Portable power supply and socket panel assembly

Abstract

The application discloses a portable power supply and a socket panel assembly, the portable power supply comprising: a housing in which a cavity is defined; a plurality of battery cells disposed in the case; and a socket panel assembly, wherein the socket panel assembly is removably connected to the housing. The receptacle panel assembly includes a panel, a receptacle mechanically connected to the panel and electrically connected to the battery cells, and a current interruption circuit mechanically connected to the panel and electrically connected to the plurality of battery cells and the receptacle.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to co-pending U.S. Provisional Patent Application No. 63 / 495,868, filed on April 13, 2023, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present disclosure relates to a portable power source, and more particularly to a portable power source having an electrical interruption structure connected to a modular outlet panel. Background Art

[0004] The conventional portable power supply has a complex connection structure. When the portable power supply or the socket panel on the power supply needs to be repaired, it is difficult to disassemble and repair. The portable power supply of the present application has a removable socket panel assembly connected thereon, and a current interruption circuit is connected to the socket panel assembly, so that the socket panel assembly and the current interruption circuit can be easily removed from the portable power supply, so as to facilitate the repair of the portable power supply, the socket panel assembly, and the current interruption circuit. Utility Model Content

[0005] The portable power supply may include a modular outlet panel that is removable from the portable power supply to service the portable power supply and the modular outlet panel. The portable power supply includes an electrical interruption structure that interrupts current flow to the outlet when an overcurrent condition (e.g., a ground leakage) occurs. The electrical interruption structure is connected to the modular outlet panel to be removed with the modular outlet panel.

[0006] In one aspect, the present disclosure provides a portable power source including a housing, a plurality of battery cells, and a socket panel assembly. A cavity is defined in the housing. The battery cells are disposed in the housing. The socket panel assembly is removably connected to the housing and includes a panel, a socket, and a current interruption circuit. The socket is mechanically connected to the panel and electrically connected to the battery cells. The current interruption circuit is mechanically connected to the panel and electrically connected to the plurality of battery cells and the socket.

[0007] In some implementations, the current interrupt circuit includes a reset switch engageable by a user.

[0008] In another aspect, the present disclosure provides a socket panel assembly, which includes a panel, a socket, a switch, and a current interruption circuit. The socket, the switch, and the current interruption circuit are connected to the panel, and the current interruption circuit is at least partially disposed between the socket and the switch.

[0009] On the other hand, the present disclosure provides a portable power supply including a housing, a plurality of battery cells, a junction box, a socket panel, a socket, and a current interruption circuit. The housing includes a cavity in which the battery cells are disposed. The junction box is connected to the housing and includes a plurality of walls defining a recess, the recess being separated from the cavity by the wall. The socket panel defines a rear side that faces the recess when the socket panel is connected to the junction box. The socket panel at least partially covers the recess. The socket is connected to the socket panel and is electrically connected to the plurality of battery cells. The current interruption circuit is connected to the socket panel and is electrically connected to the socket and the battery cells.

[0010] Other features and aspects of the disclosure will become apparent by consideration of the detailed description and accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Figure 1 is a front elevation view of a portable power supply according to embodiments disclosed herein.

[0012] Figure 2 yes Figure 1 Detailed perspective view of the portable power supply showing the socket panel removed.

[0013] Figure 3 yes Figure 1 An exploded perspective view of the junction box and socket panel of a portable power supply.

[0014] Figure 4 It is a three-dimensional diagram of a circuit breaker.

[0015] Figure 5 is a detailed rear perspective view of a socket panel of a portable power supply according to embodiments disclosed herein.

[0016] Figure 6 yes Figure 5 A front elevation view of a socket panel for a portable power supply.

[0017] Figure 7 is a front perspective view of a current interrupt circuit according to embodiments disclosed herein.

[0018] Figure 8 is a front elevation view of a current interrupt circuit according to another embodiment disclosed herein. DETAILED DESCRIPTION

[0019] Before explaining any embodiments of the present disclosure in detail, it should be understood that the subject matter is not limited in its application to the construction details and component arrangements set forth in the following description or shown in the following figures. The subject matter can have other embodiments and can be practiced or implemented in a variety of different ways. In addition, it should be understood that the words and terms used herein are for descriptive purposes and should not be considered restrictive.

[0020] Figure 1 and Figure 2 An embodiment of a portable power supply 10 is shown. The portable power supply 10 has a housing 14 and a socket panel assembly 18 attached to the housing 14. The socket panel assembly 18 can be a modular socket panel assembly, that is, a socket panel assembly that can be replaced by another socket panel assembly having a similar or different configuration. The portable power supply 10 is suitable for providing power at a remote location (e.g., a construction site). In the case where a permanent power source (e.g., mains power) is not available and power is required to operate power tools, the portable power supply 10 can provide power to be used for these tools. The portable power supply 10 can provide alternating current (AC) power for tools (e.g., corded drills, saws, etc.) and battery charging units and / or provide DC power for direct current (DC) powered tools. The housing 14 of the portable power supply 10 has, for example, an opening 22 on a front face 26 and a cavity 30 inside the housing 14. The housing 14 is a durable material (e.g., metal, plastic, etc.) that can withstand scratches, dents, or other similar wear common on construction sites. A plurality of battery cells 34 (e.g., lithium-ion battery cells, etc.) are arranged in the cavity 30. The battery cells 34 can be recharged, for example by using the mains as a power source to recharge the battery cells 34. Figure 2 As shown, the socket 38 is disposed in the housing 14 and electrically connected to the battery cell 34 to facilitate charging of the battery cell 34. An external power source (e.g., mains power) is connected to the socket 38 via a power cord or other power transmission device. In such embodiments, an inverter may be included to convert AC power into DC power to charge the battery cell 34. An example of a portable power source according to the present disclosure is described in U.S. patent application serial number 17 / 969,222 filed on October 19, 2022, the entire contents of which are incorporated herein by reference.

[0021] The portable power supply 10 may include a sensing structure (eg, a switch engaged by a protrusion, a permanent magnet and a Hall Effect sensor, or other structure) to sense the presence of the outlet panel assembly 18 .

[0022] refer to Figures 1 to 3 , the socket panel assembly 18 is removably connected to the housing 14. In the present embodiment, the socket panel assembly 18 is connected to the front face 26 of the housing 14. The socket panel assembly 18 is connected to the housing 14 by a plurality of fasteners 42. The present embodiment includes ten screws for removably attaching the socket panel assembly 18 to the housing 14. Other numbers and types of fasteners may be used, such as bolts, clips, etc. The socket panel assembly 18 covers at least a majority of the opening 22. As shown in the present embodiment, the socket panel assembly 18 covers the entire opening 22.

[0023] Continue to refer Figure 2 and Figure 3 , a terminal box 46 is connected to the housing 14 and disposed therein, behind the socket panel assembly 18. The terminal box 46 includes a plurality of walls 50 defining a recess 54 having an opening 56 and a perimeter 58. The walls 50 of the terminal box 46 separate the recess 54 from the cavity 30 of the housing 14. The perimeter 58 includes a plurality of fastening locations 62. A plurality of fasteners 42 removably connect the socket panel assembly 18 to the terminal box 46 at the plurality of fastening locations 62. The socket panel assembly 18 may be connected to the fastening locations 62 by bolts, screws, or other fastening members. The recess 54 of the terminal box 46 receives the socket panel assembly 18.

[0024] like Figure 4 As shown, a typical portable power supply 66 includes a circuit breaker 70 connected to a wall 74 in a manner that the circuit breaker 70 cannot be removed with a cover. For example, the typical portable power supply 66 includes a rail 86 connected to the wall 74 via fasteners 92. The circuit breaker 70 includes a circuit breaker housing 94 that includes a recess 96 or slot that receives the rail 86 and connects the circuit breaker 70 to the rail 86.

[0025] refer to Figure 5 and Figure 6 , the socket panel assembly 18 according to the present disclosure includes a panel 106 that defines a rear side or inner side 110 and a front side or outer side 114. The panel 106 is connected to the terminal box 46 so that the rear side 110 of the panel 106 faces the cavity 30. The sockets 118 (e.g., three sockets) and the current interruption circuit 122 (e.g., using fasteners) according to the present disclosure are mechanically connected to the panel 106 (e.g., connected to the rear side 110) and can be removed with the socket panel assembly 18. In this embodiment, the socket panel assembly 18 may also include a switch 120 (e.g., three switches) that is used to selectively disable the electrical output of the socket 118 (or each corresponding socket). The socket 118 can be removably connected to the socket panel assembly 18. The socket panel assembly 18 is electrically connected to the battery cells 34 (e.g., via Figure 1 1, which extend through the junction box 46 and can be connected to an inverter, charging electronics, etc. in addition to the battery cells 34 for providing an electrical output to a power tool or other device that can be removably connected to the socket 118. The socket 118 can be an AC or DC socket. The portable power supply 10 can provide DC power while providing AC power to the socket panel assembly 18.

[0026] refer to Figure 7 and Figure 8, the current interrupt circuit 122 is supported in a body 126 connected to the rear side 110 of the panel 106. The body 126 has a front face 130 that includes an interface 134 for engaging the current interrupt circuit 122. Figure 7 As shown, the interface 134 includes three buttons 138 that can be engaged by a user and engage a switch 140 (shown schematically inside the body 126) of the current interruption circuit 122 for testing, resetting, and closing the current interruption circuit 122. The current interruption circuit 122 also includes an indicator 144 (e.g., an LED) that indicates whether current is flowing through the current interruption circuit 122 or whether the flow of current has been interrupted. In other embodiments, the body 126 can include other interface structures (e.g., a switch with an open position and a closed position, an audible signal, etc.), different combinations of buttons, etc. The body 126 also includes one or more electrical connectors 145 (e.g., a fastener 145a and a conductive back plate 145b) for electrically connecting the current interruption circuit 122 to the receptacle 118, the battery cell 34, the circuit breaker 70, or other electrical structures of the portable power source 10.

[0027] The body 126 includes one or more mounting protrusions extending from the body 126. Figure 7 In one embodiment shown, the body 126 includes two mounting protrusions 146a extending from opposite sides of the body 126. Each mounting protrusion 146a includes a tab 150 having a hole 154 (e.g., a closed elongated hole) defined in the mounting protrusion 146a. The hole 154 receives a fastener 158 ( Figure 5 106) to connect (e.g., threadedly connect) the current interrupt circuit 122 to the panel 106. Figure 8 In another embodiment shown, the body 126 includes two mounting tabs 146b extending from opposite sides of the body 126. Each mounting tab 146b includes a pair of arms 162 having a slot 166 (e.g., an open-ended slot) defined between the arms 162. The slot 166 receives a fastener 158 to connect (e.g., threadedly connect) the current interrupt circuit 122 to the panel 106. Figure 7 and Figure 8 The mounting seat projections 146a, 146b in FIG. 1 are shown as extending from the lateral side of the body 126 (ie, as shown in FIG. Figure 7 and Figure 8 In other embodiments, the mounting seat protrusions 146a, 146b can be extended from the left and right sides as shown. Figure 7 and Figure 8The body 126 may extend from the top and bottom sides as shown, or from the front or back sides. In other embodiments, the body 126 may include other structures (e.g., a clip extending from the panel 106 and engaging a tab extending from the body 126 to connect the current interrupt circuit 122 to the panel 106. In some embodiments, the body 126 may include a sealed interface disposed between the body 126 and the panel 106 to reduce the ingress of water, dust, etc. into the housing 14.

[0028] The current interrupt circuit 122 is mechanically connected to the panel 106 at least partially between the receptacle 118 and the switch 120. In other embodiments, the current interrupt circuit 122, the receptacle 118, and the switch 120 can be connected to the panel 106 in other arrangements. The body 126 is connected to the panel 106 such that a majority of the body 126 is disposed on the rear side 110 of the panel 106 and the interface 134 is disposed on the front side 114 of the panel 106. The body 126 can alternatively be supported by having a majority of the body 126 disposed on the front side 114 of the panel 106.

[0029] The current interrupt circuit 122 automatically interrupts the connection to the outlet 118 when the current exceeds a predefined threshold (e.g., an overcurrent) or a fault condition (e.g., a ground fault) occurs. The current interrupt circuit 122 may be a residual current device (“RCD”), such as a residual current circuit breaker (“RCCB”). The current interrupt circuit 122 may alternatively be a ground fault circuit interrupter (“GFCI”). The current interrupt circuit 122 may alternatively be a fuse, or other structure that permits current to flow from the battery cell 34 to one or more outlets 118 and automatically interrupts the connection from the battery cell 34 to the one or more outlets 118. When an event indicating a ground leakage or ground fault occurs, the current interrupt circuit 122 may automatically interrupt the flow of current to the outlet 118. Alternatively, when an event indicating a short circuit occurs, the current interrupt circuit 122 may automatically interrupt the flow of current to the outlet 118. Alternatively, the current interrupt circuit may automatically interrupt the flow of current to the outlet 118 in an event indicating an arc fault. Alternatively, when the current exceeds a predefined threshold (e.g., a threshold for safe operation of the portable power source 10 or a power tool or other device electrically connected to the portable power source 10), the current interrupt circuit 122 can automatically interrupt the connection from the battery cell 34 to one or more outlets 118. The current interrupt circuit 122 can be rated for 20 amps, rated for 100 to 250 volts AC, 50 Hz or 60 Hz, residual operating current of 30 mA, and residual non-operating current of 15 mA. The current interrupt circuit 122 can be a Type A RCD.

[0030] It will be appreciated that the current interrupt circuit 122 of the present embodiment, wherein the current interrupt circuit 122 is removable with the outlet panel assembly 82, facilitates servicing of the current interrupt circuit 122 through the outlet panel assembly 82. Those skilled in the art will also appreciate that connecting the current interrupt circuit 122 to the outlet panel assembly 82 optimizes the space within the recess 54 defined by the terminal block 46 by, for example, reducing the depth of the recess 54 required to accommodate the current interrupt circuit 122, the outlets 118, the switches 120, and other components. Connecting the current interrupt circuit 122 to the outlet panel assembly 82 also reduces manufacturing complexity by reducing the number of parts and the number of assembly steps.

Claims

1. A portable power source, characterized in that: This portable power supply includes: a housing defining a cavity therein; a plurality of battery cells disposed in the housing; and A socket panel assembly is removably connected to the housing, the socket panel assembly comprising panel, a socket mechanically connected to the panel and electrically connected to the battery cells, and A current interrupt circuit is mechanically connected to the panel and electrically connected to the plurality of battery cells and the receptacle.

2. The portable power source according to claim 1, characterized in that: The panel defines an inner side facing the cavity, and the current interrupt circuit is connected to the panel on the inner side.

3. The portable power source according to claim 1, characterized in that: The current interrupt circuit automatically interrupts the connection to the outlet when an overcurrent condition or fault occurs.

4. The portable power source according to claim 1, characterized in that: The current interrupting circuit includes a ground fault circuit interrupter.

5. The portable power source according to claim 1, characterized in that: The current interruption circuit comprises a residual current device.

6. The portable power source according to claim 5, characterized in that: The current interruption circuit comprises a residual current circuit breaker.

7. The portable power source according to claim 1, wherein: The current interrupt circuit is housed in a body that includes a mounting seat protrusion.

8. The portable power source according to claim 7, characterized in that: The mount projection includes a tab having a hole defined therein.

9. The portable power source according to claim 7, characterized in that: The mounting seat projection includes a pair of arms and a slot defined between the arms.

10. The portable power source according to claim 1, wherein: The current interrupt circuit includes a reset switch engageable by a user.

11. The portable power source according to claim 1, wherein: The portable power supply further includes a junction box connected to the housing, the junction box defining an opening, the outlet panel assembly connected to the junction box and at least partially covering the opening.

12. The portable power source according to claim 11, characterized in that: The junction box defines a recess, and the current interrupt circuit is disposed in the recess.

13. A socket panel assembly, characterized in that: The socket panel assembly includes: panel; The sockets connected to this panel; a switch connected to the panel; and A current interrupt circuit is connected to the panel, the current interrupt circuit being disposed at least partially between the receptacle and the switch.

14. The socket panel assembly according to claim 13, wherein: The current interrupt circuit is disposed in a body, includes an interface, and is mounted such that a majority of the body is disposed on the rear side of the panel and the interface is disposed on the front side of the panel.

15. The socket panel assembly according to claim 14, wherein: The current interrupt circuit is connected to the rear side of the panel.

16. The socket panel assembly according to claim 14, wherein: The body includes a mounting seat projection having a tab with a hole defined therein.

17. The socket panel assembly according to claim 14, wherein: The body includes a mounting boss having a pair of arms and a slot defined therebetween.

18. A portable power source, characterized in that: This portable power supply includes: a housing including a cavity defined therein; A plurality of battery cells, the plurality of battery cells being disposed in the cavity; a junction box connected to the housing, the junction box including a plurality of walls defining a recess, the walls separating the recess from the cavity; a socket panel defining a rear side, the socket panel connected to the junction box and at least partially covering the recess, the rear side facing the recess; a socket connected to the socket panel, the socket being electrically connected to the plurality of battery cells; and A current interrupt circuit is connected to the socket panel and electrically connected to the socket and the battery cells.

19. The portable power source according to claim 18, wherein: The current interrupt circuit is supported in a body including a mounting boss including a tab having an aperture defined therein.

20. The portable power source of claim 18, wherein: The current interrupt circuit is supported in a body including a mounting boss including a pair of arms defining a slot therebetween.

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