Battery charger for charging single or multiple battery packs

Abstract

A battery charger for charging a single or multiple battery packs includes a housing, first and second charger interfaces, first and second vents, and a shutter. A first charger interface and a second charger interface are formed on the housing. Each charger interface receives and charges a respective battery pack. First and second vents are defined in the housing. Each vent provides an airflow path defined through a respective battery pack and housing. A shutter is provided for each charger interface and is movable between an actuated position, in which the shutter is oriented to at least partially block the airflow path, and a non-actuated position, in which the shutter is outside the airflow path.

Description

[0001] Cross-reference to related applications

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 596,057, filed November 3, 2023, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This invention relates to a battery charger, and more specifically to a method for cooling a battery pack connected to the battery charger. Background Technology

[0004] Battery chargers and the batteries connected to them are prone to overheating during charging. Solutions to overheating include cooling and / or regulating the charging process. Utility Model Content

[0005] In one aspect, the present invention provides a battery charger for charging multiple battery packs. The battery charger includes a housing and first and second charger interfaces formed on the housing. Each charger interface is configured to receive and charge a corresponding battery pack from the plurality of battery packs. The battery charger also includes a first vent and a second vent defined within the housing and respectively for the first and second charger interfaces. Each vent is configured to provide an airflow path defining an airflow path through the corresponding battery pack and the housing. Furthermore, the battery charger includes a gate provided for each charger interface. The gate is movable between an actuated position, in which the gate is oriented to at least partially block the airflow path, and in an unactuated position, the gate is outside the airflow path.

[0006] On the other hand, the present invention provides a battery charger for charging a battery pack. The battery charger includes a housing and a charger interface formed on the housing. The charger interface is configured to receive and charge the battery pack. The battery charger includes a plurality of vents defined in the housing and at least one fan disposed in the housing. The fan is configured to draw air into the housing through the plurality of vents. Furthermore, the battery charger includes a baffle plate disposed near the plurality of vents. The baffle plate selectively blocks at least partially the plurality of vents.

[0007] In some embodiments, the plurality of vents are a first plurality of vents, the gate is a first gate, and the battery charger further includes a second plurality of vents and a second gate that selectively blocks at least partially the second plurality of vents.

[0008] In another aspect, the utility model provides a battery charger for charging a battery pack. The battery charger includes a housing and a charger interface formed on the housing. The charger interface is configured to receive a battery pack and charge the battery pack. The battery charger further includes a plurality of vents defined in the housing and configured to provide an airflow path defined through the battery pack and the housing. The battery charger further includes a shutter disposed proximate the plurality of vents. The shutter selectively at least partially obstructs the airflow path. In addition, the battery charger includes an actuator disposed within the housing and configured to move the shutter and a controller disposed within the housing. The controller is configured to determine that the battery pack has made an electrical connection with the charger interface and operate the actuator to at least partially move the shutter out of the airflow path.

[0009] In some embodiments, the controller is further configured to determine whether the battery pack is a first type or a second type and, upon determining that the battery pack is the second type, operate the actuator to move the shutter to at least partially obstruct the airflow path. BRIEF DESCRIPTION OF DRAWINGS

[0010] Figure 1 is a front perspective view of a battery charger and a first type of battery pack in accordance with an embodiment of the utility model.

[0011] Figure 2 is Figure 1 a front perspective view of the battery pack of

[0012] Figure 3 is a cross-sectional view of the battery charger and battery pack of Figure 2 taken along line 3-3 in Figure 2

[0013] Figure 4 is a cross-sectional view of the battery charger and battery pack of Figure 2 taken along line 4-4 in Figure 2

[0014] Figure 5 is a bottom perspective view of the battery pack of Figure 1

[0015] Figure 6 is a perspective view of the battery charger and a second type of battery pack of Figure 1

[0016] Figure 7 is a top view of the battery charger of Figure 1 with portions removed, the battery charger having a shutter positioned within an actuated position.

[0017] Figure 8 is​​​​Figure 6 A perspective view of the battery pack, with its electrical connections... Figure 1 Battery charger.

[0018] Figure 9 yes Figure 1 A top view of the battery charger, with a portion removed, and the battery charger's gate positioned in the non-actuated position.

[0019] Figure 10 It is along Figure 8 The middle line 10-10 section Figure 8 A cross-sectional view of the battery charger and battery pack.

[0020] Figure 11 It is along Figure 8 Section 11-11 in the middle Figure 8 A cross-sectional view of the battery charger and battery pack.

[0021] Figure 12 yes Figure 6 A bottom view of the battery pack.

[0022] Figure 13 This is a top view of a battery charger according to another embodiment of the present invention, the battery charger having a gate positioned in an actuated position.

[0023] Figure 14 yes Figure 13 A top view of the battery charger, with the battery charger's gate positioned in the non-actuated position.

[0024] Figure 15 This is a front view of a multi-battery pack charger according to another embodiment of the present invention.

[0025] Figure 16 yes Figure 15 A top view of a multi-battery pack charger, with the battery packs connected to it.

[0026] Figure 17 yes Figure 15 A top view of a multi-battery pack charger, with the battery packs connected to it.

[0027] Figure 18 yes Figure 15 A top view of a multi-battery pack charger, with the battery packs connected to it.

[0028] Figure 19 This is a top view of a multi-battery pack charger according to another embodiment of the present invention.

[0029] Figure 20 yes Figure 19 A top view of a multi-battery pack charger, with the battery packs connected to it.

[0030] Figure 21 is Figure 19 a top view of a multi-battery pack charger, with a battery pack connected thereto.

[0031] Figure 22 is a top view of a multi-battery pack charger according to another embodiment of the present utility model.

[0032] Before any embodiments of the present utility model are explained in detail, it is to be understood that the application of the present utility model is not limited in scope to the details of construction and the arrangement of the components and the instrumentalities set forth in the following description or illustrated in the following drawings. The present utility model is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. DETAILED DESCRIPTION

[0033] Figure 1 and Figure 2 A battery charger 10 is shown configured to charge various battery packs, such as power tool battery packs. In the illustrated embodiment, the battery charger 10 is operable to charge a first battery pack 14a. In other embodiments, the battery charger 10 is operable to charge a second battery pack 14b (not shown) in addition to the first battery pack 14a. Figure 6 and Figure 10

[0034] Referring to Figures 1-4 , the battery charger 10 includes a housing 18 having a top portion 20 and a bottom portion 22 connected to the top portion 20. A charger interface 24 is provided on the top portion 20 of the housing 18 and has charger rails 26a, 26b. The charger rails 26a, 26b are spaced apart from one another and are configured to engage the first battery pack 14a to slidably connect the first battery pack 14a to the battery charger 10. The charger interface 24 also has a charger terminal block 30 having a set of charger terminals (e.g., charger terminals 428) configured to electrically connect the battery charger 10 to the first battery pack 14a for charging operations. Further, the housing 18 includes a first plurality of inlet vents 34a, a second plurality of inlet vents 34b, and a third plurality of inlet vents 34c. The first plurality of inlet vents 34a and the second plurality of inlet vents 34b are defined along each side of the charger interface 24. The third plurality of inlet vents 34c is defined along a surface 35 of the charger interface 24. The housing 18 of the battery charger 10 also includes a plurality of outlet vents 36 defined along the bottom portion 22 of the housing 18. The inlet vents 34a-c and the outlet vents 36 are configured to allow air to enter and exit the housing 18 of the battery charger 10. Figure 13 and 14 Figure 3 The battery charger 10 is configured to charge the first battery pack 14a. In other embodiments, the battery charger 10 is configured to charge the second battery pack 14b (not shown) in addition to the first battery pack 14a. The battery charger 10 is configured to charge the first battery pack 14a in a first charging mode and the second battery pack 14b in a second charging mode. The first charging mode is a fast charging mode and the second charging mode is a slow charging mode. The battery charger 10 is configured to charge the first battery pack 14a in the fast charging mode and the second battery pack 14b in the slow charging mode simultaneously.​​

[0035] The battery charger 10 also includes a power button 37 disposed on the top 20 of the housing 18 and charger electronics 38 supported within the bottom 22 of the housing 18. The power button 37 is configured to be pressed by a user to activate the battery charger 10. The charger electronics 38 are configured to output a charging current through the charger interface 24 to charge the first battery pack 14a. The charger electronics 38 include, among other things, a printed circuit board (PCB) 42, a microcontroller 44, and a charging circuit for the charger terminals. The microcontroller 44 includes an electronic processor and a memory storing instructions that are executed by the electronic processor to implement various functions of the microcontroller 44.

[0036] Further, the battery charger 10 includes a fan 46 supported within the bottom 22 of the housing 18 and disposed proximate the charger electronics 38. The fan 46 is in fluid communication with the inlet vents 34a-c through an air duct 50 connected to the top 20 of the housing 18. The air duct 50 includes a main body 54 and a flange 58 extending from the main body 54 to abut the top 20 of the housing 18. The air duct 50 is disposed directly below the inlet vents 34a, 34b, thereby surrounding the periphery of the inlet vents 34a-c to capture airflow entering the inlet vents 34a-c. The main body 54 of the air duct 50 is also connected to a portion of the fan 46 to further place the fan 46 in fluid communication with the inlet vents 34a-c. In the illustrated embodiment, the fan 46 is an axial fan. The fan 46 is configured to draw air into the first battery pack 14a and the housing 18 of the battery charger 10 to create an airflow through the first battery pack 14a and the battery charger 10. Ultimately, the airflow is directed to the charger electronics 38 for cooling and through the fan 46 to be expelled from the battery charger 10 through the outlet vent 36 of the battery charger 10.

[0037] With continued reference to Figures 1-4 , the battery charger 10 includes a pair of dampers 62a, 62b disposed below the first plurality of inlet vents 34a and the second plurality of inlet vents 34b, respectively. Each damper 62a, 62b includes a comb portion 66a, 66b and a pair of tabs 70a, 70b extending through the top 20 of the housing 18 of the battery charger 10. The comb portion 66a, 66b of each damper 62a, 62b has three tabs 74a, 74b( Figure 7 and 9 ). The dampers 62a, 62b are slidably connected to the top 20 of the housing 18 and are configured to block airflow through the first plurality of inlet vents 34a and the second plurality of inlet vents 34b.

[0038] The dampers 62a, 62b are configured to be in an actuated position Figure 7) and non-actuated positions ( Figure 9 The gates 62a and 62b are slidably movable between the gates. In the actuated position, spring 82 biases each gate 62a, 62b such that tabs 70a, 70b extend through housing 18. Additionally, comb-like portions 66a, 66b of each gate 62a, 62b are respectively disposed within openings 84a, 84b defined by first and second plurality of inlet vents 34a, 34b to block the inlet vents 34a, 34b. A plurality of pins 86 extend through each tab 74a, 74b such that a first side of each tab 74a, 74b abuts a corresponding pin 86 to place each gate 62a, 62b in the actuated position. Thus, gates 62a, 62b are positioned to block inlet vents 34a, 34b and prevent airflow through them. In the non-actuated position, gates 62a, 62b move rearward in the direction indicated by arrow 90. The second side of each tab 74a, 74b abuts a corresponding pin 86 to place each gate 62a, 62b in a non-actuated position. Tabs 70a, 70b are pushed into the housing 18 of the battery charger 10. The comb-like portions 66a, 66b of each gate 62a, 62b are positioned to align with the inlet vents 34a, 34b to expose the openings 84a, 84b. Thus, when the gates 62a, 62b no longer obstruct the inlet vents 34a, 34b, airflow is allowed through the first and second plurality of inlet vents 34a, 34b.

[0039] refer to Figures 1-5 The first battery pack 14a includes a housing 94 having a top 98 and a bottom 102. The first battery pack 14a is a small battery pack defining a first battery width W1. The housing 94 supports a plurality of battery cells 106 and battery pack electronics 110. A battery pack interface (not shown) is provided on the housing 94 of the first battery pack 14a and includes a terminal block (not shown) that can engage with a charger terminal block 30 of a battery charger 10 to electrically connect the first battery pack 14a to the battery charger 10. Battery rails 114a, 114b extend from a pair of walls 118a, 118b integrally formed with the first bottom surface 104 of the housing 94. Therefore, recesses 122a, 122b are individually defined between the battery rails 114a, 114b and the first bottom surface 104. Figure 5 Battery rails 114a and 114b are interconnected via a second bottom surface 126 of housing 94. The first battery pack 14a also includes a plurality of inlet vents 130 defined at the top 98 of housing 94 and a plurality of outlet vents 132 defined along the second bottom surface 126.

[0040] When the first battery pack 14a is connected to the battery charger 10, the battery rails 114a, 114b and the recesses 122a, 122b of the first battery pack 14a are configured to mate with the charger rails 26a, 26b of the battery charger 10. In particular, the charger rails 26a, 26b are received within the recesses 122a, 122b of the first battery pack 14a to slidably connect the first battery pack 14a to the battery charger 10. Once the first battery pack 14a is electrically connected to the battery charger 10, the second bottom face 126 of the first battery pack 14a is oriented over the third plurality of inlet vents 34c to place the outlet vents 132 of the first battery pack 14a in fluid communication with the third plurality of inlet vents 34c. An airflow path is then defined between the battery charger 10 and the first battery pack 14a. The small structure of the first battery pack 14a prevents the housing 94 from coupling with the tabs 70a, 70b of each of the flapper doors 62a, 62b. As such, the flapper doors 62a, 62b remain in the actuated position when the first battery pack 14a is connected to the battery charger 10.

[0041] During a charging operation, the fan 46 of the battery charger 10 is configured to cause air to flow through the first battery pack 14a and into the housing 18 of the battery charger 10. In particular, the fan 46 generates an airflow 134 that is configured to flow through the inlet vents 130 of the first battery pack 14a and into the housing 94 to cool the battery cells 106 and the battery pack electronics 110. The airflow 134 is then directed out of the housing 94 of the first battery pack 14a through the outlet vents 132. Thereafter, the airflow 134 is directed through the third plurality of inlet vents 34c into the housing 18 of the battery charger 10. The airflow 134 is then directed toward the charger electronics 38 for cooling purposes and out of the battery charger 10 through the outlet vents 36 by the fan 46. When the flapper doors 62a, 62b remain in the actuated position, the cooling efficiency and performance of the first battery pack 14a is maximized. Furthermore, keeping the first and second pluralities of inlet vents 34a, 34b closed when not in use will further provide intrusion protection for the battery charger 10. Additionally, leakage of the airflow 134 from the first and second pluralities of inlet vents 34a, 34b can be minimized.

[0042] Referring to Figures 6 to 12 , the second battery pack 14b is connected to Figures 1 to 4 the battery charger 10. The second battery pack 14b is similar to the first battery pack 14a of Figures 1-5 ; therefore, like structures will be identified by the same reference number plus “200” and only the differences will be discussed hereinafter.

[0043] In Figures 6-12In embodiments, the second battery pack 14b is a large battery pack and defines a second battery width W2 that is greater than the first battery width Wl of the first battery pack 14a. The second battery pack 14b has a first plurality of outlet vents 332a and a second plurality of outlet vents 332b defined along the first bottom surface 304. The outlet vents 332a, 332b are configured to exhaust air from the housing 294 of the second battery pack 14b. When the second battery pack 14b is electrically connected to the battery charger 10, the first bottom surface 304 is oriented to extend above the top 20 of the battery charger 10 to place the outlet vents 332 of the second battery pack 14b in fluid communication with the first and second pluralities of inlet vents 34a, 34b. The housing 294 of the second battery pack 14b engages the tabs 70a, 70b of each of the flapper gates 62a, 62b, thereby placing the flapper gates 62a, 62b in the unactuated position. As a result, the openings 84a, 84b of the first and second pluralities of inlet vents 34a, 34b are exposed to define an airflow path between the second battery pack 14b and the battery charger 10.

[0044] During a charging operation of the second battery pack 14b, the fan 46 of the battery charger 10 is configured to cause air to flow through the second battery pack 14b and into the housing 18 of the battery charger 10. Specifically, the fan 46 generates an airflow 334 that is configured to flow through the inlet vents 330 of the second battery pack 14b and into the housing 294 to cool the battery cells 306 and the battery pack electronics 310. The airflow 334 is then exhausted from the housing 294 of the second battery pack 14b through the outlet vents 332a, 332b. Thereafter, the airflow 334 is directed through the first and second pluralities of inlet vents 34a, 34b into the housing 18 of the battery charger 10. The airflow 334 is then directed to the charger electronics for cooling purposes and is exhausted from the battery charger 10 through the outlet vents 36 via the fan 46.

[0045] Finally, the battery charger 10 is configured to charge battery packs having various sizes and venting locations. As a result, the first plurality of inlet vents 34a and the second plurality of inlet vents 34b are selectively obstructed depending on the size of the battery pack. Moreover, selectively obstructing the inlet vents 34a, 34b allows the battery charger 10 to accommodate battery packs having similar battery interfaces and different venting locations. Large battery packs, such as the second battery pack 14b, will move the flapper gates 62a, 62b to unobstruct the inlet vents 34a, 34b. Small battery packs, such as the first battery pack 14a, will not engage the flapper gates 62a, 62b and leave the flapper gates 62a, 62b in the actuated position to obstruct the inlet vents 34a, 34b.

[0046] Reference Figure 13 and 14This illustrates another embodiment of the battery charger 400. The battery charger 400 is similar to... Figures 1-4 The battery charger 10; therefore, the same structure will be identified by the same reference numerals plus "400", and only the differences will be discussed below. The battery charger 400 functions similarly to... Figures 1 to 4 The battery charger is 10. However, the battery charger 400 is... Figures 1-4 The battery charger in the middle is 10 small.

[0047] refer to Figure 15 and 16 The image shows a multi-battery pack charger 500. The charger 500 includes a housing 504 having a top 508 and a bottom 512, a handle 516 integrally formed with the top 508, and a base 520 disposed on the bottom 512. The handle 516 is configured to be gripped by a user for transporting the charger 500.

[0048] The charger 500 also includes a plurality of charger interfaces 524 formed on the housing 504. The charger interfaces 524 are disposed on the front side 528 and the rear side 532 of the housing 504. In the illustrated embodiment, there are three charger interfaces 524 on the front side 528 and three charger interfaces 524 on the rear side 532 of the charger 500. Each charger interface 524 includes a charger rail 536 and a charger terminal block 540 having charger terminals 544 configured to electrically connect each charger interface 524 to a corresponding battery pack for charging operation. The charger rail 536 is disposed on opposite sides of the charger terminal block 540. Charger electronics 546 are disposed within the housing 504 of the charger 500 and configured to output charging current through each charger interface 524 to charge the respective battery packs. The charger electronics may include a printed circuit board (PCB), a microcontroller 545, and charging circuitry (not shown) for each charger terminal block 540, such that each battery pack can be charged simultaneously and independently.

[0049] Furthermore, the charger 500 includes multiple sets of inlet vents, multiple outlet vents (not shown), a first fan 554a, and a second fan 554b. The multiple inlet vents 548a and 548b are respectively defined on the side of each charger interface 524. The outlet vents are also defined on a first side 556 and a second side 560 of the charger 500. The first fan 554a is disposed on the first side 556 of the charger 500, and the second fan 554b is disposed on the second side 560 of the charger 500. Thus, the first fan 554a and the second fan 554b are in fluid communication with each of the multiple inlet vents 548a and 548b and each of the multiple outlet vents.

[0050] A pair of flapper doors 564 are also provided to obstruct the respective plurality of inlet vents 548a, 548b to prevent air from entering the housing 504 of the charger 500. Each flapper door 564 has a comb structure (not shown) with tabs 566 configured to extend through the openings of each plurality of inlet vents 548a, 548b. In the actuated position, the flapper doors 564 are configured to be biased by a biasing member (not shown) toward the corresponding inlet vents 548a, 548b such that the flapper doors 564 extend through the corresponding inlet vents 548a, 548b. In the non-actuated position, the flapper doors 564 are configured to be pushed into the housing 504 of the charger 500 to uncover the openings of the corresponding inlet vents 548a, 548b. Airflow is then allowed through the respective inlet vents 548a, 548b.

[0051] Figure 16 Two battery packs 578a, 578b are shown electrically connected to the charger interface 524. Each battery pack 578a, 578b includes a housing 580 having a top and a bottom. A plurality of battery cells (not shown) and battery pack circuitry are disposed within the housing 580 of each battery pack 578. A battery pack interface (not shown) is disposed on the housing 580 and has a terminal block that is engageable with the charger terminal block 540. Each battery pack 578a, 578b also includes a slide rail (not shown) that cooperates with the charger slide rails 536 to slidably connect the battery pack 578a, 578b to the charger 500. A first plurality of vents (not shown) are defined on the bottom of each battery pack 578a, 578b. In addition, a second plurality of vents (not shown) are defined on the top of each battery pack 578a, 578b and adjacent to the battery pack interface. When the battery pack 578a, 578b is connected to the charger 500, the battery pack 578a, 578b is oriented such that the second plurality of vents are positioned in alignment and fluid communication with the inlet vents 548a, 548b of the corresponding charger interface 524.

[0052] During a charging operation, the battery packs 578a, 578b are electrically connected to the charger interface 524 to be charged. When the battery packs 578a, 578b are inserted into the charger interface 524, the housing 580 of each battery pack 578 engages and moves the corresponding gate 564 to the non-actuated position. The corresponding inlet vent 548a, 548b is positioned in fluid communication with the second plurality of vents of the battery pack 578a, 578b, thereby providing an airflow path defined between the battery pack 578a, 578b and the housing 504 of the charger 500. The gates 564 at the other charger interfaces 524 without a battery pack remain in the actuated position. While the battery packs 578a, 578b are being charged, the fans 554a, 554b are operable to cause air to flow through the battery packs 578a, 578b and into the housing 504 of the charger 500. The fans 554a, 554b produce various airflows depending on the location of the one or more battery packs electrically connected to the charger 500.

[0053] In the illustrated embodiment, the fans 554a, 554b produce a first airflow 558a and a second airflow 558b. The first airflow 558a is configured to flow through the first plurality of vents of the first battery pack 578a and into the housing 580 to cool the battery circuitry and battery cells. The first airflow 558a then exits the first battery pack 578b through the second plurality of vents. Thereafter, the first airflow 558a passes directly through the corresponding inlet vent 548a, 548b to enter the charger 500. Since the first battery pack 578a is disposed adjacent to the second fan 554b, the first airflow 558a is directed toward the second fan 554b. In this manner, the first airflow 558a exits the charger 500 through the outlet vent defined on the second side 560 of the charger 500.

[0054] The second airflow 558b is configured to flow into the first plurality of vents of the second battery pack 578b and out of the second plurality of vents of the second battery pack 578b to cool the battery circuitry and battery cells. The second airflow 558b then flows through the corresponding inlet vent 548a, 548b disposed at the center of the charger 500. As the second airflow 558b flows through the housing 504 of the charger 500, the second airflow 558b is divided into two separate airflow portions 558bl, 558b2 due to the fans 554a, 554b being oppositely disposed on the second battery pack 578b. Specifically, the first airflow portion 558bl is directed to the first fan 554a to exit the charger 500 through the outlet vent defined on the first side 556 of the charger 500. The second airflow portion 558b2 is directed to the second fan 554b to exit the charger 500 through the outlet vent defined on the second side 560 of the charger 500.

[0055] The charger 500 is configured to provide cooling operation only at the charger interface 524 where the battery pack is electrically connected. Thus, when there is no battery pack at the charger interface 524, the damper 564 is configured to block the airflow through the inlet vents 548a, 548b provided at the charger interface 524. Thus, the airflow leakage can be prevented to improve the cooling efficiency of the battery packs 578a, 578b electrically connected to the charger 500. Further, the number of fans 554a, 554b provided within the charger 500 can be reduced. The fans 554a, 554b provided within the charger 500 can be low power fans.

[0056] Referring to Figure 17 , another embodiment of the battery pack 678 electrically connected to the multi-battery pack charger 600 is shown. The embodiment shown is similar to the embodiment of Figure 15 and 16 ; thus, the same structures will be identified by the same reference numbers with "100" added and only the differences will be discussed hereinafter.

[0057] In the embodiment of Figure 17 , the first battery pack 678a, the second battery pack 678b, and the third battery pack 678c are electrically connected to the charger interface 624 provided on the first side 656 and the second side 660 of the charger 600. During the charging operation, the fans 654a, 654b generate the first airflow 658a, the second airflow 658b, and the third airflow 658c. Specifically, the first airflow 658a is configured to flow into and out of the first battery pack 678a through the first and second plurality of vents (not shown) defined in the first battery pack 678a. The first airflow 658a then flows directly through the inlet vents (not shown) of the corresponding charger interface 624 to enter the housing 604 of the charger 600. As the first airflow 658a flows through the charger 600, the first airflow 658a is directed to the first fan 654a to be exhausted from the charger 600 through the outlet vents (not shown) defined on the first side 656 of the charger 600.

[0058] The second airflow 658b is similar to the first airflow 658a as described above. However, the second airflow 658b is configured to flow through the second battery pack 678b. Further, the second airflow 658b is divided into two separate airflow portions 658b1, 658b2 to be exhausted from the outlet vents at the first side 656 and the second side 660 of the charger 600. The third airflow 658c is also similar to the first airflow 658a as described above. However, the third airflow 658c is configured to flow through the third battery pack 678c. The third airflow 658c is also divided into two separate airflow portions 658c1, 658c2 to be exhausted from the outlet vents at the first side 656 and the second side 660 of the charger 600.

[0059] refer to Figure 18 This illustrates another embodiment where battery packs 778a-f are electrically connected to a multi-battery pack charger 700. The illustrated embodiment is similar to... Figure 15 and 16 The embodiments are as follows; therefore, the same structure will be identified by the same reference numeral "200", and only the differences will be discussed below.

[0060] exist Figure 18 In this embodiment, each charger interface 724 of the charger 700 is electrically connected to a battery pack 778a-f. During charging operation, fans 754a, 754b generate a plurality of airflows 758a-f, which are configured to flow along airflow paths defined between the housing 704 of the charger 700 and each battery pack 778a-f. For example, a first airflow 758a is configured to flow through a first battery pack 778a disposed at a first side 756 of the charger 700. The first airflow 758a flows into and out of the first battery pack 778a, and then flows directly into the housing 704 of the charger 700 through an inlet vent (not shown) defined at the corresponding charger interface 724. As the first airflow 758a flows through the charger 700, it is directed toward the first fan 754a to exit from an outlet vent (not shown) on the first side 756 of the charger 700. A second airflow 758b is similar to the first airflow 758a as described above. However, the second airflow 758b is configured to flow through the second battery pack 778b, which is positioned opposite to the first battery pack 778a.

[0061] The third airflow 758c is configured to flow through the third battery pack 778c disposed in the center of the charger 700. Therefore, the third airflow 758c flows into and out of the third battery pack 778c, and then flows directly into the housing 704 of the charger 700 through an inlet vent defined at the corresponding charger interface 724. The third airflow 758c is then divided into two separate airflow portions 758c1 and 758c2, which are configured to exit from outlet vents defined on the first side 756 and the second side 760 of the charger 700. The fourth airflow 758d is similar to the third airflow 758c as described above. However, the fourth airflow 758d is configured to flow through the fourth battery pack 778d disposed opposite to the third battery pack 778c.

[0062] A fifth airflow 758e is configured to flow through a fifth battery pack 778e disposed at the second side 760 of the charger 700. The fifth airflow 758e flows into and out of the fifth battery pack 778e and then directly into the housing 704 of the charger 700 through an inlet vent defined at the corresponding charger interface 724. As the fifth airflow 758e flows through the charger 700, the fifth airflow 758e is directed to the second fan 754b to be exhausted out of an outlet vent on the second side 760 of the charger 700. A sixth airflow 758f is similar to the fifth airflow 758e as described above. However, the sixth airflow 758f is configured to flow through a sixth battery pack 778f disposed opposite the fifth battery pack 778e.

[0063] Referring to Figure 19 , another embodiment of a multi-battery pack charger 800 is shown with battery packs 878a, 878b electrically connected to the charger 800. The illustrated embodiment is similar to the embodiment of Figure 15 and 16 ; therefore, like structures will be identified by the same reference number plus "300" and only the differences will be discussed hereinafter.

[0064] In the illustrated embodiment, the first battery pack 878a and the second battery pack 878b are electrically connected to the charger interface 824 for charging operations. The charger 800 also includes an actuator 890 (e.g., solenoid, motor, etc.) for each charger interface 824. Each actuator 890 is configured to engage a shutter 864 disposed at the corresponding charger interface 824. Initially, the shutter 864 is biased by a biasing member to an actuated position. When actuated, the actuator 890 moves the shutter 864 to a non-actuated position. When the actuator 890 is de-activated, the shutter 864 is then biased by the biasing member back to the actuated position. In other embodiments, the actuator 890 can move the shutter 864 between the actuated position and the non-actuated position.

[0065] During charging operations, the microcontroller 845 receives a first signal from each battery pack 878a, 878b. The first signal indicates that the first battery pack 878a and the second battery pack 878b have been electrically connected with the charger interface 824. A charging current is then allowed to be output through the charger interface 824 to charge the battery packs 878a, 878b. After receiving the first signal, the microcontroller 845 activates the corresponding actuator 890 to move the corresponding shutter 864 to the non-actuated position. Accordingly, an airflow path is defined between the battery packs 878a, 878b and the housing 804 of the charger 800, respectively, to cool the battery circuitry and the battery cells.

[0066] The illustrated embodiment shows the first charge level LI of the first battery pack 878a and the second charge level L2 of the second battery pack 878b after a period of time has elapsed. The first charge level LI indicates that the first battery pack 878a has reached or exceeded the charge threshold (i.e., fully charged). As such, the first battery pack 878a sends a second signal to the microcontroller 845 to indicate that the first battery pack 878a has reached or exceeded the charge threshold. The microcontroller 845 operates the actuator 890 to allow the gate 864 of the corresponding charger interface 824 to be biased towards the actuated position and to prevent airflow from flowing through the first battery pack 878a and the charger 800. In another embodiment, the microcontroller 845 operates the actuator 890 to move the gate 864 to the actuated position. The second charge level L2 indicates that the second battery pack 878b is below the charge threshold (i.e., not fully charged). Accordingly, the gate 864 for the corresponding charger interface 824 remains in the non-actuated position.

[0067] The fans 854a, 854b generate an airflow 858 that is configured to flow through the second battery pack 878b through the vent defined therein. The airflow 858 then flows into the housing 804 of the charger 800 through the inlet vent defined at the corresponding charger interface 824. As the airflow 858 flows through the charger 800, the airflow 858 is split into two separate airflow portions 858a, 858b to be expelled from the outlet vents defined at the first side 856 and the second side 860 of the charger 800.

[0068] The actuator 890 disposed within the battery charger 800 is configured to move the gate 864 based on the charge level of the battery packs 878a, 878b. Accordingly, blocking the inlet vent of the corresponding charger interface 824 of a battery pack that has been fully charged will improve the cooling efficiency of the other charger interfaces 824 that are connected with battery packs that have not been fully charged. Moreover, blocking the inlet vent of the corresponding charger interface 824 will prevent the airflow provided for the other charger interfaces 824 from leaking. The number of fans disposed within the charger 500 can also be reduced such that the fans 854a, 854b can be low-power fans.

[0069] Figure 20 An alternative embodiment of the battery pack 878 and the multi-battery pack charger 800 is illustrated. Accordingly, the illustrated embodiment shows a first battery pack 878a, a second battery pack 878b, and a third battery pack 878c electrically connected with the charger interfaces 824. In particular, the first battery pack 878a and the second battery pack 878b are disposed opposite each other at the first side 856 of the charger 800. The third battery pack 878c is disposed at the second side 860 of the charger 800. The other charger interfaces 824 are not connected with a battery pack, and accordingly the corresponding gates 864 are disposed in the actuated position. Figure 19 The actuator 890 disposed within the battery charger 800 is configured to move the gate 864 based on the charge level of the battery packs 878a, 878b. Accordingly, blocking the inlet vent of the corresponding charger interface 824 of a battery pack that has been fully charged will improve the cooling efficiency of the other charger interfaces 824 that are connected with battery packs that have not been fully charged. Moreover, blocking the inlet vent of the corresponding charger interface 824 will prevent the airflow provided for the other charger interfaces 824 from leaking. The number of fans disposed within the charger 500 can also be reduced such that the fans 854a, 854b can be low-power fans.

[0070] The first battery pack 878a has a first charge level LI that is below the charge threshold. As such, the corresponding flap 864 is maintained in the unactuated position to define an airflow path between the first battery pack 878a and the housing 804 of the charger 800. The second battery pack 878b has a second charge level L2 that has reached or exceeded the charge threshold. When the microcontroller 845 receives a signal indicating that the second battery pack 878b has reached or exceeded the charge threshold, the actuator 890 is deactivated so that the corresponding flap 864 can be biased toward the actuated position. The third battery pack 878c has a third charge level L3 that is similar to the first charge level LI of the first battery pack 878a. As such, another airflow path is defined between the third battery pack 878c and the housing 804 of the charger 800.

[0071] The fans 854a, 854b are configured to generate a first airflow 858a and a second airflow 858b. The first airflow 858a is configured to flow through the first battery pack 878a through a vent defined in the housing 880 of the first battery pack 878a. Thereafter, the first airflow 858a is directed into the housing 804 of the charger 800 through an inlet vent defined at the corresponding charger interface 824. The first airflow 858a is split into two separate airflow portions 858al, 858a2 to be expelled from outlet vents defined at the first side 856 and the second side 860 of the charger 800. The second airflow 858b is similar to the first airflow 858a as described above. However, the second airflow 858b is configured to flow through the third battery pack 878c.

[0072] Figure 21 An alternative embodiment of the battery pack 878 and the multi-battery pack charger 800 is shown. Figure 19 Each charger interface 824 of the charger 800 is electrically connected to a respective battery pack 878a-f. The plurality of battery packs 878a-e have charge levels LI-5 that are below the charge threshold. As such, the respective flaps 864 are maintained in the unactuated position to define respective airflow paths between the battery packs 878a-e and the housing 804 of the charger 800. The single battery pack 878f has a charge level L6 that has reached or exceeded the charge threshold. As such, the microcontroller 845 receives a signal indicating the charge level L6 of the battery pack 878f. The microcontroller 845 deactivates the actuator 890 to allow the corresponding flap 864 to be biased toward the actuated position. Similar to the embodiment described above Figure 18 The fans 854a, 854b are configured to generate a plurality of airflow paths 858a-e.

[0073] Referring to Figure 22 Another embodiment of the battery pack 978 electrically connected to the multi-battery pack charger 900 is shown. The illustrated embodiment is similar toFigure 15 and 16 The embodiments are as follows; therefore, the same structure will be identified by the same reference numerals plus "400", and only the differences will be discussed below.

[0074] In the illustrated embodiment, each charger interface 924 of the charger 900 is electrically connected to a corresponding battery pack 978a-f. Battery packs 978a-f are configured as either a first battery type or a second battery type. The first battery type corresponds to a cold-cycle battery pack, and the second battery type corresponds to a conventional battery pack. Therefore, the first battery pack 978a and the second battery pack 978b are cold-cycle battery packs. Each of the first battery pack 978a and the second battery pack 978b has a housing 980 and a battery cell frame (not shown) with vents for providing direct convection cooling to the battery cells disposed within the battery packs 978a and 978b. The other battery packs 978c-f are conventional battery packs cooled by ambient cooling.

[0075] The charger 900 also includes an actuator 990 (e.g., a solenoid, motor, etc.) for each charger interface 924. Each actuator 990 is configured to engage a gate 964 of the corresponding charger interface 924. Initially, a biasing member is configured to bias the gate 964 toward an actuated position when the corresponding charger interface 924 is not electrically connected to a battery pack. When the microcontroller 945 receives a signal indicating that the battery pack 978c-f is a second battery type, the gate 964 is also configured to bias toward the actuated position. In other embodiments, the actuator 990 can move the gate 964 between an actuated position and an unactuated position.

[0076] In the illustrated embodiment, the first battery pack 978a and the second battery pack 978b each send a signal to the microcontroller 945 to indicate that battery packs 978a-f are electrically connected to the charger interface 924. Based on this signal, the microcontroller can also determine that the first battery pack 978a and the second battery pack 978b are of a first battery type. The microcontroller 945 then operates the actuator 990 to move the corresponding gate 964 toward the non-actuated position. Thus, the airflow path is defined between the first battery pack 978a and the second battery pack 978b and the housing 904 of the charger 900, thereby allowing airflow through the battery packs 978a and 978b to cool the battery circuitry and battery cells. Battery packs 978a-f send additional signals to the microcontroller 945. These additional signals indicate the temperature and charge level of the battery packs 978a-f. When the signal indicates that the corresponding battery pack 978a-f has a temperature below a temperature threshold, the microcontroller 945 operates the corresponding actuator 990 to move the gate 964 toward the actuated position.

[0077] During the charging operation, the fans 954a, 954b generate a first airflow 958a and a second airflow 958b. The first airflow 958a is configured to flow through the first battery pack 978a through the vent defined in the first battery pack 978a. The first airflow 958a is then directed into the housing 804 of the charger 900 through the inlet vent defined at the corresponding charger interface 924. As the first airflow 958a flows through the charger 900, the first airflow 958a is split into two separate airflow portions 958al, 958a2 to be expelled from the outlet vents defined at the first side 956 and the second side 960 of the charger 900. The second airflow 958b is similar to the first airflow 958a as described above. However, the second airflow 958b is configured to flow through the second battery pack 978b.

[0078] The charger 900 is configured to provide cooling operation only at the charger interface 924 that is electrically connected with the battery pack of the first battery type. Since the first battery pack 978a and the second battery pack 978b are cooling cycle battery packs, the battery packs 978a, 978b have higher cooling efficiency than the conventional battery packs 978c-f. Therefore, in order to further improve the cooling efficiency of the cooling cycle battery packs 978a, 978b, it is necessary to prevent the airflow from flowing between the conventional battery packs 978c-f and the charger 900. Because sufficient cooling will be provided only to the corresponding charger interface 924, the cooling cycle battery packs 978a, 978b are able to be charged at a fast charging rate.

[0079] While the present application has been described in detail with respect to certain preferred embodiments, variations and modifications exist within the scope and spirit of one or more aspects of the described application.

Claims

1. A battery charger for charging multiple battery packs, characterized in that, The battery charger includes: a housing; a first charger interface and a second charger interface formed on the housing, each charger interface configured to receive a respective battery pack of the plurality of battery packs and charge the respective battery pack; a first vent and a second vent defined in the housing and for the first charger interface and the second charger interface, respectively, each vent configured to provide an airflow path defined through the respective battery pack and the housing; and a shutter provided for each charger interface, the shutter movable between an actuated position in which the shutter is oriented to at least partially obstruct the airflow path and a non-actuated position in which the shutter is out of the airflow path.

2. The battery charger of claim 1, wherein, The first vent is one of a first plurality of vents and the second vent is one of a second plurality of vents.

3. The battery charger of claim 1, wherein, The first vent and the second vent are in fluid communication with a vent defined in the respective battery pack.

4. The battery charger of claim 1, wherein, The shutter is biased toward the actuated position.

5. The battery charger of claim 1, wherein, Each shutter is configured to move to the non-actuated position when the respective charger interface is engaged with the respective battery pack.

6. The battery charger of claim 1, wherein, Further comprising a fan disposed in the housing and configured to generate an airflow that flows along the airflow path.

7. A battery charger for charging a battery pack, characterized in that, The battery charger includes: a housing; a charger interface formed on the housing, the charger interface configured to receive the battery pack and charge the battery pack; a plurality of vents defined in the housing; at least one fan disposed in the housing, the fan configured to draw air into the housing through the plurality of vents; and a shutter disposed adjacent to the plurality of vents, the shutter selectively at least partially obstructing the plurality of vents.

8. The battery charger of claim 7, wherein, The shutter is disposed within the housing.

9. The battery charger of claim 8, wherein, The shutter includes at least one tab configured to extend outwardly from the housing for engagement with the battery pack.

10. The battery charger of claim 8, wherein, The shutter includes a comb portion.

11. The battery charger of claim 7, wherein the battery charger is configured to: The plurality of vents is a first plurality of vents, the shutter is a first shutter, and wherein the battery charger further includes a second plurality of vents and a second shutter that selectively at least partially obstructs the second plurality of vents.

12. The battery charger of claim 11, wherein, The charger interface is disposed at least partially between the first plurality of vents and the second plurality of vents.

13. A battery charger for charging a battery pack, characterized in that, The battery charger includes: a housing; a charger interface formed on the housing, the charger interface configured to receive the battery pack and charge the battery pack; a plurality of vents defined in the housing and configured to provide an airflow path defined through the battery pack and the housing; a shutter disposed adjacent to the plurality of vents, the shutter selectively at least partially obstructing the airflow path; an actuator disposed within the housing and configured to move the shutter; and a controller disposed in the housing, the controller configured to determine that the battery pack has been electrically connected with the charger interface, and operate the actuator to at least partially move the shutter out of the airflow path.

14. The battery charger of claim 13, wherein, The controller is further configured to: determine whether the battery pack is a first type or a second type, and upon determining that the battery pack is the second type, operate the actuator to move the shutter to at least partially obstruct the airflow path.

15. The battery charger of claim 13, wherein, The controller is further configured to determine a charge level of the battery pack.

16. The battery charger of claim 15, wherein, The controller is further configured to, upon determining that the charge level has reached or exceeded a charge threshold, operate the actuator to move the shutter to at least partially obstruct the airflow path.

17. The battery charger of claim 13, wherein, The shutter is biased toward a position that at least partially obstructs the airflow path.

18. The battery charger of claim 13, wherein, A fan is also included, the fan being disposed in the housing and configured to generate an airflow that flows along the airflow path.

19. The battery charger of claim 13, wherein, The controller is further configured to: determine a temperature of the battery pack, and upon determining that the temperature of the battery pack is below a temperature threshold, operate the actuator to move the shutter to at least partially obstruct the airflow path.

20. The battery charger of claim 13, wherein, The battery pack is a power tool battery pack.

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