Self-adaptive charging controller for cordless electric appliance and cordless electric appliance

Abstract

The present disclosure provides an adaptive charge controller for a cordless appliance and a cordless appliance. The adaptive charge controller for a cordless appliance includes an input interface arranged to receive an input power signal and an output interface arranged to output an enhanced power signal to a battery. The controller also includes a processor arranged to: monitor an input voltage of the input power signal; monitoring an output voltage and an output current of the enhanced power signal; and adjusting a pulse width modulation (PWM) signal based on the input voltage, the output voltage, and the output current. The controller also includes an electronic switch arranged to receive the PWM signal from the processor and to adjust the enhanced power signal in response to the received PWM signal.

Description

Technical Field

[0001] The present disclosure relates to cordless appliances, and more particularly, to electronically charging a battery of a cordless appliance. Background Art

[0002] Cordless household appliances include devices such as handheld vacuum cleaners, portable blenders, food processors, electric bottle openers, can openers, electric knives, and coffee grinders. Portable and rechargeable blenders are known and available to consumers. Such portable blenders typically have a base assembly, a container assembly, and a control circuitry. The base assembly typically includes a rechargeable battery configured to power a motor during blending of the blender. The base assembly typically includes an electronic charging port that receives power from a standard-based charging cable, which may include a Universal Serial Bus (USB) charging interface.

[0003] Unfortunately, existing standard-based charging interfaces, such as USB interfaces, cannot charge at a rate that is not optimized based on the requirements or existing conditions of the battery or environment associated with a particular rechargeable cordless appliance. Accordingly, there is a need for more efficient, rapid, and adaptive charging of cordless rechargeable appliances. Summary of the Utility Model

[0004] The present disclosure describes systems, devices, and methods that address the need for more efficient, rapid, and adaptive charging of cordless appliances such as portable food processing devices or other types of cordless rechargeable electronic appliances or devices.

[0005] In one aspect, an adaptive charging controller for a cordless appliance includes an input interface arranged to receive an input power signal and an output interface arranged to output an enhanced power signal to a battery. The adaptive charging controller further includes a processor arranged to: monitor an input voltage of the input power signal; monitor an output voltage and an output current of the enhanced power signal; and adjust a Pulse Width Modulation (PWM) signal based on the input voltage, the output voltage, and the output current. The adaptive charging controller further includes an electronic switch arranged to receive the PWM signal from the processor and adjust the enhanced power signal in response to the received PWM signal.

[0006] In some embodiments, the electronic switch includes a transistor. The transistor can be a MOSFET. The PWM signal can include a PWM frequency and a PWM duty cycle. The battery can include a plurality of battery cells. The adaptive charge controller can include a memory having a look-up table or interact with the memory. The processor can be arranged to adjust the PWM signal based on comparing the monitored input voltage, output voltage, and output current with the input voltage settings, output voltage settings, and output current settings in the look-up table.

[0007] The processor can also be arranged to control other operations of the cordless appliance, and the other operations include the operation of the motor. In some embodiments, the input interface receives an input power signal from a charger and / or an adapter. The charger can be a standard-based charger. The charger can include a USB 2.0 charger, a USB 3.0 charger, a USB 3.1 charger, a USB BC 1.2 charger, a USB Type C1.2 charger, and / or a USB PD 3.0 charger.

[0008] On the other hand, a method for adaptively charging a battery of a cordless appliance includes: connecting a charger to an input interface of a charge controller; receiving an input power signal from the charger; monitoring an input voltage of the input power signal; monitoring an output voltage and an output current of an enhanced power signal output from the charge controller; adjusting a PWM signal by a processor based on the input voltage, the output voltage, and the output current; receiving the PWM signal at an electronic switch; and adjusting the enhanced power signal by the electronic switch in response to the received PWM signal.

[0009] On the other hand, a cordless appliance includes a housing arranged to accommodate a motor, a battery, a user interface, and an adaptive charge controller. The adaptive charge controller includes an input interface arranged to receive an input power signal and an output interface arranged to output an enhanced power signal to the battery. The adaptive charge controller further includes a processor arranged to: monitor an input voltage of the input power signal; monitor an output voltage and an output current of the enhanced power signal; and adjust a PWM signal based on the input voltage, the output voltage, and the output current. The adaptive charge controller further includes an electronic switch arranged to receive the PWM signal from the processor and adjust the enhanced power signal in response to the received PWM signal.

[0010] Reading the following detailed description and reviewing the associated drawings will make the advantages of these and other structures apparent. The foregoing general description and the following detailed description are merely explanatory and do not limit the aspects of the claimed disclosure. Description of the Drawings

[0011] A more complete understanding of the present disclosure will be obtained with reference to the following drawings, in which:

[0012] Figure 1A and Figure 1B show a front view and a rear view of an exemplary cordless appliance including a charging interface port, respectively;

[0013] Figure 2 is a block diagram of a cordless appliance including an adaptive charging controller;

[0014] Figure 3 is a schematic diagram of an adaptive charging control circuit;

[0015] Figure 4 is a flowchart of a process for adaptively charging a battery of a cordless appliance; and

[0016] Figures 5A to 5G shows Figure 1A and Figure 1B various views of a container for use with the cordless appliance. DETAILED DESCRIPTION

[0017] In the following description, like components have like reference numerals, regardless of the different illustrated embodiments. For the purpose of clarity and conciseness in illustrating the embodiments, the drawings may not necessarily reflect proper proportions and may show some structures in a somewhat schematic form. The present disclosure may describe and / or illustrate a structure in one embodiment and describe and / or illustrate the structure in the same or a similar manner and / or in combination with or in place of the structure of one or more other embodiments.

[0018] In the specification and claims, for the purpose of describing and defining the present invention, the terms "about" and "substantially" represent the inherent degree of uncertainty attributable to any quantitative comparison, value, measurement, or other representation. In addition, the terms "about" and "substantially" represent the degree to which a quantitative representation may differ from the stated reference without causing a fundamental change in the basic function of the subject matter being discussed. Open-ended terms such as "comprising," "including," and / or the plural form of each term encompass the listed parts and may include additional parts not listed, while terms such as "and / or" encompass one or more of the listed parts and combinations of the listed parts. The use of terms such as "top," "bottom," "above," "below," etc. is only for the purpose of clearly describing the present disclosure and does not limit the structure, orientation, and / or operation of the cordless appliance in any way.

[0019] The present disclosure describes systems, devices, and methods for addressing the need for more efficient, rapid, and adaptive charging of cordless appliances such as portable food processing devices or other types of cordless rechargeable electronic devices.

[0020] As more and more products are charged using USB chargers, a complex landscape of USB chargers has emerged. The recently introduced USB Type-C TM and Power Delivery (PD) technologies have revolutionized cable connectivity with the ability to carry various data and negotiate and supply up to 100W of power to charge connected devices. Fewer cables, fewer connectors, and more versatile chargers are just some of the major benefits. In fact, USB Type-C TM cables and connectors support up to 15W (5V at 3A), which rises to 100W (up to 20V at 5A) through the USB Power Delivery function.

[0021] However, even with the new generation of USB Type-C TM adapters, previous versions of USB chargers are still widely adopted in the market and in consumers' homes. These connectors typically include a USB-A type connector that can be connected to a cable. There are also many USB-A to USB-C cables available, and they continue to be shipped with cordless appliances and / or products.

[0022] Therefore, consumers (users) expect that any charger that can physically connect to their products should be able to charge their products. This poses a unique challenge for small cordless appliances such as cordless blenders and handheld vacuum cleaners. These small cordless appliances typically use a USB-C connector to help "charge" their internal lithium batteries. Many of these products contain at least two Li-ON batteries in series, requiring a charging voltage of up to 8.4 volts to fully charge the battery. So in the case of using an external USB-A to USB-C cable, in addition to a USB-C charger, the product should also be able to connect to any traditional USB-A charger and be charged with it. An example of a hybrid connector is a charger that has both a traditional USB-A and a USB-C connector to which a compatible cable can be connected. As shown in Table 1 below, the product table of the charger, it can also be seen that the "output" capacity of the charger varies depending on the connector connected to the charger (5V / 3A vs. 5V / 2.4A). In addition, Table 1 describes how the maximum power of traditional chargers exceeds the USB specifications.

[0023] Specification Maximum Voltage Maximum Current Maximum Power USB 2.0 5 V 500mA 2.5W USB 3.0 and 3.1 5V 900 mA 4.5W USB BC 1.2 5V 1.5A 7.5W USB Type-C 1.2 5V 3A 15W USB PD 3.0 20V 5A 100W

[0024] Table 1 USB Specifications and Maximum Voltage, Current, and Power

[0025] There are four main categories of USB chargers that can be supported to minimize consumer dissatisfaction in cases where the charger is unable to provide sufficient output to charge a consumer's electrical appliances and / or products. Thus, it is beneficial to be able to charge cordless appliances and / or products such as dual-battery cordless blenders with all chargers, regardless of their maximum output power. Table 1 shows all new USB Type-C TM chargers provide up to 3A of current at 5V, with a maximum power of 15W, thus ensuring an upper limit on the input current at 5V. For example, the USB Type-C of power supply 214 or 310 TM power adapters need to have an output of at least 5V. Table 1 shows that there are traditional USB 2.0 chargers that only have an output of 5V and the output is limited to 500mA at 5V, indicating a lower limit on the input current at 5V.

[0026] In some embodiments, a fixed-frequency or fixed-PWM duty cycle DC-DC boost converter and / or charging controller is used, which can charge cordless appliances and / or products having one or two or more internal Li-ON battery cells, and can be compatible with some traditional USB chargers and some new USB Type-C TM chargers. In various embodiments, the present disclosure incorporates the use of a microcontroller that changes the output PWM frequency and duty cycle of the electronic switches, such as "MOSFET switches", applied to the DC-DC boost converter circuit. A microcontroller such as processor 206 or processor 216 can incorporate intelligent programs and / or algorithms while monitoring inputs such as input voltage, output charging current, and output charging voltage to ensure optimal charging is possible within the range of USB chargers available on the market. This microcontroller is also known as an "adaptive charging controller".

[0027] Figure 1A and Figure 1B respectively show a front view and a rear view of an exemplary portable and rechargeable blender 100, which is a type of cordless appliance, and the blender includes a charging controller interface port 104. Blender 100 includes a base housing 102 that can accommodate a motor 220, a battery 208, a user interface 106 and / or 222, and an adaptive charging controller 204, a processor 216, a memory 218, and other components 224. Blender 100 can include a container 108 that is configured to receive and process food using a blade assembly. A blade assembly (not shown) that can be located in the lower part of container 108 can be operatively coupled to motor 220 via a drive shaft and a blade assembly coupler interface between container 108 and base housing 102.

[0028] Figure 2FIG. 200 is a block diagram of a housing 102 for an electronic assembly including a cordless appliance 100 that includes an adaptive charging controller 204. The adaptive charging controller 204 may include a processor 206 that is arranged to control a charging rate applied to a battery 208 by adjusting a PWM signal applied to an electronic switch 302, and in turn adjusting an output power signal from the charging controller 204 to optimize charging of the battery 208. The output power signal from the charging controller 204 may be referred to as a modified power signal and / or an enhanced power signal because in various embodiments, the charging controller 204 is arranged to enhance an input power signal from a charger 212 and / or 310, such as a USB charger. The charger 212 may receive power from a voltage source 214 such as an alternating current (AC) outlet.

[0029] A processor 216 may control various operations of the blender 100, such as but not limited to operations of a motor 220 or other components 224. For example, the processor 216 may control the speed, duration, start time, and stop time of the motor 220 to control the timing and / or duration of blending food within a container 108 using a blade assembly 110. In some embodiments, the processor 216 may perform the functions of the processor 206 with respect to controlling the output power signal applied to the battery 208. Thus, in some embodiments, a single processor 216 performs the operations of the blender 100, including the operations of the charging controller 204.

[0030] For example, the user interface 222 may have a keyboard, keypad, touchpad, or sensor reader (e.g., biometric scanner) and one or more output devices such as a display, a speaker for audio, an LED indicator, and / or a light indicator. The power interface 210 may also include a communication interface, such as a network communication unit that may include a wired communication component and / or a wireless communication component, which may be communicatively coupled to the processor 206 and / or 216. The network communication unit may utilize any of a variety of proprietary or standardized network protocols, such as Ethernet, TCP / IP (to name a few of many protocols), to enable communication between the processor 206 and / or 216 and another device, network, or system. The network communication unit may also include one or more transceivers that utilize Ethernet, power line communication (PLC), Wi-Fi, cellular, and / or other communication methods.

[0031] Processor 206 and / or 216 may include one or more hardware processors, and each hardware processor may have a single or multiple processor cores. In one embodiment, processor 206 and / or 216 includes at least one shared cache that stores data (e.g., computing instructions) utilized by one or more other components of processor 206 and / or 216. For example, the shared cache may be cache data stored locally in a memory (e.g., memory 218) for faster access by components that make up the processing elements of processor 206 and / or 216. Examples of processors include but are not limited to a central processing unit (CPU) and / or a microprocessor. Processor 206 and / or 216 may utilize a computer architecture based on but not limited to Intel 8051 architecture, Motorola 68HCX, Intel 80X86, etc. Processor 206 and / or 216 may include but are not limited to 8-bit, 12-bit, 16-bit, 32-bit, or 64-bit architectures. Processor 206 and / or 216 may include, for example, the microcontroller CMS80F2539 produced by Cmsemicon. Although Figure 2 not shown, the processing elements that make up processor 206 and / or 216 may also include one or more other types of hardware processing components, such as a graphics processing unit (GPU), an application specific integrated circuit (ASIC), a field-programmable gate array (FPGA), and / or a digital signal processor (DSP).

[0032] Memory 218 can operate and be communicatively coupled to processor 206 and / or 216. Memory 218 can be a non-transitory medium configured to store various types of data. For example, memory 218 can include one or more storage devices that include non-volatile storage devices and / or volatile memory. Volatile memory such as random-access memory (RAM) can be any suitable non-permanent storage device. The non-volatile storage device can include one or more disk drives, optical drives, solid-state drives (SSDs), tape drives, flash memories, read-only memories (ROMs), and / or any other type of memory designed to maintain data for a duration after a power-down or shutdown operation. In some configurations, if the size of the allocated RAM is insufficient to hold all working data, the non-volatile storage device can be used to store overflow data. The non-volatile storage device can also be used to store programs that are loaded into RAM when such programs are selected for execution. The program can implement one or more algorithms used by processor 206 and / or 216 to achieve adaptive control of charging by charge controller 204. Memory 218 can store one or more databases and / or lookup tables, such as lookup table 400.

[0033] Processor 206 and / or 216 can be configured to execute stored instructions or process steps in memory 218 and / or internal memory to execute instructions or process steps to transform charge controller 204 into a non-generic, specific, specially programmed machine or device. The stored data, such as the data stored by the device and / or memory 218, can be accessed by processor 206 and / or 216 during the execution of computer-executable instructions or process steps to indicate one or more components within cordless appliance 100.

[0034] User interface 222 can include a display, a position input device (such as a mouse, touchpad, touch screen, etc.), a keyboard, a keypad, one or more buttons, or other forms of user input and output devices. The user interface components can be communicatively coupled to processor 216. When the user interface output device is or includes a display, the display can be implemented in various ways, including through a liquid crystal display (LCD) or a light emitting diode (LED) display.

[0035] Existing DC-DC boost converters use a fixed PWM frequency and duty cycle output from a timing device such as a 555 timer integrated circuit (IC). The output of the 555 timer IC is applied to an electronic switch, such as a MOSFET, that grounds the inductor. When the switch is closed, the inductor voltage (VL) = dI / dT causes a voltage higher than the input voltage to flow through the diode and charge the output capacitor. In this way, a voltage higher than the input voltage can be generated across the output capacitor, resulting in an increased output voltage.

[0036] Due to the fixed PWM frequency and duty cycle output by the 555 timer IC, the charging current and charging voltage (minimum 8.4V for a 2-cell LiON cordless product) determine the minimum input power (Vin, Iin) required for the charging circuit to operate well. For example, to achieve the shortest charging time, the output current at 8.4V is desirably 1A. Given a typical circuit efficiency of 70%, this requires a minimum of 12W. As can be seen from Table 1 above, this means that the design will not be compatible with USB2.0, USB3.0, USB3.1, USB BC1.2, and possibly some USB Type-C 1.2 chargers.

[0037] Alternatively, the charging current can be set lower, as low as 200mA at 8.4V at minimum. At 70% efficiency, the circuit will require an input of 480mA at 5V and is suitable for all chargers. However, the charging time of typical Li-ON cordless products and / or appliances will be sacrificed and will increase significantly, thus bringing an unpleasant experience to consumers. Simply comparing the charging currents of 1A and 200mA, the charging time is extended by 5 times.

[0038] It should also be noted that when the power drawn from the charger is more than its maximum output power (i.e., too much load), the result is that the charger output shuts off. For example, connecting a 1-ohm load to a 5V charger rated at 2.5W will not produce an output from the charger because the inferred power consumption of the 1-ohm load is 5W, exceeding the charger's rated power. Therefore, the charger self-protects and shuts off its output.

[0039] This disclosure describes embodiments with technical improvements that include an adaptive charge controller 204 that changes the application to the electronic switch 302 ( Figure 3Both the PWM frequency and the duty cycle of the PWM signal of M1), and the electronic switch may include a MOSFET. In this way, the efficiency of circuit 300 can also be increased to exceed the efficiency that an existing circuit may have. It generates more charging current with less input power required. Additionally, the PWM frequency and the duty cycle, i.e., the PWM signal, can be changed to minimize the input power required for the matching connected charger 212 so as to provide the most appropriate charging current to, for example, the battery 208 that the connected charger 212 can support. In this way, the embodiments described herein can ensure that all the chargers shown in Table 1 will charge the connected cordless appliance, such as the household appliance 100, with the most efficient charging current. Therefore, the embodiments disclosed herein solve at least one technical problem regarding existing charging systems, that is, how to more efficiently and adaptively optimize the battery charging of cordless appliances that can be connected to different types of standard-based chargers with different charging capabilities.

[0040] Figure 3 Schematic diagram of the adaptive charging control circuit 300 of the adaptive charging controller 204. The adaptive charging controller 204 and / or the charging control circuit 300 may include an input interface 304 and an output interface 306. The input interface 304 can receive an input power signal from the voltage source 310 and / or the charger 212. The input interface 304 may include a voltage divider (shown as R3 and R4 in Figure 3 which provides the voltage VIN monitored by the processor 206 (shown as UI in Figure 3 ). The adaptive charging control circuit 300 may also include an electronic switch 302 (shown as M1 in Figure 3 ), and the electronic switch may be a MOSFET. The circuit 300 may include an output capacitor 312 (shown as C1 in Figure 3 and a current sensing resistor 308 (shown as Rsense in Figure 3 ). The circuit 300 may include additional components to provide proper biasing for the electronic switch and / or the transistor 302.

[0041] In some embodiments, to ensure that the output of 5V is selected from any new USB Type-C TM power delivery charger, such as charger 212, the CC1 and CC2 pins on the product side USB connector, such as the charging controller interface port 104, are connected to the ground pin of the USB-C connector via a 5.1K + / - 10% resistor defined in the USB specification to enable power capability detection and ensure that the charger 212 only outputs 5V.

[0042] In various embodiments, the processor 206 ( Figure 3U1) Based on determining the type of adapter and / or charger 212 that the consumer is using, control the output from the adaptive charging controller 204 and / or the switching duration of the enhanced electric power signal. Table 1 indicates that there are at least 4 categories of chargers 212 with different maximum output powers.

[0043] The processor 206 and / or 216 determines the type of adapter and / or charger 212 by monitoring three signals not available in existing implementations. First, for example, the input voltage is monitored at the VIN port of the processor 206. This corresponds to the output voltage of the connected charger 212. Second, for example, the output voltage of the boost circuit, i.e., the voltage of the output capacitor 312 ( Figure 3 C1), the voltage at the battery 208, and / or the voltage at the output interface 306 is monitored via the FB1 port of the processor 206. The output voltage can be monitored and / or determined by the processor 206 via the FB3 port by detecting the voltage between the resistors R5 and R6 of the detection circuit 300. Third, the output current is monitored via the FB2 port of the processor 206 using the current sense resistor 308 in the output charge path of the capacitor 312 and / or the battery 208. The current sense resistor generates a voltage across the resistor 308 that is proportional to the current flowing through the resistor 308. The processor 206 can convert this "Rsense" voltage to current by using a lookup table (V = IR) that can be stored in the memory 218. Each of these signals can be monitored by the processor 206 by using the analog-to-digital converter (ADC) ports of the processor 206. In some implementations, the processor 216 can perform the functions described for the processor 206.

[0044] Table 400 is a lookup table accessed by the adaptive charging controller 204 to adjust the enhanced power signal applied to the battery 208. Table 400 contains an index row 416 and columns 402 for the input voltage (VIN), column 404 for the output voltage (VBAT or Vout), column 406 for the PWM frequency, column 408 for the PWM duty cycle %, column 410 for the expected Iout, column 412 for the expected Iout maximum, column 414 for the expected power input (PIN), column 418 for the efficiency, and column 420 for the charger category. In various implementations, the PWM frequency and duty cycle, i.e., the PWM signal, are determined by the processor 206 based on the characterization of the circuit 300 and the connected battery cells of the battery 208, through a combination of, for example, algorithms and lookup values in the memory 218. An exemplary process is described below:

[0045] 1. The charger 212 is connected to the blender 100, and the input voltage (VIN) to the adaptive charging controller 204 is detected by the processor 206

[0046] ( Figure 3 U1 of).

[0047] 2. VIN is confirmed by the processor 206 ( Figure 3 U1 of) to be 5V.

[0048] 3. The starting voltage of the battery is determined with the PWM duty cycle set to 0% (no boost voltage is generated). The output voltage (Vout) from the adaptive charging controller 204 is measured, which is the voltage of the output capacitor 312 ( Figure 3 C1 of) connected to the battery cell (e.g., battery 208). The PWM ratio and frequency are determined from the look-up table 400 using the highest index number within the voltage Vout range (e.g., for Vout measured as 7V, index row 12 will be selected).

[0049] 4. The output of the processor 206 (e.g., the PWM signal) is turned on and / or adjusted based on the determination in step 3. When turned on, the output voltage (Vout) connected to the battery cell (e.g., battery 208) will gradually rise as current flows into the battery (the battery is charging).

[0050] 5. The processor 206 determines whether the Iout (Rsense current) matches the expected value of the current in the look-up table 400 for a given PWM ratio and frequency, i.e., the PWM signal.

[0051] 6. The processor 206 determines whether VIN is still present (i.e., 5V is detected at the VIN port of the processor 206) or whether the output has self-protected, i.e., the charger 212 has been turned off.

[0052] 7. If the output current (Iout) from the adaptive charging controller 204 matches and VIN is still present as monitored by the processor 206, the values of the PWM ratio and frequency from the previous index row (e.g., index row 11) of the look-up table 400 are used.

[0053] 8. As the battery voltage continues to rise over time, steps 3, 4, 5, and 6 are repeated. If the output of the processor 206 (e.g., the PWM signal) has been turned on, it does not need to be turned off before measuring the output voltage (Vout) from the adaptive charging controller 204.

[0054] 9. If Iout does not match or VIN is not present, the previous values of the PWM ratio and frequency from the look-up table 400 are used.

[0055] 10. If the measured Iout exceeds the Iout maximum of 412, the output of the processor 206 can be turned off (duty cycle 0%) because the circuit may have malfunctioned or there may be a battery cell fault. In such a case, a message can be displayed on the user interface 222 to indicate that repair may be required or to warn of a circuit fault.

[0056]

[0057] Table 400 is accessed by the adaptive charge controller 204 to adjust the look-up table of the enhanced power signal applied to the battery 208

[0058] In various embodiments, this is a periodic monitoring and adjustment process and / or algorithm. It ends when it is determined that the battery 208 is fully charged or the charger 212 has been removed / unplugged. Table 400 only shows two categories of chargers, 5W and 10W, but the table can be extended to have multiple categories. Additionally, the number of index rows can be increased to have a greater resolution for Vout. The number of rows in the look-up table 400 is only limited by the available memory 218. Table 400 can include PWM duty cycle look-up tables associated with various power ranges, as shown in Table 400, Tables 430 to 460.

[0059] Table 430 is a PWM duty cycle look-up table for charger power ranges greater than or equal to 10W. Table 440 is a PWM duty cycle look-up table for charger power ranges greater than or equal to 7.5W and less than 10W. Table 450 is a PWM duty cycle look-up table for charger power ranges greater than or equal to 5W and less than 7.5W. Table 460 is a PWM duty cycle look-up table for charger power ranges greater than or equal to 2.5W and less than 5W.

[0060] Battery Pack Voltage Range (V) PWM Duty Cycle <4.5 25％ (4.5，4.6) 30％ (4.6，4.7) 30％ (4.7，4.8) 30％ (4.8，4.9) 30％ (4.9，5.0) 30％ (5.0，5.1) 35％ (5.1，5.2) 35％ (5.2，5.3) 35％ (5.3，5.4) 35％ (5.4，5.5) 35％ (5.5，5.6) 39％ (5.6，5.7) 40％ (5.7，5.8) 42％ (5.8，5.9) 42％ (5.9，6.0) 43％ (6.0，6.1) 43％ (6.1，6.2) 44％ (6.2，6.3) 45％ (6.3，6.4) 46％ (6.4，6.5) 47％ (6.5，6.6) 47％ (6.6，6.7) 47％ (6.7，6.8) 48％ (6.8，6.9) 49％ (6.9，7.0) 49％ (7.0，7.1) 50％ (7.1，7.2) 50％ (7.2，7.3) 51％ (7.3，7.4) 52％ (7.4，7.5) 52％ (7.5，7.6) 53％ (7.6，7.7) 54％ (7.7，7.8) 54％ (7.8，7.9) 55％ (7.9，8.0) 56％ (8.0，8.1) 56% (Note: Turn off <80mA only when Vbatt > 8.0V) (8.1，8.2) 56％ >8.2 54％

[0061] Table 430 PWM duty cycle look-up table for charger power ranges greater than or equal to 10W

[0062] Battery Pack Voltage Range (V) Original PWM Duty Cycle <4.5 24％ (4.5，4.6) 30％ (4.6，4.7) 30％ (4.7，48) 30％ (4.8，49) 30％ (4.9，5.0) 30％ (5.0，5.1) 35％ (5.1，5.2) 35％ (5.2，5.3) 35％ (5.3，5.4) 35％ (5.4，5.5) 35％ (5.5，5.6) 39％ (5.6，5.7) 39％ (5.7，5.8) 39％ (5.8，5.9) 39％ (5.9，6.0) 40％ (6.0，6.1) 41％ (6.1，6.2) 42％ (6.2，6.3) 43％ (6.3，6.4) 44％ (6.4，6.5) 44％ (6.5，6.6) 45％ (6.6，6.7) 46％ (6.7，6.8) 47％ (6.8，6.9) 47％ (6.9，7.0) 48％ (7.0，7.1) 49％ (7.1，7.2) 50％ (7.2，7.3) 51％ (7.3，7.4) 51％ (7.4，7.5) 52％ (7.5，7.6) 52％ (7.6，7.7) 53％ (7.7，7.8) 53％ (7.8，7.9) 53％ (7.9，8.0) 53％ (8.0，8.1) 54% (Note: Turn off <80mA only when Vbatt > 8.0V) (8.1，8.2) 54％ ＞8.2 53％

[0063] Table 440 PWM duty cycle look-up table for charger power ranges greater than or equal to 7.5W and less than 10W

[0064] Battery Pack Voltage Range (V) Original PWM Duty Cycle ＜4.5 23％ (4.5，4.6) 27％ (4.6，4.7) 27％ (4.7，4.8) 27％ (4.8，4.9) 27％ (4.9，5.0) 27％ (5.0，5.1) 33％ (5.1，5.2) 33％ (5.2，5.3) 33％ (5.3，5.4) 33％ (5.4，5.5) 33％ (5.5，5.6) 36％ (5.6，5.7) 37％ (5.7，5.8) 37％ (5.8，5.9) 38％ (5.9，6.0) 38％ (6.0，6.1) 39％ (6.1，6.2) 40％ (6.2，6.3) 41％ (6.3，6.4) 42％ (6.4，6.5) 43％ (6.5，6.6) 43％ (6.6，6.7) 44％ (6.7，6.8) 44％ (6.8，6.9) 45％ (6.9，7.0) 45％ (7.0，7.1) 46％ (7.1，7.2) 47％ (7.2，7.3) 48％ (7.3，7.4) 50％ (7.4，7.5) 50％ (7.5，7.6) 50％ (7.6，7.7) 50％ (7.7，7.8) 51％ (7.8，7.9) 51％ (7.9，8.0) 51％ (8.0，8.1) 52% (Note: Turn off <80mA only when Vbatt > 8.0V) (8.1，8.2) 53％ ＞8.2 53％

[0065] Table 450 PWM duty cycle look-up table for charger power ranges greater than or equal to 5W and less than 7.5W

[0066] Battery Pack Voltage Range (V) PWM Duty Cycle <4.5 23％ (4.5，46) 27％ (4.6，4.7) 27％ (4.7，4.8) 27％ (4.8，4.9) 27％ (4.9，5.0) 27％ (5.0，5.1) 31％ (5.1，5.2) 31％ (5.2，5.3) 31％ (5.3，5.4) 31％ (5.4，5.5) 31％ (5.5，5.6) 32％ (5.6，5.7) 32％ (5.7，5.8) 33％ (5.8，5.9) 33％ (5.9，6.0) 34％ (6.0，6.1) 35％ (6.1，6.2) 36％ (6.2，6.3) 37％ (6.3，6.4) 38％ (6.4，6.5) 38％ (6.5，6.6) 39％ (6.6，6.7) 40％ (6.7，6.8) 41％ (6.8，6.9) 42％ (6.9，7.0) 43％ (7.0，7.1) 43％ (7.1，7.2) 44％ (7.2，7.3) 44％ (7.3，7.4) 45％ (7.4，7.5) 46％ (7.5，7.6) 46％ (7.6，7.7) 48％ (7.7，7.8) 48％ (7.8，7.9) 48％ (7.9，8.0) 49％ (8.0，8.1) 49% (Note: Turn off <80mA only when Vbatt > 8.0V) (8.1，8.2) 50％ ＞8.2 50％

[0067] Table 460 PWM duty cycle look-up table for charger power ranges greater than or equal to 2.5W and less than 5W

[0068] Figure 4 A flowchart of process 500 for adaptively charging the battery 208 of a cordless electrical appliance such as cordless electrical appliance 100. Process 500 includes the following operations: connecting charger 212 to the input interface 304 of charging controller 204 (step 502); receiving an input power signal from charger 212 (step 504); monitoring, by processor 206, the input voltage of the input power signal (step 506); monitoring, by processor 206, the output voltage and output current of the boosted power signal output from charging controller 204 (step 508); adjusting, by processor 206, the PWM signal based on the input voltage, output voltage, and output current (step 510); receiving the PWM signal at electronic switch 302 (step 512); and adjusting, by electronic switch 302, the boosted power signal in response to the received PWM signal (step 514).

[0069] Look-up table 400 may include rows that change both the PWM frequency 406 and the PWM duty cycle % 408 to optimize the DC-DC conversion efficiency 418 at different battery voltages (Vout). In index row 1 and index row 2 of look-up table 400, when the battery voltage (Vout) is 4.5V, different PWM frequencies are selected because a lower PWM duty cycle % generates more heat in L1 of the adaptive control circuit 300. Therefore, instead of reducing the PWM duty cycle to less than 30%, it may be advantageous to reduce the PWM frequency to 50KHz. Thus, look-up table 400 provides the flexibility and ability to determine the highest efficiency of the adaptive control circuit 300 over the entire battery voltage Vout range (shown in table 400 as 4.5V to 8.4V).

[0070] Index row 11 and index row 12 of look-up table 400 show that a higher PWM duty cycle % 408 results in a higher Iout expected current 410. By selecting index row 12 instead of index row 11, a greater charging current is provided to the battery, thus making the charging time of the battery shorter.

[0071] Index rows 14 to 18 of look-up table 400 show that the increase in the PWM duty cycle % does not have a linear relationship with the increase in the battery voltage Vout. Therefore, using a look-up table is beneficial because it allows the PWM duty cycle % to be optimally adjusted based on the measured battery voltage Vout to achieve a shorter charging time.

[0072] Index lines 1 to 2, index lines 3 to 4, and index lines 5 to 6 show that changing the PWM frequency while maintaining the same PWM duty cycle % and changing the PWM duty cycle % while maintaining the same PWM duty cycle % can have the same effect in changing Iout. Changing both the PWM duty cycle % and the PWM frequency in the same index line further illustrates the advantage of the lookup table 400 defining a countless number of line combinations that achieve the highest charging efficiency in all categories of chargers and charging voltage Vout.

[0073] In some embodiments, table 400 may include more fine-grained rows of battery voltage resolution and range (e.g., a 2-cell LiON battery is typically 4.5V to 8.4V), which may be every 1mV instead of every 0.5V as shown in table 400. Table 400 may include independent settings for the PWM duty cycle % and the PWM frequency, resulting in a countless number of configurations for the adaptive charging controller. System 200 may be configured to provide a warning of abnormal charging to the user based on monitoring the charging condition.

[0074] Figures 5A to 5G Shows in relation to Figure 1A and Figure 1B Various views of a container for use with a cordless appliance. Figure 5A Front view 600 of the container 108 with the lid not attached is shown. Figure 5B Rear view 602 of the container 108 is shown. Figure 5C Left view 604 of the container 108 is shown. Figure 5D Right view 606 of the container 108 is shown. Figure 5E Top view 608 of the container 108 is shown. Figure 5F Bottom view 610 of the container 108 is shown. Figure 5G Perspective view 612 of the container 108 is shown.

[0075] Although the present disclosure specifically shows and describes some embodiments, those skilled in the art will understand that various changes in form and detail may exist without departing from the spirit and scope of the present application as defined by the appended claims. The scope of the present application is intended to cover such variations. Therefore, the foregoing description of the embodiments of the present application is not intended to limit the full scope conveyed by the appended claims.

Claims

1. An adaptive charging controller for a cordless electrical appliance, characterized in that, The adaptive charging controller for the cordless appliance includes: An input interface arranged to receive an input power signal; An output interface arranged to output an enhanced power signal to the battery; A memory containing a look-up table including input voltage settings, output voltage settings, and output current settings; A processor arranged to: Monitor the input voltage of the input power signal; Monitor the output voltage and output current of the enhanced power signal; Based on comparing the input voltage, the output voltage, and the output current with the input voltage settings, the output voltage settings, and the output current settings in the look-up table, control the charging rate applied to the battery by adjusting a Pulse Width Modulation (PWM) signal; and Control at least one operation of the motor of the cordless appliance; and An electronic switch arranged to receive the PWM signal from the processor and adjust the enhanced power signal in response to the received PWM signal.

2. The adaptive charging controller according to claim 1, wherein, The electronic switch includes a transistor.

3. The adaptive charging controller according to claim 2, wherein, The transistor includes a MOSFET.

4. The adaptive charging controller according to claim 1, wherein, The PWM signal includes a PWM frequency and a PWM duty cycle.

5. The adaptive charging controller according to claim 1, wherein, The battery includes a plurality of battery cells.

6. The adaptive charging controller according to claim 1, wherein, The processor is further arranged to control other operations of the cordless appliance, the other operations including the operation of the motor.

7. The adaptive charging controller according to claim 1, wherein, The input interface receives the input power signal from a charger.

8. The adaptive charging controller according to claim 7, wherein the charger includes at least one selected from the group consisting of: a USB 2.0 charger, a USB 3.0 charger, a USB 3.1 charger, a USB BC 1.2 charger, a USB Type C 1.2 charger, and a USB PD 3.0 charger.

9. A cordless electrical appliance, characterized in that, The cordless appliance includes: A housing arranged to accommodate a motor, a battery, a user interface, and an adaptive charging controller; The adaptive charging controller includes: An input interface arranged to receive an input power signal; An output interface arranged to output an enhanced power signal to the battery; and A memory containing a look-up table including input voltage settings, output voltage settings, and output current settings; A processor arranged to: Monitor the input voltage of the input power signal; Monitor the output voltage and output current of the enhanced power signal; Based on comparing the input voltage, the output voltage, and the output current with the input voltage settings, the output voltage settings, and the output current settings in the look-up table, control the charging rate applied to the battery by adjusting a Pulse Width Modulation (PWM) signal; and Control at least one operation of the motor; and An electronic switch arranged to receive the PWM signal from the processor and adjust the enhanced power signal in response to the received PWM signal.

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