Starter system for portable internal combustion engine electric generators using a portable universal battery pack

• US 20060170218A1
• Filed: 12/29/2005
• Published: 08/03/2006
• Est. Priority Date: 06/06/2002
• Status: Active Grant

• Current Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Original Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Inventors: Forster, Michael K., Grant, Jeffrey P.
• Granted Patent: US 7,309,928 B2
• Time in Patent Office: Days
• US Class Current: 290/1.R
• CPC Class Codes: F02D 2200/503 Battery correction, i.e. corrections as a function of the state of the battery, its output or its type
• CPC Class Codes: F02D 29/06 peculiar to engines driving electric generators
• CPC Class Codes: F02N 11/14 Starting of engines by means of electric starters with external current supply F02N11/12 takes precedence
• CPC Class Codes: F02N 2011/0888 DC/DC converters
• CPC Class Codes: H01M 50/202 Casings or frames around the primary casing of a single cell or a single battery
• CPC Class Codes: H01M 50/213 adapted for cells having curved cross-section, e.g. round or elliptic H01M50/209, H01M50/216 take precedence
• CPC Class Codes: H01M 50/244 Secondary casings; Racks; Suspension devices; Carrying devices; Holders characterised by their mounting method
• CPC Class Codes: H01M 50/251 specially adapted for stationary devices, e.g. power plant buffering or backup power supplies
• CPC Class Codes: H02K 7/1815 structurally associated with reciprocating piston engines general aspects of generating sets, e.g. housing, F02B63/04
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

A portable electrical generator has a manually movable frame. An internal combustion engine and a generator device that generates AC power are supported on the frame. The internal combustion engine drives the generator device. An electrically powered starting device is coupled to the internal combustion engine. A control panel is coupled to the frame and includes at least one AC outlet and a battery receptacle that is electrically coupled to the starting device. The battery receptacle is materially the same as a foot of a cordless power tool that receives a battery pack. The battery pack for the cordless power tool is received in the battery receptacle and provides electrical power to the starting device. In another aspect, the battery receptacle is disposed in an enclosure supported by the frame. In an aspect, the enclosure further includes a battery charger. In an aspect, the enclosure also includes an AC outlet electrically coupled to the generator device with the charger being a stand alone charger plugged into the AC outlet of the enclosure. In an aspect, the battery receptacle receives a battery pack that is one of a plurality of battery packs having different voltages and the generator includes a voltage regulation circuit that couples the battery receptacle to the starting device. The voltage regulation circuit provides at an output coupled to the starting device a voltage at a desired level for the starting device regardless of the voltage of the battery pack received in the battery receptacle.

Claims

1. A portable electrical generator system, comprising:

a manually movable frame supporting an internal combustion engine that drives a generator device supported on the frame that generates AC power, the internal combustion engine coupled to the generator device;

an electrically powered starting device coupled to the internal combustion engine;

a control panel coupled to the frame including at least one AC outlet electrically coupled to the generator device and a battery receptacle electrically coupled to the starting device;

the battery receptacle materially the same as a foot of a cordless power tool that receives a battery pack; and

the battery pack received in the battery receptacle and providing electrical power to the starting device.

2. The system of claim 1, wherein the at least one AC outlet includes at one ground fault interrupter outlet and at least one twist-lock outlet.

3. The system of claim 2 wherein the battery receptacle includes a housing having an outer plate that conforms to an upper plate of the battery pack and a central bore that conforms to a tower of the battery pack.

4. The system of claim 3 wherein the housing of the battery receptacle includes catches at opposed sides of the outer plate that mate with latches of the battery pack.

5. The system of claim 4 wherein the outer plate of the housing of the battery pack includes a keyway projecting from the bore in the housing of the battery pack that receives a key at a base of the tower of the battery pack.

6. The system of claim 1 wherein the housing of the battery receptacle includes catches at opposed sides that mate with latches of the battery pack.

7. The system of claim 1 including a collar surrounding the housing of the battery receptacle and secured to the control panel to secure the battery receptacle to the control panel.

8. The system of claim 7 wherein the housing of the battery receptacle includes flanges that project from opposed sides of the outer plate that define slots therebetween that mate with inwardly extending projections of the collar.

9. The system of claim 7, wherein the at least one AC outlet includes at one ground fault interrupter outlet and at least one twist-lock outlet.

10. The system of claim 9 wherein the battery receptacle includes a housing having an outer plate that conforms to an upper plate of the battery pack and a bore that conforms to a tower of the battery pack.

11. The system of claim 10 wherein the housing of the battery receptacle includes catches at opposed sides of the outer plate that mate with latches of the battery pack.

12. The system of claim 1 wherein the battery receptacle receives a battery pack that is one of a plurality of battery packs having different voltages, the system including a voltage regulation circuit coupling the battery receptacle to the starting device, the voltage regulation circuit providing at an output coupled to the starting device a voltage at a desired level for the starting device regardless of the voltage of the battery pack received in the battery receptacle.

13. A portable electrical generator system, comprising:

a manually movable frame supporting an internal combustion engine that drives a generator device supported on the frame that generates AC power, the internal combustion engine coupled to the generator device;

a starting device coupled to the internal combustion engine;

a control panel coupled to the frame having at least one AC outlet coupled to the generator device; and

an enclosure supported by the frame having a battery receptacle therein electrically coupled to the starting device, the battery receptacle configured to receive a battery pack from a cordless power tool, the battery pack received in the battery receptacle and providing electrical power to the starting device.

14. The system of claim 13 wherein the enclosure includes a hinged lid and a base portion, the base portion having the battery receptacle.

15. The system of claim 14 wherein the base portion further includes a charger configured to receive the battery pack from the cordless power tool.

16. The system of claim 15 wherein the base portion includes an AC outlet electrically coupled to the generator device, the charger a stand alone charger that is mounted in the base portion of the enclosure and plugged into the AC outlet of the base portion.

17. The system of claim 13 wherein the battery receptacle is configured to receive a tower type battery pack.

18. The system of claim 13 wherein the battery receptacle is configured to receive a rail type battery pack.

19. The system of claim 13 wherein the battery receptacle receives a battery pack that is one of a plurality of battery packs having different voltages, the system including a voltage regulation circuit coupling the battery receptacle to the starting device, the voltage regulation circuit providing at an output coupled to the starting device a voltage at a desired level for the starting device regardless of the voltage of the battery pack received in the battery receptacle.