Vehicle battery jumper starter powered by removable and rechargeable battery pack

Abstract

A vehicle battery jumper starter powered by a removable and rechargeable battery pack, such as a battery pack used with various hand-held power tools. The battery pack is removably connected to the vehicle battery jumper starter and may be selectively used to charge a power boost module within the vehicle battery jumper starter. The power boosting module includes, for example, a plurality of supercapacitors or lithium polymer battery cells. A power boost module is combined with a battery pack (100) for bridging a start-up vehicle battery. A vehicle battery jumper starter includes a charge control circuit configured to control charging of a power boost module based on battery information obtained from a battery pack.

Description

Related Applications

[0001] This application claims the benefit of and priority to U.S. Provisional Patent Application No. 63 / 592,439, filed on October 23, 2023, the entire contents of which are hereby incorporated by reference into this application. Background Art

[0002] The present invention relates to a vehicle battery jumpstarter powered by a removable and rechargeable battery pack. Summary of the invention

[0003] Vehicle battery jump starters are subject to many design limitations that make the implementation of vehicle battery jump starters difficult. For example, vehicle battery jump starters must meet requirements related to voltage magnitude (e.g., vehicle battery overvoltage), power supply undervoltage (e.g., jump starter power supply undervoltage), sparks and short circuits, and current magnitude. Due to these limitations, current vehicle battery jump starters are dedicated devices with internal power supplies that can be charged and then used to jump-start vehicles as needed. These jump starters can include sealed lead-acid batteries, multiple lithium polymer batteries, or supercapacitor banks. Such devices are typically charged by AC mains. However, because AC mains is not always readily available, in an emergency, the vehicle battery jump starter may lack sufficient charge to jump-start the vehicle battery. A depleted vehicle battery can be used to slowly charge the supercapacitor bank, but a single supercapacitor bank may not always be sufficient to jump-start the vehicle battery.

[0004] As an alternative to these conventional vehicle battery jump starters, a vehicle battery jump starter that can be powered by a battery pack for a cordless handheld power tool will greatly enhance the versatility of the vehicle battery jump starter. As long as the battery pack is available, this jump starter can be used anytime and anywhere. One of the difficulties in implementing a vehicle battery jump starter powered by a battery pack for a power tool is the size of the current that the battery pack can produce. If the battery pack is first used to charge a supercapacitor pack or a lithium polymer battery cell, the current limitation of the battery pack in the case of a vehicle battery jump starter can be alleviated or eliminated. After the supercapacitor or lithium polymer battery cell is charged, the current can be discharged from both the battery pack and the supercapacitor or lithium polymer battery cell. The battery pack discharge current combined with the discharge current from the supercapacitor or lithium polymer battery cell may be sufficient to jump-start the vehicle battery. In some cases, just as the exhausted vehicle battery can be used to charge the supercapacitor pack, the exhausted battery pack can be used alone or in combination with the exhausted vehicle battery to charge the supercapacitor pack. Then, the supercapacitor pack can be used to try to jump-start the vehicle battery.

[0005] In some aspects, the technology described in the present invention relates to a vehicle battery jump starter device, which includes a controller, a battery pack interface, and a power boost module, wherein the controller includes an electronic processor and a charging control circuit, the battery pack interface is configured to receive a removable and rechargeable battery pack, and the power boost module includes one or more energy storage devices, wherein the power boost module is configured to charge through the battery pack interface using a discharge current from the removable and rechargeable battery pack, wherein the charging control circuit is configured to control the discharge current from the removable and rechargeable battery pack to the power boost module based on one or more monitored conditions of the removable and rechargeable battery pack.

[0006] In some aspects, the technology described herein relates to an apparatus wherein a charge control circuit is configured to determine a no-load voltage of a removable and rechargeable battery pack and calculate an allowable load voltage threshold based on the determined no-load voltage. In some aspects, the technology described herein relates to an apparatus wherein the charge control circuit is configured to control a discharge current from the removable and rechargeable battery pack to a power boost module to maintain a voltage of the removable and rechargeable battery pack above the allowable load voltage threshold.

[0007] In some aspects, the technology described herein relates to a device in which a charge control circuit is configured to modulate a discharge current to maintain a voltage of a removable and rechargeable battery pack at or above an allowable load voltage threshold.

[0008] In some aspects, the technology described herein relates to a device in which a charge control circuit calculates an allowable load voltage threshold based on a type of a removable and rechargeable battery pack, the type of the removable and rechargeable battery pack comprising a high impedance battery pack or a low impedance battery pack. In some aspects, the technology described herein relates to a device in which the charge control circuit determines the type of the removable and rechargeable battery pack based on battery information transmitted from the battery pack.

[0009] In some aspects, the technology described herein relates to an apparatus wherein a charge control circuit determines a type of a removable and rechargeable battery pack based on a monitored discharge characteristic of the battery pack. In some aspects, the technology described herein relates to an apparatus wherein a controller is configured to prevent the removable and rechargeable battery pack from being used to jump-start a vehicle battery if a voltage of the removable and rechargeable battery pack is below a second tolerable voltage threshold. In some aspects, the technology described herein relates to an apparatus wherein a power boost module includes a plurality of ultracapacitors, and wherein the power boost module includes a plurality of lithium polymer battery cells.

[0010] In some aspects, the technology described herein relates to a method for jump starting a vehicle battery using a vehicle battery jump starter and a removable and rechargeable battery pack, the method comprising electrically connecting the removable and rechargeable battery pack to a power boost module within the vehicle battery jump starter, determining one or more parameters of the removable and rechargeable battery pack via a first electronic processor of the removable and rechargeable battery pack, charging the power boost module using power from the removable and rechargeable battery pack via the first electronic processor based on the determined parameters, electrically disconnecting the removable and rechargeable battery pack from the power boost module via the first electronic processor after the power boost module is charged, electrically connecting the vehicle battery jump starter to a vehicle battery, monitoring a voltage of the vehicle battery via a second electronic processor, and attempting to start the vehicle in response to an indication of the voltage of the vehicle battery, providing power from the charged power boost module to the vehicle battery via the second electronic processor.

[0011] In some aspects, the technology described herein relates to a method further comprising: preventing, via a second electronic processor, the removable and rechargeable battery pack from being used to jump-start a vehicle battery if the voltage of the removable and rechargeable battery pack is below a voltage threshold. In some aspects, the technology described herein relates to a method wherein determining one or more parameters of a connected removable and rechargeable battery pack comprises determining a no-load voltage of the removable and rechargeable battery pack, and calculating, via a first electronic processor, an allowable load voltage threshold based on the determined no-load voltage.

[0012] In some aspects, the technology described herein relates to a method, further comprising: controlling, via a first electronic processor, a discharge current from a removable and rechargeable battery pack to a power boost module to maintain a voltage of the removable and rechargeable battery pack above an allowable load voltage threshold. In some aspects, the technology described herein relates to a method, further comprising: modulating, via a first electronic processor, the discharge current to maintain a voltage of the removable and rechargeable battery pack at or above the allowable load voltage threshold.

[0013] In some aspects, the technology described in the present invention relates to a battery pack powered vehicle battery jump starter system, the system including: a removable and rechargeable battery pack, the battery pack including a battery pack housing, a plurality of rechargeable battery cells within the battery pack housing; a support portion for supporting the battery pack on a vehicle battery jump starter, a coupling mechanism for selectively electrically coupling the battery pack to the vehicle battery jump starter, and a battery pack controller within the battery pack housing, the battery pack controller being configured to control the operation of the removable and rechargeable battery pack. The system further includes a vehicle battery jump starter including a jump starter housing, a support portion for receiving a removable and rechargeable battery pack and coupling it to the vehicle battery jump starter, a plurality of terminals for electrically connecting the removable and rechargeable battery pack to the vehicle battery jump starter, and a jump starter controller within the jump starter housing, the jump starter controller configured to control operation of the vehicle battery jump starter, wherein in response to the battery pack controller controlling operation of the removable and rechargeable battery pack, the jump starter controller controls the vehicle battery jump starter to jump start the vehicle.

[0014] In some aspects, the technology described herein relates to a system wherein a battery pack controller is configured to transmit battery pack information to a jump starter controller, and the jump starter controller is configured to use the transmitted battery pack information to control operation of a vehicle battery jump starter, and wherein the battery pack information includes at least one of a battery capacity level, a battery impedance level, a battery life, a battery temperature, a battery voltage level, a number of battery charge / discharge cycles, a number of battery usage times, or a number of battery over-temperature events.

[0015] In some aspects, the technology described herein relates to a system wherein a jump starter controller is configured to monitor discharge characteristics of a removable and rechargeable battery pack during operation of a vehicle battery jump starter, and to predict a discharge rate of the removable and rechargeable battery pack based on the monitored discharge characteristics. In some aspects, the technology described herein relates to a system wherein the jump starter controller is configured to adjust performance of the vehicle battery jump starter in response to a monitored voltage of the removable and rechargeable battery pack being below an allowable load voltage threshold, and wherein adjusting performance includes at least one of reducing power consumption, extending run time, or modifying performance of a power boost module within the vehicle battery jump starter.

[0016] In some aspects, the technology described herein relates to a system in which a jump starter controller is configured to prevent a removable and rechargeable battery pack from being used to jump start a vehicle battery in response to a voltage of the removable and rechargeable battery pack being below a second tolerable voltage threshold.

[0017] In some aspects, the technology described herein relates to a system wherein a vehicle battery jump starter further includes a power boost module having one or more energy storage devices, wherein a jump starter controller is configured to charge the power boost module using power from a removable and rechargeable battery pack, and wherein the jump starter controller controls the charging of the power boost module based on one or more parameters of the removable and rechargeable battery pack.

[0018] Before explaining any embodiment of the present invention in detail, it should be understood that the application of the present invention is not limited to the details of the configuration and arrangement of the components described in the following description or shown in the accompanying drawings. The present invention can have other embodiments and can be implemented or realized in various ways. In addition, it should be understood that the words and terms used herein are for illustrative purposes and should not be regarded as restrictive. The use of "including", "comprising" or "having" and their variations herein is intended to cover the items listed thereafter and their equivalents and additional items. Unless otherwise specified or limited, the terms "mounting", "connecting", "supporting" and "coupling" and their variations are used in a broad sense and cover direct and indirect mounting, connection, support and coupling.

[0019] In addition, it should be understood that embodiments of the present invention may include hardware, software, and electronic components or modules, which, for purposes of discussion, may be illustrated and described as if most of the components are implemented only in hardware. However, a person of ordinary skill in the art will recognize, based on a reading of the detailed description, that in at least one embodiment, the electronic-based aspects of the present invention may be implemented in software that is executable by one or more processing units (such as microprocessors and / or application-specific integrated circuits ("ASICs")) (e.g., stored on a non-transitory computer-readable medium). Therefore, it should be noted that the present invention may be implemented using a plurality of hardware- and software-based devices and a plurality of different structural components. For example, the "server" and "computing device" described in the present invention may include one or more processing units, one or more computer-readable medium modules, one or more input / output interfaces, and various connectors (e.g., a system bus) connecting the components.

[0020] Other aspects of the invention will become apparent by careful examination of the detailed description and accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 is a perspective view of a battery pack according to an embodiment of the present invention.

[0022] Figure 2 yes Figure 1 A top view of the battery pack.

[0023] Figure 3 FIG. 1 is a diagram showing a battery cell according to an embodiment of the present invention. Figure 1 A cross-sectional view of a battery pack.

[0024] Figure 4 According to an embodiment of the present invention Figure 1 Electromechanical diagram of the battery pack.

[0025] Figure 5 A device configured to receive, support, and Figure 1 The battery pack is composed of Figure 1 A vehicle battery jump starter powered by a battery pack.

[0026] Figure 6 According to an embodiment of the present invention Figure 5 Electromechanical diagram of a vehicle battery jump starter.

[0027] Figure 7 is used according to an embodiment of the present invention by Figure 1 Battery powered Figure 5 The process of jump starting a vehicle battery using a vehicle battery jump starter. DETAILED DESCRIPTION

[0028] The present invention relates to a vehicle battery jump starter, which is powered by a removable and rechargeable battery pack, such as a battery pack used with various hand-held power tools. The battery pack is removably connected to the vehicle battery jump starter. The battery pack or a plurality of battery packs connected together can be used to power the vehicle battery jump starter and jump-start the vehicle battery. The battery pack can also be selectively used to charge a power boost module within the vehicle battery jump starter. The power boost module includes, for example, a plurality of supercapacitors or lithium polymer battery cells. The power boost module is combined with the removable and rechargeable battery pack to jump-start the vehicle battery.

[0029] Figure 1-3 A battery pack 100 is shown for use with a vehicle battery jump starter (also referred to as a battery pack powered vehicle battery jump starter system). The battery pack 100 can be connected to and supported by a handheld power tool, such as a drill, fastener, saw, pipe cutter, grinder, nail gun, stapler, vacuum cleaner, etc. The battery pack 100 can also be connected to and supported by an outdoor power tool, such as a string trimmer, hedge trimmer, blower, chain saw, etc. Figures 1 to 3 As shown, the battery pack 100 includes a housing 105 and at least one rechargeable battery cell 110 (eg, Figure 3). The battery pack 100 also includes a support portion 115 for supporting the battery pack 100 on a tool, and a coupling mechanism 120 for selectively coupling the battery pack 100 to or releasing the battery pack 100 from the tool. The support portion 115 can be connected to a complementary support portion on the tool.

[0030] The battery pack 100 includes a plurality of terminals 125 located within the support portion 115 and operable to electrically connect the battery cell 110 to the PCB 130 within the battery pack 100. The plurality of terminals 125 include, for example, a battery positive terminal, a ground terminal, and a sensing or data terminal. The battery pack 100 is removably and interchangeably connected to a tool to provide operating power to the tool. The terminal 125 is configured to mate with a corresponding power terminal extending from a tool or the tool of a complementary receiving portion.

[0031] The battery pack 100 shown includes ten battery cells 110. In other embodiments, the battery pack 100 may include additional or fewer battery cells 110. The battery cells may be arranged in series, in parallel, or in a series-parallel combination. For example, the battery pack may include a total of ten battery cells configured in a series-parallel arrangement of five groups of two cells connected in series. The series-parallel combination of battery cells allows the battery pack to have a higher voltage and a greater capacity. In some embodiments, the battery pack 100 includes five battery cells connected in series. In other embodiments, the battery pack 100 includes a different number of battery cells (e.g., between three and thirty battery cells) connected in series, in parallel, or in a series-parallel combination to produce a battery pack having a desired combination of a nominal battery pack voltage and a battery capacity.

[0032] The battery cells 110 are lithium-based battery cells having a chemical composition such as lithium cobalt ("Li-Co"), lithium manganese ("Li-Mn"), or Li-Mn spinel. In some embodiments, the battery cells 110 have other suitable lithium or lithium-based chemical compositions, such as lithium-based chemical compositions including manganese, etc. The battery cells within the battery pack 100 provide operating power (e.g., voltage and current) to the tool. In one embodiment, each battery cell 110 has a nominal voltage of approximately 3.6 V, so that the battery pack has a nominal voltage of approximately 18 V. In other embodiments, the battery cells have different nominal voltages, such as between 3.6 V and 4.2 V, and the battery pack has different nominal voltages, such as 10.8 V, 12 V, 14.4 V, 24 V, 28 V, 36 V, 60 V, 80 V, between 10.8 V and 80 V, etc. The battery cells 110 also each have a capacity, such as approximately between 1.0 ampere-hour ("Ah") and 6.0 Ah. In an exemplary embodiment, the battery cells each have a capacity of approximately 1.5 Ah, 2.4 Ah, 3.0 Ah, 4.0 Ah, 6.0 Ah, between 1.5 Ah and 6.0 Ah, etc. In some embodiments, a battery pack 100 having a total battery pack capacity of approximately 5.0 Ah or greater (e.g., 5.0 Ah to 12.0 Ah) is used in combination with a vehicle battery jump starter. In other embodiments, a battery pack 100 having a total battery pack capacity of approximately 1.5 Ah or greater (e.g., 1.5 Ah to 12.0 Ah) is used in combination with a vehicle battery jump starter.

[0033] The power output by the battery pack 100 to the tool is controlled, monitored and regulated using control electronics within the battery pack 100, the tool, or a combination thereof. Figure 4 A controller 200 is shown associated with the battery pack 100. The controller 200 is electrically and / or communicatively connected to various modules or components of the battery pack 100. For example, the controller 200 shown is connected to a fuel gauge 205 (optional within the battery pack), one or more sensors 210, a tool interface 215, a plurality of battery cells 220, and a charge / discharge control module 225. The controller 200 includes a combination of hardware and software that is operable to control the operation of the battery pack 100, activate the fuel gauge 205, monitor the operation of the battery pack 100, etc. The fuel gauge 205 includes, for example, one or more indicators, such as light emitting diodes ("LEDs"). The fuel gauge 205 can be configured to display a condition of the state of charge of the battery cell 220 or information associated with the state of charge of the battery cell 220. The controller 200 also includes various preset or calculated fault condition values ​​related to temperature, current, voltage, etc. associated with the operation of the tool.

[0034] In some embodiments, the controller 200 includes a plurality of electrical and electronic components that provide power, operational control, and protection to the components and modules within the controller 200 and / or the battery pack 100. For example, the controller 200 includes, among other things, a processing unit 230 (e.g., an electronic processor, a microprocessor, a microcontroller, or another suitable programmable device), a memory 235, an input unit 240, and an output unit 245. The processing unit 230 includes, among other things, a control unit 250, an arithmetic logic unit ("ALU") 255, and a plurality of registers 260 (in Figure 4 200 is shown as a set of registers) and is implemented using known computer architectures, such as modified Harvard architecture, von Neumann architecture, etc. The processing unit 230, memory 235, input unit 240, and output unit 245, as well as various modules connected to the controller 200, are connected via one or more control and / or data buses (e.g., common bus 265). For illustration purposes, Figure 4 , and the like. The use of one or more control and / or data buses for interconnection and communication between various modules and components will be known to those skilled in the art in view of the inventions described herein. In some embodiments, the controller 200 is partially or completely implemented on a semiconductor (e.g., a field programmable gate array ["FPGA"] semiconductor) chip, such as a chip developed through a register transfer level ("RTL") design process.

[0035] The memory 235 is a non-transitory computer-readable medium that includes, for example, a program storage area and a data storage area. The program storage area and the data storage area may include a combination of different types of memory, such as read-only memory ("ROM"), random access memory ("RAM") (e.g., dynamic RAM ["DRAM"], synchronous DRAM ["SDRAM"], etc.), electrically erasable programmable read-only memory ("EEPROM"), flash memory, hard disk, SD card, or other suitable magnetic, optical, physical or electronic memory devices. The processing unit 230 is connected to the memory 235 and executes software instructions that can be stored in the RAM of the memory 235 (e.g., during execution), the ROM of the memory 235 (e.g., on a substantially permanent basis), or another non-transitory computer-readable medium such as another memory or disk. The software included in the implementation of the battery pack 100 can be stored in the memory 235 of the controller 200. The software includes, for example, firmware, one or more applications, program data, filters, rules, one or more program modules, and other executable instructions. The controller 200 is configured to retrieve from the memory and execute instructions related to the control of the battery pack described in the present invention, in particular. The controller 200 may also store various battery pack parameters and characteristics including battery pack nominal voltage, chemistry, cell characteristics, maximum allowable discharge current, maximum allowable temperature, etc. In other configurations, the controller 200 includes additional, fewer, or different components.

[0036] The tool interface 215 includes a combination of mechanical components (e.g., support portion 115) and electrical components (e.g., a plurality of terminals 125) that are configured and operable to interface (e.g., mechanically, electrically, and communicatively connect) the battery pack 100 with a tool or another device. For example, power provided from the battery pack 100 to the tool or device is provided to the tool interface 215 via a charge / discharge control module 225. The charge / discharge control module 225 includes, for example, one or more switches (e.g., FETs) for controlling the charging current to and the discharging current from the battery cell 220. In some embodiments, the power provided from the battery pack 100 to the tool or device (or from the charger) is controlled by the charge / discharge control module 225 external to the battery pack 100 (i.e., inside the tool, device, or charger). The tool interface 215 also includes, for example, a communication line 270 for providing a communication line or link between the controller 200 and the tool or device (e.g., a vehicle battery jump starter).

[0037] The sensor 210 includes, for example, one or more current sensors, one or more voltage sensors, one or more temperature sensors, etc. For example, the controller 200 uses the sensor 210 to monitor the individual state of charge of each battery cell 220, monitor the current discharged from the battery cell 220, monitor the temperature of one or more battery cells 220, etc. If the voltage of one of the battery cells 220 is equal to or higher than the upper voltage limit (e.g., the maximum charging voltage), the charge / discharge control module 225 prevents the battery cell from being further charged or requests a battery charger (not shown) to provide a constant voltage charging scheme. Alternatively, if one of the battery cells 220 is below the lower voltage limit, the charge / discharge control module prevents the battery cell 220 from further discharging. Similarly, if the upper or lower operating temperature limit of the battery cell 220 is reached, the controller 200 can prevent the battery pack 100 from being charged or discharged until the temperature of the battery cell 220 or the battery pack 100 is within an acceptable temperature range.

[0038] The battery pack 100 may be connected to and supported by a vehicle battery jump starter, such as Figure 5 The vehicle battery jump starter 300 shown in FIG. The vehicle battery jump starter 300 includes a housing 305, a support portion 310 for receiving and supporting a battery pack 100, a plurality of terminals 315 for electrically connecting the battery pack 100 to the vehicle battery jump starter 300, an on or power button 320 for turning on or activating the vehicle battery jump starter 300, a first cable 325, a second cable 330, a first terminal clamp 335, and a second terminal clamp 340. The battery pack 100 is connected to the vehicle battery jump starter 300 through the support portion 310 and the plurality of terminals 315. Thus, the battery pack 100 operates as a power source for the vehicle battery jump starter 300.

[0039] The vehicle battery jump starter 300 includes a controller 400, such as Figure 6 Controller 400 is electrically and / or communicatively connected to various modules or components of vehicle battery jump starter 300. For example, controller 400 is shown connected to one or more indicators 405, power input module 410, battery pack interface 415, one or more sensors 420, user input module 425, and FET switch module 430. Controller 400 includes a combination of hardware and software that is operable to control the operation of vehicle battery jump starter 300, activate one or more indicators 405 (e.g., LEDs), monitor the operation of vehicle battery jump starter 300, etc. One or more sensors 420 include, among others, one or more voltage sensors, one or more current sensors, one or more temperature sensors, etc.

[0040] The vehicle battery jump starter 300 additionally includes a pre-charge circuit 505 controlled by the controller 400. In some embodiments, the pre-charge circuit 505 is directly connected to the charge control circuit 275. In some embodiments, the pre-charge circuit 505 electrically interfaces with the user input 245 and, in response to receiving the user input, electrically connects the battery pack 100 to the power boost module 480 to charge the power boost circuit 480 before the vehicle battery jump starter 300 is coupled to the vehicle battery 500. The method of controlling the pre-charge circuit 505 is described in detail in the process 700 below and in Figure 7 Shown in.

[0041] In some embodiments, the controller 400 includes a plurality of electrical and electronic components that provide power, operational control, and protection to the components and modules within the controller 400 and / or the vehicle battery jump starter. For example, the controller 400 includes, among other things, a processing unit 435 (e.g., a microprocessor, a microcontroller, or another suitable programmable device), a memory 440, an input unit 445, and an output unit 450. The processing unit 435 includes, among other things, a control unit 455, an ALU 460, and a plurality of registers 465 (in Figure 6 4 (shown as a set of registers) and implemented using known computer architectures, such as modified Harvard architecture, von Neumann architecture, etc. The processing unit 435, memory 440, input unit 445, and output unit 450, as well as various modules connected to the controller 400, are connected via one or more control and / or data buses (e.g., common bus 470). For illustration purposes, Figure 6 400 is generally shown in FIG. 401. In view of the inventions described herein, it will be known to those skilled in the art to use one or more control and / or data buses for interconnection and communication between various modules and components. In some embodiments, controller 400 is partially or completely implemented on a semiconductor (e.g., FPGA semiconductor) chip.

[0042] The memory 440 is a non-transitory computer-readable medium, including, for example, a program storage area and a data storage area. The program storage area and the data storage area may include a combination of different types of memory, such as ROM, RAM (e.g., DRAM, SDRAM, etc.), EEPROM, flash memory, hard disk, SD card, or other suitable magnetic, optical, physical or electronic memory devices. The processing unit 435 is connected to the memory 440 and executes software instructions that can be stored in the RAM of the memory 440 (e.g., during execution), the ROM of the memory 440 (e.g., on a substantially permanent basis), or another non-transitory computer-readable medium such as another memory or disk. The software included in the implementation of the vehicle battery jump starter can be stored in the memory 440 of the controller 400. The software includes, for example, firmware, one or more applications, program data, filters, rules, one or more program modules, and other executable instructions. The controller 400 is configured to retrieve from the memory and execute instructions related to the control process and method described in the present invention, in particular. In other configurations, the controller 400 includes additional, fewer or different components.

[0043] The battery pack interface 415 includes a combination of mechanical components (e.g., support portion 310) and electrical components (e.g., a plurality of terminals 315) that are configured and operable to interface (e.g., mechanically, electrically, and communicatively connect) the vehicle battery jump starter with the battery pack 100. For example, power provided by the battery pack 100 to the vehicle battery jump starter is provided to the power input module 410 through the battery pack interface 415. The power input module 410 includes a combination of active and passive components to condition or control the power received from the battery pack 100 before providing the power to the controller 400. The battery pack interface 415 also includes, for example, a communication line 475 for providing a communication line or link between the controller 400 and the battery pack 100. The battery pack interface 415 provides power to the FET switch module 430 to be switched by the switch FET to selectively provide power to the clamps 335, 340.

[0044] The FET switch module 430 is also connected to a power boost module 480. The power boost module 480 includes, for example, a plurality of supercapacitors or lithium polymer battery cells. The power boost module 480 is selectively charged by the controller 400 using power from the battery pack 100. In some embodiments, the power boost module 480 is charged by the vehicle battery (for example, the supercapacitor can be charged from a depleted vehicle battery). The power boost module 480 can be used in conjunction with the battery pack 100 to provide power to the vehicle battery to jump-start the vehicle battery. In some embodiments, the power boost module 480 alone (i.e., without the battery pack 100) can be used to attempt to jump-start the vehicle battery. However, without the battery pack 100, the capabilities of the vehicle battery jump starter 300 are limited. For example, a supercapacitor alone may not have the energy capacity to jump-start the vehicle without the battery pack 100. Alternatively, the lithium polymer battery cells need to be charged, which may be difficult or impossible based on the location of the vehicle when the vehicle battery needs to be jumped started.

[0045] In some embodiments, the vehicle battery jump starter 300 may include optimization features configured to be implemented by the charging control circuit 275. For example, before releasing current from the battery pack 100, the charging control circuit 275 determines one or more parameters of the battery pack 100. In one embodiment, the parameter is the no-load voltage of the battery pack 100, which can be determined using, for example, the sensor 210. The charging control circuit 275 then uses the determined battery pack voltage to calculate an allowable load voltage (also referred to as a threshold or predetermined threshold) of the battery pack 100 when discharged by the charging control circuit 275. In some embodiments, the allowable load voltage is a predetermined voltage level.

[0046] In response to the allowable load being determined, the charging control circuit 275 then controls the vehicle battery jump starter 300 to draw current from the battery pack 100 until the allowable load level is reached. In some embodiments, the load level is determined based on the voltage drop during discharge. The charging control circuit 275 can prevent the vehicle battery jump starter 300 from drawing current that would cause the voltage of the battery pack 100 to unexpectedly drop (e.g., below a load voltage threshold). In some embodiments, the charging control circuit 275 continues to measure the voltage of the battery pack 100 during discharge and modulates the discharge current to maintain the battery voltage at or above the allowable load voltage threshold. In some embodiments, the functions of the charging control circuit 275 are performed by the controller 400.

[0047] In some cases, the charging control circuit 275 can calculate the permissible load voltage threshold based on the type of battery pack 100 connected, or control the discharge of the battery pack 100. For example, when a low-performance battery (e.g., a battery with high impedance) is connected to the vehicle battery jump starter 300, the permissible voltage threshold can be reached with a lower total discharge current. On the other hand, when a high-performance battery (e.g., a battery with low impedance) is connected to the vehicle battery jump starter 300, the permissible voltage threshold can be reached with a higher total discharge current. In other words, a low-performance battery pack can produce an overall lower discharge current compared to a high-performance battery pack, and thus result in a longer charging time. The charging control circuit 275 is configured to control the vehicle battery jump starter 300 to maximize the efficiency of the connected battery pack 100, regardless of its performance level. In some embodiments, battery information (such as impedance, capacity, health status, charge status, temperature, etc.) can be transmitted to the vehicle battery jump starter 300 by the battery controller 200. In other embodiments, the battery information may be determined by the controller 400 and / or the charging control circuit 275 when the battery pack 100 is electrically coupled to the vehicle battery jump starter 300 .

[0048] In some embodiments, the vehicle battery jump starter 300 can be used as a charging device when connected to the battery pack 100. For example, the controller 400 of the vehicle battery jump starter 300 can be configured to communicate with the controller 200 of the battery pack to obtain battery-specific information. The battery-specific information can be, for example, a battery capacity level, an impedance level, a battery life, a battery temperature, a battery voltage level, or historical data such as the number of battery charge / discharge cycles, the number of battery uses, or the number of battery over-temperature events. Once the controller 400 obtains the battery-specific information, the charging control circuit 275 can use some or all of the battery-specific information to calculate an appropriate discharge current. For example, as previously described, high / low performance batteries may have different impedance levels. The charging control circuit 275 can calculate an appropriate discharge current (and therefore a predetermined load voltage level) based on the battery-specific impedance level obtained from the battery pack 100.

[0049] In some embodiments, the vehicle battery jump starter 300 is configured to monitor characteristics of the battery pack 100 during operation. For example, the charging control circuit 275 is configured to monitor the discharge characteristics of the battery pack 100 during operation of the vehicle battery jump starter 300 to predict behavior. In other words, the monitored characteristics are used by the charging control circuit 275 to determine the optimal discharge rate of the battery pack 100. The prediction can also be used to determine whether the selected battery pack is a high-performance battery or a low-performance battery (e.g., a high-impedance battery or a low-impedance battery). In addition, the charging control circuit 275 can use the predicted behavior to modulate the discharge rate of the battery pack 100. In some cases, the prediction uses machine learning to create a prediction profile for the battery pack 100. The prediction profile can contain historical data from previous use of the battery pack 100 and is used by the charging control circuit 275 to determine the capabilities of the battery pack (e.g., optimal discharge rate, allowable voltage threshold, etc.).

[0050] In some embodiments, the vehicle battery jump starter 300 is configured to monitor the voltage level of the battery pack 100 as previously described, and adjust the performance of components within the vehicle battery jump starter 300 based on the voltage of the battery pack 100 during discharge. For example, in response to the monitored voltage of the battery pack 100 being below an allowable voltage threshold, the controller 400 may reduce power consumption, extend operating time, modify the performance of the power boost module 480, and / or perform other operations required for a given application, as previously described.

[0051] Figure 7is a flow chart illustrating a process 700 for operating a combination of a battery pack 100 and a vehicle battery jump starter 300. The process 700 begins by attaching the battery pack 100 to the vehicle battery jump starter 300 at process block 705. Following process block 705, at process block 710, the controller 400 of the vehicle battery jump starter 300 is configured to control the pre-charge circuit 505 to electrically connect the battery pack 100 to the power boost module 480. At process block 712, in response to the battery pack 100 being connected to the power boost module 480, one or more parameters of the connected battery pack 100 are determined, as described in detail above. At process block 715, in response to determining the parameters of the battery pack 100, stored energy from the battery pack 100 may be used to charge the power boost module 480 based on the determined parameters. In some embodiments, the charge control circuit 275 regulates the current released from the battery pack 100 as previously described. At process block 720, in response to the power boost module 480 being fully charged, the controller 400 is configured to control the pre-charge circuit 505 to electrically disconnect the battery pack 100 from the power boost module 480. With the power boost module 480 charged and the battery pack 100 connected to the vehicle battery jump starter 300, the combination of the battery pack 100 and the vehicle battery jump starter can be used to jump start the vehicle battery 500.

[0052] If the voltage of the battery pack 100 is so low that attempting to jump-start the vehicle battery 500 may damage the battery pack 100, the charging control circuit 275 may selectively prevent the battery pack 100 from being used to jump-start the vehicle battery 500. For example, in addition to the tolerable voltage threshold of the battery pack 100, a second tolerable voltage threshold may be implemented to prevent the battery pack 100 from being used for jump-starting of a vehicle. In some embodiments, when the voltage of the battery pack 100 is below the second threshold, the charging control circuit 275 may prevent the battery pack 100 from discharging current, and the discharge current will cause the voltage of the battery pack 100 to drop below the second tolerable voltage threshold (e.g., 2.6 V per cell). The second voltage threshold is selected to correspond to the amount of energy required to jump-start the vehicle battery 500 or the expected voltage drop caused by the discharge of the high current required to jump-start the vehicle battery. In the event that the battery pack 100 has less charge than is required to jump-start the vehicle battery 500 and attempting to jump-start the vehicle battery 500 would cause the voltage of the battery pack 100 to drain or drop below a standard low voltage cutoff value, the charge control circuit 275 prevents the battery pack 100 from attempting to jump-start the vehicle battery 500. In some embodiments, the controller 400 of the vehicle battery jump starter 300 or the controller 200 of the battery pack 100 may perform these functions.

[0053] The vehicle battery jump starter 300 is then connected to the vehicle battery 500 via the terminal clamps 335 and 340 (at 725). In response to the vehicle battery jump starter 300 being connected to the vehicle battery 500, the controller 400 monitors the voltage across the vehicle battery 500 at process block 730. When attempting to start the vehicle, the voltage of the vehicle battery 500 decreases. This decrease in the voltage of the vehicle battery 500 signals to the controller 400 that an attempt has been made to start the vehicle (at 735).

[0054] Thus, the present invention provides, inter alia, a vehicle battery jump starter powered by a removable and rechargeable battery pack.

Claims

1. A vehicle battery jump starter device, comprising: a controller including an electronic processor and a charging control circuit; a battery pack interface configured to receive a removable and rechargeable battery pack; a power boost module, the power boost module comprising one or more energy storage devices; wherein the power boost module is configured to be charged via the battery pack interface using a discharge current from the removable and rechargeable battery pack, Wherein the charging control circuit is configured to control a discharge current from the removable and rechargeable battery pack to the power boost module based on one or more monitored conditions of the removable and rechargeable battery pack.

2. The device according to claim 1, wherein: The charging control circuit is configured to determine a no-load voltage of the removable and rechargeable battery pack and calculate an allowable load voltage threshold based on the determined no-load voltage.

3. The device according to claim 1, wherein: The charge control circuit is configured to control a discharge current from the removable and rechargeable battery pack to the power boost module to maintain a voltage of the removable and rechargeable battery pack above an allowable load voltage threshold.

4. The device as claimed in claim 3, wherein: The charge control circuit is configured to modulate the discharge current to maintain a voltage of the removable and rechargeable battery pack at or above the tolerable load voltage threshold.

5. The device according to claim 2, wherein: The charge control circuit calculates the allowable load voltage threshold based on a type of a removable and rechargeable battery pack, which includes a high impedance battery pack or a low impedance battery pack.

6. The device according to claim 5, wherein: The charging control circuit determines the type of the removable and rechargeable battery pack based on battery information transmitted from the removable and rechargeable battery pack.

7. The device according to claim 5, wherein: The charge control circuit determines the type of the removable and rechargeable battery pack based on the monitored discharge characteristics of the battery pack.

8. The device of claim 1, wherein: The controller is configured to prevent the removable and rechargeable battery pack from being used to jump-start the vehicle battery if the voltage of the removable and rechargeable battery pack is below a second tolerable voltage threshold.

9. The device of claim 1, wherein: The power boost module includes a plurality of supercapacitors and / or a plurality of lithium polymer battery cells.

10. A method of jump starting a vehicle battery using a vehicle battery jump starter and a removable and rechargeable battery pack, the method comprising: electrically connecting the removable and rechargeable battery pack to a power boost module within the vehicle battery jump starter; determining, via a first electronic processor of the removable and rechargeable battery pack, one or more parameters of the removable and rechargeable battery pack; charging the power boost module via the first electronic processor using power from the removable and rechargeable battery pack based on the determined parameters; after the power boost module is charged, electrically disconnecting, via the first electronic processor, the removable and rechargeable battery pack from the power boost module; electrically connecting the vehicle battery jump starter to the vehicle battery; monitoring, via a second electronic processor, a voltage of the vehicle battery; and Responsive to a voltage of the vehicle battery indicating an attempt to start the vehicle, power is controlled via the second electronic processor from the charged power boost module to the vehicle battery.

11. The method according to claim 10, further comprising: If the voltage of the removable and rechargeable battery pack is below a voltage threshold, the removable and rechargeable battery pack is prevented, via the second electronic processor, from being used to jump-start the vehicle battery.

12. The method of claim 10, wherein determining one or more parameters of the connected removable and rechargeable battery pack comprises determining a no-load voltage of the removable and rechargeable battery pack, and calculating, via the first electronic processor, an allowable load voltage threshold based on the determined no-load voltage.

13. The method according to claim 12, further comprising: A discharge current from the removable and rechargeable battery pack to the power boost module is controlled via the first electronic processor to maintain a voltage of the removable and rechargeable battery pack above the allowable load voltage threshold.

14. The method according to claim 13, further comprising: The discharge current is modulated via the first electronic processor to maintain a voltage of the removable and rechargeable battery pack at or above the tolerable load voltage threshold.

15. A battery pack powered vehicle battery jump starter system, the system comprising: A removable and rechargeable battery pack, the removable and rechargeable battery pack comprising: Battery pack housing; a plurality of rechargeable battery cells, the plurality of rechargeable battery cells being within the battery pack housing; a supporting portion, the supporting portion being used to support the battery pack on the vehicle battery jump starter; a coupling mechanism for selectively electrically coupling the removable and rechargeable battery pack to the vehicle battery jump starter; a battery pack controller located within the battery pack housing, the battery pack controller being configured to control operation of the removable and rechargeable battery pack; and A vehicle battery jump starter, the vehicle battery jump starter comprising: Jump starter housing; a support portion for receiving the removable and rechargeable battery pack and coupling it to the vehicle battery jump starter; a plurality of terminals for electrically connecting the removable and rechargeable battery pack to the vehicle battery jump starter; and a jump starter controller located within the jump starter housing, the jump starter controller being configured to control operation of the vehicle battery jump starter; wherein, in response to the battery pack controller controlling operation of the removable and rechargeable battery pack, the jump starter controller controls the vehicle battery jump starter to jump start a vehicle.

16. The system of claim 15, wherein: The battery pack controller is configured to communicate battery pack information to the jump starter controller, and the jump starter controller is configured to control operation of the vehicle battery jump starter using the communicated battery pack information, and The battery pack information includes one item selected from the group consisting of: battery capacity level, battery impedance level, battery life, battery temperature, battery voltage level, battery charge / discharge cycle number, battery usage number and battery over-temperature event number.

17. The system of claim 15, wherein: The jump starter controller is configured to monitor a discharge characteristic of the removable and rechargeable battery pack during operation of the vehicle battery jump starter and predict a discharge rate of the removable and rechargeable battery pack based on the monitored discharge characteristic.

18. The system of claim 15, wherein: The jump starter controller is configured to adjust performance of the vehicle battery jump starter in response to a monitored voltage of the removable and rechargeable battery pack being below an allowable load voltage threshold, and Wherein adjusting performance comprises one selected from the group consisting of reducing power consumption, extending runtime, and modifying performance of a power boost module within the vehicle battery jump starter.

19. The system of claim 15, wherein: The jump starter controller is configured to prevent the removable and rechargeable battery pack from being used to jump start a vehicle battery in response to a voltage of the removable and rechargeable battery pack being below a second tolerable voltage threshold.

20. The system of claim 15, wherein: The vehicle battery jump starter further includes a power boost module having one or more energy storage devices, wherein the jump starter controller is configured to charge the power boost module using power from the removable and rechargeable battery pack, and The jump starter controller controls charging of the power boost module based on one or more parameters of the removable and rechargeable battery pack.

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