc.)
• Original Assignee: Henry Shum, Mathew Inskeep
• Inventors: Shum, Henry, Inskeep, Mathew
• Primary Examiner(s): AMAYA, CARLOS DAVID
• Application Number:
  US13/490,590
• Publication Number:
  US 20120313431A1
• Time in Patent Office: 1,580 Days
• Field of Search: 307/9.1, 429/163
• US Class Current: 1/1
• CPC Class Codes: H01M 2220/20 Batteries in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H02J 2207/20 Charging or discharging characterised by the power electronics converter
• CPC Class Codes: H02J 7/0042 characterised by the mechanical construction
• CPC Class Codes: H02M 7/003 Constructional details, e.g. physical layout, assembly, wiring or busbar connections
• CPC Class Codes: H05K 7/1432 specially adapted for power drive units or power converters
• CPC Class Codes: H05K 7/14324 comprising modular units, e.g. DIN rail mounted units
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing

Abstract

A vehicle battery having an integrated power inverter includes an outer housing having a positive terminal and a negative terminal located exterior to the outer housing; a battery located in the outer housing, the battery having a positive output and a negative output that together output a DC current, wherein the positive output is coupled to the positive terminal and the negative output is coupled to the negative terminal; a power inverter located in the outer housing, the power inverter having a DC input coupled to the positive and negative outputs of the battery, and an AC output; and an AC socket coupled to the AC output. A shell for a vehicle battery having an integrated power inverter, and a method of making a vehicle battery having an integrated power inverter are also described.

Claims

1. An integrated DC and AC power supply constructed to fit into a space provided in a vehicle for an existing battery, comprising:

an outer housing having a positive terminal and a negative terminal located exterior to the outer housing;

a partition inside the outer housing defining a battery compartment and a second compartment, the partition constructed to at least one of conductively and thermally isolate the battery compartment from the second compartment;

a battery located in the battery compartment of the outer housing, the battery having a positive output and a negative output that together output a DC current, wherein the positive output is coupled to the positive terminal and the negative output is coupled to the negative terminal;

a power inverter located in the second compartment of the outer housing, the power inverter having a DC input coupled to the positive and negative outputs of the battery, and an AC output accessible from an exterior of the outer housing; and

an AC socket coupled to the AC output;

wherein the outer housing of the integrated DC and AC power supply has dimensions to fit in the space provided for the existing battery so that the integrated power system comprises a drop-in replacement for the existing battery.

2. The integrated DC and AC power supply of claim 1, wherein the outer housing includes a top surface, and the positive and negative terminals extend from the top surface of the outer housing.

3. The integrated DC and AC power supply of claim 1, wherein the AC socket is located on an exterior surface of the outer housing.

4. The integrated DC and AC power supply of claim 1, further comprising:

a cable extending from the AC output of the power inverter to the AC socket, wherein the AC socket is located remotely from the outer housing.

5. The integrated DC and AC power supply of claim 1, further comprising:

a switch adapted to turn the power inverter on and off.

6. The integrated DC and AC power supply of claim 1, wherein the battery compartment is a hollow space located below the second compartment and having an open top.

7. The integrated DC and AC power supply of claim 6, wherein the partition comprises a top cover located on the open top and covering the battery compartment, wherein the power inverter is housed in the top cover.

8. The integrated DC and AC power supply of claim 7, wherein the positive terminal and the negative terminal extend from the top cover.

9. The integrated DC and AC power supply of claim 1, further comprising a USB port located on the outer housing and powered by the battery.

10. The integrated DC and AC power supply of claim 1, wherein the vehicle battery is generally rectangular and defines a maximum length of between about 7 inches and about 21 inches, a maximum width of between about 4 inches and about 12 inches, and a maximum height of between about 6 inches and about 12 inches.

23. The integrated DC and AC power system of claim 1, further comprising:

a remote module located remotely from the outer housing and connected to the outer housing by a cable, wherein the AC socket is located on the remote module;

a USB port located on the remote module and electrically coupled to the battery by the cable; and

a switch located on the remote module and adapted to turn at least one of the power inverter or the USB port on an off.

24. The integrated DC and AC power system of claim 1, wherein the outer housing is adapted with mounting features to fix the outer housing in the space provided in the vehicle for the existing battery.

11. A shell for use with a vehicle battery and a power inverter to form an integrated DC and AC power supply, the shell comprising:

an outer housing;

a partition inside the outer housing defining a battery compartment adapted to hold a battery and a second compartment, the partition constructed to at least one of conductively and thermally isolate the battery compartment from the second compartment;

a positive terminal and a negative terminal located exterior to the outer housing, the positive and negative terminals extending into the battery compartment and adapted to couple to a positive output and a negative output of the battery, respectively;

a power inverter located in the second compartment of the outer housing, the power inverter having a DC input adapted to couple to the positive and negative outputs of the battery, the power inverter also having an AC output; and

an AC socket connected to the AC output;

wherein the outer housing has dimensions to fit in a space of a vehicle provided for an existing battery so that the integrated DC and AC power supply comprises a drop-in replacement for the existing battery.

12. The shell of claim 11, wherein the outer housing includes a top surface, and the positive and negative terminals extend from the top surface of the outer housing.

13. The shell of claim 11, wherein the AC socket is located on an exterior surface of the outer housing.

14. The shell of claim 11, further comprising:

a cable extending from the AC output of the power inverter to the AC socket, wherein the AC socket is located remotely from the outer housing.

15. The shell of claim 11, wherein the battery compartment is located below the second compartment and the outer housing includes an open top, and the shell further comprises a top cover covering the open top, wherein the power inverter is housed in the top cover.

16. The shell of claim 11, further comprising a USB port located on the outer housing and adapted to be powered by the battery.

17. The shell of claim 11, wherein the shell is generally rectangular and defines a maximum length of between about 7 inches and about 21 inches, a maximum width of between about 4 inches and about 12 inches, and a maximum height of between about 6 inches and about 12 inches.

25. The shell of claim 11, wherein the outer housing is adapted with mounting features to fix the outer housing in the space provided in the vehicle for the existing battery.

18. A method of making an integrated DC and AC power supply for a vehicle, the method comprising:

providing an outer housing having a hollow interior region and outer dimensions to fit in a space of a vehicle provided for an existing battery so that the integrated DC and AC power supply comprises a drop-in replacement for the existing battery;

inserting a battery into a first portion of the hollow interior region, the battery having a positive output and a negative output and providing DC power suitable for powering DC systems of the vehicle;

separating the first portion of the hollow interior region containing the battery with a partition to at least one of conductively and thermally separate the hollow interior region containing the battery from a second portion of the hollow interior region of the outer housing;

installing a power inverter in the second portion of the outer housing;

coupling a DC input of the power inverter to the positive and negative outputs of the battery, wherein the power inverter has an AC output;

coupling the positive output of the battery to a positive terminal located exterior to the outer housing;

coupling the negative output of the battery to a negative terminal located exterior to the outer housing; and

coupling an AC socket of the power inverter to the AC output of the power inverter.

19. The method of claim 18, wherein installing the power inverter in the outer housing comprises:

attaching a top cover to an open top portion of the outer housing; and

installing the power inverter in the top cover.

20. The method of claim 18, further comprising:

mounting the AC socket to the outer housing.

21. The method of claim 18, further comprising:

connecting a cable between the AC output of the power inverter and the AC socket, wherein the AC socket is located remotely from the outer housing.

22. The method of claim 18, wherein the outer housing is generally rectangular and defines a maximum length of between about 7 inches and about 21 inches, a maximum width of between about 4 inches and about 12 inches, and a maximum height of between about 6 inches and about 12 inches.

26. The method of claim 18, including providing the housing with mounting features to fix the housing containing the battery and the power inverter in the space provided in the vehicle for the existing battery.