Portable power supply powered by high-power battery

Abstract

A portable power source includes a housing defining a first battery support, a second battery support, and a power outlet, an electrical circuit supported by the housing and including input terminals on the battery supports, output terminals on the power outlet, a first battery power source, a second battery power source, and a frame, and an inverter electrically connected between the input terminal and the output terminal, the first battery power supply including a battery case supported on the first battery support, a battery cell, and a battery terminal connected to the battery cell and electrically connectable to the input terminal; a second battery power supply including a battery case supported on a second battery support, a battery cell, and a battery terminal connected to the battery cell and electrically connectable to the input terminal; a frame is connected to the housing and extends beyond an outer periphery of the housing and outer peripheries of the supported first and second battery power sources, the frame preventing contact with the housing and the battery power sources.

Description

[0001] This application is a divisional application of the Chinese patent application with application number 201980022519.0, application date March 25, 2019, and name “High-power battery-powered portable power supply”.

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS

[0003] This application claims priority to U.S. Provisional Patent Application No. 62 / 648,276, filed on March 26, 2018, the entire contents of which are incorporated herein by reference. Technical Field

[0004] The present invention relates to battery powered portable power supplies and, more particularly, to such portable power supplies powered by high power battery packs. Background Art

[0005] Users of power tools, outdoor tools, and other power equipment use a wide variety of corded alternating current (AC) products every day. These products include low- to high-power tools and equipment, variable speed tools, and chargers for cordless batteries (referred to as "multiple corded devices" or "corded devices"). These corded devices often do not have suitable cordless options. Even when cordless options are available, users may still prefer corded devices (e.g., due to the additional cost associated with cordless solutions) because users do not believe that cordless solutions can provide the performance, runtime, etc. required to complete heavier applications, etc.

[0006] In some cases, the plant may not provide power or sufficient power, or the available power may be unreliable or insufficient for corded device applications. Such scenarios may force the user to obtain power from a remote location where reliable power is available (e.g., via an extension cord) or utilize a fuel-based generator (which may be bulky and loud).

[0007] In some cases, a workplace may be enclosed or inadequately ventilated prohibiting the use of generators (due to emissions from the generators). In these cases, users may need to use long extension cords that may reduce the performance and life of corded AC products. This can result in lost productivity, ongoing inconvenience, an overall poor user experience, etc.

[0008] Therefore, there may be a need for a non-fuel based portable power source that is reliable and can provide high power for corded device applications for extended periods of time. Summary of the invention

[0009] In an independent aspect, a portable power source may generally include: a housing defining a battery support and an AC power outlet; a circuit supported by the housing and including input terminals located on the battery support, output terminals located on the power outlet, and an inverter electrically connected between the input terminals and the output terminals; a battery power source including a battery housing supported on the battery support, at least one battery cell, and battery terminals connected to the battery cell and electrically connectable to the input terminals, power being transferable from the battery cell to the circuit for output through the AC power outlet; and a frame connected to the housing and extending beyond the periphery of the housing and the periphery of the supported battery power source.

[0010] In another independent aspect, a portable power source may generally include: a housing that is supportable relative to a support surface, the housing having a lower surface facing the support surface and an upper surface facing away from the lower surface, the housing including a first battery support located on the first surface, a second battery support located on the second surface, and an AC power outlet; a circuit supported by the housing and including a first input terminal located on the first battery support, a second input terminal located on the second battery support, and an output terminal located on the power outlet, and an inverter electrically connected between the input terminal and the output terminal; a first battery pack and a second battery pack, the first battery pack being supportable on the first battery support and the second battery pack being supportable on the second battery support, each battery pack including a battery housing supported on an associated battery support, at least one battery cell, and a battery terminal connected to the battery cell and electrically connectable to the associated input terminal, power being delivered from the battery cells of each battery pack to the circuit for output through the AC power outlet.

[0011] In yet another independent aspect, a portable power source may generally include: a housing defining a battery support and an AC power outlet; a circuit supported by the housing and including an input terminal located on the battery support, an output terminal located on the power outlet, and an inverter electrically connected between the input terminal and the output terminal; a battery power source including a battery housing supported on the battery support, at least one battery cell, and battery terminals connected to the battery cell and electrically connectable to the input terminal, power being transferable from the battery cell to the circuit for output through the AC power outlet; and a fuel gauge configured to display a charge status of the battery power source, the fuel gauge and the power outlet being located on one side of the housing.

[0012] Other independent aspects of the invention will become apparent by consideration of the following detailed description and accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 is a perspective view of a portable power source, such as a battery-powered portable power source.

[0014] Figure 2 yes Figure 1 A top plan view of a portable power source.

[0015] Figure 3 yes Figure 1 A bottom plan view of a portable power supply.

[0016] Figure 4 yes Figure 1 Front plan view of a portable power source.

[0017] Figure 5 yes Figure 1 Rear plan view of a portable power source.

[0018] Figure 6 yes Figure 1 A first side plan view of a portable power supply.

[0019] Figure 7 yes Figure 1 A second side plan view of a portable power supply.

[0020] Fig. 8A and Figure 8B Shows Figure 1 Padlock interface for portable power supply.

[0021] Fig. 9 Shows Figure 1 User interface for portable power supply.

[0022] Fig.10 yes Figure 1 A perspective view of a portable power supply with a power tool battery charger installed.

[0023] Fig.11 yes Figure 1 Block diagram of a portable power supply.

[0024] Fig.12 yes Figure 1 Internal view of a portable power supply.

[0025] Fig.13 yes Figure 1 A perspective view of a portable power source with the battery pack removed.

[0026] Fig.14 yes Fig.13 A front view of the portable power supply is shown.

[0027] Fig.15 yes Fig.13 A front perspective view of a portion of a portable power supply is shown.

[0028] Fig.16 yes Fig.13 A side cross-sectional view of a portable power supply is shown.

[0029] Fig.17 Included for Figure 1 A perspective view of a transport assembly of a portable power source. DETAILED DESCRIPTION

[0030] Before explaining any independent embodiment of the present invention in detail, it should be understood that the application of the present invention is not limited to the construction details and component arrangements set forth in the following description or shown in the accompanying drawings. The present invention can have other embodiments and can be practiced or implemented in various ways. In addition, it should be understood that the words and terms used herein are for descriptive purposes and should not be considered as limiting.

[0031] As used herein, the use of "including" and "comprising" and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. As used herein, the use of "consisting of" and variations thereof is meant to encompass only the items listed thereafter and equivalents thereof.

[0032] In addition, functions described herein as being performed by one component may be performed by multiple components in a distributed manner. Similarly, functions performed by multiple components may be combined and performed by a single component. Similarly, components described as performing a particular function may also perform additional functions not described herein. For example, a device or structure that is "configured" in a certain manner is configured in at least that manner, but may also be configured in unlisted manners.

[0033] In addition, some embodiments described herein may include one or more electronic processors configured to perform the described functions by executing instructions stored in a non-transitory computer-readable medium. Similarly, the embodiments described herein may be implemented as a non-transitory computer-readable medium storing instructions executable by one or more electronic processors to perform the described functions. As used in this application, "non-transitory computer-readable medium" includes all computer-readable media, but does not include temporary propagating signals. Therefore, non-transitory computer-readable media may include, for example, a hard disk, a CD-ROM, an optical storage device, a magnetic storage device, a ROM (read-only memory), a RAM (random access memory), a register memory, a processor cache, or any combination thereof.

[0034] Many of the modules and logical structures described can be implemented in software executed by a microprocessor or similar device, or can be implemented in hardware using various components including, for example, an application specific integrated circuit ("ASIC"). Terms such as "controller" and "module" may include or refer to hardware and / or software. Capitalized terms are used in accordance with convention and help to associate the description with coding examples, equations, and / or drawings. However, no specific meaning is implied by the use of capital letters or should be inferred because of the use of capital letters. Therefore, the claims should not be limited to the specific examples or terms, or to any specific hardware or software implementation or combination of software or hardware.

[0035] Figures 1 to 7 A portable power source 10 according to one embodiment of the present invention is shown. The portable power source 10 shown is powered by one or more high power battery packs 54 (e.g., two battery packs 54A, 54B are shown) and is operable to power various corded devices, such as power tools, outdoor tools, other power equipment (e.g., lights, chargers for cordless batteries, etc.).

[0036] The battery pack 54 may include one or more battery cell strings, each battery cell string having a plurality (e.g., 20) of battery cells connected in series to provide a desired discharge output (e.g., a nominal voltage (e.g., 20V, 40V, 60V, 80V, 120V) and an amount of current). The battery pack 54 may include a plurality of battery cell strings connected in parallel (e.g., a single battery cell string "20S1P", two battery cell strings "20S2P", three battery cell strings "20S3P", etc.). In other embodiments, other combinations of battery cells (series, parallel, series-parallel configurations) are also possible.

[0037] Each battery cell may have a nominal voltage between 3V and 5V and a nominal capacity between 3Ah and 5Ah. The battery cells may be any rechargeable battery cell chemistry type, such as lithium (Li), lithium ion (Li-ion), other lithium-based chemistries, nickel cadmium (NiCd), nickel metal hydride (NiMH), etc.

[0038] A similar battery pack 54 is described and illustrated in U.S. Provisional Patent Application No. 62 / 527,735, filed on June 30, 2017, and entitled “HIGH-POWER BATTERY-POWERED SYSTEM,” the entire contents of which are incorporated herein by reference.

[0039] The weight of a single "20S1P" configured battery pack 54 is about 6 pounds. The weight of a single "20S2P" configured battery pack 54 is about 11 pounds. The weight of a single "20S3P" configured battery pack 54 is in the range of about 15 pounds to about 20 pounds. In some embodiments, the weight of a single "20S3P" configured battery pack 54 is about 18 pounds.

[0040] The portable power source 10 shown includes a housing 14 having a top 18, a bottom 22, a front 26, a rear 30, and opposing sides 34, 38. A roll cage 42 (e.g., a frame) is secured to the housing 14, for example, to provide protection for the portable power source 10 and to enable handling of the portable power source 10. The roll cage 42 prevents contact with the housing 14 and a battery pack 54 (e.g., a battery power source). As shown, the roll cage 42 is secured to the front 26 and rear 30 of the housing 14 by fasteners 46. In some embodiments, the roll cage 42 may be secured to other sides of the housing 14.

[0041] A battery support 50 is provided for each battery pack 54. In the illustrated structure, a first battery support 50A is disposed on the top 18 of the housing 10 and supports the first battery pack 54A; a second battery support 50B is disposed on the bottom 22 of the housing 10 and supports the second battery pack 54B.

[0042] The roll cage 42 includes a first frame portion 58 and a second frame portion 62 secured to the front 26 and rear 30 of the shell 14, respectively, and a pair of spaced-apart horizontal bars 66 connecting the frame portions 58, 62 on the top 18. The roll cage 42 is made of a hollow metal bar having, for example, a rectangular or circular cross-section.

[0043] The structure of the roll cage 42 prevents the battery pack 54 and the housing 14 from absorbing any impact during a drop event. The roll cage 42 absorbs impact forces and can withstand a drop of up to 4 feet from the ground. In some embodiments, the roll cage 42 can absorb 220J of impact energy from a drop event.

[0044] The frame portions 58, 62 extend on each side 18-38 beyond the perimeter of the housing 14. In particular, the frame portions 58, 62 extend on the top 18 above the first battery support 50A and the supported first battery pack 54A, and on the bottom 22 below the second battery support 50B and the supported second battery pack 54B.

[0045] A carrying handle 70 is connected to and generally perpendicular to the horizontal bar 66. The carrying handle 70 is parallel to the frame portions 58, 62. The carrying handle 70 includes a grip portion 72, which may include an elastomeric material to improve the user's grip and comfort during movement of the portable power supply 10. Rubber feet 74 are fixed to the bottom of the frame portions 58, 62 (e.g., covering the corners). The rubber feet 74 provide a non-slip, non-scratch surface when the portable power supply 10 is placed on a surface (such as a floor in a workshop).

[0046] In the illustrated construction, the housing 14 is not vertically centered on the frame portions 58, 62. The center of the housing 14 is located below the vertical center of the frame portions 58, 62 to provide a lower center of gravity for the portable power source 10, as described in further detail below. The frame portions 58, 62 extend beyond the top 18 as compared to the bottom 22. This position also spaces the handle 70 from the uppermost portion of the supported first battery pack 54A to allow a user's hand to be placed between the handle 70 and the first battery pack 54B.

[0047] refer to Figure 4 , the portable power supply 10 shown defines a height 78 within a range of about 520 mm to about 540 mm. In some embodiments, the height 78 is about 527.5 mm. The portable power supply 10 shown defines a width 82 within a range of about 370 mm to about 390 mm. In some embodiments, the width 82 is about 374 mm. Figure 6 , the portable power source 10 is shown to define a depth 86 in the range of about 280 mm to about 300 mm. In some embodiments, the depth 86 is about 289 mm.

[0048] refer to Figure 5 , a cross-sectional dimension 90 (e.g., wall length for a rectangular tube, diameter for a round tube) of roll cage 42 is in a range of about 0.8 inches to about 1.2 inches. In some embodiments, rod dimension 90 is about 1 inch. A wall thickness 94 of roll cage 42 is in a range of about 0.8 millimeters to about 1.7 millimeters. In some embodiments, wall thickness 94 is about 1.0 millimeters. In some embodiments, wall thickness 94 is about 1.5 millimeters.

[0049] The total weight of the portable power supply 10 including two "20S2P" configured battery packs 54 is in the range of about 48 pounds to about 55 pounds (e.g., about 53.8 pounds). In some embodiments, the total weight of the portable power supply 10 including two "20S2P" configured battery packs 54 is about 50 pounds. As described above, the weight of a single "20S2P" battery pack 54 is about 11 pounds, making the weight of the portable power supply 10 itself about 26 pounds to about 33 pounds.

[0050] In the configuration shown (see Figure 4), the portable power supply 10 can define a horizontal centerline 102. The portable power supply 10 is configured to have a center of gravity 98 that is slightly below the horizontal centerline 102 of the portable power supply 10. The horizontal centerline 102 is midway between the top and bottom ends of the portable power supply 10.

[0051] refer to Figure 4 , the center of gravity 98 is within a range of about 15 mm to about 25 mm below the centerline 102. The center of gravity 98 of the portable power supply 10 is between about 2.5% and about 5% of the height 78 of the portable power supply 10 below the horizontal centerline. In some embodiments, the center of gravity 98 is about 20 mm below the centerline 102. In some embodiments, the center of gravity is about 243 mm from the bottom of the portable power supply 10.

[0052] refer to Figure 4 , the center of gravity 98 is located on the vertical centerline 106 of the portable power supply 10. The vertical centerline 106 is located midway between the first side 34 and the second side 38 of the portable power supply 10. In some embodiments, the center of gravity 98 is about 186.5 millimeters from the first side 34 of the portable power supply 10. In some embodiments, the center of gravity 98 is slightly toward the first side 34 from the vertical centerline 106. The center of gravity 98 can be about 6.6 millimeters from the centerline 106 toward the first side 34. The center of gravity 98 is about 1.5% of the depth 86 to about 3% of the depth from the vertical centerline 106 toward the front of the case. The center of gravity 98 is about 5 millimeters to about 8 millimeters from the vertical centerline 106 toward the front of the case.

[0053] When the portable power supply 10 is resting on the ground, the lower center of gravity 98 can inhibit or prevent the portable power supply 10 from tipping. In addition, the lower center of gravity 98 can allow the portable power supply 10 to be carried more easily.

[0054] refer to Fig. 8A and Figure 8B , the portable power supply 10 includes a battery locking point 110 for each battery pack 54A, 54B. A padlock 114 can be installed at the battery locking point 100 to prevent the battery pack 54 from being separated from the housing 14. The padlock 114 can engage with the battery support 50 to prevent the removal of the battery packs 54A, 54B. When installed, each padlock 114 can extend into and block the removal path of the associated battery pack 54A, 54B. Additionally or alternatively, the installed padlock 114 may interfere with the operation of the associated battery latch mechanism (described below) to prevent the removal of the battery packs 54A, 54B.

[0055] Additional locking points, such as a padlock cover (not shown), may be provided on the front 26 of the housing 24 to prevent access to components of the portable power source 10 (eg, to prevent access to a power outlet).

[0056] Fig. 9 A user interface 118 is shown disposed on the front 26 of the housing 14. In the example shown, the user interface 118 includes a power button 122, an AC outlet 126, and a plurality of indicators (e.g., an over-condition indicator 130, a wireless connection indicator 134, a fuel gauge 138, a battery charge indicator 142, etc.). The indicators shown include visual indicators, and in other configurations (not shown), other types of indicators may be included, such as auditory, tactile, etc.

[0057] The power button 122 may be implemented as a push button, a two-way switch, a touch button, etc. The power button 122 is used to control the power output to the user interface 118, and can be activated to start or shut down the portable power supply 10. When the power button 122 is used to start the portable power supply 10, the power output through the AC outlet 126 is enabled, and the over-condition indicator 130 and the fuel gauge 138 are enabled to display an indication. When the power button 122 is used to shut down the portable power supply 10, the power output through the AC outlet 126 is disabled, and the over-condition indicator 130 and the fuel gauge 138 are disabled.

[0058] The AC outlet 126 is a 15A, 120V AC outlet that provides a power output similar to a wall outlet. The AC outlet 126 is powered by the battery pack 54. In the illustrated example, the excessive condition indicator 130 includes an over-temperature indicator 146 and an overload indicator 150. Labels 154, 158 may be provided next to the over-temperature indicator 146 and the overload indicator 150, respectively.

[0059] When the temperature of the portable power supply 10 or the battery pack 54 exceeds a predetermined temperature threshold, the over-temperature indicator 146 is enabled. When the load output of the portable power supply 10 exceeds a predetermined load threshold, the over-load indicator 150 is enabled.

[0060] Wireless connection indicator 134 indicates whether portable power source 10 is wirelessly connected to a remote device (e.g., a smartphone or other user device). Fuel gauges 138A, 138B indicate the state-of-charge of the associated battery packs 54A, 54B, respectively. Charging indicators 142A, 142B indicate the charging state of the associated battery packs 54A, 54B.

[0061] refer to Figure 1 and Figure 6, an AC input 162 is provided on the first side 34 of the housing 14. The AC input 162 may include a retractable or removable cable that can be plugged into an external power source (e.g., a 15A, 120V wall outlet). The AC input 162 is used to provide power to charge the battery pack 54 supported on the portable power supply 10. When connected to an external power source, the portable power supply 10 can pass AC power to the AC outlet 126 in addition to charging the supported battery pack 54.

[0062] refer to Figure 6 to Figure 7 The first vent 166 and the second vent 170 are respectively disposed on opposite sides 36, 38 of the housing 14. The first vent 166 and the second vent 170 allow cooling air to circulate within the housing 14 to cool components (eg, electronic components) of the portable power source 10.

[0063] refer to Figure 5 and Fig.10 A charger mounting point 174 is provided on the rear portion 30 of the housing 14. A separate battery charger 178 may be mounted (e.g. Fig.10 174, the battery charger 178 is operable to charge a battery pack 182 for a battery-powered power tool, outdoor tool, or other electrical device. The battery charger 178 receives operating power from the battery pack 54 to charge the supported battery pack 182. The battery charger 178 can be simultaneously powered to output power to the AC outlet 126.

[0064] Fig.11 is a simplified block diagram of one embodiment of a portable power source 10. In the example shown, the portable power source 10 includes battery packs 54A, 54B, AC outlet 126, AC input 162, electronic controller 210, charging circuit 214, power multiplexer 218, inverter 222, wireless module 226, low power battery cell 230, and indicator 234.

[0065] In some embodiments, the controller 210 is implemented as a microprocessor with a separate memory. In other embodiments, the controller 210 may be implemented as a microcontroller (where the memory is located on the same chip). In other embodiments, the controller 210 may be partially or completely implemented as, for example, a field programmable gate array (FPGA), an application specific integrated circuit (ASIC), a hardware-implemented state machine, etc., and the memory may not be required or the memory may not be modified accordingly. The controller 210 may communicate with the battery controller of each battery pack 54 via a data connection (e.g., an RS485 full-duplex standard connection).

[0066] The charging circuit 214 is controlled by the controller 210 to provide a charging current to the battery pack 54 through the multiplexer 218. The charging circuit 214 receives input power from the AC input 162 and provides a charging current to the multiplexer 218.

[0067] The multiplexer 218 receives the charging current from the charging circuit 214 and provides the charging current to the battery pack 54. The multiplexer 218 also receives a low voltage power source (e.g., a 15 volt direct current (VDC) power source) from the battery pack 54 and / or the inverter 222. The multiplexer 218 provides the low voltage power source to power the electronic components of the portable power source 10. For example, the multiplexer 218 powers the controller 210 and the indicator 234 with the low voltage power source.

[0068] The multiplexer 218 also receives a high voltage direct current (DC) power source (e.g., 80V, 120V, etc.) from the battery pack 54. The multiplexer 218 provides the high voltage DC power source to the inverter 222. The multiplexer 218 receives a control signal (e.g., a selection signal) from the controller 210. The controller 210 provides the control signal to the multiplexer 218 to control the charging and discharging of the battery pack 54.

[0069] The inverter 222 receives the high voltage DC power from the multiplexer 218 and converts the high voltage DC power to an AC output (e.g., a 15A, 120VAC power output). The AC output is then provided to the AC outlet 126. The inverter 222 also receives input power from the AC input 162 and provides a low voltage power supply (e.g., 15VDC) to the multiplexer 218. When the portable power supply 10 is connected to an external power source (e.g., a wall outlet), the multiplexer 218 can be controlled to use the low voltage power supply from the inverter 218 instead of the battery pack 54 to save energy of the battery pack 54.

[0070] The inverter 222 can be controlled by the controller 210, for example, based on the power button 122. The controller 210 provides an enable / disable signal to the inverter 22 to enable or disable the inverter 222 from providing an AC output to the AC outlet 126. The inverter 222 provides additional feedback to the controller 210. For example, the inverter 222 provides an over-temperature signal when the temperature of the inverter 222 exceeds a predetermined temperature threshold, the inverter 222 provides an overload feedback signal when the load on the AC outlet 126 exceeds a predetermined load threshold, and the inverter 222 provides a current sensor feedback that indicates the amount of output current flowing to the AC outlet 126.

[0071] The wireless module 226 is, for example, a Bluetooth Low Energy ( The wireless module 226 may be powered by a dedicated low-power battery cell 230 .

[0072] The controller 210 controls the indicator 234 (e.g., visual, audible, tactile, etc.) based on the status of the portable power source 10. The indicator 234 includes a visual indicator (e.g., wireless connection indicator 134, fuel gauge 138, over-temperature indicator 146, and overload indicator 150) and an audible indicator (e.g., a buzzer (not shown)). In other embodiments, the indicator 234 may include a Fig.11 More or fewer status indicators 234 are shown.

[0073] In some embodiments, the controller 210 determines whether the portable power source 10 is wirelessly connected to a remote device and controls the wireless connection indicator 134 based on the determination. When the controller 210 determines that the portable power source 10 is wirelessly connected to the user device through the wireless module 226, the controller 210 enables the wireless connection indicator 134. When the controller 210 determines that the portable power source 10 is not wirelessly connected to the external device through the wireless module 226, the controller 210 disables the wireless connection indicator 134.

[0074] refer to Fig. 9 In the illustrated construction, the fuel gauge 138 is located on the same side of the user interface 118 as the AC outlet 126. The first fuel gauge 138A provides an indication of the charge state of the first battery pack 54A, and the second fuel gauge 138B provides an indication of the charge state of the second battery pack 54B. The controller 210 receives battery charge state information from the battery controller of each battery pack 54. The controller 210 controls the fuel gauge 138 to indicate the battery charge of the battery pack 54 based on the charge state information received from the corresponding battery controller.

[0075] The controller 210 enables or disables the over-temperature indicator 146 based on the temperature signals received from the battery pack 54 and the inverter 222. The controller 210 enables or disables the over-load indicator 150 based on the over-load feedback received from the inverter 222.

[0076] The exemplary buzzer provides an audible indication to the user based on a control signal received from the controller 210. The buzzer can provide an audible indication for various threshold conditions of the portable power supply 10. The threshold conditions may include a low voltage condition (one or both battery packs 54 are below a low voltage threshold (e.g., 50V or less)), an overload condition (an overload threshold based on a power curve (e.g., output power over a period of time - 1800W in 7 seconds or more, 3600W in 3.5 seconds or more, etc.)), a temperature condition (the temperature of the portable power supply 10 or its components (e.g., 110°C)).

[0077] The portable power supply 10 may include additional visual, audible, tactile or other indicators to provide the low voltage, overload and over temperature indications described above with respect to the audible buzzer.

[0078] Fig.12 The arrangement of the electronic components of the portable power source 10 within the housing 14 is shown. The controller 210 is provided by the bottom 22 of the housing 14 along the bottom surface. The charging circuit 214 is provided by the rear 30 of the housing along the rear surface. The multiplexer 218 is provided by the top 18 of the housing 14 along the top surface. The inverter 222 is provided by the front 26 of the housing 14 along the front surface. An open area is provided along the middle portion of the interior of the housing 14 to allow cooling air to flow through the housing 14. The cooling fan 238 can be provided near the first vent 166 and / or the second vent 170 to draw cooling air into the housing 14 through the first vent 166 and / or the second vent 170 and circulate the cooling air through the housing 14.

[0079] The portable power supply 10 shown is a multi-bay portable power supply including two bays (i.e., battery supports 50) to receive battery packs 54. Multiple battery packs 54 can be charged and discharged sequentially or simultaneously by the portable power supply 10. For example, the controller 210 can implement pulse width modulation (PWM) control of the multiplexer 218 to charge and discharge the battery packs. As a result, a single charging circuit 214 and a single inverter 222 can be used to charge and discharge multiple battery packs 54.

[0080] In some embodiments, controller 210 can detect the presence of input power through AC input 162 (eg, via data communication with charging circuit 214). For example, charging circuit 214 can provide an indication to controller 210 when AC input 162 is connected to a wall outlet.

[0081] The controller 210 may automatically switch between charging control and discharging control of the multiplexer 218 based on an indication received from the charging circuit 214. For example, upon detecting input power at the AC input 162, the controller 210 may control the multiplexer 218 to stop discharging the battery pack 54 and perform charging of the battery pack 54. Similarly, upon detecting that the AC input 162 is not receiving input power, the controller 210 may control the multiplexer 218 to stop charging the battery pack 54 and, if the battery pack 54 has sufficient capacity, perform discharging of the battery pack 54.

[0082] In some embodiments, the peak power output of the portable power supply 10 is in the range of about 3000 W to about 4000 W (e.g., 3400 W) within a short period of time between about 2 seconds and about 4 seconds (e.g., 3 seconds). The portable power supply 10 is operable to output a peak power output between about 3000 W and about 4000 W for at least 2 seconds. In some embodiments, the portable power supply 10 can provide a peak output power of about 3600 W for at least about 3.5 seconds.

[0083] In some embodiments, the sustained or continuous maximum output power is in the range of about 1500 W to 2000 W. The portable power source 10 is operable to output a sustained maximum output power between about 1500 W and about 2000 W for at least about 6 minutes. In some embodiments, the sustained or continuous maximum output power is about 1800 W. The portable power source 10 may be operable to output a sustained maximum output power of 1800 W for at least about 6 minutes.

[0084] The operating time of the portable power supply 10 with a single "20S3P" battery pack at maximum output power is in the range of about 18 minutes to about 21 minutes (e.g., about 20.5 minutes). In some embodiments, the operating time of the portable power supply 10 with a single "20S3P" battery pack at maximum output power is about 19.5 minutes. In some embodiments, the operating time of the portable power supply 10 with two "20S3P" battery packs at maximum output power is in the range of about 36 minutes to about 42 minutes. In some embodiments, the operating time of the portable power supply 10 with two "20S3P" battery packs at maximum output power is about 39 minutes.

[0085] The operating time of the portable power supply 10 with a single "20S2P" battery pack at maximum output power is in the range of about 12 minutes to about 14 minutes (e.g., about 12.25 minutes). In some embodiments, the operating time of the portable power supply 10 with a single "20S2P" battery pack at maximum output power is about 13 minutes. In some embodiments, the operating time of the portable power supply 10 with two "20S2P" battery packs at maximum output power is in the range of about 24 minutes to about 28 minutes. In some embodiments, the operating time of the portable power supply 10 with two "20S2P" battery packs at maximum output power is about 26 minutes.

[0086] The operating time of the portable power supply 10 with a single "20S1P" battery pack at maximum output power is in the range of about 6 minutes to about 7 minutes. In some embodiments, the operating time of the portable power supply 10 with a single "20S1P" battery pack at maximum output power is about 6.5 minutes. In some embodiments, the operating time of the portable power supply 10 with two "20S1P" battery packs at maximum output power is in the range of about 12 minutes to about 14 minutes. In some embodiments, the operating time of the portable power supply 10 with two "20S1P" battery packs at maximum output power is about 13 minutes.

[0087] Figures 13 to 16 The portable power source 10 is shown without the battery packs 54A, 54B to illustrate the battery support 50A, 50B for each battery pack 54A, 54B. The illustrated battery support 50A, 50B includes a stepped recess 304 and a latch mechanism 308 to facilitate coupling of the battery pack 54 to the battery support 50. In other embodiments (not shown), the recess 304 may be generally linear.

[0088] The latch mechanism 308 shown includes (see Fig.15 ) Double-acting latch mechanism. In other words, two separate actions are required to operate the latch mechanism 308 to release the battery 54 from the battery support 50. The latch mechanism 308 shown includes a primary actuator 312 that supports a secondary actuator 316. In the blocking position, the secondary actuator 316 prevents actuation of the primary actuator 312, and in the release position, the primary actuator 312 is operable to unlock the battery pack 54.

[0089] As described above, the padlock 114 can prevent removal of the supported battery pack 54 by interfering with the latch mechanism 308. For example, when installed, the padlock 114 can prevent the second actuator 316 from moving from the blocking position. As another example, when installed, the padlock 114 can prevent movement of the primary actuator to unlock the battery pack 54.

[0090] The contact member 320 is supported on the battery support member 50 and is configured to be mechanically and electrically connected to the battery pack 54 to transfer electrical energy therebetween. The latch mechanism 308 shown also includes (see Fig.16 ) switch 324 (e.g., a micro switch) that facilitates electrical coupling / decoupling of the battery pack 54 during actuation of the main actuator 312. The switch 324 can be used to electrically decouple the battery pack 54 from the battery support 50 and the portable power source 10 before the battery pack 54 is removed from the battery support 50.

[0091] The ejector 328 is supported on the battery support 50. The ejector 328 includes an ejection member biased by a biasing member (e.g., one or more springs (not shown)). When the battery pack 54 is attached to the battery support 50, the ejection member compresses the biasing member. From this position, the ejector 328 is configured to exert a force on the battery pack 54 to push the battery pack 54 out of engagement with the battery support 50 (e.g., when the latch mechanism 308 is released).

[0092] In the configuration shown (see Fig.16 ), a switch 332 (e.g., an AC switch) is incorporated into the ejector 328. The switch 332 is configured to enable / disable components of the portable power source 10 based on the position of the battery pack 54 relative to the battery support 50. In one example, when the battery pack 54 is initially inserted but before the contacts 320 are enabled (e.g., for a charging operation), pressing the ejector 328 results in the activation of the switch 332 to allow power to be delivered to portions of the portable power source 10 (e.g., the charging circuit 214, the power multiplexer 218, the inverter 222, etc.).

[0093] Similar battery supports for battery packs are described and shown in U.S. patent application Ser. No. 15 / 845,063, filed on Dec. 18, 2017, and entitled “BATTERY PACK INTERFACE,” the entire contents of which are incorporated herein by reference.

[0094] Fig.17 A transport assembly 336 is shown for the portable power source 10. The transport assembly 336 includes a wheeled dolly or cart 340 and a connector 344 connectable between portions of the cart 340 (e.g., the base) and portions of the portable power source 10 (e.g., the frame portions 58, 62). The connector 344 is shown releasably connectable (e.g., clamped) to each of the cart 340 and the portable power source 10.

[0095] The portable power source 10 can be taken anywhere a corded device user works and can power at least most of the corded devices they use. Users can eliminate long extension cords, improve the performance of their corded devices, easily move from one work area to another within the workplace, and ultimately increase productivity. This use of the battery-powered power source 10 can change the perception of cordless functionality, promote the development of cordless worksites, promote the popularity and expansion of battery-powered devices in the future, and change the way users work.

[0096] Although the present invention has been described in detail with reference to certain preferred embodiments, various changes and modifications exist within the scope and spirit of one or more independent aspects of the present invention described. One or more independent features and / or independent advantages of the present invention may be set forth in the claims.

Claims

1. A portable power source, include: a housing defining a first battery support member facing a first direction, a second battery support member facing a second direction opposite to the first direction, and a power socket, A circuit supported by the housing and comprising An input terminal, which is located on the battery support, output terminals, which are located on the power socket, and an inverter electrically connected between the input terminal and the output terminal, A first battery power source comprising a battery housing supported on the first battery support, battery cells, and a battery terminal connected to the battery cell and electrically connectable to the input terminal, wherein power can be transferred from the battery cell to the circuit for output through the power outlet, and A second battery power source comprising a battery housing supported on the second battery support, battery cells, and a battery terminal connected to the battery cell and electrically connectable to the input terminal, wherein power can be transferred from the battery cell to the circuit for output through the power outlet, and a frame connected to the housing and extending beyond the periphery of the housing and the periphery of the supported first and second battery power sources; wherein the frame comprises: a first frame portion located on a first side of the housing, a second frame portion, which is located on an opposite side of the housing, a pair of rods connected between the first frame portion and the second frame portion, and a handle connected between the pair of rods, the handle extending perpendicular to the rods and generally parallel to the first frame portion and the second frame portion; wherein the handle is located in the same plane as the pair of rods; and The center of the housing is vertically offset relative to the frame such that the frame extends beyond the first battery support more than it extends beyond the second battery support.

2. The portable power source according to claim 1, in, The portable power supply defines a horizontal centerline, and wherein a center of gravity of the portable power supply is below the horizontal centerline.

3. The portable power source according to claim 2, in, The center of gravity is located below the horizontal centerline by a distance between 2.5% and 5% of the height of the portable power source.

4. The portable power source according to claim 2, in, The center of gravity is between 15 mm and 25 mm below the horizontal centerline.

5. The portable power source according to claim 1, in, The portable power supply defines a vertical centerline between a first side and an opposite side of the housing, and wherein a center of gravity of the portable power supply is toward the first side of the housing from the vertical centerline.

6. The portable power source according to claim 5, in, The center of gravity is spaced from the vertical centerline a distance between 1.5% and 3% of the depth of the portable power supply.

7. The portable power source according to claim 5, in, The center of gravity is spaced apart from the vertical centerline by a distance between 5 mm and 8 mm.

8. The portable power source according to claim 1, in, The frame prevents contact with the housing and the battery power source.

9. The portable power source according to claim 1, in, The portable power source has a total weight of between 48 pounds and 55 pounds.

10. The portable power source according to claim 1, in, The portable power source is operable to output a peak power output of between 3000W and 4000W for at least 2 seconds and a sustained maximum output power of between 1500W and 2000W for at least 6 minutes.

11. The portable power supply of claim 1, further comprising a fuel gauge configured to display a charge status of the battery power source, the fuel gauge and the power outlet being located on a side of the housing.

12. The portable power source of claim 1, further comprising a battery locking point disposed on the first battery support and / or the second battery support, in, The battery locking point is configured to be engageable with a padlock to prevent removal of the battery power source.

13. A portable power source, include: a housing supportable relative to a support surface; The portable power source is adapted to be placed on the support surface; The housing has a first surface facing the support surface and a second surface facing away from the first surface. a first battery support, which is located on the first surface, a second battery support located on the second surface, and Power socket; A circuit supported by the housing and comprising a first input terminal, which is located on the first battery support, a second input terminal, which is located on the second battery support, output terminals, which are located on the power socket, and an inverter electrically connected between the input terminal and the output terminal; A first battery group and a second battery group, the first battery group can be supported on the first battery support member, the second battery group can be supported on the second battery support member, each battery group includes a battery housing, which is supported on an associated battery support, battery cells, and battery terminals connected to the battery cells and electrically connectable to associated input terminals, wherein power may be delivered from the battery cells of each battery pack to the circuitry for output through the power outlet; and a frame connected to the housing and extending beyond a perimeter of the housing, the first battery power source, and the second battery power source; The center of the housing is vertically offset relative to the frame such that the frame extends further beyond the first battery support than beyond the second battery support.

14. The portable power source according to claim 13, in, The framework also includes a first frame portion located on a first side of the housing, a second frame portion, which is located on an opposite side of the housing, a pair of rods connected between the first frame portion and the second frame portion, and A handle is connected between the rods, the handle extending perpendicular to the rods and generally parallel to the first frame portion and the second frame portion.

15. The portable power source according to claim 13, in, The portable power source has a total weight between 48 pounds and 55 pounds, and wherein the portable power source is operable to output a peak power output between 3000W and 4000W for at least 2 seconds and a sustained maximum output power between 1500W and 2000W for at least 6 minutes.

16. A portable power source, include: a housing defining a battery support and a power receptacle; a frame connected to the housing, the frame being made of hollow metal rods having a rectangular cross-section; A circuit supported by the housing and comprising An input terminal, which is located on the battery support, output terminals, which are located on the power socket, and an inverter electrically connected between the input terminal and the output terminal; Battery power supply, which includes a battery housing supported on the battery support, at least one battery cell, and a battery terminal connected to the battery cell and electrically connectable to the input terminal, wherein power can be transferred from the battery cell to the circuit for output through the power outlet; and a fuel gauge configured to display a charge status of the battery power source, the fuel gauge and the power socket being located on one side of the housing; wherein the portable power source has a total weight of between 48 pounds and 55 pounds, and wherein the portable power source is operable to output a peak power output of between 3000 W and 4000 W for at least 2 seconds and a sustained maximum output power of between 1500 W and 2000 W for at least 6 minutes; The frame is configured such that in the event of a drop, the frame can absorb 220 J of impact energy from the drop event.

17. The portable power source according to claim 16, in, The portable power supply defines a horizontal centerline, wherein the portable power supply defines a vertical centerline between a first side of the housing and an opposite side of the housing, wherein a center of gravity of the portable power supply is between 15 mm and 25 mm below the horizontal centerline, and wherein the center of gravity is spaced apart from the vertical centerline by a distance between 5 mm and 8 mm.

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