Totally-enclosed explosion-proof flame-retardant lithium battery charger

Abstract

The utility model relates to a totally-enclosed explosion-proof flame-retardant lithium battery charger, which comprises a totally-enclosed shell, a connecting cable and a charging main control board, the totally-enclosed shell comprises insulating end plates positioned on two sides and an alloy shell positioned in the center, and the outer surface of the alloy shell is provided with a plurality of radiating fins which are arranged in an extending manner in the length direction; a pulse activation bypass circuit of the charging main control board is connected to a DCDC conversion circuit, a power supply input end passes through a rectification filter circuit and then is connected with a charging output end through the DCDC conversion circuit and the pulse activation bypass circuit, an input end of a single-chip microcomputer control circuit is connected with a charged battery, and an output end of the single-chip microcomputer control circuit is connected with the DCDC conversion circuit and the pulse activation bypass circuit. According to the totally-closed explosion-proof flame-retardant lithium battery charger shell, the safe and good heat dissipation effect can be achieved, assembly, disassembly and maintenance are convenient, and the mainboard has the auxiliary functions of battery damage charging stopping, current limiting protection, backflow prevention and the like on the basis that the mainboard has the functions of output reverse connection prevention and under-voltage pulse activation.

Description

Technical Field

[0001] This utility model relates to the field of vehicle-to-grid device technology, specifically to a fully enclosed explosion-proof and flame-retardant lithium battery charger. Background Technology

[0002] Currently available portable chargers on the market generally suffer from highly homogenized casing designs and lack sufficient design and improvement for explosion-proof and flame-retardant features. Furthermore, these chargers typically lack pulse activation charging functionality, usually charging directly upon power-on. This charging method, especially in cases of reverse connection, can easily damage both the battery and the charger, posing unnecessary risks and losses to users. Additionally, when lithium batteries are left unused for extended periods and enter undervoltage protection mode, direct power from the charger cannot activate the battery, thus preventing charging. This not only limits the application scenarios of lithium batteries but also inconveniences users and reduces the user experience. Moreover, for damaged batteries, prolonged use can lead to bulging, deformation, or even fire and explosion. Therefore, existing portable chargers and power adapters on the market have significant deficiencies in safety and functionality and urgently require improvement. Utility Model Content

[0003] The technical problem this utility model aims to solve is to overcome the shortcomings of existing chargers in terms of shell structure design, motherboard safety, and functionality, and to provide a fully enclosed explosion-proof and flame-retardant lithium battery charger. This charger is safe, reliable, durable, and has a low failure rate. Its shell design achieves a safe and effective explosion-proof and flame-retardant effect. The motherboard, in addition to providing reverse connection protection and undervoltage pulse activation functions, also has a certain repair function for lithium batteries. Furthermore, it features auxiliary functions such as battery damage-related charging stop, current limiting protection, and backflow prevention. This solves the problems of existing chargers being unable to activate deeply discharged batteries, and the battery swelling or even fire and explosion caused by prolonged high-current charging of damaged batteries.

[0004] This fully enclosed explosion-proof and flame-retardant lithium battery charger includes a fully enclosed housing, connecting cables, and a charging main control board. The charging main control board is installed and fixed inside the fully enclosed housing. Two connecting cables are threaded and fixed at both ends of the fully enclosed housing and extend into the fully enclosed housing to connect with the charging main control board. The fully enclosed housing includes insulating end plates on both sides and an alloy shell in the center. The two ends of the alloy shell are sealed and connected to the two insulating end plates. The four outer surfaces of the alloy shell are provided with several heat dissipation fins extending in the longitudinal direction. The charging main control board integrates a rectifier and filter circuit, a DC-DC converter circuit, a pulse activation bypass circuit, and a microcontroller control circuit. The pulse activation bypass circuit is connected to the DC-DC converter circuit. The power input terminal is rectified and filtered, and then connected to the charging output terminal via the DC-DC converter circuit and the pulse activation bypass circuit. The input terminal of the microcontroller control circuit is connected to the battery being charged, and the output terminal is connected to the DC-DC converter circuit and the pulse activation bypass circuit.

[0005] The optimized pulse activation bypass circuit is equipped with a P-channel MOSFET for controlling pulse output, a current-limiting PTC, and an anti-backflow diode.

[0006] Furthermore, the output terminal of the microcontroller control circuit is connected to a P-channel MOS transistor.

[0007] Furthermore, the connecting cables are integrally fixed to the insulating end plate, and the outer ends of the two connecting cables are respectively provided with plugs for connecting AC power and for connecting the load charging port; the inner ends of the two connecting cables extend into the fully enclosed housing and are respectively connected to the power input terminal and the charging output terminal integrated on the charging main control board.

[0008] This utility model discloses a fully enclosed explosion-proof and flame-retardant lithium battery charger, which overcomes the shortcomings of existing chargers in terms of shell structure design, motherboard safety, and functionality. It is safe, reliable, durable, and has a low failure rate. Its shell design achieves a safe and effective explosion-proof and flame-retardant effect, and is easy to assemble, disassemble, and maintain. Its motherboard has the functions of reverse connection protection and undervoltage pulse activation, and has a certain repair function for lithium batteries. It also has auxiliary functions such as battery damage stop charging, current limiting protection, and reverse flow prevention. It solves the problems of existing chargers being unable to activate deeply discharged batteries, and the battery swelling or even fire and explosion caused by prolonged high-current charging of damaged batteries. Attached Figure Description

[0009] The following description, in conjunction with the accompanying drawings, further illustrates the present invention: a fully enclosed explosion-proof and flame-retardant lithium battery charger.

[0010] Figure 1 This is a schematic diagram of the main plan view of this fully enclosed explosion-proof and flame-retardant lithium battery charger;

[0011] Figure 2 yes Figure 1 A top-view planar structural diagram;

[0012] Figure 3 yes Figure 1 A schematic diagram of the planar structure viewed from below;

[0013] Figure 4 This is a schematic diagram of the logic structure and connection principle of the charging main control board of this fully enclosed explosion-proof and flame-retardant lithium battery charger.

[0014] Figure 5 This is a circuit diagram of the rectifier and filter circuit, DC-DC conversion circuit, and pulse activation bypass circuit of the main control board of this fully enclosed explosion-proof and flame-retardant lithium battery charger.

[0015] Figure 6 This is a circuit diagram of the microcontroller control circuit of the main control board of this fully enclosed explosion-proof and flame-retardant lithium battery charger.

[0016] In the picture:

[0017] 1-Fully enclosed housing; 11-Insulating end plate; 12-Alloy housing; 13-Heat dissipation fins;

[0018] 2- Connecting cables;

[0019] 3-Charging main control board; 31-Rectifier and filter circuit; 32-DC-DC conversion circuit; 33-Pulse activation bypass circuit; 34-Microcontroller control circuit. Detailed Implementation

[0020] In this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. For those skilled in the art, the specific meaning of the above terms in this utility model can be understood according to the specific circumstances.

[0021] In the description of this utility model, it should be understood that the terms "left", "right", "front", "rear", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0022] The present invention will be further described below with specific embodiments, but the scope of protection of the present invention is not limited to the following embodiments.

[0023] Implementation method 1: such as Figures 1 to 6 As shown, this fully enclosed explosion-proof and flame-retardant lithium battery charger includes a fully enclosed housing 1, connecting cables 2, and a charging main control board 3. The charging main control board 3 is installed and fixed inside the fully enclosed housing 1. Two connecting cables 2 are threaded and fixed at both ends of the fully enclosed housing 1 and extend into the fully enclosed housing 1 to connect with the charging main control board 3. The fully enclosed housing 1 includes insulating end plates 11 located on both sides and an alloy housing 12 located in the center. The two ends of the alloy housing 12 are sealed and connected to the two insulating end plates 11. The four outer surfaces of the alloy housing 12 are provided with a number of heat dissipation fins extending in the elongation direction. The charging main control board 3 integrates a rectifier filter circuit 31, a DC-DC converter circuit 32, a pulse activation bypass circuit 33, and a microcontroller control circuit 34. The pulse activation bypass circuit 33 is connected to the DC-DC converter circuit 32. The power supply input terminal is connected to the charging output terminal via the rectifier filter circuit 31, the DC-DC converter circuit 32, and the pulse activation bypass circuit 33. The input terminal of the microcontroller control circuit 34 is connected to the battery being charged, and the output terminal of the microcontroller control circuit 34 is connected to the DC-DC converter circuit 32 and the pulse activation bypass circuit 33. During operation: The microcontroller control circuit first detects whether the battery is reverse-connected. If the battery is reverse-connected, the pulse-activated bypass circuit controlled by the microcontroller control circuit does not work. If the battery is not reverse-connected, the microcontroller control circuit controls the pulse-activated bypass circuit to send a small current pulse charge. If the battery is in undervoltage protection state, after the charger stops sending the pulse voltage, the battery voltage rises due to the pulse charging. When the microcontroller control circuit detects that the battery has a certain voltage, it starts the main circuit to charge the battery in pre-charge mode. At this time, the low voltage current is generally 0.3*Imax, which facilitates battery repair. At the same time, the pre-charge has a time limit to prevent faulty batteries from bulging and deforming due to prolonged charging. After charging to a certain voltage, it charges with a constant current Imax, then charges with a constant voltage after charging to a certain voltage, and finally trickle charging. When the voltage and current meet the conditions, the green light turns on to indicate that the battery is fully charged. The microcontroller control circuit presets the time for each stage and the total time to prevent faulty batteries from being charged for a long time.

[0024] Implementation method 2: such as Figure 5 , 6As shown, this fully enclosed explosion-proof and flame-retardant lithium battery charger includes a P-channel MOSFET, a current-limiting PTC, and an anti-reverse-current diode on the pulse activation bypass circuit 33 for controlling the pulse output. The pulse activation bypass circuit uses a P-channel MOSFET, controlled by the output signal of the microcontroller control circuit. Since the P-channel MOSFET can conduct at low voltage, it can be well controlled without an external power supply. The PTC is connected in series in the pulse activation bypass circuit to limit the pulse current and prevent damage to the battery. The diode in the pulse activation bypass circuit prevents reverse current from the battery from damaging the charger body. The output terminal of the microcontroller control circuit 34 is connected to the P-channel MOSFET. It is used to receive the output signal of the microcontroller control circuit and execute the output of the pulse activation bypass circuit. The remaining structures and components are as described in Embodiment 1 and will not be repeated.

[0025] Implementation method 3: such as Figures 1 to 3 As shown, the connecting cables 2 of this fully enclosed explosion-proof and flame-retardant lithium battery charger are integrally fixed to the insulating end plate 11. The outer ends of the two connecting cables 2 are respectively provided with plugs for connecting to AC power and for connecting to the load charging port; the inner ends of the two connecting cables 2 extend into the fully enclosed housing 1 and are respectively connected to the power input terminal and charging output terminal integrated on the charging main control board 3. The housing is designed as a fully enclosed sealed structure surrounded by an alloy housing and an insulating end plate, which gives it explosion-proof and flame-retardant functions. A large number of heat dissipation fins are designed on the alloy housing, so that the internal heat can be quickly diffused outward and carried away by the ambient air, providing a good, reasonable and safe heat dissipation effect. The remaining structures and components are as described in Embodiment 1 and will not be described again.

[0026] This fully enclosed explosion-proof and flame-retardant lithium battery charger overcomes the shortcomings of existing chargers in terms of shell structure design, mainboard safety, and functionality. It is safe, reliable, durable, and has a low failure rate. Its shell design achieves excellent explosion-proof and flame-retardant performance while facilitating assembly, disassembly, and maintenance. The mainboard, in addition to reverse connection protection and undervoltage pulse activation functions, has a certain repair function for lithium batteries. It also features auxiliary functions such as battery damage-related charge stop, current limiting protection, and reverse flow prevention. This solves the problems of existing chargers being unable to activate deeply discharged batteries and the battery swelling or even fire and explosion caused by prolonged high-current charging of damaged batteries. The specific parameters of this charger are: Input voltage: 176VAC-264VAC; Output power: 900W-950W; Voltage range: 24Vdc-88Vdc; Current: Maximum 18A. It is widely applicable to several charging stages such as activation, pre-charging, constant current, and constant voltage for lithium battery packs (ternary lithium batteries, lithium iron phosphate batteries, lithium titanate batteries, etc.) in electric two-wheelers, electric tricycles, electric cars, sightseeing vehicles, police cars, forklifts, communications, power and other fields, as well as ships.

[0027] The above description illustrates the main features, basic principles, and advantages of this utility model. It will be apparent to those skilled in the art that this utility model is not limited to the details of the exemplary embodiments or examples described above, and that it can be implemented in other specific forms without departing from the spirit or basic characteristics of this utility model. Therefore, the above embodiments or examples should be considered exemplary and not restrictive. The scope of this utility model is defined by the appended claims rather than the foregoing description, and therefore all variations falling within the meaning and scope of equivalents of the claims are intended to be included within this utility model. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0028] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A fully enclosed explosion-proof and flame-retardant lithium battery charger, characterized in that: The device includes a fully enclosed housing (1), connecting cables (2), and a charging main control board (3). The charging main control board (3) is installed and fixed inside the fully enclosed housing (1). Two connecting cables (2) are threaded and fixed at both ends of the fully enclosed housing (1) and extend into the fully enclosed housing (1) to connect with the charging main control board (3). The fully enclosed housing (1) includes insulating end plates (11) on both sides and an alloy housing (12) in the center. The alloy housing (12) is sealed at both ends to the two insulating end plates (11). The four outer surfaces of the alloy housing (12) are provided with a number of heat dissipation fins (13) extending in the elongation direction. The charging main control board (3) integrates a rectifier filter circuit (31), a DC-DC converter circuit (32), a pulse activation bypass circuit (33), and a microcontroller control circuit (34). The pulse activation bypass circuit (33) is connected to the DC-DC converter circuit (32). The power supply input terminal is connected to the charging output terminal via the rectifier filter circuit (31), the DC-DC converter circuit (32), and the pulse activation bypass circuit (33). The input terminal of the microcontroller control circuit (34) is connected to the battery being charged, and the output terminal of the microcontroller control circuit (34) is connected to the DC-DC converter circuit (32) and the pulse activation bypass circuit (33).

2. The fully enclosed explosion-proof and flame-retardant lithium battery charger according to claim 1, characterized in that: The pulse activation bypass circuit (33) is equipped with a P-channel MOS transistor for controlling pulse output, a current-limiting PTC, and an anti-backflow diode.

3. The fully enclosed explosion-proof and flame-retardant lithium battery charger according to claim 2, characterized in that: The output terminal of the microcontroller control circuit (34) is connected to the P-channel MOS transistor.

4. The fully enclosed explosion-proof and flame-retardant lithium battery charger according to claim 3, characterized in that: The connecting cables (2) are fixed integrally on the insulating end plate (11). The outer ends of the two connecting cables (2) are respectively provided with plugs for connecting AC power and for connecting the load charging port. The inner ends of the two connecting cables (2) extend into the fully enclosed housing (1) and are respectively connected to the power input terminal and the charging output terminal integrated on the charging main control board (3).

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