Battery pack and charger system

Abstract

A charger is disclosed, comprising a housing having an interface positioned in a front wall and configured to engage a battery pack. The interface includes a charging terminal positioned between a first guide rail and a second guide rail, a first groove positioned between the first guide rail and a wall of the housing, and a second groove positioned between the second guide rail and the wall of the housing. The interface communicates with the interior of the housing. A fan is coupled adjacent to the interface within the housing, and an air passage member includes a hollow body having a first end coupled to the fan and a second end spaced apart from the first end, the second end extending through another wall of the housing. The fan is operable to draw airflow from the outside of the housing into the housing and guide the airflow through the air passage member to the interface.

Description

[0001] Cross-references to related applications

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 62 / 942,889, filed December 3, 2019, which is a priority filing and is co-pending. The entire contents of that patent application are incorporated herein by reference. Background Technology

[0003] This invention relates to battery packs and chargers for charging battery packs.

[0004] A typical battery charger includes a battery charging circuit that can be connected to a power source and a rechargeable battery and is operable to charge the battery. Summary of the Invention

[0005] In one independent configuration, a charger has a housing comprising a front wall, a rear wall, a top wall, a bottom wall, a first side wall, and a second side wall. An interface is located in the front wall and configured to engage a battery pack. The interface includes a charging terminal positioned between a first rail and a second rail, a first groove positioned between the first rail and a wall of the housing, and a second groove positioned between the second rail and the wall of the housing. The interface communicates with the interior of the housing. A fan is coupled adjacent to the interface within the housing, and an air passage member includes a hollow body having a first end and a second end spaced apart from the first end. The first end is coupled to the fan, and the second end extends through one of the walls. The fan is operable to draw airflow from the outside of the housing into the housing and guide the airflow through the air passage member to the interface.

[0006] In another configuration, a charging system includes a charger housing having a front wall, a rear wall, a top wall, a bottom wall, a first side wall, and a second side wall. The charger housing has a first connection interface located in the front wall, and the interface includes a charging terminal located between a first guide rail and a second guide rail, a first groove located between the first guide rail and a wall of the housing, and a second groove located between the second guide rail and the wall of the charger housing. Each of the first and second guide rails includes an aperture extending through it. A fan is coupled adjacent to the first connection interface within the housing. An air passage member includes a hollow body having a first end and a second end spaced apart from the first end, the first end being coupled to the fan and the second end, the second end extending through one of the walls. The charging system further includes a battery pack having a battery housing having a longitudinal axis, a first portion, and a second portion coupled to the first portion. The battery housing is configured to enclose a plurality of battery cells, and the second connection interface extends from the wall of the first portion and is symmetrical about the longitudinal axis. The second connection interface includes a battery terminal positioned between a first guide rail and a second guide rail, a first groove positioned between the first guide rail and a wall of the first portion, and a second groove positioned between the second guide rail and the wall of the first portion. A first plurality of vent holes extend adjacent to the first guide rail and through the wall of the first portion, and a second plurality of vent holes extend adjacent to the second guide rail and through the wall of the first portion. The second connection interface of the battery pack is connectable to the first connection interface such that an opening in the first guide rail of the first connection interface communicates with the first plurality of vent holes, and an opening in the second guide rail of the first connection interface communicates with the second plurality of vent holes. The fan is operable to draw airflow from outside the housing into the housing of the charger and guide the airflow through the air passage member to the openings in each of the first and second guide rails, as well as the first and second plurality of vent holes, so that the airflow enters the battery pack housing.

[0007] In another configuration, a charger for charging a battery pack having a housing encapsulating multiple battery cells and one or more vents includes a housing comprising a battery pack receiving portion and separate charger electronics portions. The charger electronics portions include charger electronics housings. The charger further includes a battery pack interface supported on the battery pack receiving portion and including charging terminals. A first plurality of vents are positioned adjacent to the battery pack interface in a first outer wall of the battery pack receiving portion. A first cooling air passage extends from the first plurality of vents through the battery pack receiving portion to an opening in a second outer wall of the battery pack receiving portion, and a first fan is positioned adjacent to the first plurality of vents in the battery pack receiving portion and operable to move air through the first plurality of vents from the outside of the battery pack receiving portion into the first cooling air passage. The charger further includes a printed circuit board including electrical components electrically connected to the charging terminals. The printed circuit board is encapsulated within the charger electronics housing. A second plurality of vents are positioned in a third outer wall of the charger electronics portions. A second cooling air passage extends from the second plurality of vents through the charger electronics portion to an opening in the fourth outer wall of the charger electronics portion. This second cooling air passage is in fluid communication with the charger electronics housing to remove heat generated by the electrical components, and is sealed away from the first cooling air passage. A second fan is positioned adjacent to the second plurality of vents within the charger electronics portion, outside the charger electronics housing, and is operable to move air through the second plurality of vents from the outside of the charger electronics portion into the second cooling air passage.

[0008] Other independent aspects of the invention will become clear upon consideration of the detailed description and accompanying drawings. Attached Figure Description

[0009] Figure 1 This is a three-dimensional view of the battery charger based on the first construction.

[0010] Figure 2 yes Figure 1 Another 3D view of the charger.

[0011] Figure 3 yes Figure 1 A top view of the charger.

[0012] Figure 4 yes Figure 1 A 3D view of the charger from below.

[0013] Figure 5 yes Figure 1A rear 3D view of the charger.

[0014] Figure 6 yes Figure 1 A bottom-view perspective view of a portion of the charger's casing.

[0015] Figure 7 yes Figure 1 A top-view perspective of the charger, with part of the casing removed and air passages shown.

[0016] Figure 8 yes Figure 1 Another top-view perspective of the charger, in which part of the casing has been removed and the air passage and fan are shown.

[0017] Figure 9 yes Figure 1 The charger along Figure 3 The section view of line 9-9.

[0018] Figure 10 yes Figure 1 The charger along Figure 5 Another cross-sectional view of line 10-10.

[0019] Figure 11 yes Figure 7 and Figure 8 A 3D diagram of the air passage and fan.

[0020] Figure 12 yes Figure 7 and Figure 8 A three-dimensional diagram of the air passageway.

[0021] Figure 13 This is a 3D diagram of the first type of battery pack.

[0022] Figure 14A This is a rear 3D view of the second type of battery pack.

[0023] Figure 14B yes Figure 14A A front 3D view of the battery pack.

[0024] Figure 15 yes Figures 14A to 14B The battery pack along Figure 14A Sectional view of line 15-15.

[0025] Figure 16 It is connected to Figure 1 The charger Figure 14A The battery pack along Figure 1 Sectional view of line 16-16.

[0026] Figure 17This is a 3D diagram of a battery charger based on another construction.

[0027] Figure 18 yes Figure 17 The battery charger is shown in a cross-sectional view along line 18-18.

[0028] Figure 19 This is a three-dimensional diagram of a battery charger connected to a complementary battery pack according to another construction.

[0029] Figure 20 yes Figure 19 An exploded view of the battery charger and battery pack. Figure 21 yes Figure 19 A 3D view of the battery charger.

[0030] Figure 21 yes Figure 19 A 3D view of the battery charger.

[0031] Figure 22 yes Figure 19 A 3D view of the battery charger, with part of the casing removed and the fan orientation shown.

[0032] Figure 23 yes Figure 19 Another perspective view of the battery charger, in which part of the casing has been removed and the fan orientation is shown.

[0033] Figure 24A This is a 3D view of the battery charger, with part of the casing removed and another fan orientation shown.

[0034] Figure 24B This is a 3D view of the battery charger, with part of the casing removed and another fan orientation shown.

[0035] Figure 24C This is a schematic diagram of a battery charger having an air passage component with dual air passages.

[0036] Figure 25 yes Figure 19 The battery charger along Figure 21 The cross-sectional view of the inserted axis K is shown.

[0037] Figure 26 yes Figure 19 An exploded view of the charger's electronic components within the casing of the battery charger.

[0038] Figure 27 yes Figure 19 The side view of the battery charger shows the cooling air passage.

[0039] Figure 28It is based on another construction. Figure 19 A three-dimensional view of the battery charger casing and the charger's electronic components.

[0040] Figure 29 It is based on another construction. Figure 19 An exploded view of the charger's electronic components within the casing of the battery charger.

[0041] Figure 30 yes Figure 19 The side view of the battery charger shows the first set of cooling air passages.

[0042] Figure 31 yes Figure 19 Rear view of the battery charger, showing through Figure 28 or Figure 29 The second set of cooling air passages for the charger's electronic component housing. Detailed Implementation

[0043] Before explaining any independent construction of the invention in detail, it should be understood that the application of the invention is not limited to the construction details and component arrangements set forth in the following description or shown in the following drawings. The invention can have other independent constructions and can be practiced or implemented in a variety of different ways.

[0044] As used herein, “including” and “comprise” and their variations are intended to cover all items listed below and their equivalents, as well as additional items. As used herein, “consisting of” and its variations are intended to cover only the items listed below and their equivalents.

[0045] Figures 1 to 5 A charging system according to a first configuration and including a battery charger 10 is shown, the battery charger being operable to charge battery packs 14A, 14B connected to the charger 10. Figures 13 to 15 ) to charge. In the illustrated configuration, the battery charger 10 is operable to charge a first battery pack 14A of the first type ( Figure 13 ) and the second type of second battery pack 14B ( Figures 14A to 15 The battery charger 10 shown is operable to charge high-output battery packs (e.g., with a current capacity of 12 ampere-hours (Ah) or greater), which would require approximately three times the power of a typical charger over a period of about 60 minutes.

[0046] refer to Figures 13 to 15The battery pack type can be defined by the nominal voltage, current capacity, and connection configuration (e.g., "tower" and "slide-in") of battery packs 14A and 14B. For example, the first battery pack 14A may include a high-power battery pack with a nominal voltage of approximately 12 volts (V) and a tower configuration, and the second battery pack 14B may include a high-power battery pack with a nominal voltage of 18V and a slide-in configuration. In other configurations (not shown), battery packs 14A and 14B may be the same type of battery pack.

[0047] like Figures 14A to 15 As shown, battery pack 14B may include a battery pack housing 30, which includes a longitudinal axis A, a first (e.g., top) portion 34, and a second (e.g., bottom) portion 38 coupled to the first portion 34. The housing 30 encloses a plurality of battery cells 42, which are connected by a battery holder 46 (…). Figure 15 The battery pack 14B is fixed inside the housing. The housing 30 also encloses the battery pack circuitry (not shown). The first portion 34 is symmetrical about the longitudinal axis A, engageable with the charger 18, and includes a wall 50 and a battery pack interface 54 extending from the wall 50. The battery pack interface 54 includes a terminal block 58 having openings 62 extending through it, allowing access to battery pack terminals (not shown) positioned within the housing 30. Rails 66, 70 and recesses 74, 78 defined between the respective rails 66, 70 and the wall 50 are located on opposite sides of the battery pack interface 54. A first plurality of vent holes 82 and a second plurality of vent holes 86 extend through the wall 50 and communicate with the interior of the battery pack 14B. The first plurality of vent holes 82 and the second plurality of vent holes 86 are located on opposite sides of the battery pack interface 54 and are adjacent to and parallel to the respective rails 66, 70 and recesses 74, 78. The battery pack 14B further includes a latching mechanism 90, which includes an actuator 94 and a latching member 98. In the illustrated configuration, two latching mechanisms 90 are present on opposite sides of the first portion 34; however, in other configurations, a single latching mechanism may be present. The second portion 38 includes a plurality of holes 102 that allow communication between the interior and exterior of the battery pack 14B.

[0048] Each battery pack 14A, 14B can be connected to and operated to supply power to a variety of motorized power tools (e.g., cross-cut saws, miter saws, table saws, core drills, augers, crushers, demolition hammers, compactors, vibrators, compressors, drain cleaners, welders, cable pullers, pumps, etc.), outdoor tools (e.g., chainsaws, string trimmers, hedge trimmers, blowers, lawnmowers, etc.), other motorized devices (e.g., vehicles, utility vehicles, material handling vehicles, etc.), and non-motorized electrical devices (e.g., power supplies, lights, AC / DC adapters, generators, etc.).

[0049] Re-reference Figures 1 to 5 The charger 10 has a charger housing 100, which includes a front wall 110, a rear wall 114, a top wall 118, a bottom wall 122, a first side wall 126, and a second side wall 130. The front wall 114 includes a first portion 134 and a second portion 138 inclined relative to the first portion 134. The first side wall 126 and the second side wall 130 are spaced apart from each other, and the lateral axis B of the charger housing 100 is defined between the first side wall and the second side wall. As shown, the charger housing 100 has a top portion 142 (… Figure 2 The housing portions 142 and 146 are connected (e.g., by fasteners (not shown)) to the opposite bottom portion 146 of the top portion 142. The housing portions 142 and 146 may be formed of plastic, each molded as a single piece. In other configurations, the housing 100 may include other housing configurations (e.g., a flip-top housing, etc.). A power input port 150 for connection to a power source (e.g., via a power cord, not shown) is located within the housing 100. In the illustrated configuration, the power input port 150 is located in the front wall, but in other configurations, the power input port 150 may be located at any suitable location on the housing.

[0050] refer to Figures 7 to 8 The charger electronics 154 is supported by a bottom portion 146, and specifically by a bottom wall 122. The charger electronics 154 is operable to output charging current to one or both of the battery packs 14A, 14B to charge the battery packs 14A, 14B. The charger electronics 154 particularly includes a printed circuit board (PCB) 158 and a charger microcontroller (not shown). The charger electronics 154 may include charging circuit portions (not shown; e.g., on separate PCBs) for each of the battery packs 14A, 14B, such that each battery pack 14A, 14B can be charged simultaneously and independently. The charging current provided to each battery pack 14A, 14B may be the same or different.

[0051] The charger housing 100 further includes charger interfaces 200A, 200B that are engageable with and support corresponding battery packs 14A, 14B. Each charger interface 200A, 200B is at least partially located substantially on the front wall of the housing (e.g., at least partially located on the inclined portion 138).

[0052] refer to Figures 1 to 3 , Figure 5 and Figure 9 The charger interface 200A is limited to insertion into axis C ( Figure 9The recess 204 (e.g., a battery pack receiving port) is defined by the inclined portion 138 of the top wall 118 and the front wall 110. The insertion axis C is perpendicular to the transverse axis B of the housing and forms a non-perpendicular and non-parallel angle with respect to the inclined portion 138 of the front wall 110. The recess 204 is configured to receive at least a portion of the battery pack 14A (e.g., the tower portion 208). Figure 13 First set of charger terminals 212 ( Figure 3 The charger terminal 212 extends from inside the housing 100 into the recess 204 through a hole. The charger terminal 212 is configured to be electrically connected to the battery pack terminal (not shown) of the battery pack 14A received in the recess 204 for charging.

[0053] refer to Figures 1 to 3 , Figure 5 and Figures 9 to 10 Charger interface 200B limits insertion into axis D ( Figure 9 It also includes guide rail components 220, 224 and charger terminal block 228. Figure 1 The guide rail members 220 and 224 are spaced apart, substantially parallel, and positioned on the inclined portion 138 of the front wall 110. Orifices 232 and 236 extend through each of the guide rail members 220 and 224. Orifices 232 and 236 are respectively connected to the interior 240 of the housing 100 via a first chamber 244 positioned within the charger housing 100. Figure 10 The grooves 248 and 252 are defined between the inclined portion 138 of the front wall 110 and the associated guide rail members 220 and 224. The insertion axis D is oriented differently from the insertion axis B. In particular, the insertion axis D is parallel to the guide rail members 220 and 224. The guide rail members 220 and 224 and the grooves 248 and 252 are engageable with the corresponding grooves 74 and 78 and guide rails 66 and 70 on the battery pack 14B. The orifices 232 and 236 in the guide rail members 220 and 224 of the charger interface 200B are configured to align and communicate with the corresponding first plurality of vent holes 82 and second plurality of vent holes 86 in the wall 50 of the first portion 34 of the battery pack 14B. Figure 16 The charger terminal block 228 is positioned within an opening 256 in the inclined portion 138, which is located between guide rail members 220 and 224. The charger terminal block 228 includes a second set of charger terminals 260. Figure 1 The second set of charger terminals is configured to be electrically connected to the battery pack terminals of the battery pack 14B for charging.

[0054] At least refer to Figure 6 The first chamber 244 is defined by a first chamber wall 270 extending from the inclined portion 138 of the front wall 110 into the charger housing 100. (As...) Figure 6As shown, the first chamber wall 270 defines a polygonal opening 274 and has a post 278 extending therefrom. The first chamber 244 defines an axis E perpendicular to the inclined portion 138 of the front wall 110. Figure 9 ). Slot 282 ( Figure 6 It extends through the chamber 270.

[0055] like Figures 7 to 11 As shown, a first fan 300 or blower (e.g., a DC blower) is positioned adjacent to a first chamber 244. Regarding Figure 7 , Figure 8 and Figure 11 The first fan 300 includes a fan housing 304, which is positioned adjacent to and connected to the first chamber wall 270. Specifically, the fan housing 304 includes a through-hole 308. Figure 7 and Figure 11 These through-holes receive pillars 278 extending from chamber wall 270. An opening 312 of fan housing 304 (e.g., along axis E) is aligned with first chamber 244, and one or more blades 316 are rotatably positioned within this opening. First fan 300 is a multi-speed fan operable to rotate at more than one speed. The rotational speed of fan 300 can be determined based on the temperature of one or more of the charger electronics 154 or battery pack 14B. In some configurations, first fan 300 produces between approximately 13.6 m³ / s at full speed. 3 / h and approximately 25.5m 3 Airflow between / h. Furthermore, in some configurations, the first fan 300 can generate approximately 20.4 cubic feet per minute (CFM) and up to approximately 35 m³ / h. 3 / h or less of airflow. In some other configurations, the fan 300 can produce less or more than 31 CFM of airflow at full speed.

[0056] Air passage component 350 is positioned within housing 100 and extends from first fan 300 through opening 354 in rear wall 114. Figure 9 ).about Figure 7 , Figure 8 , Figure 11 and Figure 12The air passage component 350 includes a hollow body 358 having: a first (e.g., top) wall 362, a second (e.g., bottom) wall 366 opposite to the first wall 362, and a pair of side walls 370, 374 connected to opposite sides of the first wall 362 and the second wall 366 and extending between the two walls. A first angled wall 378 is connected to and extends from the first wall 362 and extends between the pair of side walls 370, 374. The first angled wall 378 is connected to a second angled wall 382. The second angled wall 382 is connected to and extends from the second wall 366 and extends between the pair of side walls 370, 374. An opening 386 extends through the first angled wall 378 and communicates with a second chamber 390 defined by the hollow body 358.

[0057] The air passage component 350 (and therefore the second chamber 390) includes two axes F (the second axis) and H (the third axis). One of the axes, F (the second axis), passes through the center of the orifice 386 in the first angled wall 378 and is configured to coincide with the axis E (the first axis), while the other axis, H, extends between and parallel to the first wall 362 and the second wall 366. F and H are positioned at a non-perpendicular and non-parallel angle relative to each other. In the illustrated configuration, the angle between axes F and H is an oblique angle, and the angle is measured between 100 and 150 degrees. A preferred angle between axes F and H is 129 degrees. In other or additional embodiments, the angle between F and H can be a right angle or an acute angle. Furthermore, axis H is positioned at a non-perpendicular and non-parallel angle relative to the insertion axis D. In the illustrated configuration, the angle between axes D and H is an acute angle, and the angle is measured between 15 and 60 degrees. A preferred angle between axes D and H is 39 degrees. In other or additional embodiments, the angle between D and H can be a right angle or an oblique angle. The air passage can be constructed of plastic (acrylonitrile butadiene styrene (ABS), polycarbonate acrylonitrile butadiene styrene (PC-ABS)) and / or aluminum, but other suitable thermoplastics, thermoplastic polymers and metals can be used in the same or alternative ways.

[0058] like Figures 9 to 12As shown, the air passage member 350 is coupled to the first fan 300. Specifically, the first angled wall 378 includes through holes 394 that align with through holes 308 in the fan housing 304 and receive posts 278. Therefore, orifices 386 in the first angled wall 378 align with openings 312 and the first chamber 244 in the first fan 300, allowing communication between the first chamber 244 and the second chamber 390. The axis F of the orifice 386 coincides with the axis E of the first chamber 240, as discussed above, and the axis H is parallel to the bottom wall 122 of the housing 100. Furthermore, the length L of the air passage member 350 is greater than 50% of the depth D1 of the housing 100. Preferably, the length L of the air passage member 350 ranges from 55% to 75% of the depth D1 of the housing 100.

[0059] refer to Figure 9 and Figure 16 The openings 312 in the first chamber 244, the fan housing 304, and the second chamber 390 define a first airflow path or passage X that receives the first airflow X from the outside of the charger housing 100. The distal end or protruding end 398 of the air passage member 350 extending from the housing 100 defines an air inlet, and orifices 232, 236 define an air outlet of the first air passage, such that the first airflow X moves from the outside of the charger housing 100 sequentially through the second chamber 390, the fan 300, and the first chamber 244 to the battery pack 14B. Therefore, when the fan 300 is actuated, it draws air into the air passage, causing the first airflow X to travel laterally (e.g., horizontally) along axis H from the outside of the charger housing 100 through the second chamber 390 and vertically along axes E, F through the fan 300 and the first chamber 244. The first airflow X then enters the battery pack 14B via orifices 232 and 236 in the guide rails 220 and 224 of the charger interface 200B and a first plurality of vent holes 82 and a second plurality of vent holes 86 in the first portion 34 of the battery pack 14B. Once inside the battery pack housing 100, the first airflow X is directed from the corresponding plurality of vent holes 82 and 86 between the battery cell 42 and the second portion 38 of the battery pack 14B toward the hole 102 in the second portion 38 of the battery pack 14B. Therefore, the first airflow X can be used to cool the battery cell 42 during charging of the first battery pack 14B.

[0060] In other configurations, the distal or protruding end 398 may define an air outlet, and orifices 232, 236 may define air inlets for the first air passage, such that a first airflow X moves from the battery pack 14B sequentially through the first plurality of vents 82 and the second plurality of vents 86, the first chamber 244, the fan 300, and the second chamber 390 to the outside of the charger housing 100. In this case, when actuated, the fan 300 draws air into the air passage, thereby generating a reverse airflow (e.g., an airflow moving in the opposite direction to airflow X). Thus, air travels vertically from the interior of the battery pack along axes E, F through the first chamber 244 and the fan 300 and laterally (e.g., horizontally) along axis H through the second chamber 390. Therefore, the first airflow X or the reverse airflow can be used to cool the battery cells 42 during charging of the first battery pack 14B.

[0061] In some configurations, air can be directed through an air passage 350 in a first direction (e.g., toward battery pack 54) and air can be directed through another air passage in a second direction (e.g., away from battery pack 54). Furthermore, one of the air passages may include a heating element or cooling component electrically connected to charger electronics. A movable valve or seal selectively opens and closes one or both of the air passages. Similarly, an exemplary view of this configuration is shown in... Figure 24C As shown herein, a heating element or cooling component can be actuated to blow air (e.g., via the heating element) at a temperature higher than or (e.g., via the cooling element) lower than ambient air temperature into the battery pack 54 to heat or cool the cells of the battery pack 54, respectively. The seal is movable between a first closed position when the heating or cooling element is not in use and a second open position when the heating or cooling element is in use. The heating or cooling element and the seal can be manually actuated by a user or automatically actuated via charger electronics (e.g., a controller and a temperature sensor). As discussed herein, another air passage can remain open to draw in or blow ambient air into the battery pack 54 via the charger 10. In other configurations, the seal can alternatively open and close these air passages, depending on which one is in use.

[0062] In other configurations, the air passage 350 may be divided into separate air passages, thereby forming a dual-air-passage component. In these configurations, air may be directed through one of the dual air passages in a first direction (e.g., toward the battery pack 54) and air may be directed through the other of the dual air passages in a second direction (e.g., away from the battery pack 54). Similarly, one of the dual air passages may include a heating element or cooling component electrically connected to the charger electronics, such that air is directed through the dual air passages, as described above and below. Figure 24C The discussion.

[0063] In other or alternative configurations, the first chamber may be omitted. In this case, the housing may include a column extending therefrom, receiving and supporting the fan 304 and the air passage member 350.

[0064] In some other configurations, the charger interface 200B may be positioned and supported by other walls of the housing 100. Similarly, the air passage member 350 may extend through an opening in another wall of the housing 100 (e.g., one of the bottom wall 122 or side walls 126, 130). Thus, the air passage member 350 may include other suitable configurations such that the air passage member 350 may extend through and from the other walls of the housing 100 to orifices 232, 236 in the guide rails 220, 224 of the charger interface 200B.

[0065] In some other or additional structures ( Figure 17 and Figure 18 In this configuration, the air passage component 350 can be omitted, and the opening in the rear wall 114 can be replaced by a vent or slot 400 (e.g., an air inlet). Furthermore, additional vents 400 can exist in other walls, or the vents 400 can be located in other walls of the housing (e.g., closer to or further from the fan 300). Therefore, when the fan 300 is actuated, it draws air into the interior of the charger housing 100 (instead of the first air passage), causing the first airflow X' to travel laterally from the outside of the charger housing 100 through the vent 400 to the fan 300, and then along axes E and F into the first chamber 244. The first airflow X' then enters the battery pack 14B, as discussed above regarding the first airflow X. Alternatively, when actuated, the fan 300 draws air into the interior of the charger housing 100 (instead of the first air passage), causing a reverse airflow (e.g., an airflow moving in the opposite direction of airflow X') to enter the first chamber 244 from the battery pack 14B along axes E and F to reach the fan 300 and travel laterally through the vent 400 to the exterior of the charger housing 100.

[0066] refer to Figures 1 to 4 The charger 10 may have additional or auxiliary air passages extending between other air inlets and outlets within the housing 100. For example, the housing 100 also defines air inlets 520, 524 located in the sidewall 126 of the housing 100 and near the rear wall 114. Figure 2 Inlet 520, 524 includes slots 528, 532 extending through sidewall 126. In other configurations (not shown), slots 520, 524 may extend in a latitudinal direction, a combination of longitudinal and latitudinal directions, etc. Slots 528, 532 are configured to facilitate airflow into housing 100.

[0067] The housing 100 further includes an vent 500 positioned below the first charging interface 200A (e.g., recess 204). Thus, the vent 500 shown is located below the battery pack 14A when it is connected to the charger 10. Furthermore, the vent 500 shown includes slots 504 (e.g., longitudinal slots) defined in and extending through the inclined portion 138, and partially defined by the first portion 132. In other configurations (not shown), the slots 504 may extend in a latitudinal direction, a combination of longitudinal and latitudinal directions, etc. The slots 504 are configured to facilitate airflow into the housing 100. Other vents 508 configured as one or more slots 512 may also extend through the bottom wall 122. Figure 4 Imports 520 and 524 and exports 500 and 508 are located at different positions on the shell 100.

[0068] refer to Figure 7 and Figure 8 The charger 10 may also include a heat sink 530 and a second fan 534 or blower (e.g., a DC blower) within the housing 100 to provide a heat dissipation structure. A temperature sensor (not shown) is disposed within the housing 100 and positioned near the charger electronics 154 (e.g., near the components(s) generating the most heat (e.g., CPU, transformer, field-effect transistor (FET), etc.)) or near the heat sink 530. In the illustrated configuration, the heat sink 530 is disposed within the housing 100, near the rear wall 114. In other configurations (not shown), the heat sink 530 may be positioned at other locations within the housing 100. The heat sink 530 is in a thermally conductive relationship with the components of the charger electronics 154 (e.g., mounted to and in contact with the PCB 158). In other words, heat is transferred from the heat-generating components of the charger 10 to the heat sink 530 via conduction.

[0069] In the illustrated configuration, the heat sink 530 is formed of a thermally conductive material (such as aluminum) and extends between opposite ends 538, 542. Furthermore, the illustrated heat sink 530 comprises one or more hollow tubes 546 (in... Figure 7 The radiator 530 shown is constructed of three hollow tubes, each having a rectangular shape and stacked on top of each other. Tubes 546 extend between opposite ends 538 and 542. Thus, the radiator 530 formed is a tubular radiator. The first end 542 forms an inlet for each tube 546 to allow airflow into the radiator 530, and the second end 538 forms an outlet for each tube 546 to allow airflow out of the radiator 530. Figure 7 As shown, the inlet of each tube 546 is angled toward the front of the housing 100. In other or additional embodiments, the heat sink may be a flat heat sink instead of a tubular heat sink.

[0070] A second fan 534 is positioned between the first end 542 of the heat sink 530 and the inlets 520, 524. A deflector 550 extends between the first end 542 and the fan 534 to guide airflow from the heat sink 530 to the outlets 500, 508. The second fan 534 is a multi-speed fan operable to rotate at more than one speed and guide airflow from the inlets 520, 524 through the housing 100 and to the outlets 500, 508. The rotational speed of the fan 534 can be determined based on the temperature of one or more of the charger electronics 154, the heat sink 530, the supported battery packs 14A, 14B, etc. A temperature sensor is configured to measure the temperature and transmit a signal output to a microcontroller to determine the temperature of the charger 10. The microcontroller then controls the speed of the second fan 354 based on the temperature (e.g., that of the heat sink 530 shown). In some configurations, the second fan 354 produces between approximately 13.6 m³ / s at full speed. 3 / h and approximately 25.5m 3 Airflow between / h. Furthermore, in some configurations, the second fan 154 can generate approximately 20.4 cubic feet per minute (CFM) and up to approximately 35 m³ / h. 3 / h or less airflow.

[0071] like Figure 7 As shown, the charger 10 defines a second flow path or passage Y through the housing 100, separate from the first airflows X, X'. In the illustrated configuration, the second airflow flows along the flow path Y from inlets 520, 524 through the charger electronics 154 (e.g., PCB 158) to the inlet of the heat sink 530 and through the heat sink 530 to outlets 500, 508. A second fan 354 guides the second airflow along the flow path Y. Furthermore, the second fan 354 directs the second airflow Y into the inlet 542 and outlet 538 of each tube 546. The second airflow Y operates to dissipate heat generated by the charger electronics 154 from the housing 100. In other configurations (not shown), the second fan 354 may operate in reverse, such that the second flow path Y through the housing 100 is reversed.

[0072] In operation, one or both of battery packs 14A and 14B are connected to corresponding charger interfaces 200A and 200B (e.g., support sections 64A and 64B) for charging. A first set of terminals 212 is electrically connected to the battery pack terminals of the first battery 14A, and / or a second set of terminals 260 is electrically connected to the battery terminals of the second battery 14B. The charger 10 provides charging current to the first battery 14A and / or the second battery 14B.

[0073] Figures 19 to 31 A charging system according to another configuration is shown, including a battery charger 600 operable to charge a battery pack 614. Figures 19 to 29 The battery pack is similar to Figures 14A to 15 The battery pack. Therefore, battery pack 614 will not be described in detail again, and the same reference numeral "600" will refer to the same structure in the following description.

[0074] about Figure 19 The battery charger 600 includes housings 750 and 754 having a longitudinal axis J and a frame member 758 coupled to the housings. Housings 750 and 754 include a battery pack receiving portion 750 and a charger electronics portion 754 coupled to the battery pack receiving portion 750. In some configurations, the battery pack receiving portion 750 may be sealed relative to the charger electronics portion 754.

[0075] like Figure 21 As shown, the battery pack receiving portion 750 includes a first wall 770, a second wall 774, a third wall 778, a fourth wall 782, a fifth wall 786, and a sixth wall 790. In the illustrated configuration, the first wall 770 is the top wall and the second wall 774 is the bottom wall, and therefore the first wall 770 and the second wall 774 are spaced apart from each other. Specifically, the first wall 770 and the second wall 774 are positioned opposite each other. The third wall 778 is the front wall and the fourth wall 782 is the rear wall, and therefore the third wall 778 and the fourth wall 782 are spaced apart from each other. Specifically, the third wall 778 and the fourth wall 782 are positioned opposite each other. The fifth wall 786 and the sixth wall 790 connect the first wall 770, the second wall 774, the third wall 778, and the fourth wall 782. In the illustrated embodiment and as shown... Figure 21 As shown, the battery pack receiving portion 750 is defined by a first portion 794 and a second portion 798. The first portion 794 includes a first wall 770 and a fourth wall 782, while the second portion 798 includes a second wall 774. The first portion 794 and the second portion 798 together define a third wall 778, a fifth wall 786, and a second wall 774. The first portion 794 and the second portion 798 (and therefore, walls 770, 774, 778, 782, 786, and 790) are molded from a plastic material.

[0076] The first wall 770 includes an elongated opening 806 and a plurality of vent holes 810 extending through the first wall. The elongated opening 806 has a closed end 814 adjacent to the fourth wall 782 and an open end 818 adjacent to the third wall 778. A charger interface 822 is positioned in the elongated opening 806, at least partially supported by the first wall 770, and configured to receive a battery pack interface 654. A first set of the plurality of vent holes 810 is positioned on one side of the elongated opening 806, and a second set of the plurality of vent holes 810 is positioned on the opposite side of the elongated opening 806. The second wall 774 includes a plurality of vent holes 826 extending through it. Figure 22 and Figure 23The handle 830 extends from the third wall 778 and is movable (e.g., pivotable) relative to the third wall.

[0077] Figures 19 to 21 The charger interface 822 has an insertion axis K parallel to the longitudinal axis J and at least partially defined by the first support member 840 and the second support member 844. Figure 21 ).about Figure 22 The first support member 840 includes a first sidewall 848 positioned adjacent to one side of the elongated opening 806, a first recessed wall 852 extending from the first sidewall 848, and a first portion 856 of a terminal block 860 positioned adjacent to the closed end 814 within the battery pack receiving portion 750. The first sidewall 848 includes a first guide member 864 extending therefrom, and a first groove 868 positioned between the first guide member 864 and the first recessed wall 852. The second support member 844 includes a second sidewall 876 positioned adjacent to the opposite side of the elongated opening 806, a second recessed wall 880 extending from the second sidewall 876, and a second portion 884 of the terminal block 860 positioned adjacent to the closed end 814 and the first portion 856 of the terminal block 860 within the battery pack receiving portion 750. The second sidewall 876 includes a second guide member 888 extending therefrom, and a second groove 892 positioned between the second guide member 888 and the second recessed wall 880. The surface of each of the guide rail members 864 and 888 is co-existing with the adjacent surface of the first wall 770, and the surfaces of the recessed walls 852 and 880 are recessed relative to the surface of the first wall 770. The guide rail members 864 and 888 are spaced apart and substantially parallel to each other. The insertion axis K is parallel to the guide rail members 864 and 888. Charging terminals 896 extend from each portion 856 and 884 of the terminal block 860.

[0078] like Figures 21 to 22 As shown, the first support member 840 further includes one or more (two in the illustrated embodiment) fan or blower support members 910 extending from the first sidewall 848 opposite to the first recessed wall 852. The fan support members 910 of the first support member 840 are positioned adjacent to the first set of vents 810 within the battery pack receiving portion 750. Similarly, the second support member 844 further includes one or more (two in the illustrated embodiment) fan or blower support members 914 extending from the second sidewall 876 opposite to the second recessed wall 880. The fan support members 914 of the second support member 840 are positioned adjacent to the second set of vents 810 within the battery pack receiving portion 750.

[0079] like Figures 22 to 23As shown, each of the fan support members 910, 914 receives and supports a fan 918 or a blower (e.g., a DC blower), such that the plurality of fans 918 or blowers are positioned within the battery pack receiving portion 750, between the first wall 770 and the second wall 774. Each of the fans 918 is thus positioned at or adjacent to one or more vents 810 in the first wall 770. The fans 918 are supported by the fan support members 910 such that they are spaced apart from (e.g., positioned above) the second wall 774 and one or more vents 826 in the second wall 774. In other configurations, one or more vents may additionally or alternatively be present in one or both of the fifth side wall 786 and the sixth side wall 790. Figure 24B In the illustrated configuration, each of the fans 918 has a rotation axis L positioned at a non-parallel angle relative to the insertion axis K. In the illustrated configuration, each of the fans 918 has a rotation axis L perpendicular to the insertion axis K. In the illustrated configuration, the rotation axes L of the fans 918 are oriented parallel to each other; however, in other or additional configurations, the rotation axes K may be oriented parallel to each other or at a non-parallel angle relative to each other.

[0080] exist Figures 19 to 27 In the configuration, a cooling air path or passage 922 extends from one or more of a plurality of vents 810 in the first wall 770 through each of the fans 918 to one or more of a plurality of vents 826 in the second wall 774. Thus, each of the fans 918 is operable to move cooling air between one or more of the vents 810 in the first wall 770 and one or more of the vents 826 in the second wall 774. In the illustrated embodiment, four fans 918 are present, two on each side of the charger interface 822. Therefore, four cooling air passages 922 are present, defined within and extending through the battery pack receiving portion 750 of the charger housing. In other or additional configurations, additional or additional fans 918 and cooling air passages 922 may be present, defined within and extending through the battery pack receiving portion 750. Additionally, as... Figure 26 As shown, the cooling air passage 922 guides airflow in a direction parallel to the rotation axis L of the corresponding fan 918. Therefore, in the illustrated configuration, the cooling air in the cooling air passage 922 moves perpendicular to the insertion axis K. Furthermore, as... Figure 27 As shown, the air moves vertically. In other or additional configurations, vents may be present at other locations in the battery pack receiving portion, allowing the cooling air passage to allow air to move in a direction perpendicular and vertical relative to the insertion axis K, but also in a direction not perpendicular and horizontal relative to the insertion axis K.

[0081] In other or different constructions, similar to the above regarding Figures 1 to 18 The described air passage member may define each of the cooling air passages 922. That is, in other or additional configurations, the cooling air passage 922 may be at least partially defined by an air passage member having a hollow body having a first end positioned at or adjacent to a fan support member and a second end positioned at or adjacent to one or more vents in a second wall 774. In these configurations, each fan 918 will be supported at or adjacent to the first end of the air passage member.

[0082] In addition, such as Figure 24A , Figure 24B As shown, although only one is shown, a conduit member 928 can be positioned on each side of the charger interface 822. Each conduit member 928 can define one or more of air passage members 932, 936, through which a corresponding cooling air passage 922 extends. In other words, the conduit member 928 can define a first air passage member 932 and a second air passage member 936. The corresponding first air passage member 932 includes an inlet 940 configured to be located at or adjacent to and in communication with a corresponding fan 918, and the air passage member 936 includes an inlet 944 configured to be located at or adjacent to and in communication with an adjacent fan 918. Each of the corresponding first air passage member 932 and second air passage member 936 includes an outlet 948, 952 located at or adjacent to and in communication with one or more of a second plurality of vents 826.

[0083] like Figure 24CAs shown, air can be directed in a first direction (e.g., toward the battery pack 654) through one of the air passages 932 and can be directed in a second direction (e.g., away from the battery pack 654) through the other air passage 936. Furthermore, one of the air passages 932 and 936 may include a heating element or cooling member 934 electrically connected to charger electronics. A movable valve or seal 935 selectively opens and closes the air passages 932a and 932b. In the illustrated configuration, the seal 935 is positioned between the fan 918 and the vent 810, but in other configurations, the seal 935 may be positioned elsewhere (e.g., within the air passages 932 and 936). The heating element or cooling member 934 can be actuated to blow air (e.g., via the heating element) at a temperature higher than or (e.g., via the cooling element) lower than the ambient air temperature into the battery pack 654 to heat or cool the cells of the battery pack 654, respectively. The seal 935 is movable between a first closed position when the heating or cooling element 934 is not in use and a second open position when the heating or cooling element 934 is in use. The heating or cooling element 934 and the seal 935 can be manually actuated by a user or automatically actuated via charger electronics (e.g., a controller and a temperature sensor). As discussed herein, another of the air passages 932, 936 can remain open to draw in or blow ambient air into the battery pack 654 via the charger 600. In other configurations, the seal 935 can alternatively open and close these air passages 932, 936, depending on which one is in use.

[0084] In other configurations, one or both of the air passage members 932 and 936 may be divided into separate air passages, thereby forming a dual air passage member. In these configurations, air can be guided through one of the dual air passages in a first direction (e.g., toward the battery pack 654) and air can be guided through the other of the dual air passages 936 in a second direction (e.g., away from the battery pack 654). Similarly, one of the dual air passages may include a heating element or cooling member 934 electrically connected to the charger electronics, such that air is guided through the dual air passages, as described above regarding... Figure 24C The discussion.

[0085] like Figure 25As shown, the charger 600 includes a discharge member 960 configured to discharge fluid from a charger interface 822 to an area outside the charger 600. In the illustrated configuration, the discharge member 960 includes a first end 964 positioned adjacent to and communicating with an adjacent area of ​​the terminal block 860, and a second end 968 positioned at or adjacent to and communicating with an opening (not shown) extending through one of the other walls of the battery pack receiving portion 750. In the illustrated configuration, the second end 968 is positioned at or adjacent to and communicating with an opening extending through a second wall 774. In other configurations, the second end 968 is positioned at or adjacent to and communicating with an opening extending through another wall spaced apart from the first wall 770.

[0086] about Figure 22 , Figure 23 , Figure 26 and Figure 27 The charger electronics portion 754 includes a cover 1000, a fan 1004 or blower (e.g., a DC blower), and a charger electronics housing 1008. In the configuration of FIG. 24, the cover 1000 is formed of a plastic material and includes a rear wall 1012 ( Figure 27 ), top wall 1016 ( Figure 22 , Figure 23 , Figure 27 ), bottom wall 1020( Figure 27 ), First sidewall 1024 ( Figure 23 ) and second sidewall 1028 ( Figure 22 Each of walls 1016, 1020, 1024, and 1028 is connected to and extends from rear wall 1012. Regarding Figure 27 The rear wall 1012 includes a first plurality of vent holes 1032, and one or more of the walls 1016, 1020, 1024, and 1028 include a second plurality of vent holes 1036. In the illustrated configuration, the second plurality of vent holes 1036 are located in the bottom wall 1020, but in other configurations, the second plurality of vent holes 1036 may be located in other walls in the same or alternative manner.

[0087] about Figure 26The charger electronics housing 1008 is constructed of metal and has multiple walls that define a sealed (e.g., fluid and debris) box-like structure enclosing the charger electronics 1050. In the illustrated construction, the metal is aluminum, but other suitable metals may be used instead of aluminum. A first wall 1054 of the charger electronics housing 1008 includes multiple heat dissipation fins 1058 (or other heat dissipation components) extending therefrom, and a second opposing wall 1062 supports the charger electronics 1050. Multiple sidewalls 1062 extend from the first wall 1054 toward the second wall 1058. The multiple sidewalls 1062 are coupled to the second wall for sealing (e.g., enclosing the charger electronics therein). The multiple heat dissipation fins 1058 are formed in a size and shape determined to receive a recess 1066 of a fan 1004. The charger electronics 1050 includes, in particular, a printed circuit board (PCB) 1070 and a charger microcontroller. The charger electronics can include any suitable configuration. Figure 26 In one embodiment, PCB 170 is positioned adjacent to the first wall 1054.

[0088] A cover 1000 (e.g., by fasteners, etc., not shown) is coupled to a battery pack receiving portion 750. Specifically, the walls of the cover 1000 are coupled to and enclosed by the second wall 774, fourth wall 782, fifth wall 786, and sixth wall 790 of the battery pack receiving portion 750. A fan 1004 and a charger electronics housing 1008 are positioned between and enclosed by the cover 1000 and the battery pack receiving portion 750. As shown, a first wall 1054 with heat dissipation fins 1054 is positioned adjacent to a rear wall 1012, such that the fan 1004, which is received in a recess 1066 and movable (e.g., rotatable) relative to the recess, is positioned adjacent to a first plurality of vent holes 1032. A cooling air passage 1080 is defined between the first plurality of vent holes 1032 and a second plurality of vent holes 1036, and the fan 1004 is positioned between the first plurality of vent holes 1032 and the second plurality of vent holes 1036.

[0089] In use and such Figure 19 and Figure 26As shown, guide rail members 864, 888 and grooves 868, 892 are engageable with corresponding grooves 674, 678 and guide rails 666, 670 on battery pack 614 to electrically and physically engage charging terminal 896 with battery terminal, enabling charger 600 to charge the battery in battery pack 614. When battery pack 614 is connected to charger interface 822, vent holes 810 in first wall 770 are configured to align and communicate with corresponding first plurality of vent holes 682 and second plurality of vent holes 686 in wall 650 of first portion 634 of battery pack 614. When battery pack 614 is connected to battery charger 600, each of the fans 918 in battery pack receiving portion 750 is operable to move cooling air between the interior of battery pack 614 and the exterior of charger 600 via corresponding cooling air passage 922. In the illustrated configuration, fan 918 is operable to draw ambient air through holes 702 in battery pack 614, through the interior of battery pack 614, and via corresponding plurality of vent holes 810 in first wall 770 to charger 600 (e.g., battery pack receiving portion 750), and exhaust air through corresponding plurality of vent holes 826 in second wall 774, such that air can move through battery pack 614 and be removed from battery pack by flowing through charger 600. In other configurations, fan 918 draws air from the interior of battery pack 614 into charger 600 (e.g., battery pack receiving portion 750) via corresponding plurality of vent holes 810 in first wall 770, and exhausts air through corresponding plurality of vent holes 826 in second wall 774, such that hot air from the interior of battery pack 614 is removed from battery pack by flowing through charger 600. In some other configurations, the fan 918 draws air from an area outside the charger 600 (e.g., the battery pack receiving portion 750) into the charger 600 via corresponding plurality of vents 826 in the second wall 774, and exhausts air into vents 682, 686 in the battery pack 614 via corresponding plurality of vents 810 in the first wall 770, thereby blowing ambient air from an area outside the charger 600 into the battery pack 614 to cool the cells of the battery pack 614. In other configurations, air at a temperature lower or higher than the ambient air temperature can be drawn into or blown into the charger 600 and / or the battery pack 654, as described above regarding... Figure 24C As discussed. In some configurations, the battery pack 654 completely covers or extends beyond the first wall 770, forcing air through the battery pack 654 rather than around it. The terminal block 860 is not sealed relative to the battery pack receiving portion 750, so water or other fluids can be discharged from the interior of the battery pack 654 and the charger interface 822 to an area outside the charger 600 via the discharge member 960.

[0090] Additionally, the fan 1004 and cooling air passage 1080 of the charger electronics section 754 are operable to cool the charger electronics housing 1008. In the illustrated configuration, the fan 1004 draws ambient air into the charger electronics section 754 from the region adjacent to the first plurality of vents 1032 in the rear wall 1012, and exhausts the air through the corresponding second plurality of vents 1036 in the second wall 1020, such that the cooling air moves to the second plurality of vents 1036 by convection around the charger electronics section 754 (and therefore within the charger electronics section in any direction), where the air exits the charger electronics section 754. The cooling air passage 922 of the battery pack receiving section 750 and the cooling air passage 1080 of the charger electronics section 754 are substantially separate from each other, and therefore the air does not mix.

[0091] exist Figure 28 and Figures 30 to 31 In another configuration shown, the charger electronics section 754 has an alternative configuration. Figure 28 The charger electronic components 754 and Figure 26 The charger electronics section 754 is similar, and therefore will only be discussed. Figure 26 and Figure 28 The differences between the charger electronic components 754.

[0092] like Figure 31 As shown, the first sidewall 1024 of the cover 1000 includes a first plurality of vent holes 1032, and the second sidewall 1028 of the cover 1000 includes a second plurality of vent holes 1036. Figure 28 In its construction, the air passage member 1100 is integrally formed with or otherwise coupled to one of the plurality of sidewalls 1062 of the charger electronics housing 1008, and has an air passage 1104 extending therethrough. Thus, the sidewall 1062 coupled to the air passage member 1100 defines a partition wall 1062 that separates the interior of the charger electronics housing 1008 (which houses the charger electronics 1050 and is filled with potting compound) from the air passage 1104 of the air passage member 1100. The air passage member 1100 has a first open end 1108 and a second open end 1112. The fan 1004 can be supported at the first open end 1108 or the second open end 1112 of the air passage member 1100. In the illustrated embodiment, the fan is supported at the first open end 1108. Figure 27 The air passage component has multiple heat dissipation fins 1116 (or other heat dissipation components) extending from one side across at least a portion of the air passage 1104. Figure 28In the illustrated configuration, the air passage member 1100 is not completely enclosed because an elongated opening is defined on the side opposite to the sidewall. In other configurations, the side opposite to the sidewall may be defined by a wall that may or may not have an opening extending through it.

[0093] Figure 28 The charger electronic housing is positioned within the cover 1000 and between the cover 1000 and the battery pack receiving portion 750, such that a first end 1108 of the air passage member 1100 (and therefore, the fan 1004) is positioned adjacent to either a first plurality of vents 1032 or a second plurality of vents 1036, and a second end 1112 of the air passage member 110 is positioned adjacent to the other of the first plurality of vents 1032 and the second plurality of vents 1036. A cooling air passage 1140 is defined between the first plurality of vents 1036 or the second plurality of vents 1036 in the cover 1000, the fan 1004, the second end of the air passage member 1112, and the other of the first plurality of vents 1032 or the second plurality of vents 1036.

[0094] exist Figures 29 to 31 In another configuration shown, the charger electronics section 754 has an alternative configuration. Figure 29 The charger electronic components 754 and Figure 26 and Figure 28 The charger electronics section 754 is similar, and therefore will only be discussed. Figure 26 , Figure 28 and Figure 29 Differences between the electronic components of the charger.

[0095] like Figure 31 As shown and as Figure 28 The cover 1000 has a first sidewall 1024 including a first plurality of vent holes 1032, and a second sidewall 1028 including a second plurality of vent holes 1036. Figure 29In its construction, the charger electronic device housing defines a first housing portion 1150 and a second housing portion 1154. The first housing portion 1150 includes a first wall 1054 and portions of first and second sidewalls 1062 extending therefrom. The first and second sidewalls 1062 are located on opposite sides of the housing 1008. Each of the first and second sidewalls 1062 defines a flange 1160 extending along the length of the respective wall 1062. Additionally, a partition wall 1162 extends from the first wall 1054 between the first and second sidewalls 1062 and extends the length of both sidewalls 1062. The partition wall 1162 of the first housing portion 1150 has a flange 1160 projecting therefrom and extending along the length of the wall 1162. The second housing portion 1154 includes a second wall 1058 and portions of the first and second sidewalls 1062 extending therefrom. Each of the first and second sidewalls 1062 of the second housing portion 1154 has a connecting groove 1164 protruding therefrom and extending along the length of the respective wall 1062. Additionally, the connecting groove 1164 extends from the second wall 1058 between the first and second sidewalls 1062 and extends the length of both sidewalls 1062. The connecting groove 1164 on each of the first and second sidewalls 1062 of the second housing portion 1154 is configured to receive a flange 1160 on the respective first and second sidewalls 1062 of the first housing portion 1150. Similarly, the connecting groove 1164 extending from the first wall 1054 is configured to receive a flange 1160 of the partition wall 1162. Each of the first and second sidewalls 1062 includes a heat dissipation fin 1172 (or other heat dissipation member) extending therefrom.

[0096] A third sidewall 1062 of the box-like structure of the charger electronic device housing 1008 is connected (e.g., by fasteners, etc.) between the first wall 1054 and the second wall 1058 and the first sidewall 1054 and the second sidewall 1058. The third sidewall 1062 defines an opening 1176 extending therethrough. A fourth sidewall 1062 of the box-like structure of the charger electronic device housing 1008 is connected (e.g., by fasteners, etc.) between the first wall 1054 and the second wall 1058 and the first sidewall 1062. The fourth sidewall 1062 includes a plurality of vent holes 1180 extending therethrough. A partition wall 1162 extends between the third sidewall and the fourth sidewall 1062 of the charger electronic device housing 1000.

[0097] The interior of the charger electronics housing 1008 is divided into a first portion 1190 and a second portion 1194 by a partition wall 1162. The partition wall 1162 ensures that the first portion 1190 and the second portion 1194 are separated from each other. The first portion 1190 is completely enclosed by the partition wall 1162 and other walls 1054, 1058, and 1062 of the box-like structure of the charger electronics housing 1008. The charger electronics 1050 is positioned within the first portion 1190 and is filled with a potting compound. Figure 29 In the construction, the auxiliary plate 1198 (e.g., an aluminum or other metal plate) can support at least a portion of the charger electronics 1050 and is positioned adjacent to and in thermal communication with the partition wall 1162.

[0098] The second portion 1194 is enclosed by a partition wall 1162 and other walls 1054, 1058, 1062 of the box-like structure of the charger electronics housing 1008. An opening 1176 of the third sidewall 1062 is positioned to communicate with and align with the second portion 1194 and to accommodate a fan 1004 positioned within the second portion 1194. A plurality of vent holes 1180 of the fourth sidewall 1062 are positioned to communicate with the second portion 1194, such that the vent holes 1180 are located on the side of the charger electronics housing 1008 opposite to the fan 1004. In the illustrated configuration, the partition wall 1162 includes heat dissipation fins 1202 extending therefrom into the second portion 1194.

[0099] The charger electronics housing 1008 is positioned within the cover 1000 and between the cover 1000 and the battery pack receiving portion 750, such that the fan 1004 is positioned adjacent to either the first plurality of vents 1032 or the second plurality of vents 1036, and a plurality of vents 1180 in the charger electronics housing 1008 are positioned adjacent to another of the first plurality of vents 1032 and the second plurality of vents 1036. A cooling air passage 1206 is defined between the first plurality of vents 1032 or the second plurality of vents 1036 in the cover 1000, the fan 1004, and the plurality of vents 1180 in the charger electronics housing 1008 and another of the first plurality of vents 1032 or the second plurality of vents 1036.

[0100] Regardless of the construction of the charger electronics section 754, the airflow through the battery pack receiving section 750 remains the same, as described above. Figure 26 As discussed. However, as Figure 31 As shown, using Figure 28 or Figure 29 The charger electronics section 754 of either of them allows cooling air to flow between their opposite sides. Specifically, Figure 28 and Figure 29The fan 1004 and cooling air passages 1140, 1206 of the charger electronics section 754 are operable to cool the charger electronics housing 1008 and dissipate heat from it. In the illustrated configuration, each of the fans 1004 draws ambient air into the charger electronics section 754 from a region adjacent to the first or second plurality of vents 1032 or 1036 (depending on the location of or adjacent to the fan 1004) via a corresponding first or second plurality of vents 1032 or 1036, and exhausts air through the opposing first or second plurality of vents 1032 or 1036. Specifically regarding Figure 28 The fan 1004 draws ambient air from the area adjacent to or adjacent to the second end 1112 of the air passage 1104 via corresponding first plurality of vents 1032 or second plurality of vents 1036 (depending on the location of or adjacent to the second end 1112 of the air passage 1104) into the charger electronics section 754, and exhausts air through the opposing first plurality of vents 1032 or second plurality of vents 1036, causing cooling air to move through the air passage 1104. Specifically regarding Figure 29 The fan 1004 draws ambient air from the area adjacent to or adjacent to the plurality of vents 1180 in the charger housing 1008 via corresponding first plurality of vents 1032 or second plurality of vents 1036 (depending on the location of or adjacent to the plurality of vents 1180 in the charger housing 1008) into the charger electronics portion 754, and exhausts air through the opposing first plurality of vents 1032 or second plurality of vents 1036, causing cooling air to move through the second portion 1194 of the charger electronics housing 1008. In any case, Figure 28 and Figure 29 In each of the embodiments, the cooling air passage guides the cooling air along an axis M oriented at an angle not parallel to the insertion axis K. In the illustrated configuration, the axis M is oriented at a right angle to the insertion axis K.

[0101] exist Figures 19 to 31 In the demonstrated configuration, each of fans 918 and 1004 is a multi-speed fan operable to rotate at more than one speed. The rotational speed of each of fans 918 and 1004 can be determined based on the temperature of one or more of the charger electronics 1050 or the battery pack 614. In some configurations, fans 918 and 1004 produce between approximately 13.6 m³ / s at full speed. 3 / h and approximately 25.5m 3Airflow between / h. Furthermore, in some configurations, fans 918 and 1004 can produce approximately 20.4 cubic feet per minute (CFM) and up to approximately 35 m³ / h. 3 / h or less of airflow. In some other configurations, fans 918 and 1004 can produce less or more than 31 CFM of airflow at full speed. For example, fans 918 and 1004 can use 31.64 CFM / amp per unit under no-load conditions.

[0102] The configuration discussed in this paper is designed to allow air to move through the respective charger and battery pack. Other configurations may be designed to allow other cooling fluids to move through the respective charger and battery pack.

[0103] While this disclosure has been described with reference to certain preferred aspects, variations and modifications exist within the scope and spirit of one or more independent aspects of this disclosure as described. Various features and advantages of this disclosure are set forth in the following claims.

Claims

1. A charger, comprising: A housing, comprising a front wall, a rear wall, a top wall, a bottom wall, a first side wall, and a second side wall; An interface, located in the front wall and configured to engage a battery pack, includes a charging terminal located between a first guide rail and a second guide rail, a first groove located between the first guide rail and the front wall of the housing, and a second groove located between the second guide rail and the front wall of the housing, the interface communicating with the interior of the housing. A fan, which is connected to the housing adjacent to the interface; as well as An air passage component comprising a hollow body having a first end and a second end spaced apart from the first end, the first end being coupled to the fan and the second end extending through one of the walls; and The fan is operable to draw airflow from the outside of the housing into the housing and guide the airflow through the air passage member to the interface; Each of the first and second guide rails includes an opening extending through it; A first chamber, positioned within the housing and defined by a chamber wall, communicates with an opening in each of the first and second guide rails and defines a first axis. A second chamber extends through the air passage member and includes a second axis and a third axis positioned at an angle relative to the second axis, the second axis coinciding with the first axis. The fan is positioned between the first chamber and the second chamber.

2. The charger as claimed in claim 1, wherein, The second end of the air passage component extends through the rear wall of the housing.

3. The charger as described in claim 2, wherein, The housing defines a depth between the front wall and the rear wall, and the length of the air passage member is at least 50% of the depth.

4. The charger as claimed in claim 1, wherein, The second axis is oriented at an angle relative to the insertion axis defined by the interface, and the angle between the second axis and the insertion axis is different from the oblique angle between the second axis and the third axis.

5. The charger as claimed in claim 1, wherein, The interface defines a fourth axis that is substantially perpendicular to the first axis and the second axis.

6. A charging system, comprising: The charger includes: The housing includes a front wall, a rear wall, a top wall, a bottom wall, a first side wall, and a second side wall. A first connection interface, positioned within the front wall, includes a charging terminal located between a first guide rail and a second guide rail, a first groove located between the first guide rail and the front wall of the housing, and a second groove located between the second guide rail and the front wall of the charger housing. Each of the first and second guide rails includes an opening extending therethrough. A fan, which is connected adjacent to the first connection interface within the housing, and An air passage component comprising a hollow body having a first end and a second end spaced apart from the first end, the first end being coupled to a fan and the second end extending through one of the walls, and The battery pack includes: A battery housing including a longitudinal axis, a first portion, and a second portion connected to the first portion, the battery housing being configured to enclose a plurality of battery cells. The second connection interface extends from the wall of the first portion and is symmetrical about the longitudinal axis. The second connection interface includes a battery terminal positioned between the first guide rail and the second guide rail, a first groove positioned between the first guide rail and the wall of the first portion, and a second groove positioned between the second guide rail and the wall of the first portion. A first plurality of vent holes, the first plurality of vent holes extending adjacent to the first guide rail through the wall of the first portion, A second plurality of vent holes, which extend adjacent to the second guide rail and pass through the wall of the first portion, The second connection interface of the battery pack can be connected to the first connection interface, so that the opening in the first guide rail of the first connection interface is connected to the first plurality of vent holes, and the opening in the second guide rail of the first connection interface is connected to the second plurality of vent holes. The fan is operable to draw airflow from the outside of the housing into the housing of the charger, and guide the airflow through the air passage member to the openings in each of the first guide rail and the second guide rail, as well as the first plurality of vent holes and the second plurality of vent holes, so that the airflow enters the battery pack housing. A first chamber, positioned within the charger housing and defined by a chamber wall, communicates with an opening in each of the first and second guide rails and defines a first axis. A second chamber extends through the air passage member and includes a second axis and a third axis positioned at an angle relative to the second axis, the second axis coinciding with the first axis. The fan is positioned between the first chamber and the second chamber.

7. The charging system as described in claim 6, wherein, The second axis is oriented at an angle relative to the insertion axis defined by the first connection interface, and the angle between the second axis and the insertion axis is different from the oblique angle between the second axis and the third axis.

8. The charging system as described in claim 6, wherein, The first connection interface defines a fourth axis that is substantially perpendicular to the first axis and the second axis.

9. The charging system as claimed in claim 7, wherein, The second end of the air passage component extends through the rear wall of the housing.

10. The charging system as claimed in claim 8, wherein, The housing defines a depth between the front wall and the rear wall, and the length of the air passage member is at least 50% of the depth.

11. A charger for charging a battery pack having a housing encapsulating a plurality of battery cells and one or more vents, the charger comprising: The housing includes a battery pack receiving portion and a separate charger electronics portion, the charger electronics portion including a charger electronics housing; A battery pack interface, which is supported on the battery pack receiving portion, includes a charging terminal. A plurality of vent holes are located adjacent to the battery pack interface in the first wall of the battery pack receiving portion; A first cooling air passage extends from the first plurality of vents through the battery pack receiving portion to an opening in the second wall of the battery pack receiving portion; A first fan is positioned adjacent to the first plurality of vents in the battery pack receiving portion, and the first fan is operable to move air from the outside of the battery pack receiving portion to the first cooling air passage via the first plurality of vents. as well as A printed circuit board, which includes electrical components electrically connected to these charging terminals, is enclosed within a charger electronics housing; The second plurality of vents are located in the third wall of the charger's electronic component section; A second cooling air passage extends from the second plurality of vents through the charger electronics portion to an opening in the fourth wall of the charger electronics portion. The second cooling air passage is in fluid communication with the charger electronics housing to remove heat generated by these electrical components, and the second cooling air passage is sealed and separated from the first cooling air passage. as well as A second fan is positioned adjacent to the second plurality of vents in the charger electronics section, outside the charger electronics housing, and is operable to move air from the outside of the charger electronics section to the second cooling air passage via the second plurality of vents.

12. The charger as claimed in claim 11, wherein, The first fan is operable to draw cooling air from the outside of the battery pack receiving portion into the first cooling air passage member and guide the air into the interior of the battery pack.

13. The charger as claimed in claim 11, wherein, The first fan is operable to draw cooling air from inside the battery pack into the cooling air passage member and guide the air through an opening in the second wall of the battery pack receiving portion.

14. The charger as claimed in claim 11, wherein, The charger's electronic device housing is at least partially formed of a metallic material, making the charger's electronic device housing a heat sink.

15. The charger as claimed in claim 11, wherein, The battery pack interface defines the battery pack insertion axis, a first guide rail parallel to the insertion axis, and a second guide rail positioned opposite to the first guide rail and parallel to the insertion axis, wherein the rotation axis of the first fan is perpendicular to the insertion axis.

16. The charger as claimed in claim 15, wherein, The battery pack's vents include one or more vents located adjacent to the first guide rail and one or more vents located adjacent to the second guide rail.

17. The charger as claimed in claim 16, wherein, The first cooling air passage is positioned adjacent to the one or more vents adjacent to the first guide rail, and the charger further includes: a third cooling air passage extending from the one or more vents adjacent to the second guide rail; and a third fan positioned adjacent to the one or more vents adjacent to the second guide rail in the battery pack receiving portion, and the third fan being operable to move air from the outside of the battery pack receiving portion into the third cooling air passage via the one or more vents adjacent to the second guide rail into the third cooling air passage, wherein each of the first cooling air passage and the third cooling air passage is oriented perpendicular to the insertion axis.

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