Multistation modular charging system for cordless units

• US 4,739,242 A
• Filed: 05/08/1986
• Issued: 04/19/1988
• Est. Priority Date: 12/17/1984
• Status: Expired due to Fees

• Current Assignee: Solid State Chargers Research and Development Limited Partnership
• Original Assignee: Solid State Chargers Research and Development Limited Partnership
• Inventors: McCarty, George W., Smith, Somers H. III
• Primary Examiner(s): Hickey, R. J.
• Application Number:
  US06/860,805
• Time in Patent Office: 712 Days
• Field of Search: 320/2-5, 320/15, 320/21, 429/96-100, 30/DIG. 1, 310/50
• US Class Current: 320/110
• CPC Class Codes: H02J 7/0013 acting upon several batteries simultaneously or sequentially H02J7/1423 takes precedence
• CPC Class Codes: H02J 7/0042 characterised by the mechanical construction
• CPC Class Codes: Y10S 30/01 Rechargeable battery operated

Abstract

A multistation charging system is provided for charging batteries within a plurality of cordless tools, appliances or the like, each of which has at least one rechargeable battery therein. A plurality of modules, which act as charging stations, are arranged substantially adjacent to one another. Normally closed pairs of conductive contacts are provided in each of the modules. The electrical pairs of contacts in the modules are connected in a series circuit arrangement with each other. On one of the modules, electrical connection is provided to a single current regulated solid-state charging device which produces charging current pulses. The device may alternatively be in the one module. Each of the modules removably supports a respective tool or appliance and each tool or appliance has means for electrically connecting the respective battery therein within the series circuit arrangement and in series therewith only one wall outlet or a.c. power connection is required. Any combination of batteries per tool or appliance and any number of tools or appliances may be provided. Any number of the modules may be unoccupied. The modules are of standard construction, allowing charging of batteries or cells within many different tools and appliances provided with standardized connections.

Claims

1. A multistation modular charging system for charging a plurality of units, each of which has at least one rechargeable battery therein and at least one electric contact means therein for conducting d.c. current to the at least one rechargeable battery, the charging system comprising an electrically conductive series circuit having a plurality of normally closed pairs of contacts, each of said pairs of contacts being in electrical series with each other of said pairs of contacts;

a power source;

a charging means receiving current from said power source, said charging means being connected to said electrically conductive series circuit; and

a plurality of modules including circuitry for completing said electrically conductive series circuit, each of said modules having therein at least one pair of said plurality of normally closed pairs of contacts, each of the units having a respective said at least one electrical contact means connected to the respective at least one rechargeable battery therein, each of said modules having a releasable connection means for incorporating the respective electrical contact means of respective said units, when the units are in place, into said electrically conductive series circuit via respective pairs of said normally closed pairs of contacts by effecting opening thereof, at least all of said modules other than one constituted by a last module of said plurality of modules having a respective further normally closed pair of contacts, at least all of said modules other than one constituted of a first of said plurality of modules having further contact means for engaging a respective one pair of said further normally closed pairs of contacts in an adjacent one of said modules;

whereby rechargeable batteries within the units may be placed in series with said electrically conductive series circuit and each other to be charged by the d.c. current flowing in the series circuit.

2. The multistation modular charging system according to claim 1, wherein said last module has a pair of additional normally closed pair of contacts and at least all of said modules other than the first and last thereof have a respective one of said further contact means engaging a respective one of said further normally closed pair of contacts in an adjacent one of said modules, said additional normally closed pair of contacts being provided so that an additional module may be added.

3. The multistation modular charging system according to claim 2, wherein said first module has an additional contact means therein for receiving d.c. current for delivery to the electrically conductive series circuit, said additional contact means being substantially similar to said further contact means;

and wherein all of the modules are interchangeable.

4. The multistation modular charging system according to claim 3, wherein all of the modules are substantially identical.

5. The multistation modular charging system according to claim 1, wherein said first module has an additional contact means therein for receiving d.c. current for delivery to the electriclly conductive series circuit.

6. A charging system according to claim 1, wherein one of said modules is a base module, the system further comprising a line cord and plug to be connected to the power source.

7. A charging system according to claim 6, wherein said charging means at least partially is disposed in said plug.

8. A charging system according to claim 6, wherein said charging means is at least partially disposed in a portion of said line cord.

9. A charging system according to claim 1, wherein said charging means comprises a solid-state device generating a series of current pulses to charge the respective batteries in the units, said solid-state device being current regulated.

10. A charging system according to claim 1, wherein each of said modules includes latching means for securing said modules in abutting relationship with one another in a linear array thereof.

11. A charging system according to claim 1, wherein said series circuit includes a pair of conductor strips in each of said modules.

12. A charging system according to claim 1, wherein said charging means comprises a current regulated, d.c. current pulse producing circuit.

13. A multistation modular charging system for charging a plurality of cordless devices such as tools, appliances or other battery powered units from a power source, comprising a base module, a line cord associated with the base module, means for connecting the line cord to the power source, a solid state charging device electrically connected to the line cord and the power source and generating a plurality of charging current pulses, first normally closed spring contact means carried by the base module, means on the base module for supporting a first cordless device, said last-named means including means for electrically engaging the first normally closed spring contact means to receive charging current for charging the first cordless device, at least one satellite module laterally of the base module, means for mechanically supporting the satellite module on the base module, second normally closed spring contact means carried by the satellite module and in series with the first normally closed spring contact means, means including respective further normally closed spring contact means in each of said modules for completing the series circuit, and means on the satellite module for supporting a second cordless device, said last-named means including means for electrically engaging the second normally closed spring contact means to receive charging current for charging the second cordless device.

14. The multistation modular charging system according to claim 13, wherein said solid state charging device comprises a current regulated, d.c. current pulse producing circuit.

15. A multistation modular charging system for charging a plurality of cordless devices such as tools, appliances or other battery powered units comprising a base module, means for supporting the base module on a wall or other surface, charging means associated with the base module, a plurality of substantially identical satellite modules, means for removably connecting one of the satellite modules to the base module laterally thereof, means for removably securing the remaining satellite modules to each other and to the one satellite module and hence to the base module, in sequence, and progressively laterally thereof in a direction away from the base module, respectively normally closed contact means in the base module and in each of the satellite modules and including a respective pair of spring contacts normally engaging one another, means including further normally closed contact means in each of said modules for connecting the first said respective normally closed contact means in series with each other as the satellite modules are connected sequentially to each other and to the base module and for completing the series circuit, means on the base module and on the satellite modules, respectively, for supporting the respective cordless devices and adapted to engage and to be received between the respective spring contacts in electrical engagement therewith when the respective cordless device is supported on the base module or on one of the satellite modules, whereby the cordless devices may be charged simultaneously by the charging means, and whereby all of the cordless devices are charged in electrical series.

16. The multistation modular charging system according to claim 15, wherein said charging means comprises a current regulated, d.c. current pulse producing circuit.

17. A multistation modular charging system for charging a plurality of cordless devices such as tools, appliances or other battery powered units from a power source, comprising a plurality of modules, at least some of which are substantially identical, means for removably connecting the modules together in sequence, electrical contact means within each of the modules, means including a respective pair of normally closed spring contacts in each of said modules for serially connecting the respective electrical contact means as the modules are connected together, adjacent ones of said modules having cooperating mechanical securing means adapted to engage each other as the respective electrical contact means are serially connected, charging means connected between the power source and the electrical contact means on at least one of the modules, means on each module for supporting a respective cordless device, each of the electrical contact means including a pair of additional normally closed spring contacts, and conductive rod means carried by each of the cordless devices and adapted to engage and to be received between the respective additional normally closed spring contacts in electrical engagement therewith when the respective cordless device is supported on a selected one of the modules.

18. The multistation charging system according to claim 17, wherein said charging means comprises a current regulated, d.c. current pulse producing circuit.

19. A multistation modular charging system for charging a plurality of cordless devices such as tools, appliances or other battery powered units from a power source, comprising a base module having a line cord connected to the power source, a charging device operatively associated with the base module, means on the base module for storing an excess portion of the line cord, means for supporting a first cordless device having a first electrically conductive means therein to carry d.c. charging current to at least one rechargeable battery therein on the base module, first electrical contact means in said base module for providing a conductive d.c. current path between the charging device and the first electrically conductive means in the first cordless device, a satellite module, means for mounting the satellite module on the base module, second electrical contact means in the satellite module for providing a conductive d.c. current path, means including a pair of normally closed spring contacts in said base module and a pair of fixed contacts in said satellite module which engage and spread said pair of normally closed spring contacts for connecting the second electrical contact means in electrical series with the first electrical contact means and with the charging device operatively associated with the base module, means for supporting a second cordless device having a second electrically conductive means therein to carry d.c. charging current to at least one rechargeably battery therein, and electrical connection means within said base module and within said satellie module providing a series connection between the second electrical contact means within the satellite module and the second electrical contact means within the base module.

20. The multistation modular charging system according to claim 19, wherein said charging device comprises a current regulated, d.c. current pulse producing circuit.

21. In a multistation charging system for charging a plurality of units from an alternating current source, each of the units having at least one rechargeable battery therein, the combination of a plurality of charging stations arranged substantially adjacent to one another, respective first normally closed electrical contact means in each of the charging stations, means including respective second normally closed electrical contact means in each of said charging stations for connecting the first normally closed respective electrical contact means in all of the adjacent charging stations in an electrically conductive series circuit with each other, means operatively associated with one of the charging stations for connecting the electrically conductive series circuit including the respective electrical contact means therein to the current source, said last-named means including a charging device having a current regulating circuit and generating a series of charging current pulses, means on each of the charging stations for removably supporting a respective one of said plurality of units, and means on each unit for electrically connecting the respective battery therein within the electrically conductive series circuit and in series therewith and in series with other batteries within the series circuit.

22. The combination of claim 21, wherein each of the charging stations comprises a respective module.

23. The combination of claim 21, wherein the charging stations are arranged laterally of one another.

24. The combination of claim 21, further including means for removably latching the charging stations together.

25. The combination of claim 21, wherein the charging device comprises an integrated circuit.

26. The combination of claim 21, wherein each of the units comprises a cordless battery-operated device having a substantially cylindrical handle, and wherein the means for removably supporting the cordless device comprises, in each of the charging stations, a respective shaped recess formed therein for receiving the handle of the cordless device, a protruding boss formed on the recess, and the handle having a complementary recess formed therein for receiving the boss.

27. The multistation charging system according to claim 26, wherein said charging device comprises an integrated circuit.

28. In a multistation charging system for charging a plurality of units from an alternating current source, each of the units having at least one rechargeable battery therein, the combination of a plurality of charging stations arranged substantially adjacent to one another, electrical contact means in each of the charging stations, means including a respective pair of normally closed spring contacts in each of the stations for connecting the respective electrical contact means in the adjacent charging stations in a series circuit arrangement with each other, means on one of the charging stations for connecting the respective electrical contact means therein to the current source, said last-named means including a solid-state charging device having a current regulating circuit and generating a series of current pulses, means on each of the charging stations for removably supporting a respective unit, and means on each unit for electrically connecting the respective at least one rechargeable battery therein within the series circuit arrangement, wherein each of the units comprises a cordless battery-powered device having a substantially cylindricl handle, and wherein the means for removably supporting a respective unit comprises at each of the charging stations a scalloped recess formed therein for receiving the handle of the cordless device and a protruding boss formed on the recess, the handle having a complementary recess formed therein for receiving the boss, and wherein the means on each unit for electrically connecting the respective at least one rechargeable battery therein within the series circuit arrangement comprises a rod carried by the handle within the recess therein, a pair of conductive strips on the rod, means for electrically connecting the respective battery between the pair of conductive strips, the electrical contact means in the respective charging station comprising a pair of substantially parallel conductive strips, one of the pair of strips comprising respective elements normally engaging one another and resiliently biased towards each other, and the rod being inserted between the respective elements such that the conductive strips on the rod engage the respective elements.

29. The multistation charging system according to claim 28, wherein said solid-state charging device comprises an integrated circuit.

30. A modular system for charging batteries in cordless devices such as tools or the like, the system comprising housing means having a plurality of shaped recesses formed therein;

a plurality of cordless devices, each of which has a shaped portion adapted to be received in the respective recesses and supported therein;

at least one battery in each of the devices, each of the shaped portions having an opening therein;

a respective boss associated with each of the recesses and adapted to be received within a respective said opening in a respective said shaped portion, thereby removably supporting a respective said cordless device within its associated said recess in the housing means;

respective pairs of spaced apart contacts within each of the shaped portions and associated with its respective said opening therein;

a respective pair of normally closed contacts associated with a respective said boss in each of the respective recesses in the housing means, such that when the shaped portion of a respective cordless device is removably received within one of the respective recesses in the housing means, the respective boss fits within the respective opening in the shaped portion, and the respective spaced apart contacts spring the contacts of a respective said normally closed pair of contacts apart and engage these contacts in electrical series therewith;

normally conductive means for electrically serially connecting the pairs of normally closed contacts; and

current regulated charging means for supplying a series of battery charging current pulses to the serially connected normally closed pairs of contacts in the housing via said normally conductive means;

whereby batteries within the devices may receive, via the spaced apart contacts and the normally conductive means, the charging current pulses.

31. The modular system according to claim 30, wherein at least some of said shaped portions of said devices are constituted by a respective handle of respective said devices.

32. The modular system according to claim 31, wherein the respective said at least one battery is carried within the respective said handle.

33. The modular system according to claim 30, wherein said recesses are substantially identical to each other and said shaped portions are substantially identical to each other.

34. The modular system according to claim 30, wherein said current regulated charging means comprises an integrated circuit.

35. A modular system for cordless devices such as tools or the like, comprising a housing, the housing having a plurality of substantially identical recesses formed therein, a plurality of cordless devices, each of which has a handle portion adapted to be received interchangeably in the respective recesses and supported therein, a battery in each of the handles, each of the handles having an opening therein, a protuberance associated with each of the recesses and adapted to be received within the opening of a respective handle, thereby removably supporting the respective cordless device within its recess in the housing, first spaced contacts carried by each of the handles and associated with its respective opening therein, second, normally closed contacts associated with the protuberance in the respective recess in the housing, such that when the handle of a respective cordless device is removably received within the recess in the housing, the protuberance fits within the opening in the handle, and the first spaced contacts spring the second, normally closed contacts apart and engage these second contacts in electrical series therewith, normally conductive means for serially connecting the respective second, normally closed contacts in the plurality of recesses in the housing, and current regulated charging means for supplying a series of battery charging pulses to the serially connected second, normally closed contacts in the housing via said normally conductive means.

36. The modular system according to claim 35, wherein said current regulated charging means comprises an integrated circuit.

37. A modular system for cordless battery powered devices, the system comprising housing means having a plurality of substantially identical recesses formed therein, a corresponding plurality of cordless, battery-powered devices removably and interchangeably mounted in the respective recesses, means for mechanically supporting the devices within the recesses, charging means associated with the system, the charging means delivering a series of charging current pulses, the charging means including current regulating means for regulating d.c. charging current, means independent of the mechanical supporting means for establishing electrical contact between the charging means and batteries within the respective cordless, battery-powered devices when the devices are received within the respective recesses in the housing means, means for establishing electrical communication between the charging means and batteries, the means for establishing electrical communication including respective normally closed pairs of contacts, and normally conductive means for connecting said respective normally closed pairs of contacts in electrical series with the charging means;

whereby the batteries within the devices may be recharged.