Battery charger

Abstract

A battery charger is disclosed that includes a housing having a first end, a second end, a front side, a rear side, a top side, and a bottom side. The housing also has a first support structure for selectively coupling to the battery pack and a second support structure for selectively coupling to the battery pack. The housing also has a first air inlet in the front side and a second air inlet in the rear side. The housing also has a first air outlet in the first end and a second air outlet in the second end. Charger electronics are supported in the housing and are operable to output a charging current to charge the battery pack. The fan is operable to generate an airflow through the housing. An airflow extends from the first and second air inlets to the first and second air outlets.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 492,115 filed on March 24, 2023, the entire contents of which are incorporated herein. Technical Field

[0003] The present disclosure relates to battery chargers and, more particularly, to cooling battery chargers. Background Art

[0004] Conventional battery chargers are prone to overheating when charging the associated batteries, leading to dangerous conditions. It is well known that introducing airflow through the battery charger helps solve these problems. When the battery charger of the present application charges the battery pack, it can guide air to and around the battery pack, and in combination with the cooling airflow generated by the battery fan, it can actively cool the battery pack. Utility Model Content

[0005] In an independent embodiment, a battery charger includes a housing having a first end, a second end opposite the first end, a front side, a rear side opposite the front side, a top side, and a bottom side opposite the top side. The housing also has a first support structure configured to selectively couple to a battery pack and a second support structure configured to selectively couple to the battery pack. The housing also has a first air inlet located in the front side and a second air inlet located in the rear side. The housing also has a first air outlet located in the first end and a second air outlet located in the second end. The battery charger also includes charger electronics supported in the housing and operable to output a charging current to charge the battery pack. The battery charger further includes a fan operable to generate an airflow through the housing extending from the first air inlet and the second air inlet to the first air outlet and the second air outlet.

[0006] In some embodiments, the shell further has a first axis extending between the first end and the second end, a second axis extending between the front side and the rear side, and a third axis extending between the top side and the bottom side, wherein the first axis, the second axis and the third axis are orthogonal to each other, and the first air outlet and the second air outlet are each oriented normal to the first axis.

[0007] In another independent embodiment, a battery charger includes a housing having a first end, a second end opposite the first end, a front side, a rear side opposite the front side, a top side, and a bottom side opposite the top side. The housing also has a first support structure located in the top side and configured to selectively couple to a battery pack and a second support structure located in the top side and configured to selectively couple to a battery pack. The housing further has a first air inlet located in the bottom side and below the first support structure and a second air inlet located in the bottom side and below the second support structure. The housing also has a first air outlet located in the top side adjacent to the first support structure and a second air outlet located in the top side adjacent to the second support structure. The battery charger also includes charger electronics supported in the housing and operable to output a charging current to charge the battery pack. The battery charger further includes a first fan assembly operable to generate a first airflow extending from the first air inlet to the first air outlet, the first fan assembly including a first fan adjacent to the first air inlet and a first duct coupled to the first fan, the first duct extending from the first fan to the first air outlet. The battery charger also includes a second fan assembly operable to generate a second air flow extending from a second air inlet to a second air outlet, the second fan assembly including a second fan adjacent to the second air inlet and a second duct coupled to the second fan, the second duct extending from the second fan to the second air outlet. When the battery pack is coupled to the first support structure, the first air outlet directs the first air flow to the battery pack. When the battery pack is coupled to the second support structure, the second air outlet directs the second air flow to the battery pack.

[0008] In some embodiments, the shell further has a first axis extending between the first end and the second end, a second axis extending between the front side and the rear side, and a third axis extending between the top side and the bottom side, wherein the first axis, the second axis and the third axis are orthogonal to each other, and wherein the first air inlet, the second air inlet, the first air outlet and the second air outlet are each oriented normal to the third axis.

[0009] In some implementations, the battery charger further includes a first terminal block supported by the housing, adjacent to the first support structure and configured to be selectively coupled to the battery pack, and wherein the first fan assembly directs the first airflow to the first terminal block.

[0010] In yet another independent embodiment, a battery charger includes a housing having a first end, a second end opposite the first end, a front side, a rear side opposite the front side, a top side, and a bottom side opposite the top side. The housing also has a support structure located in the top side and configured to selectively couple to a battery pack. The housing further has a first air inlet located in the bottom side and below the support structure and a first air outlet located in the top side adjacent to the support structure. The housing also has a second air inlet located in at least one of the front side and the rear side and a second air outlet located in at least one of the first end and the second end. The battery charger also includes charger electronics supported in the housing and operable to output a charging current to charge the battery pack. The battery charger further includes a first fan assembly operable to generate a first airflow extending from the first air inlet to the first air outlet, the first fan assembly including a first fan adjacent to the first air inlet and a duct coupled to the first fan, the duct extending from the first fan to the first air outlet. The battery charger also includes a second fan operable to generate a second airflow through the housing, the second airflow extending from the second air inlet to the second air outlet. The duct separates the first air flow from the second air flow.

[0011] In some embodiments, the shell further has a first axis extending between the first end and the second end, a second axis extending between the front side and the rear side, and a third axis extending between the top side and the bottom side, wherein the first axis, the second axis and the third axis are orthogonal to each other, and wherein the first air inlet and the first air outlet are each oriented normal to the third axis. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 is a perspective view of a battery charger.

[0013] Figure 2 yes Figure 1 A top view of the battery charger.

[0014] Figure 3 is a top view of a charging compartment of a battery charger according to another embodiment.

[0015] Figure 4 is a perspective view of a first type of battery pack.

[0016] Figure 5 is a perspective view of a second type of battery pack.

[0017] Figure 6 yes Figure 1 A perspective view of a battery charger.

[0018] Figure 7 and Figure 8 yes Figure 1 A partially exploded perspective view of a battery charger.

[0019] Fig. 9 yes Figure 1 A perspective view of a portion of a battery charger.

[0020] Fig.10 and Fig.11 yes Figure 1 A perspective view of the internal housing portion of a battery charger.

[0021] Fig.12 and Fig.13 They are Figure 1 A perspective view and an exploded perspective view of a battery fan assembly of a battery charger.

[0022] Fig.14 yes Fig.12 A perspective view of a portion of a battery fan assembly.

[0023] Fig.15 yes Figure 1 The battery charger along Figure 1 A cross-sectional view taken along line 15-15.

[0024] Fig.16 yes Figure 1 The battery charger along Figure 1 A cross-sectional view taken along line 16-16. DETAILED DESCRIPTION

[0025] Before explaining any independent embodiment of the present disclosure in detail, it should be understood that the present disclosure is not limited in its application to the construction details and component arrangements set forth in the following description or shown in the following drawings. The present disclosure is capable of other independent embodiments and can be practiced or carried out in various ways.

[0026] As used herein, "including" and "comprising" and variations thereof are intended to encompass the items listed below and equivalents thereof as well as additional items. As used herein, "consisting of" and variations thereof are intended to encompass only the items listed below and equivalents thereof.

[0027] Relative terms used in conjunction with quantities or conditions, such as "about", "approximately", "substantially", etc., will be understood by those of ordinary skill in the art to include the stated value and have the meaning dictated by the context (e.g., the term includes at least the degree of error associated with the measurement, the tolerance associated with the particular value (e.g., manufacturing, assembly, use, etc.), etc.). Such terms should also be considered to disclose a range defined by the absolute values ​​of the two endpoints. For example, the expression "from about 2 to about 4" also discloses a range "from 2 to 4". Relative terms can refer to plus or minus a percentage of the indicated value (e.g., 1%, 5%, 10%, or more).

[0028] In addition, functions described herein as being performed by one component may be performed by multiple components in a distributed manner. Likewise, functions performed by multiple components may be combined and performed by a single component. Similarly, components described as performing a specific function may also perform additional functions not described herein. For example, a device or structure that is "configured" in a certain manner is configured at least in that manner, but may also be configured in an unlisted manner.

[0029] 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 that can be executed 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 is not composed of transient propagation signals. Accordingly, 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.

[0030] Many of the modules and logic 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 both hardware and / or software. Capitalized terms are conventional and help relate the description to coding examples, equations, and / or drawings. However, any specific meaning is not implied or should not be inferred by the use of capital letters alone. Therefore, the claims should not be limited to specific examples or terms, or any specific hardware or software implementation or combination of software or hardware.

[0031] Figure 1A battery charger 10 is shown that is operable to charge a battery pack and further operable to provide active cooling to both the battery charger 10 itself and the battery pack. In the illustrated configuration, the battery charger 10 is operable to charge a first battery pack 14A ( Figure 4 ) for charging. More specifically, the battery charger 10 is operable to charge two first battery packs 14A of the first type simultaneously. Figure 3 In the other configurations shown, the battery charger 10 may also be operable to charge a second battery pack 14B ( Figure 5 The illustrated battery charger 10 may be operable to charge a high output battery pack (e.g., having a current capacity of 12 ampere hours (Ah) or greater), which requires approximately three times the power of a typical charger in just 60 minutes.

[0032] The battery pack type may be defined by the battery packs 14A, 14B's nominal voltage, current capacity, connection configuration (e.g., "tower" vs. "slide-in" or two different slide-in interfaces), etc. For example, the first battery pack 14A may include a high-power battery pack having a nominal voltage of 18V and a slide-in configuration, and the second battery pack 14B may include a high-power battery pack having a nominal voltage of approximately 12 volts (V) and a tower configuration. In other configurations (not shown), the battery packs 14A, 14B may be the same type of battery pack.

[0033] Each battery pack 14A, 14B can be connected to a variety of different motorized power tools (e.g., cross-cut saws, miter saws, table saws, core drills, augers, breakers, demolition hammers, compactors, vibrators, compressors, drain cleaners, welders, cable pullers, pumps, etc.), outdoor tools (e.g., chain saws, string trimmers, hedge trimmers, blowers, lawn mowers, etc.), other motorized devices (e.g., vehicles, utility vehicles, material handling vehicles, etc.), and non-motorized electrical devices (e.g., power supplies, lights, AC / DC adapters, generators, etc.), and can be operated to power them.

[0034] refer to Figure 1In one embodiment, the charger 10 includes a housing 18 having a first end 20, a second end 22 opposite the first end 20, a front side 24, a rear side 26 opposite the front side 24, a top side 28, and a bottom side 30 opposite the top side 28. The housing 18 has a longitudinal axis or first axis 32 extending generally between the first end 20 and the second end 22. The housing 18 also has a transverse axis or second axis 34 extending generally between the front side 24 and the rear side 26 and generally perpendicular to the first axis 32. The housing 18 further has a vertical axis or third axis 36 extending generally between the top side 28 and the bottom side 30.

[0035] Continue to refer Figure 1 The charger 10 also includes a first charging bay 37A and a second charging bay 37B, each of which is operable to be mechanically and electrically coupled to the battery pack 14A to facilitate charging of the battery pack. Each charging bay 37A, 37B includes a corresponding support structure 38A, 38B that can be mechanically engaged with the battery pack 14A, and a corresponding terminal block 39A, 39B that can be mechanically and electrically engaged with the battery pack 14A. The support structures 38A, 38B are both disposed at the top side 28 of the housing 18, wherein the first support structure 38A is positioned closest to the first end 20, and the second support structure 38B is positioned closest to the second end 22. Reference Figure 3 In another embodiment, one or more of the charging bays 37A, 37B may alternatively include a combined support structure 38C that can be engaged with each of the battery packs 14A, 14B. The combined support structure 38C may be provided in place of the first support structure 38A, or in place of the second support structure 38B, or in place of both support structures 38A, 38B. The battery support structures 38A, 38B, 38C are operable to form a releasable mechanical connection between the battery packs 14A, 14B and the charger 10. Each terminal block 39A, 39B is positioned adjacent to its corresponding support structure 38A, 38B. Each terminal block 39A, 39B includes a plurality of block terminals (not shown) for connecting to corresponding battery pack terminals (not shown) provided on the battery pack 14A to electrically connect the battery pack 14A to the charger 10.

[0036] refer to Figures 6 to 8 The charger 10 also includes a power input port 40 for connecting to a power source (e.g., via a power cord 42) and a charger electronics 44 operable to output a charging current to one or both of the batteries 14A, 14B to charge the batteries 14A, 14B. The power cord 42 extends from the housing 18 ( Figure 6 ) extends to a power source via the power input port 40.

[0037] refer to Figure 1 and Figures 6 to 8 , the housing 18 is formed as an assembly and includes an upper housing member 46A, a lower housing member 46B, a first handle member 48A, and a second handle member 48B. The upper housing member 46A is coupled to the lower housing member 46B (e.g., by fasteners (not shown)), and the handle members 48A, 48B are held between the upper housing member 46A and the lower housing member 46B at the front side 24 and the rear side 26, respectively. The housing members 46A, 46B and the handle members 48A, 48B can be formed of plastic, each of which is molded as a single piece. In other embodiments (not shown), the handle members 48A, 48B can be integrally formed with one or both of the upper housing member 46A and the lower housing member 46B.

[0038] The upper shell member 46A includes a top wall 50 that extends generally between the first end 20 and the second end 22 and between the front side 24 and the rear side 26. The top wall 50 includes a central raised portion 52 that projects upward toward the top side 28, a first lower portion 54A located between the central raised portion 52 and the first end 20, and a second lower portion 54B located between the central raised portion 52 and the second end 22. The upper shell member 46A further includes a top skirt wall 56 that extends generally downward from the top wall 50, i.e., toward the lower shell member 46B, and generally around the perimeter of the top wall 50.

[0039] The lower housing member 46B includes a bottom wall 58 that extends generally between the first end 20 and the second end 22 and between the front side 24 and the rear side 26. The bottom wall 58 is generally planar except that it defines a pair of recessed areas 60A, 60B that are generally located toward the front side 24 and toward the first end 20 and the second end 22, respectively. The lower housing member 46B also includes a bottom skirt wall 62 that extends generally upwardly, i.e., toward the upper housing member 46A, from the bottom wall 58 and generally around the perimeter of the bottom wall 58. The bottom skirt wall 62 generally cooperates with the top skirt wall 56 to form a generally enclosed cavity within the housing 18.

[0040] refer to Figures 7 to 9 The charger electronics 44 are supported within the housing 18 and are operable to output a charging current to one or both of the batteries 14A when one or both of the batteries are coupled to the terminal blocks 39A, 39B. The charger electronics 44 include, among other things, a first printed circuit board assembly (PCBA) 64 and a second PCBA 66.

[0041] In the illustrated embodiment, the first PCBA 64 is an AC / DC PCBA 64 operable to convert alternating current to direct current. The first PCBA 64 includes, for example, a transformer 68 and other circuitry to rectify and condition AC power received (e.g., via an AC wall outlet) and provide a DC power output to the second PCBA 66 and other components of the battery charger 10.

[0042] The second PCBA 66 is a DC / DC PCBA 66 that is operable to output a DC charging current to one or both of the batteries 14A. The second PCBA 66 includes a charger microcontroller 70. The charger electronics 44 may include a charging circuit for each of the terminal blocks 39A, 39B so that each battery pack 14A connected to the terminal blocks can be charged simultaneously and independently. The charging current provided to each battery pack 14A may be the same or different. The microcontroller 70 includes an electronic processor and a memory storing instructions that are executed by the electronic processor to implement the functions of the microcontroller 70 described herein. The microcontroller 70 controls the charging circuit to charge the (multiple) battery packs 14A connected to one or both of the charging bays 37A, 37B. For example, the charging circuit may include controllable power switching elements (e.g., field effect transistors, IGBTs, etc.), which the microcontroller 70 selectively enables to provide power from the first PCBA 64 to the corresponding battery packs 14A. The microcontroller 70 further determines the temperature of the PCBAs 64, 66 based on output signals from one or more temperature sensors (not shown), and determines the temperature of the battery pack 14A during charging. Based on the determined temperature, the microcontroller 70 activates and controls one or more cooling fans, as described in further detail below.

[0043] like Fig. 9 As shown, the first PCBA 64 is supported within the lower housing member 46B adjacent the bottom wall 58. The first PCBA 64 may be secured to the bottom wall 58 (eg, via fasteners).

[0044] like Figure 7 , Figure 8 , Fig.10 and Fig.11As shown, the housing 18 further includes an inner housing member 72 located between the upper housing member 46A and the lower housing member 46B and supporting the second PCBA 66. The inner housing member 72 can be coupled to the upper housing member 46A, the lower housing member 46B, or both housing members 46A, 46B by, for example, threaded fasteners. The inner housing member 72 includes a central wall 74, a first upper baffle wall 76A and a second upper baffle wall 76B projecting upward from the central wall 74 toward the upper housing member 46A, and a first lower baffle wall 78A and a second lower baffle wall 78B projecting from the central wall 74 toward the lower housing member 46B. The first upper baffle wall 76A and the second upper baffle wall 76B are positioned toward the first end 20 and the second end 22 of the housing 18, respectively, while the first lower baffle wall 78A and the second lower baffle wall 78B are positioned toward the front side 24 and the rear side 26, respectively. The central wall 74 defines a fan aperture 80 and is further configured to support a charger cooling fan 82 adjacent to the fan aperture 80. The second PCBA 66 is supported by the first upper baffle wall 76A and the second upper baffle wall 76B with its heat generating electrical components facing downward, ie, toward the central wall 74 .

[0045] A first airflow aperture 84A and a second airflow aperture 84B are defined between the central wall 74, the first upper baffle wall 76A and the second upper baffle wall 76B, and the second PCBA 66. Figure 7 , Fig.16 ), and the first and second air flow apertures are respectively positioned proximate to the front side 24 and the rear side 26 of the housing 18. Similarly, the first and second lower baffle walls 78A and 78B extend generally toward the first PCBA 64, so that a third and fourth air flow apertures 85A and 85B are defined between the central wall 74, the first and second lower baffle walls 78A and 78B, and the first PCBA 64 ( Fig.15 The third airflow aperture 85A and the fourth airflow aperture 85B are located proximate to the first end 20 and the second end 22 of the housing 18, respectively.

[0046] refer to Figure 7 , Figure 8 as well as Figure 12 to Figure 14, the charger 10 also includes a first battery fan assembly 86A and a second battery fan assembly 86B positioned proximate to the first charging bay 37A and the second charging bay 37B, respectively. Each of the battery fan assemblies 86A, 86B includes a battery fan 88A, 88B and an airflow duct 90A, 90B. Each battery fan 88A, 88B includes a motor (not shown), an impeller 92, and a shroud housing 94. The airflow ducts 90A, 90B are coupled to the shroud housing 94 (e.g., via threaded fasteners), and one of the terminal blocks 39A, 39B is coupled to each airflow duct 90A, 90B substantially opposite to the corresponding battery fan 88A, 88B. Each airflow duct 90A, 90B includes a base wall 96 defining a fan aperture 97 and a first baffle wall 98A and a second baffle wall 98B extending upward from the base wall 96 toward the upper housing member 46A at two opposite lateral edges of the base wall 96. The first baffle wall 98A and the second baffle wall 98B generally extend beside the corresponding terminal block 39A, 39B, so that a first airflow aperture 100A and a second airflow aperture 100B are defined between each baffle wall 98A, 98B and the terminal block 39A, 39B. Accordingly, the airflow discharged from the battery fan 88A, 88B flows into the airflow duct 90A, 90B through the fan aperture 97 and leaves the airflow duct 90A, 90B through each of the first airflow aperture 100A and the second airflow aperture 100B.

[0047] refer to Figure 1 and Figure 6 , the housing 18 has a plurality of air inlets and air outlets through which air can flow into and out of the housing 18 to actively cool the charger 10 and the battery pack 14A. Specifically, the housing 18 has a first air inlet 102A and a second air inlet 102B disposed within the recessed areas 60A, 60B of the bottom wall 58 of the lower housing member 46B. The first air inlet 102A is positioned closer to the first end 20 and below the first charging compartment 37A. The second air inlet 102B is positioned closer to the second end 22 and below the second charging compartment 37B. Since the bottom wall 58 is generally flat, the recessed areas 60A, 60B provide passages for air to flow into the first air inlet 102A and the second air inlet 102B when the bottom wall 58 rests on a flat support surface. Each of the air inlets 102A, 102B is defined by a plurality of slots disposed in the bottom wall 58 and arranged in a circular profile. The air inlets 102A, 102B are oriented generally normal to the third axis 36 .

[0048] The housing 18 also includes a first air outlet 104A and a second air outlet 104B disposed in the top wall 50 of the upper housing member 46A and adjacent to the support structures 38A, 38b, respectively. As will be discussed further below, air flowing into the first air inlet 102A ultimately exits the housing 18 via the first air outlet 104A, and air flowing into the second air inlet 102B ultimately exits via the second air outlet 104B. Each of the air outlets 104A, 104B has a plurality of slots disposed in the top wall 50 and extending on two lateral sides of each of the support structures 38A, 38b, respectively. The air outlets 104A, 104B are oriented generally normal to the third axis 36. When the battery pack is coupled to the charging bays 37A, 37B, the air exiting the air outlets 104A, 104B is directed to and flows around the battery pack 14A.

[0049] The housing 18 also includes a third air inlet 106A and a fourth air inlet 106B, respectively, disposed in each of the handle members 48A, 48B. Accordingly, the air inlets 106A, 106B are located at the front side 24 and the rear side 26 of the housing 18, respectively, and are adjacent to the central raised portion 52 of the upper housing member 46A. Each of the air inlets 106A, 106B is defined by a plurality of slots disposed in the handle members 48A, 48B and arranged in a rectangular profile. The air inlets 106A, 106B are oriented generally normal to the second axis 34.

[0050] The housing 18 further includes a third air outlet 108A and a fourth air outlet 108B disposed in the bottom skirt wall 62 of the lower housing member 46B at the first end 20 and the second end 22, respectively. As will be discussed further below, air flowing into the third air inlet 106A and the fourth air inlet 106B ultimately exits the housing 18 via the third air outlet 108A and the fourth air outlet 108B. Each of the air outlets 108A, 108B is defined by a plurality of slots disposed in the bottom skirt wall 62 at the first end 20 and the second end 22 of the housing 18. The air outlets 108A, 108B are oriented generally normal to the first axis 32.

[0051] refer to Fig.15, the charger 10 defines a first airflow path A (i.e., linear arrows) and a second airflow path B. The first airflow path A extends through the housing 18 between the first air inlet 102A and the first air outlet 104A. The first battery fan 88A is operable to move air along the first airflow path A from the first air inlet 102A upward through the airflow duct 90A, around the first terminal block 39A, through the first airflow orifice 100A and the second airflow orifice 100B, and out of the slot of the first air outlet 104A. When the battery pack is coupled to the first charging bay 37A, the air leaving the first air outlet 104A is directed to the battery pack 14A and flows around the battery pack 14A. Accordingly, the first battery fan 88A generates a cooling airflow to actively cool the battery pack 14A during charging. In addition, the first battery fan assembly 86A seals the first airflow path A from the rest of the interior of the housing 18 to prevent water that may enter through the first air inlet 102A or through the first air outlet 104A from reaching the first PCBA 64 or the second PCBA 66. like Fig.14 As shown, the first baffle wall 98A and the second baffle wall 98B each include a rib or tongue 110 extending along its end surface. The upper housing member 46A includes a corresponding groove (not shown) formed in its inner surface and configured to receive the tongue 110 of the baffle walls 98A, 98B to form a tight tongue-and-groove connection. This helps seal the baffle walls 98A, 98B against the inner surface of the upper housing member 46A. The second air flow path B is substantially similar to the first air flow path A and flows through the second air inlet 102B, the second battery fan assembly 86B, the second air outlet 104B and flows through the battery pack 14A to actively cool the battery pack 14A coupled to the second charging bay 37B.

[0052] In some embodiments, each of the battery fans 88A, 88B is a multi-speed fan operable to rotate at more than one speed. The speed at which each fan 88A, 88B rotates can be determined based on the temperature of the battery pack 14A connected to the charging bay 37A, 37B and being charged. When the temperature reaches or exceeds the threshold, the microcontroller 70 can start the fans 88A, 88B to operate at the corresponding fan speed. For example, when the microcontroller 70 detects a temperature above the first threshold, the fans 88A, 88B are started at a first speed or a percentage of the maximum speed (e.g., about 50% speed). It should be understood that in other embodiments, the fans 88A, 88B can be started at different speeds (e.g., greater than 50% (100%, 75%, etc.) or less than 50% (25%, 10%, etc.)). Additionally, the speed of fans 88A, 88B may be based on a sensed temperature (e.g., higher speeds for higher temperatures, or lower speeds for lower temperatures) and / or based on a duration that a sensed temperature exceeds a threshold (e.g., higher speeds for longer durations, or lower speeds for shorter durations).

[0053] refer to Fig.15 and Fig.16 , the charger further defines a third airflow path C (i.e., linear arrows) extending through the housing 18 between the third and fourth air inlets 106A, 106B and the third and fourth air outlets 108A, 108B. The charger cooling fan 82 is operable to move air along the third airflow path C from the third and fourth air inlets 106A, 106B through the first and second airflow apertures 84A, 84B defined between the upper baffle walls 76A, 76B and the second PCBA 66 and across the components of the PCBA 66. The airflow path C initially extends laterally inwardly into the housing 18 in the direction of the second axis 34, and in particular into the central raised portion 52 of the upper housing member 46A. The airflow path C then extends downwardly (i.e., in the direction of the third axis 36) toward and through the fan aperture 80 and the charger cooling fan 82, and toward the first PCBA 64. Then, the third airflow path C diverges and passes through each of the third airflow aperture 85A and the fourth airflow aperture 85B, respectively, and toward the third air outlet 108A and the fourth air outlet 108B in the direction of the first axis 32. Then, the airflow path C extends around the battery fan assemblies 86A, 86B and exits the housing 18 via the third air outlet 108A and the fourth air outlet 108B. Accordingly, the charger cooling fan 82 is operable to move air along the third airflow path C to cool both the first PCBA 64 and the second PCBA 66.

[0054] In some embodiments, the charger cooling fan 82 is a multi-speed fan operable to rotate at more than one speed. The speed at which the fan 82 rotates can be determined based on the temperature of one or more of the charger electronics 44. When the temperature reaches or exceeds a threshold, the microcontroller 70 can start the fan 82 to operate at the corresponding fan speed. For example, when the microcontroller 70 detects a temperature above a first threshold, the fan 82 is started at a first speed or a percentage of a maximum speed (e.g., about 50% speed). It should be understood that in other embodiments, the fan 82 can be started at a different speed (e.g., greater than 50% (100%, 75%, etc.) or less than 50% (25%, 10%, etc.)). Moreover, the speed of the fan 82 can be based on the sensed temperature (e.g., higher speed for higher temperatures, or lower speed for lower temperatures) and / or based on the duration that the sensed temperature exceeds the threshold (e.g., higher speed for longer durations, or lower speed for shorter durations).

[0055] Although the disclosure has been described in detail with reference to several preferred embodiments, variations and modifications exist within the scope and spirit of one or more independent aspects of the disclosure as described. Various features and / or advantages of the disclosure are set forth in the following claims.

Claims

1. A battery charger, characterized in that: The battery charger includes: The housing has a first end, a second end opposite to the first end, a front side, a rear side opposite to the front side, a top side, and a bottom side opposite to the top side, a first support structure configured to be selectively coupled to a battery pack and a second support structure configured to be selectively coupled to the battery pack, a first air inlet in the front side and a second air inlet in the rear side, and a first air outlet located in the first end portion and a second air outlet located in the second end portion; charger electronics supported in the housing and operable to output a charging current to charge the battery pack; and A fan is operable to generate an air flow through the housing, the air flow extending from the first air inlet and the second air inlet to the first air outlet and the second air outlet.

2. The battery charger according to claim 1, wherein: The housing includes an upper housing member having the top side and a lower housing member having the bottom side, the lower housing member being removably coupled to the upper housing member; and The lower housing member has the first air outlet and the second air outlet.

3. The battery charger according to claim 2, wherein: The housing further includes a first handle member disposed at the front side and a second handle member disposed at the rear side, and wherein the first handle member has the first air inlet and the second handle member has the second air inlet.

4. The battery charger according to claim 2, wherein: The housing further includes an inner housing member positioned between the upper housing member and the lower housing member; The charger electronics include a first PCBA supported by the lower housing member and a second PCBA supported by the inner housing member; and The airflow passes through the second PCBA before passing through the first PCBA.

5. The battery charger according to claim 4, wherein: The inner housing member supports the fan.

6. The battery charger according to claim 1, wherein: The housing further has a first axis extending between the first end and the second end, a second axis extending between the front side and the rear side, and a third axis extending between the top side and the bottom side, wherein the first axis, the second axis and the third axis are orthogonal to each other, and The first air outlet and the second air outlet are each oriented normal to the first axis.

7. The battery charger according to claim 6, wherein: A maximum dimension of the housing is measured along the first axis between the first end and the second end.

8. A battery charger, characterized in that: The battery charger includes: The housing has a first end, a second end opposite to the first end, a front side, a rear side opposite to the front side, a top side, and a bottom side opposite to the top side, a first support structure located in the top side and configured to be selectively coupled to a battery pack and a second support structure located in the top side and configured to be selectively coupled to the battery pack, a first air inlet in the bottom side below the first support structure and a second air inlet in the bottom side below the second support structure, and a first air outlet located in the top side adjacent to the first support structure and a second air outlet located in the top side adjacent to the second support structure; charger electronics supported in the housing and operable to output a charging current to charge the battery pack; a first fan assembly operable to generate a first air flow extending from the first air inlet to the first air outlet, the first fan assembly comprising a first fan adjacent to the first air inlet and a first duct coupled to the first fan, the first duct extending from the first fan to the first air outlet; a second fan assembly operable to generate a second air flow extending from the second air inlet to the second air outlet, the second fan assembly comprising a second fan adjacent to the second air inlet and a second duct coupled to the second fan, the second duct extending from the second fan to the second air outlet; wherein, when the battery pack is coupled to the first support structure, the first air outlet directs the first airflow to the battery pack; and Wherein, when the battery pack is coupled to the second support structure, the second air outlet guides the second air flow to the battery pack.

9. The battery charger according to claim 8, wherein: The first air outlet has a first plurality of slots formed in a top side of the housing and positioned adjacent the first support structure.

10. The battery charger according to claim 9, wherein: The first plurality of slots extend on two lateral sides of the first support structure.

11. The battery charger according to claim 8, wherein: The housing further has a first axis extending between the first end and the second end, a second axis extending between the front side and the rear side, and a third axis extending between the top side and the bottom side, wherein the first axis, the second axis and the third axis are orthogonal to each other, and Wherein, the first air inlet, the second air inlet, the first air outlet and the second air outlet are each oriented normal to the third axis.

12. The battery charger according to claim 11, wherein: A maximum dimension of the housing is measured along the first axis between the first end and the second end.

13. The battery charger according to claim 8, wherein: The battery charger further includes a first terminal block supported by the housing, adjacent the first support structure and configured to be selectively coupled to the battery pack, and wherein the first fan assembly directs the first airflow to the first terminal block.

14. The battery charger according to claim 8, wherein: The charger electronics include a microcontroller configured to monitor the temperature of the battery pack and activate the first fan in response to the temperature of the battery pack exceeding a predetermined temperature.

15. A battery charger, characterized in that: The battery charger includes: The housing has a first end, a second end opposite to the first end, a front side, a rear side opposite to the front side, a top side, and a bottom side opposite to the top side, a support structure located in the top side and configured to be selectively coupled to the battery pack, a first air inlet located in the bottom side and below the support structure, a first air outlet located in the top side adjacent to the support structure, a second air inlet located in at least one of the front side and the rear side, and a second air outlet located in at least one of the first end and the second end; charger electronics supported in the housing and operable to output a charging current to charge the battery pack; a first fan assembly operable to generate a first air flow extending from the first air inlet to the first air outlet, the first fan assembly comprising a first fan adjacent to the first air inlet and a duct coupled to the first fan, the duct extending from the first fan to the first air outlet; and a second fan operable to generate a second air flow through the housing, the second air flow extending from the second air inlet to the second air outlet; The duct separates the first airflow from the second airflow.

16. The battery charger of claim 15, wherein: The housing includes an upper housing member having the top side and a lower housing member having the bottom side, the lower housing member being removably coupled to the upper housing member; The lower housing member has the first air inlet and the second air outlet; and The upper housing member has the first air outlet.

17. The battery charger of claim 15, wherein: The housing further has a first axis extending between the first end and the second end, a second axis extending between the front side and the rear side, and a third axis extending between the top side and the bottom side, wherein the first axis, the second axis and the third axis are orthogonal to each other, and Wherein, the first air inlet and the first air outlet are each oriented normal to the third axis.

18. The battery charger of claim 17, wherein: A maximum dimension of the housing is measured along the first axis between the first end and the second end, and wherein the second air outlet is oriented normal to the first axis.

19. The battery charger of claim 15, wherein: The first air outlet has a first plurality of slots formed in a top side of the housing and positioned adjacent the support structure.

20. The battery charger of claim 19, wherein: The first plurality of slots extend on two lateral sides of the support structure.

Images