Power supply module for mobile electrical appliances and mobile electrical appliance equipped with it

Abstract

The present invention relates to a power supply module for small mobile electrical devices such as thermoelectric cooling boxes, spotlights, compressors, and fans, comprising at least one compartment designed for the detachable mechanical mounting of an interchangeable battery pack of a voltage class in the range of 12V to 40V and with contact terminals for electrical connection to its contacts, a DC / DC voltage converter for converting the voltage of the interchangeable battery pack inserted into the compartment and electrically connected to it to 12V, a power regulator for selectively controlling the amount of current output of the converted current, and an electrical output connector in the form of a socket and / or a plug for outputting the power-regulated current and for electrically connecting the small mobile electrical device.

Description

[0001] The invention relates to a power supply module for small mobile electrical appliances and a small mobile electrical appliance equipped therewith.

[0002] Examples of small mobile electrical devices within the meaning of the invention, which are to be supplied with power by the power supply module, are typically mobile auxiliary devices used in the automotive or camping sector, such as thermoelectric cooling boxes or refrigerators, (search) lights, marker or warning lights, air compressors, fans, etc., which are also characterized in particular by the fact that they are designed for a supply voltage of 12 volts (12V) and are equipped with electrical connection connectors (or plugs) for vehicle electrical system or car sockets according to DIN ISO 4165 or cigarette lighter sockets according to the SAE J563 standard, in order to be connected directly to the 12V electrical system of vehicles.

[0003] However, the invention is particularly suitable as an external or integrated power supply module for thermoelectric cooling boxes (TE cooling boxes) or refrigerators, because these are often intended to be operated independently of a vehicle.

[0004] Since TE coolers consume an above-average amount of electricity relative to their cooling capacity, and since guidelines for the environmentally sound design of energy-related products (Ecodesign Directive 2009 / 125 / EC and currently Regulation (EU) 2024 / 1781 establishing a framework for ecodesign requirements for sustainable products (ESPR)) mandate energy-efficient design and the indication of an energy rating, consumers pay particular attention to electricity consumption and energy efficiency. Nevertheless, current TE coolers that operate on a 12V system do not have adjustable temperature settings, as the relatively low cooling capacity of a TE cooler (Delta t), for example, 48-60 watts, requires a maximum input of 12V at 4-5 amps.

[0005] TE cool boxes powered by batteries or more precisely battery packs (the term "battery" is usually used for a single cell, while the term "battery pack" refers to a connected package of several battery or accumulator cells, which is held together by a casing for practical use) are on the market, but these are new developments with a permanently integrated battery, in which the battery is usually not easily replaceable.

[0006] Small mobile electrical devices, such as battery-powered coolers, require specialized technical equipment tailored to the specific battery system, as each system has a different BMS (Battery Management System). Therefore, using existing interchangeable battery packs from different manufacturers, for example, from the power tool sector, is not readily possible.

[0007] With the introduction of battery-powered cool boxes, regulating the 12V power consumption becomes important, as this can extend battery life and, for example, eliminate the need for a 20K temperature difference (Delta t) cooling capacity at lower ambient temperatures at night or when used in an air-conditioned passenger compartment. Simple electric cool boxes that operate with a 12V supply voltage, 4-5 amps, and 48-60 watts of power typically do not have a power regulator.

[0008] However, in most portable electric cool boxes, the cooling technology is built into the lid of the boxes, so the space for installing additional electrical components is very limited and this can therefore only be achieved with substantial changes to the product concepts and designs.

[0009] Considering that at least 2 million TE standard cool boxes are sold in Europe alone each year, and assuming a minimum lifespan of 5-10 years for a TE cool box, there are approximately 10 to 20 million usable and functional cool boxes in circulation that are either not battery-operated and / or not power-regulated with a 12V supply voltage.

[0010] Further problems with regard to sustainability include the fact that permanently installed batteries cannot be economically replaced in the event of a defect or reduced capacity, simply due to the repair costs, and that even with the use of replaceable battery packs, the availability of a respective battery system is not guaranteed over longer periods.

[0011] One object of the present invention is to propose a power supply module for small mobile electrical appliances and a small mobile electrical appliance equipped therewith, with which at least some of the above problems can be solved and the aspect of sustainability is taken into account.

[0012] The invention proposes a power supply module for small mobile electrical devices with the features of claim 1 and a small mobile electrical device equipped therewith with the features of claim 14. Preferred embodiments of the power supply module are specified in the dependent claims.

[0013] In particular, the invention relates to a power supply module for small mobile electrical devices such as thermoelectric cooling boxes, spotlights, compressors, and fans, comprising at least one compartment designed for the detachable mechanical mounting of an interchangeable battery pack of a voltage class in the range of 12V to 40V and with contact connections for electrical connection to its contacts, a DC / DC voltage converter for converting the voltage of the interchangeable battery pack inserted into and connected to the compartment to 12V, a power regulator for selectively controlling the amount of current of an output of the converted current, and an electrical output connector in the form of a socket and / or a plug for outputting the power-regulated current and for electrically connecting the small mobile electrical device.

[0014] The power supply module according to the invention makes it possible to design the power supply of existing small electrical devices such as TE cool boxes with a supply voltage of 12V independently without modifying the devices, in order to expand the mobility area independently of an on-board power supply of a vehicle, for example.

[0015] Further advantages include the fact that existing interchangeable battery packs or blocks with various common nominal battery voltages (voltage classes) such as 12V, 18V, 36V, 40V can be easily exchanged for power supply and used almost like a universal adapter without complex adjustments to the device electronics, and preferably "automatically" reduced uniformly to the 12V required, for example, for the power supply of Peltier cooling systems.

[0016] In particular, if at least one slot is preferably designed for the detachable storage and electrical connection of interchangeable battery packs of different voltage classes, capacities and / or housing types, especially of tool interchangeable battery packs, this allows the use of a large number of existing interchangeable battery systems from different manufacturers or across several system generations and avoids the redundant purchase of dedicated battery systems as well as the adverse consequences of a possible “planned obsolescence”.

[0017] A technical requirement for using different interchangeable battery packs or blocks, possibly from different manufacturers, is that the power supply module has an integrated BMS (Battery Management System) that is compatible with the battery pack system being used. However, the cross-brand use of interchangeable battery packs or blocks is facilitated by the fact that several well-known manufacturers have joined forces to create compatible battery systems (for example, the CAS (Cordless Alliance System) or the AMP Share System), so that their respective interchangeable battery packs or blocks are compatible within the respective system, at least with regard to the BMS used in the battery packs and, as a rule, also with regard to mechanical and electrical connectivity.

[0018] In this respect, the dimensions of housings and the molded-on insertion devices, as well as the position and shape of the electrical contacts, vary among many interchangeable battery packs or blocks, particularly between different device generations or manufacturers. The power supply module according to the invention can be designed for use with different housing shapes, provided that the mounting device and the contact connections on the power supply module's slot are adapted to the desired compatibility. If this is ensured, the power supply module according to the invention allows almost all thermoelectric cooling boxes already on the market or in use, which operate with a 12V operating or supply voltage, to be operated portably and to be enhanced with the function of adjustable cooling capacity.

[0019] Providing a socket and / or plug for outputting power-regulated current allows for a simple, quick, and safe connection of the respective small electrical devices to the power source without special tools or technical expertise. This advantage is particularly pronounced when, in a preferred embodiment, the electrical output connector is designed as a vehicle electrical socket or plug according to DIN ISO 4165 or as a cigarette lighter socket or plug according to SAE J563, because these connector types are common and widely used in the small devices in question, such as TE cool boxes, which are used in vehicles. Therefore, a direct connection of the respective device to the power supply module is possible without additional adapters.

[0020] The integrated power control in the power supply module also allows for easy adjustment of the power output to ensure optimal energy efficiency and longer operating time of the device, especially a TE cool box, while conserving the battery pack's capacity. The power control thus prevents energy waste and increases the safety of the connected device and the power supply module by preventing overload and overheating.

[0021] The ability to convert voltage to a uniform 12V level, combined with power regulation and a universal electrical output connector, expands the power supply module's application possibilities as a practical, single energy source for a wide variety of electronic and electrical devices, thus avoiding the need to purchase numerous incompatible power supplies. In this respect, its practical advantages, particularly regarding sustainability, far exceed those of existing concepts.

[0022] To ensure the simple and unambiguous insertion of the replaceable battery pack and reliable electrical contact with its contacts, at least one slot preferably has guide elements for guiding the insertion of the replaceable battery pack into the slot and for electrically connecting the contacts. These guide elements, in conjunction with the contacts, can be designed to be compatible with various housing designs of the replaceable battery packs.

[0023] It is also preferred that at least one slot has locking means for frictionally and / or positively locking releasable securing of a replaceable battery pack inserted into the slot, so that the correct insertion position can be verified and an unintentional loosening or falling out of the battery pack or a resulting interruption of the contact can be reliably avoided.

[0024] To enable manual adjustment of the power control to defined reduction levels, the power supply module can be equipped with a power switch. This allows for intuitive and easy adjustment of various desired reduced power and consumption levels of the output from the power controller and thus the power supply module. This can be achieved, for example, using a multi-stage switch (ECO, MIN, MAX, and OFF) commonly found on 230V devices, or a switch with fewer or more control levels. By tailoring the control levels to specific device types, such as TE cool boxes, and appropriately labeling the module, possibly in conjunction with additional switches or upstream setting and selection options, compliance with prescribed energy consumption values ​​for specific device types or classes can be even more reliably ensured.

[0025] In another preferred embodiment, the power supply module can be equipped with a socket for outputting power according to the USB standard, for example, the USB-C and / or USB-A standard. Such a socket would typically have an output of 5 volts and 3 amps and is ideal for charging and operating USB devices such as navigation devices, laptops, MP3 players, mobile phones, headsets, etc. This significantly expands the application range of the power supply module as a universal mobile power source and makes it possible to use and utilize high-performance but comparatively inexpensive replaceable battery packs, such as those used in power tools, as a replacement for the typically expensive battery systems of these device classes.

[0026] Preferably, the power supply module housing, the DC / DC converter, and the power regulator are integrated within a single housing, such that the housing and, if present, the circuit breaker are accessible from the outside, and that the power supply module is designed as a compact, self-contained unit that is easily transportable and space-saving. Furthermore, such a power supply module housing can be designed with an IP rating for protection against contact, ingress of foreign objects, and water, as well as with shock resistance, to make the device robust, durable, and reliable for mobile use under demanding conditions (e.g., in areas with protection from moisture, etc.), such as those typically found outdoors.

[0027] In a further preferred embodiment, the housing of the power supply module can be designed to be detachably attached to the housing of a small mobile electrical appliance, in particular a thermoelectric cooler, such that the compartment and, if present, the circuit breaker are accessible from the outside when attached. This variant simply couples the power supply module to the associated device and facilitates compact transport and use without affecting the exchange of the battery pack.

[0028] Alternatively, the power supply unit, DC / DC converter, and power regulator can be integrated into the housing of a small mobile electrical appliance, particularly a thermoelectric cooler, in such a way that the unit and, if present, the circuit breaker are accessible from the outside of the housing. This option is particularly suitable for new designs where the power supply module and its coordinated components can be installed in the housing (for example, the lid of a cooler).

[0029] The invention is explained below with reference to the accompanying drawing and an exemplary embodiment. The drawing shows: Fig. 1. A perspective view and side views of main sides of a power supply module designed as a standalone device according to an embodiment, and Fig. 2. A perspective view of a cooler as an example of a small mobile electrical appliance, wherein the power supply module according to the embodiment of Fig. 1 is attached to a side wall of the housing.

[0030] The in the Fig. 1 and Fig. 2 The exemplary power supply module 1 shown for mobile small electrical devices such as thermoelectric cooling boxes 10, headlights, compressors, fans, etc., for a nominal operating voltage supply of 12V according to the above introductory description, has a housing 3 on which at least one slot 2 is formed, which is designed for the detachable mechanical external mounting of an interchangeable battery pack A of a voltage class in the range of 12V to 40V and with contact terminals 5 for electrical connection with the contacts of the interchangeable battery pack A.

[0031] Inside housing 3 is a DC / DC voltage converter for converting the voltage of the interchangeable battery pack A, inserted into and electrically connected to slot 2, to 12V, regardless of its nominal or actual voltage. For this purpose, the DC / DC voltage converter is connected to the contact terminals 5 on slot 2. The DC / DC voltage converter is designed to convert the voltage of an interchangeable battery pack inserted into the slot, regardless of its voltage (e.g., 12V, 18V, 36V, 40V), preferably automatically after appropriate detection or measurement, to a uniform voltage of 12V.

[0032] Inside housing 3, a BMS (Battery Management System) is integrated, which is tailored to or compatible with the battery pack system to be used. It is conceivable to further extend the compatibility of the power supply module by providing multiple BMS for different battery pack systems, which can be selected for operation manually (via a switch) or automatically (via an electronic circuit), depending on the battery pack system being used.

[0033] Inside the housing 3, a power regulator connected to the DC / DC voltage converter is arranged for selectively controlling the current output of the previously converted current. The output of the power-regulated current to the outside of the housing 3 and the electrical connection of the mobile electrical device 10 to be powered are made via an electrical output connector (not shown in the figures) in the form of a socket and / or a plug for output and electrical connection.

[0034] This electrical output connector is preferably designed as a vehicle electrical socket or plug according to DIN ISO 4165 or as a cigarette lighter socket or plug according to SAE J563, because the small devices to be powered, such as thermoelectric cooling boxes 10, headlights, compressors, fans, etc., which are designed for a nominal operating voltage of 12V and are therefore typically intended for mobile use in the automotive or camping sector and for connection to the 12V vehicle electrical system, are also equipped with such connectors. In the exemplary embodiment, a connecting cable 7 leading to the electrical output connector is routed out of the housing 3 via a moisture-protected grommet or feedthrough 6. However, the electrical output connector, particularly in the form of a socket, can also be installed directly in the housing 3 and be accessible from the outside, without the routed connecting cable 7.

[0035] Both the DC / DC voltage converter and the power regulator are known as basic electronic and electrical circuits in the state of the art and are therefore not described in detail here.

[0036] The at least one slot 2 has mechanical guide means for guiding the insertion of the interchangeable battery pack A into the slot 2 and for electrically connecting its contacts to the contact terminals 5 at the end of the slot. These guide means, as well as the position and arrangement of the contact terminals 5, are also known per se from chargers for the corresponding interchangeable battery packs. According to the invention, however, the slot, the contact terminals 5, and the guide means are preferably designed such that a detachable insertion and electrical connection with interchangeable battery packs A of various types with regard to voltage classes, capacities, and / or housing shapes, in particular tool battery packs, is possible. If a single slot cannot be designed to accommodate several suitable types orSince various battery pack designs can be accommodated, it is conceivable to provide several compartments with different configurations and contact connections on the housing. In the case of multiple compartments for different battery pack systems, each compartment can also be internally connected to the BMS (Battery Management System) that is compatible with the system.

[0037] Also not shown are locking devices for frictionally and / or positively locking releasably securing a replaceable battery pack A inserted into the slot in the area of ​​slot 2, which can prevent the battery pack from unintentionally falling out and which can only be overcome or released by a specific, targeted actuation, for example of a locking lever, or by applying a minimum force. Such locking devices are also known from chargers for the corresponding replaceable battery packs.

[0038] To set and select the different power levels of the power controller's output, the power supply module is equipped with a power switch 4, which is accessible from the outside for manual operation on a side surface of the housing 3. In the example shown, the power switch is a rotary switch with four selectable switching positions, corresponding to four power levels (ECO, MIN, MAX, and OFF) for the power controller's output.

[0039] Not shown in the exemplary embodiment is an additional power outlet for outputting power according to the USB standard. This can be installed in an easily accessible location on the housing 3, where it and any connected cable do not obstruct the replacement of the battery pack.

[0040] The housing 3 of the power supply module can be designed according to a protection class (for example, IP00 to IP6K9K (ISO 20653) or IP69 (DIN EN 60529)) against contact, ingress of foreign objects and water, and with impact resistance. The sealing of the exit of the connecting cable 7 to the electrical output connector by means of the sealed feedthrough 6 also serves to protect the electrical circuits in the housing 3 from the ingress of water and dust.

[0041] The housing 3 of the power supply module 1 can be designed as a standalone, independent housing. However, it can also be, as in Fig. The device shown in Figure 2 is designed to be detachably attached to the housing of a small mobile electrical appliance, for example, the side panel of a thermoelectric cooler 10, such that the compartment 2 and, if present, the power switch 4 are accessible from the outside when attached, allowing them to be operated. In the example shown, the connecting cable 7 leads to an external socket of the device, where a plug attached to the end of the connecting cable 7 is inserted. However, it is of course possible that the cooler 10 itself has a connecting cable that is then plugged into a suitable socket on the power supply module. Finally, intermediate connectors or adapters can also be provided to adapt plugs / sockets to one another.

[0042] The in Fig.Figure 2 shows a combination of a thermoelectric cooling box 10 with the power supply module 1, illustrating the application of the invention to existing small electrical devices in order to extend their functionality by a universal battery-based mobile power supply without having to interfere with the internal circuitry of the device and without being limited to a dedicated battery system. QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited non-patent literature

[0000] Ecodesign Directive 2009 / 125 / EC or currently Regulation (EU) 2024 / 1781

[0004]

Claims

[1] Power supply module (1) for small mobile electrical appliances such as thermoelectric cooling boxes (10), headlights, compressors, fans, with: at least one shaft (2) which is designed for the detachable mechanical reception of a replaceable battery pack (A) of a voltage class in the range of 12V to 40V and with contact terminals (5) for electrical connection with its contacts, a DC / DC voltage converter for converting the voltage of the interchangeable battery pack (A) inserted into the slot (2) and electrically contacted to 12V, a power controller for selectively regulating the amount of current at an output of the converted current, and an electrical output connector in the form of a socket and / or plug for the output of the power-controlled current and for the electrical connection of the mobile small electrical appliance (10). [2] Power supply module (1) according to claim 1, wherein the at least one shaft (2) has guide means for guiding an insertion movement of the replaceable battery pack (A) into the shaft (2) and for electrically connecting the contacts of the same with the contact terminals (5). [3] Power supply module (1) according to claim 1 or 2, wherein the at least one slot (2) has locking means for frictionally and / or positively locking releasably securing a replaceable battery pack (A) inserted into the slot. [4] Power supply module (1) according to one of claims 1 to 3, wherein the at least one slot (2) is designed for detachable reception and electrical connection with interchangeable battery packs (A) of different voltage classes, capacities and / or housing shapes, in particular of tool interchangeable battery packs. [5] Power supply module (1) according to one of claims 1 to 4, wherein the voltage converter is configured to convert a voltage of an interchangeable battery pack inserted into the slot to 12V, regardless of its voltage, preferably automatically. [6] Power supply module (1) according to any one of claims 1 to 5, wherein the power supply module is equipped with a power switch (4) via which different power levels of the output of the power controller can be manually adjusted. [7] Power supply module (1) according to any one of claims 1 to 6, wherein the electrical output connector is a vehicle electrical outlet or car socket or -plug according to DIN ISO 4165 or as a cigarette lighter or plug according to the standard SAE J563. [8] Power supply module (1) according to any one of claims 1 to 7, wherein the power supply module (1) has a socket for outputting power according to the USB standard. [9] Power supply module (1) according to one of claims 1 to 8, wherein several battery management systems for different battery pack systems are provided in the housing (3) and are connected to the DC / DC voltage converter and can be selected for operation manually, in particular by a switch, or automatically, in particular by an electronic circuit, depending on the battery pack system to be used. [10] Power supply module (1) according to any one of claims 1 to 9, wherein the shaft (2), the DC / DC voltage converter and the power regulator are housed in a housing (3) of the power supply module (1) such that the shaft (2) and, if present, the power switch (4) are accessible from the outside and that the power supply module (1) is portable and usable as a standalone device. [11] Power supply module (1) according to claim 10, wherein the housing (3) of the power supply module is designed to provide protection against contact, ingress of foreign objects and water, and with impact resistance. [12] Power supply module (1) according to claim 10 or 11, wherein the housing of the power supply module is designed to be detachably attached to a device housing of a mobile small electrical appliance, in particular a thermoelectric cooling box (10), such that the slot (2) and, if present, the power switch (4) is / are accessible from the outside when attached. [13] Power supply module according to any one of claims 1 to 9, wherein the slot, the DC / DC voltage converter and the power regulator are integrated in a device housing of a mobile small electrical appliance, in particular a thermoelectric cooling box (10), such that the slot (2) and, if present, the power switch (4) is / are accessible from the outside of the device housing. [14] Mobile small electrical appliance, in particular thermoelectric cooling box (10), with a power supply module according to any one of claims 1 to 13.

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