Battery charging device

Abstract

The utility model relates to a battery charging device. A battery charging device has thermal management systems, each including one or more thermoelectric devices for managing the temperature of one or more secondary batteries during a charging operation. Each thermoelectric device is operated to cool and / or heat a corresponding battery using the Peltier effect. Heat transfer between the battery and the corresponding thermoelectric device is achieved by thermal conduction via a thermal conduction interface between the battery and the corresponding thermoelectric device. Related methods of battery charging are also disclosed.

Description

Technical Field

[0001] The present disclosure generally relates to devices for charging secondary batteries and more particularly to battery charging devices and related methods having a thermally conductive thermal-management system for managing battery temperature during charging operations. Background Art

[0002] Conventional battery chargers typically use forced air cooling or forced liquid cooling to manage the heat generated by the battery during charging. Forced air cooling schemes can be problematic because the ambient air used for cooling can contain dust and / or other contaminants, and can also or alternatively carry excess moisture. Thus, as the ambient air flows through the interior portions of the battery charger, the contaminants and / or moisture can cause scaling and / or damage to the batteries being charged and / or components of the charger (such as circuit boards, etc.). Forced liquid cooling schemes can be problematic due to the additional components and complexity of providing liquid coolant passages, fittings, pumps, and other cooling system components, not to mention the potential damage that can occur when liquid coolant leaks from the cooling system. Utility Model Content

[0003] In one embodiment, the present disclosure relates to a battery charging device for charging a secondary battery, the secondary battery including an electrical terminal and a heat transfer surface. The battery charging device includes: a charging area that receives the secondary battery during a charging operation; a charging system that is electrically connected to the electrical terminal of the secondary battery when the secondary battery is present in the charging area and charges the secondary battery during the charging operation; a thermal management system that includes: a thermal conduction interface that receives the heat transfer surface of the secondary battery in contact when the battery is positioned in the charging area, so that heat can be conducted between the secondary battery and the thermal management system during the charging operation; a heat sink / source; and a thermoelectric device that is thermally coupled between the thermal conduction interface and the heat sink / source, wherein during the charging operation when the secondary battery is positioned in the charging area, the thermoelectric device transfers heat between the secondary battery and the heat sink / source.

[0004] In another embodiment, the present disclosure relates to a method for charging a secondary battery. The method includes causing a battery charging device to perform a charging operation on the secondary battery; and during the charging operation, causing a thermoelectric device directly thermally coupled to the secondary battery to transfer heat between the secondary battery and a heat sink / heat source by thermal conduction.

[0005] According to the implementation of the present application, the following contents are provided:

[0006] Item 1): A battery charging device for charging a secondary battery, characterized in that the secondary battery includes an electrical terminal and a heat transfer surface, and the battery charging device includes:

[0007] a charging area that receives the secondary battery during a charging operation;

[0008] a charging system that is electrically connected to electrical terminals of the secondary battery when the secondary battery is present in the charging region and charges the secondary battery during the charging operation;

[0009] A thermal management system, the thermal management system comprising:

[0010] a heat transfer interface that contactingly receives a heat transfer surface of the secondary battery when the secondary battery is positioned in the charging region so that heat can be transferred between the secondary battery and the thermal management system during the charging operation;

[0011] heat sink / heat source; and

[0012] A thermoelectric device is thermally coupled between the thermally conductive interface and the heat sink / heat source, wherein the thermoelectric device transfers heat between the secondary battery and the heat sink / heat source during the charging operation when the secondary battery is positioned in the charging region.

[0013] Item 2): A battery charging device according to Item 1), characterized in that the heat conduction interface includes a heat conduction contact plate having a battery contact surface, and when the secondary battery is positioned in the charging area for the charging operation, the battery contact surface contacts the heat transfer surface of the secondary battery.

[0014] Item 3): The battery charging device according to Item 2), characterized in that the battery charging device includes a plurality of thermoelectric devices, and the thermoelectric devices are thermally coupled between the heat conduction contact plate and the heat sink / heat source.

[0015] Item 4): The battery charging device according to Item 3), characterized in that the thermoelectric devices are spaced apart from each other and a thermal insulation portion is included in a space between adjacent ones of the thermoelectric devices.

[0016] Item 5): A battery charging device according to Item 1), characterized in that the battery charging device also includes an ambient-to-air heat transfer system, wherein the ambient-to-air heat transfer system includes a channel for providing an ambient air flow from outside the battery charging device to the heat sink / heat source so as to transfer heat between the flow and the heat sink / heat source.

[0017] Item 6): A battery charging device according to Item 5), characterized in that the ambient-air heat transfer system includes a fan for providing an ambient air flow in the channel.

[0018] Item 7): A battery charging device according to Item 5), characterized in that the channel includes an inlet for receiving ambient air from outside the battery charging device and an outlet for discharging the ambient air flow in the channel to the outside of the battery charging device.

[0019] Item 8): According to the battery charging device described in Item 1), it is characterized in that the battery charging device also includes a control system, which is configured to enable the thermoelectric device to provide heat to the secondary battery when the measured temperature of the secondary battery is lower than a preset minimum charging temperature.

[0020] Item 9): According to Item 8), the battery charging device is characterized in that the control system is also configured to enable the charging system to start charging once the measured temperature reaches the minimum charging temperature.

[0021] Item 10): A battery charging device according to Item 9), characterized in that the control system is also configured to enable the thermoelectric device to remove heat from the secondary battery when the measured temperature of the secondary battery reaches a preset cooling temperature.

[0022] Item 11) The battery charging device according to Item 10) is characterized in that the battery charging device further comprises an environment-air heat transfer system, wherein the environment-air heat transfer system comprises:

[0023] a passage for providing a flow of ambient air from an exterior of the battery charging device to the heat sink / heat source to transfer heat between the flow and the heat sink / heat source; and

[0024] a fan for providing a flow of ambient air within the passage;

[0025] Wherein the control system is further configured to activate the fan in conjunction with causing the thermoelectric device to remove heat from the secondary battery.

[0026] Item 12) The battery charging device according to Item 8) is characterized in that the battery charging device further comprises an environment-air heat transfer system, wherein the environment-air heat transfer system comprises:

[0027] a passage for providing a flow of ambient air from an exterior of the battery charging device to the heat sink / heat source to transfer heat between the flow and the heat sink / heat source; and

[0028] a fan for providing a flow of ambient air within the passage;

[0029] Wherein, the control system is further configured to activate the fan in conjunction with causing the thermoelectric device to provide heat to the secondary battery.

[0030] Item 13): The battery charging device according to Item 1) is characterized in that the battery charging device also includes a control system, which is configured to enable the thermoelectric device to remove heat from the secondary battery when the secondary battery is at a measured temperature higher than a preset cooling temperature.

[0031] Item 14) The battery charging device according to Item 13) is characterized in that the battery charging device also includes an environment-air heat transfer system, and the environment-air heat transfer system includes:

[0032] a passage for providing a flow of ambient air from an exterior of the battery charging device to the heat sink / heat source to transfer heat between the flow and the heat sink / heat source; and

[0033] a fan for providing a flow of ambient air within the passage;

[0034] Wherein the control system is further configured to activate the fan in conjunction with causing the thermoelectric device to remove heat from the secondary battery.

[0035] Item 15): A method for charging a secondary battery, the method comprising:

[0036] causing a battery charging device to perform a charging operation on the secondary battery; and

[0037] During the charging operation, a thermoelectric device directly thermally coupled to the secondary battery is caused to transfer heat between the secondary battery and a heat sink / heat source by thermal conduction.

[0038] Item 16): A method according to Item 15), wherein the charging operation includes charging the secondary battery, and causing the thermoelectric device to transfer heat between the secondary battery and the heat sink / heat source includes removing heat from the secondary battery by thermal conduction.

[0039] Item 17): The method according to Item 16) further includes measuring the temperature of the secondary battery, and when the temperature of the secondary battery exceeds a preset cooling temperature, performing an operation of causing the thermoelectric device to remove heat from the secondary battery.

[0040] Item 18): The method according to item 16) further includes causing a fan to cause ambient air to flow through the heat sink / heat source to remove heat from the heat sink / heat source.

[0041] Item 19): The method according to Item 16) further includes causing the thermoelectric device to provide heat to the secondary battery before charging the secondary battery.

[0042] Item 20): The method according to Item 19) further includes measuring the temperature of the secondary battery, and when the temperature of the secondary battery is lower than a preset minimum charging temperature, performing an operation of causing the thermoelectric device to provide heat to the secondary battery.

[0043] Item 21): The method according to Item 20) further includes causing a fan to cause ambient air to flow through the heat sink / heat source so as to provide heat to the heat sink / heat source. BRIEF DESCRIPTION OF THE DRAWINGS

[0044] For the purpose of illustration, the accompanying drawings show various aspects of one or more embodiments of the present disclosure. However, it should be understood that the scope of the present disclosure is not limited to the precise arrangements and instruments shown in the accompanying drawings, in which:

[0045] Figure 1 is a high-level schematic / block diagram of an exemplary battery charging apparatus made in accordance with aspects of the present disclosure;

[0046] Figure 2 is an isometric view of an exemplary battery charging device of the present disclosure, the battery charging device being configured to charge two battery packs in corresponding respective charging compartments;

[0047] Figure 3 yes Figure 2 An exploded isometric view of a battery charging device;

[0048] Figure 4 is with Figure 2 and Figure 3 An enlarged cross-sectional view of each battery pack operatively engaged with a corresponding one of the thermal management components of the battery charging device of the present invention; Figure 4 is shown isolated from other components of the battery charging device; and

[0049] Figure 5 is Figure 4 The detail area A is captured Figure 1 and Figure 2 A further enlarged partial cross-sectional view of the thermal management components of a battery pack and a battery charging device. DETAILED DESCRIPTION

[0050] The technical contents of the appended claims are incorporated by reference into this detailed description section, so that they are included here as if they actually exist in this section.

[0051] summary

[0052] In some aspects, the present disclosure relates to a battery charging device for charging secondary batteries of any of various types and various chemical compositions, wherein each battery charging device includes at least one thermoelectric device that is directly thermally coupled to each of one or more secondary batteries charged by the battery charging device. Examples of secondary battery types that can be used with the battery charging device of the present disclosure include, but are not limited to, secondary batteries including one or more soft-pack batteries or one or more cylindrical batteries, etc. Examples of battery chemistries include, but are not limited to, chemistries based on one or more alkali metals (such as lithium, sodium, and potassium), sulfur-based chemistries, and nickel-based chemistries, etc., and can be intercalating-de-intercalating type, plating-stripping type, or any combination thereof, etc. Basically, there is no limitation on the type of secondary battery suitable for the battery charging device of the present disclosure, except that it can be charged and the temperature of the secondary battery may need to be controlled during the charging operation. In the present disclosure and the appended claims, unless otherwise indicated, the terms "secondary battery" and "battery" are broadly used to refer to any form of rechargeable electrochemical device, including but not limited to electrochemical battery cells, battery modules including one or more electrochemical battery cells, and battery packs including one or more battery modules.

[0053] As used herein and in the appended claims, the term "thermoelectric device" means a solid-state device that, when driven by electricity, exhibits the well-known Peltier phenomenon, which results in a temperature difference at the junction of two dissimilar materials. A thermoelectric device is typically made of two dissimilar semiconductor materials, such as bismuth telluride and antimony telluride, and when a DC voltage is applied to them, the device undergoes an electron flow from one semiconductor material across the junction to the other semiconductor material, resulting in heat absorption by one semiconductor material and heat rejection by the other semiconductor material. Controlling the absolute amplitude of the DC voltage within a certain range controls the amount of electron flow that causes the temperature change within the thermoelectric device, thereby controlling the amount of heat absorption and heat rejection. Controlling the direction of the DC voltage controls the heat absorption-heat rejection behavior of the two materials, thereby controlling the ability of each side of the junction to provide heat or absorb heat.

[0054] In some aspects, the present disclosure relates to a method for performing a charging operation for charging a secondary battery in direct thermal contact with a thermoelectric device. In one example, the method of the present disclosure includes causing a battery charging device to perform a charging operation on a secondary battery. During the charging operation, a thermoelectric device directly thermally coupled to the secondary battery transfers heat between the secondary battery and a heat sink / heat source by thermal conduction. In some embodiments, if the secondary battery is initially at a temperature below a preset minimum charging temperature, the thermoelectric device is operated to provide heat to the secondary battery to raise the temperature of the battery to a minimum charging temperature or higher. When the temperature of the secondary battery rises above a maximum charging temperature during charging, the thermoelectric device is operated to remove heat from the secondary battery, thereby reducing the temperature of the secondary battery to a maximum charging temperature or below the maximum charging temperature. Other methods are disclosed. The foregoing and other aspects of the present disclosure are described in detail below.

[0055] Now referring to the accompanying drawings, Figure 1 An exemplary battery charging device 100 including various features of the present disclosure is shown. In this example, the battery charging device 100 includes a charging area 104 configured for a secondary battery 108 (hereinafter referred to as a "battery") for performing a charging operation to charge the battery. As described above, the battery 108 can be any of a variety of battery devices in various forms. In this example, the battery 108 is a battery module having a positive electrical terminal 108T(1) and a negative electrical terminal 108T(2) that are in electrical communication with a battery cell (not shown) within the battery. The battery charging device 100 has a charging system 112 that is electrically connected to the electrical terminals 108T(1) and 108T(2) of the battery 108 during the charging operation and includes all necessary electronic devices (not shown), including any necessary control software and / or hardware for charging the battery using any one or more of a variety of charging protocols, including but not limited to a constant current constant voltage protocol, a multi-level constant current protocol, and / or a constant current + pulse charging protocol, etc. Those skilled in the art are readily familiar with the charging protocols and corresponding electronics that may be used in the charging system 112, such that no further details are required herein to enable one of ordinary skill in the art to make and use the battery charging apparatus of the present disclosure, such as Figure 1 A battery charging device 100 is provided.

[0056] The battery charging device 100 of this example also includes a thermal management system 116, which includes one or more thermoelectric devices (individually and collectively shown at thermoelectric devices 120) and thermal management system electronics 124 for operating the thermoelectric devices. Each thermoelectric device 120 includes a first side 120S(1) and a second side 120S(2) made of different materials, which form a joint 120J as described above. As described above, the different materials of the first side and the second side can be, for example, any suitable different semiconductor materials, such as but not limited to bismuth telluride and antimony telluride. Those skilled in the art will readily be familiar with suitable battery charging devices (such as) suitable for use as the present disclosure. Figure 1 The invention also provides a thermoelectric device for any thermoelectric device 120 of a battery charging device 100) such that no further details are required herein for a person of ordinary skill in the art to manufacture and use such a battery charging device.

[0057] The thermal management system electronics 124 includes any and all components necessary to power and control the operation of the thermoelectric device 120, such as, but not limited to, one or more DC power supplies (not shown), such as one or more variable voltage DC power supplies, and any necessary supporting electronics (not shown). Thermoelectric devices and thermal management system electronics suitable for use in the thermal management system 116 are well known, such that no further details are required herein to a person of ordinary skill in the art to make and use the battery charging device of the present disclosure, such as Figure 1 A battery charging device 100 is provided.

[0058] In this example, the battery charging device 100 also includes a control system 128 that is configured to partially or fully automatically control all operations of the battery charging device, including controlling each of the charging system 112 and the thermal management system 116, so that the battery charging device performs the desired charging operation. In some embodiments, the charging operation includes stopping charging and starting charging, such as in conjunction with controlling the thermal management system 116 to stop and / or start charging. For example, in some cases, the battery 108 is optimally charged when the temperature of the battery is at or above a minimum charging temperature. If the battery 108 is below the minimum charging temperature before charging begins (e.g., when the battery is first placed in the battery charging area 104), the control system 128 can cause the thermal management system 116 to operate the thermoelectric device 120 in a manner that heats the battery to at least the minimum charging temperature before causing the charging system 112 to begin charging the battery. As another example, if the battery 108 is above the maximum charging temperature before charging begins (e.g., when the battery is first placed in the battery charging area 104), the control system 128 may cause the thermal management system 116 to operate the thermoelectric device in a manner that cools the battery to at most the maximum charging temperature before causing the charging system 112 to begin charging the battery.

[0059] As yet another example, charging the battery 108 causes the battery 108 to heat up. Thus, during a charging operation, when the control system 128 determines that the temperature of the battery 108 has exceeded a maximum charging temperature, it may cause the thermal management system 116 to operate the thermoelectric device 120 in a manner that removes heat from the battery, e.g., until the temperature of the battery has dropped below the maximum charging temperature. The control scheme that the control system 128 uses to cause the thermal management system 116 to maintain the battery 108 within the charging temperature range during charging may be any suitable control scheme. For example, the control system 128 may cause the thermal management system 116 to maintain the temperature of the battery 108 within a relatively narrow optimal charging temperature range by controlling the thermal management system to operate nearly continuously during charging so as to substantially balance the heat removed by the thermal management system and the heat generated by charging. As will be appreciated by those skilled in the art, such a balance may be achieved using a tight temperature control loop that varies the DC voltage applied across the first side 120S(1) and the second side 120S(2) of the thermoelectric device 120.

[0060] In another example, the control system 128 may cause the thermal management system 116 to intermittently operate in order to cool the battery 108 to a relatively low temperature, such as near a minimum charging temperature, and then allow the battery to heat to a relatively high temperature, such as near a maximum charging temperature, before causing the thermal management system to re-energize the thermoelectric device 120. Those skilled in the art will recognize that in an intermittent control scheme, in some embodiments, the control system 128 may cause the thermal management system 116 to operate the thermoelectric device 120 at or near its maximum DC voltage when the thermoelectric device 120 is energized in order to minimize the amount of cooling time. Those skilled in the art will readily recognize that these exemplary control schemes are merely exemplary and not limiting, and that the control system 128 may use any suitable control scheme to control the temperature of the battery 108 during charging.

[0061] In the illustrated embodiment, the control system 128 includes a processor 132, one or more hardware memories (individually or collectively represented as memory 136) in operative communication with the processor, machine executable instructions 140 stored in the memory and configured to be executed by the processor, and any required user interface (UI) 144. The processor 132 can be any suitable processor, such as a system on a chip or a microprocessor. In some embodiments, the processor 132, the memory 136, and the machine executable instructions 140 can be embodied in a dedicated circuit, such as a system on a chip, an application specific integrated circuit, or a field programmable gate array. The memory 136 can be any one or more hardware memories, such as RAM, ROM, cache, magnetic, optical, bubble memory, etc. Basically, there is no limitation on the type of memory 136, as long as it / they can store the machine executable instructions 140 and can transmit the machine executable instructions to the processor 132. At this point, it should be noted that the term "machine-readable hardware storage medium" as used herein and in any appended claims refers to any hardware memory that, alone or in combination with one another, stores machine-executable instructions (such as machine-executable instructions 140) that cause any one or more processors (e.g., processor 132) to perform the necessary functions. The term "machine-readable hardware storage medium" does not include transient signals, such as signals containing digital information encoded on a carrier wave and signals containing digital information encoded in pulses.

[0062] If provided, the UI 144 may include any software controls, hardware controls, or a combination of software and hardware controls required to perform the desired operations, as well as any required electronic displays required to visually convey information to the user. For example, the UI 144 may include one or more controls for turning the battery charging device 100 on and / or off, one or more controls for starting and / or stopping charging operations, one or more controls for inputting charging operation parameters, such as the type of battery 108, the capacity of the battery, the maximum state of charge for charging, the type of charging protocol, and the minimum and / or maximum charging temperature, etc. Those skilled in the art will readily appreciate what, if any, software controls and / or hardware controls are included for a particular implementation of the battery charging device 100. In some embodiments, the battery charging device 100 may be in operational communication with another device (not shown), such as a broader charging system controller, a laptop computer, etc., which provides UI functionality, including any one or more of the above-described functions, thereby eliminating the need for an onboard UI 144.

[0063] The machine-executable instructions 140 include machine-executable instructions for executing any or all of the control schemes (e.g., as one or more algorithms) that the control system 128 is configured to execute and for providing any or all of the functionality of the UI 144 (if any), not to mention for providing any other functionality that needs to be performed, such as communicating with one or more off-board devices, etc. Those skilled in the art will readily understand how to encode any required machine-executable instructions required to execute the necessary control algorithms (e.g., the charging operation control algorithm) and for providing any other desired functionality, such that it is not necessary for those skilled in the art to describe the machine-executable instructions 140 in further detail herein.

[0064] The thermal management system 116 includes a thermally conductive interface 148 between the battery 108 and the thermoelectric device 120 to provide a direct contact-type coupling between the battery and the thermoelectric device to allow heat to be thermally conductively transferred between the two elements. "Direct contact-type coupling" means that the thermally conductive interface 148 physically contacts the battery 108 and the thermoelectric device 120, so that heat transfer between the battery and the thermoelectric device is performed by thermal conduction through the thermally conductive interface. The thermally conductive interface 148 can be composed of any one or more materials and disposed in any one or more layers. For example, in some embodiments, the thermally conductive interface 148 can be a sheet, plate, or other structure composed of a highly thermally conductive material (such as a metal, etc.). Alternatively, the thermally conductive interface 148 can be simply a surface of the thermoelectric device 120 that physically contacts the battery 108. Basically, there is no limitation on the physical embodiment of the thermally conductive interface 148, except that it is capable of transferring heat between the battery 108 and the thermoelectric device 120 by thermal conduction to allow the battery charging device (such as a battery charging device) of the present disclosure. Figure 1 The degree of appropriate cooling and / or heating of the battery as expected by the battery charging device 100).

[0065] In some embodiments, the thermal management system 116 also includes a heat sink / heat source 152 that is thermally conductively coupled to the thermoelectric device 120. The "heat sink / heat source" designation is intended to indicate that the heat sink / heat source 152 functions as a heat sink or a heat source depending on the manner in which the control system 128 controls the operation of the thermoelectric device 120. That is, if the control system 128 causes the thermal management system 116 to remove heat from the battery 108, the heat sink / heat source 152 functions as a heat sink to remove heat from the thermoelectric device 120. Conversely, if the control system 128 causes the thermal management system 116 to provide heat to the battery 108, the heat sink / heat source 152 functions as a heat source to provide heat to the thermoelectric device 120. Note that any use of the designation "heat sink / heat source" herein or in the appended claims does not necessarily mean that the heat sink / heat source must function as both a heat sink and a heat source. For example, some embodiments of the battery charging device of the present disclosure may not include a battery heating function, and many embodiments never use the heat sink / heat source as a heat source. In such embodiments, the term "heat sink / heat source" should be understood to refer to "heat sink" only.

[0066] As with the thermally conductive interface 148, when the thermally conductive interface is a distinct physical structure, the heat sink / heat source 152 may be made of any one or more suitable thermally conductive materials, such as one or more metals, etc. In some embodiments, the heat sink / heat source 152 may include one or more types of features, such as fins, blades, ridges, louvers, passages, channels, etc. and any combination thereof, to increase the surface area exposed to the environment surrounding the heat sink / heat source, thereby increasing the efficiency of the heat sink / heat source in transferring heat between the heat sink / heat source and the surrounding environment.

[0067] In this regard, in some embodiments, thermal management system 116 may optionally include one or more fans 156(1) and / or 156(2) for moving ambient air (as indicated by arrows 160) across heat sink / heat source 152 to improve the efficiency of heat transfer between the heat sink / heat source and the ambient air. Each of the one or more fans (here, fans 156(1) and 156(2)) may be positioned at any suitable location for moving ambient air 160 across heat sink / heat source 152. Although in the embodiment of FIG. Figure 1 Not shown, each fan 156(1) and 156(2) provided may be controlled by the control system 128, for example based on the temperature of the first side 120S(1) and the second side 120S(2) of the thermoelectric device 120 and / or the temperature of the ambient air surrounding the battery charging device 100 and / or the amount of heat that needs to be removed from or added to the battery 108 and / or the thermoelectric device at any particular time.

[0068] In some embodiments, the battery charging device 100 may be contained within an optional housing 164. If one or more fans are provided, such as one or both of fans 156(1) and 156(2), the thermal management system 116 may further include an air passage 168 for directing ambient air 160 through the housing 164 and into contact with the heat sink / heat source 152. In some embodiments, the air passage 168 may include a dedicated duct, while in other embodiments, the air passage may be defined by other structures within the housing 164, such as one or more circuit boards (not shown), or one or more internal support structures (such as battery support structure 172) or an interior surface of the housing, etc.

[0069] As described above, the control system 128 can control the temperature of the battery 108 during the charging operation. Therefore, the control system 128 must know the temperature of the battery 108. This can be achieved in any one or more ways. For example, if the battery 108 has one or more integrated temperature sensors (not shown), it can have a data port 108P for providing temperature data to the charging system 112 and / or the control system 128. As another example, the battery charging device 100 can have one or more integrated sensors, such as integrated temperature sensors 176(1) and 176(2), each of which can be of any suitable type, such as a contact-type sensor or a standoff-type sensor. In the example shown, the temperature sensor 176(1) is a standoff-type sensor, such as an infrared sensor, and the temperature sensor 176(2) is a contact-type sensor, such as a thermocouple.

[0070] In some embodiments where the battery charging device 100 includes a housing 164, the charging area 104 may be provided as a compartment within the housing, and if provided, the compartment may include a suitable closure (not shown) that seals the compartment from the surrounding environment. Figure 1 The battery charging device 100 is shown as being designed to charge only a single battery 108 at a time, but in other embodiments, the battery charging device may be modified to accommodate charging of two or more batteries. For example, such a modified battery charging device may include multiple charging areas, such as charging area 104, each charging area being designed and configured to receive a corresponding battery for charging. In this regard, the charging system 112 may be modified to accommodate charging as many batteries as the modified battery charging device is designed to accommodate. In such a multiple battery embodiment, each battery may be connected to the charging area 104. Figure 1Multiple independently operated thermoelectric devices that are identical or similar to the thermoelectric device 120 may be provided and collectively controlled by the thermal management system electronics 124, or independently controlled by separate thermal management system electronics (not shown), which may all be controlled by a control system 128 for the entire battery charging device.

[0071] Detailed Example

[0072] Figures 2 to 5 An example battery charging device 200 is shown that is designed and configured to charge two battery packs or just batteries 204(1) and 204(2) in corresponding, separate charging compartments 208(1) and 208(2). Figure 2 and Figure 3 As best shown, the battery charging device 200 includes a housing 212 having end walls 212E(1) and 212E(2) and an upper central portion 212CP extending between the end walls. A charging compartment tray 216 and a central divider structure 220 are positioned within the upper portion of the housing 212. A pair of compartment closures 212C(1) and 212C(2) are hingedly attached to the central divider structure 220.

[0073] A pair of thermal management components 224(1) and 224(2) extend between and are supported by end walls 212E(1) and 212E(2). Charging compartment tray 216 includes a pair of openings 216O(1) and 216O(2) through which corresponding portions of thermal management components 224(1) and 224(2), i.e., portions of first and second thermoelectric devices 228(1) and 228(2) and corresponding first and second thermal conductive interfaces 232(1) and 232(2) are received. Each of the compartment enclosures 212C(1) and 212C(2), a corresponding one of the thermally conductive interfaces 232(1) and 232(2), a corresponding face of the central partition structure 220, and a corresponding face of the charging compartment tray 216 define a corresponding charging compartment 208(1), 208(2), each compartment including a similar Figure 1 The corresponding charging area (not marked) of the charging area 104.

[0074] like Figure 3 As best shown, the housing 212 includes a base 212B that contains various electronics 236 for assisting in the operation of the battery charging device 200. Figure 3 As shown, the central partition structure 220 also includes electronic components 240 for assisting in the operation of the battery charging device 200. Without going into detail, the electronic components 236 and 240 include components for the charging system (such as Figure 1The charging system 112) of the electronic components, thermal management system electronic components (such as Figure 1 Thermal management system electronics 124) and control systems such as Figure 1 control system 128) and any other necessary electronic components (such as one or more power supplies, etc.).

[0075] Figure 4 Each of the example batteries 204(1) and 204(2) is shown (for simplicity, the Figure 4 and Figure 5 204) and a corresponding one of the thermal management components 224(1) and 224(2) (for simplicity, in Figure 4 and Figure 5 224) is operably coupled. Figure 4 As shown, the thermal management component 224 includes a support structure 224S that supports the thermoelectric device 228 ( Figure 3 228(1) and 228(2)) with the battery 204. In this embodiment, the support structure 224S defines an air duct 400 that allows air to flow (indicated by arrows 404) in contact with a heat sink / heat source 408 that is thermally coupled to the thermoelectric device 228. The air duct 400 includes an inlet end 400I that is enlarged to accommodate air from the battery charging device 200 ( Figure 2 and Figure 3 ) The physical dimensions of the fan (not shown) that draws in ambient air externally. In this regard and referring back to Figure 2 and Figure 3 , each of these figures shows two pairs of openings 212O in the end wall 212E(2) of the housing, on which corresponding pairs of fans (not shown) are mounted to force ambient air into the inlet end 400I of the air duct 400 of each of the thermal management components 224(1) and 224(2).

[0076] Reference again Figure 4 and Figure 5 In this example, the thermoelectric device 228 is composed of a plurality of thermoelectric device segments 228S, each of which is in thermal contact with the heat transfer interface 232 and the heat sink / heat source 408, which is located at a different material combination of the thermoelectric device segment (not shown, but see Figure 1Adjacent ones of the thermoelectric device segments 228S are separated by insulating portions 412 that provide thermal and electrical insulation. In the example shown, each of the thermoelectric device segments 228S is in the form of a strip that includes a plurality of thermoelectric device segments 228S. Figure 4 and Figure 5 However, in other embodiments, some of the thermoelectric device segments 228S may be in the form of islands surrounded on all sides by the insulating portion 412. In other embodiments, a single thermoelectric device segment 228S may be replaced by a single continuous thermoelectric device.

[0077] like Figure 5 As best shown, in this example, the heat sink / heat source 408 is comprised of a flat plate. However, in other embodiments, the heat sink / heat source 408 may include other structures, such as fins 408F, to increase the surface area contacted by the air flow 404 passing through the air duct 400. Figure 5 Also shown are some details of the battery 204. As mentioned above, in this example, the battery 204 is a battery pack, and it is composed of a plurality of individual battery cells 204I (only a few are labeled to avoid cluttering the drawing) that are electrically connected to each other in electrical series and / or electrical parallel to form the core 204C of the battery, thereby providing the battery pack with its designed output current and voltage.

[0078] In the illustrated embodiment, due to its construction, the battery 204 needs to be engaged with the thermally conductive interface 232 in a specific orientation in order to maximize the effectiveness of thermal management of the battery during charging operations by maximizing heat conduction between the battery cells 204C and the thermally conductive interface 232. In this example, the battery 204 has an outer housing 204H having a bottom wall 204B (relative to the Figure 5 ), the bottom wall 204B is the wall of the battery, which is designed to contact the heat conduction interface 232 of the thermal management component 224. Figure 5 As shown, battery cell 204C is positioned adjacent bottom wall 204B and secured to the bottom wall using thermally conductive adhesive 204A to provide a continuous heat path from the battery cell to the bottom wall.

[0079] Various modifications and additions may be made without departing from the spirit and scope of the present invention. The features of each of the various embodiments described above may be appropriately combined with the features of other described embodiments so as to provide a variety of feature combinations in associated new embodiments. In addition, although the foregoing describes a plurality of separate embodiments, the content described herein merely illustrates the application of the principles of the present invention. In addition, although the specific methods herein may be illustrated and / or described as being performed in a particular order, it is within the technical scope of the art that the sequencing is highly variable to implement aspects of the present disclosure. Accordingly, this description is meant to be taken only as an example and does not otherwise limit the scope of the present invention.

[0080] Exemplary embodiments have been disclosed above and shown in the accompanying drawings. Those skilled in the art will appreciate that various changes, omissions and additions may be made to the specific disclosure herein without departing from the spirit and scope of the present invention.

Claims

1. A battery charging device, characterized in that: The battery charging device is used to charge a secondary battery including an electrical terminal and a heat transfer surface, and the battery charging device includes: a charging area that receives the secondary battery during a charging operation; a charging system that is electrically connected to electrical terminals of the secondary battery when the secondary battery is present in the charging region and charges the secondary battery during the charging operation; A thermal management system, the thermal management system comprising: a heat transfer interface that contactingly receives a heat transfer surface of the secondary battery when the secondary battery is positioned in the charging region so that heat can be transferred between the secondary battery and the thermal management system during the charging operation; heat sink / heat source; and A thermoelectric device is thermally coupled between the thermally conductive interface and the heat sink / heat source, wherein the thermoelectric device transfers heat between the secondary battery and the heat sink / heat source during the charging operation when the secondary battery is positioned in the charging region.

2. The battery charging device according to claim 1, characterized in that: The thermally conductive interface includes a thermally conductive contact plate having a battery contact surface that contacts a heat transfer face of the secondary battery when the secondary battery is positioned in the charging area for the charging operation.

3. The battery charging device according to claim 2, characterized in that: The battery charging device includes a plurality of thermoelectric devices thermally coupled between the thermally conductive contact plate and the heat sink / heat source.

4. The battery charging device according to claim 3, characterized in that: The thermoelectric devices are spaced apart from each other and contain thermal insulation in spaces between adjacent ones of the thermoelectric devices.

5. The battery charging device according to claim 1, characterized in that: The battery charging device also includes an ambient-to-air heat transfer system including a channel for providing a flow of ambient air from outside the battery charging device to the heat sink / heat source to transfer heat between the flow and the heat sink / heat source.

6. The battery charging device according to claim 5, characterized in that: The ambient-to-air heat transfer system includes a fan for providing a flow of ambient air within the channel.

7. The battery charging device according to claim 5, characterized in that: The passage includes an inlet for receiving ambient air from outside the battery charging device and an outlet for exhausting the flow of ambient air within the passage to outside the battery charging device.

8. The battery charging device according to claim 1, characterized in that: The battery charging device further includes a control system configured to cause the thermoelectric device to provide heat to the secondary battery when the measured temperature of the secondary battery is lower than a preset minimum charging temperature.

9. The battery charging device according to claim 8, characterized in that: The control system is further configured to cause the charging system to begin charging once the measured temperature reaches the minimum charging temperature.

10. The battery charging device according to claim 9, characterized in that: The control system is further configured to cause the thermoelectric device to remove heat from the secondary battery when the measured temperature of the secondary battery reaches a preset cooling temperature.

11. The battery charging device according to claim 10, characterized in that: The battery charging device also includes an environment-to-air heat transfer system, the environment-to-air heat transfer system including: a passage for providing a flow of ambient air from an exterior of the battery charging device to the heat sink / heat source to transfer heat between the flow and the heat sink / heat source; and a fan for providing a flow of ambient air within the passage; Wherein the control system is further configured to activate the fan in conjunction with causing the thermoelectric device to remove heat from the secondary battery.

12. The battery charging device according to claim 8, characterized in that: The battery charging device also includes an environment-to-air heat transfer system, the environment-to-air heat transfer system including: a passage for providing a flow of ambient air from an exterior of the battery charging device to the heat sink / heat source to transfer heat between the flow and the heat sink / heat source; and a fan for providing a flow of ambient air within the passage; Wherein, the control system is further configured to activate the fan in conjunction with causing the thermoelectric device to provide heat to the secondary battery.

13. The battery charging device according to claim 1, characterized in that: The battery charging device also includes a control system configured to cause the thermoelectric device to remove heat from the secondary battery when the secondary battery is at a measured temperature higher than a preset cooling temperature.

14. The battery charging device according to claim 13, characterized in that: The battery charging device also includes an environment-to-air heat transfer system, the environment-to-air heat transfer system including: a passage for providing a flow of ambient air from an exterior of the battery charging device to the heat sink / heat source to transfer heat between the flow and the heat sink / heat source; and a fan for providing a flow of ambient air within the passage; Wherein the control system is further configured to activate the fan in conjunction with causing the thermoelectric device to remove heat from the secondary battery.

Images