Portable battery charger

Abstract

A portable battery charger comprises a housing. The housing includes a battery holder configured to receive and connect to a battery. The charger also includes a heating element surrounding the battery holder and a charging circuit within the housing to charge the battery. Furthermore, the charger includes a temperature sensor located within the housing and an electronic processor that communicates with the temperature sensor, the charging circuit, and the heating element. The electronic processor is configured to use the temperature sensor to determine the battery's temperature and to check if the temperature meets a lower temperature threshold. Upon reaching the lower temperature threshold, the charging circuit is deactivated, and the heating element is activated to warm the battery.

Description

Related registrations

[0001] This application claims priority over the preliminary US patent application No. 63 / 674,934 filed on July 24, 2025, the entire contents of which are hereby incorporated by reference. Area

[0002] The present disclosure relates to battery charging systems and in particular portable battery chargers. Summary

[0003] For some batteries, such as lithium-ion batteries, charging and discharging outside a specific temperature range can be unsafe. In particular, batteries can degrade quickly or become unsafe if charged at temperatures below the manufacturer's specified operating temperature range. Therefore, there is a need for a battery charger that can charge batteries safely.

[0004] In one embodiment, a portable battery charger comprises a housing with a battery receptacle configured to receive and connect to a battery. The charger also includes a heating element surrounding the battery receptacle and a charging circuit provided within the housing to charge the battery. The charger further includes a temperature sensor located within the housing and an electronic processor that communicates with the temperature sensor, the charging circuit, and the heating element. The electronic processor is configured to determine the battery temperature using the temperature sensor and to ascertain whether the temperature meets a lower temperature threshold.The electronic processor is also configured to deactivate the charging circuit and activate the heater to warm the battery when the temperature reaches the lower temperature threshold.

[0005] The embodiments described herein are not limited in their application to the details of the configuration and arrangement of the components set forth in the following description or illustrated in the accompanying drawings. The embodiments may be practiced or implemented in various ways. Furthermore, the formulations and terms used herein are descriptive and are not to be considered limiting. The use of "including," "comprising," or "with" and variations thereof is intended to encompass the elements listed thereafter and their equivalents, as well as additional elements. Unless otherwise specified or limited, the terms "assembled," "connected," "supported," and "coupled" and variations thereof are used in a broad sense and include both direct and indirect assemblies, connections, supports, and couplings.

[0006] Furthermore, embodiments may include hardware, software, and electronic components or modules, which, for illustrative purposes, may be presented and described as if most components were implemented exclusively in hardware. However, a person skilled in the art would recognize from this detailed description that, in at least one embodiment, the electronic aspects may be implemented in software (e.g., stored on a non-volatile, computer-readable medium) that can be executed by one or more processing units, such as a microprocessor and / or application-specific integrated circuits (“ASICs”). As such, a variety of hardware- and software-based devices, as well as a variety of different structural components, may be used to implement the embodiments.For example, the “servers” and “computing units” described in the description may include one or more processing units, one or more computer-readable media modules, one or more input / output interfaces, and various connections (e.g., a system bus) that connect the components.

[0007] Further aspects of the revelation become apparent from the detailed description and the accompanying drawings. Brief description of the drawings Fig. Figure 1 is a perspective view of a portable battery charger according to some embodiments. Fig. 2 is another perspective view of the in Fig. 1 portable battery charger shown, which shows a lid in an open configuration according to some embodiments. Fig. 3 is a rear view of the in Fig. 1 portable battery charger shown according to some embodiments. Fig. 4 is a perspective view of a heating device that houses the battery compartment of the [unclear text]. Fig. 1 portable charger shown according to some embodiments surrounds. Fig. Figure 5 is a perspective view of a portable battery charger according to some embodiments. Fig. 6 is a bottom view of the in Fig. 5 portable charger shown according to some embodiments. Fig. Figure 7 is another perspective view of the portable charger from Fig. 5 with the lid open according to some embodiments. Fig. Figure 8 is a perspective view of a portable battery charger according to some embodiments. Fig. Figure 9 is a bottom view of the portable battery charger made of Fig. 8 according to some embodiments. Fig. 10 is a control diagram for each of the in Fig. 1, Fig. 2, Fig. 3, Fig. 4, Fig. 5, Fig. 6, Fig. 7, Fig. 8 to Fig. 9 portable chargers shown according to some embodiments. Fig. 11 is a flowchart that shows a process for each of the in Fig. 1, Fig. 2, Fig. 3, Fig. 4, Fig. 5, Fig. 6, Fig. 7, Fig. 8 to Fig. 9 portable chargers shown according to some embodiments are illustrated. Detailed description

[0008] Fig. 1, Fig. 2 to Fig. Figure 3 shows an example of a portable battery charger 100 (hereinafter referred to as charger 100) according to some embodiments. The charger 100 is used to charge one or more batteries 124 held in the charger 100. In some examples, the charger 100 can also be used to power a connected device from the one or more batteries 124 held in the charger 100. In some embodiments, the charger 100 is portable and can therefore be sized to fit in a user's hand. In other embodiments, the charger 100 can be larger, smaller, or of different dimensions depending on the application. For example, the charger 100 can be shaped to fit inside a person's clothing, and it can be flat.

[0009] In the illustrated embodiment, the charger 100 comprises a housing 104, which defines a body 108, a cover 112, and a locking device 116. The cover 112 is hinged 140 (see Fig. 3), which is provided on a rear side of the body 108, is pivotably attached to the body 108. The cover 112 can be positioned between an open position (in Fig. 2 shown) and a closed position (in Fig. 1 and Fig. (3 shown) can be pivoted. The locking device 116 is provided on a front face of the body 108 and can be moved or actuated to engage with the cover 112, thereby securing the cover 112 in the closed position. The body 108 and the cover 112 can include a seal to prevent the ingress (e.g., of water, cold air, etc.) into the housing 104. In one example, the cover 112 can be biased in an open position so that the cover 112 automatically moves into the open position when it is not engaged with the locking device 116. In other examples, the housing 104 can have a different configuration than the one described here.The components of the housing 104, including the body 108, the cover 112, and the locking device 116, can be made of a durable plastic material, for example, using an injection molding process, a 3D printing process, or the like. The body 108, the cover 112, and the locking device 116 can be molded separately and connected to each other, for example, using the hinge 140 or the like.

[0010] With reference to Fig. 2. The charger 100 is a two-bay charger comprising two battery receptacles 120a, 120b (here referred to as battery receptacles 120) configured to hold two rechargeable single-cell batteries 124. The battery receptacles 120 can extend through the body 108 and the cover 112. When the cover 112 is in the open position, the battery receptacles 120 are accessible, allowing the batteries 124 to be inserted into and removed from the battery receptacles 124. When the cover 112 is in the closed position, the battery receptacles 120 are inaccessible, and the batteries 124 are enclosed and secured within the body 104. In other embodiments, the charger 100 can include more or fewer battery receptacles 120, which can be configured to hold more or fewer batteries 124.Batteries 124, for example, comprise a lithium-based battery cell. Although the present disclosure is discussed in relation to lithium batteries, batteries with other chemistries can be used.

[0011] With reference to Fig. 3 The charger 100 includes a belt hook 144, which is arranged on the rear of the body 108 next to or below the joint 140. The belt hook 144 is configured to be attached to a belt, for example, a tool belt. In some embodiments, the size and shape of the belt hook 144 can be adapted to fit other articles of clothing (e.g., pockets). Additionally, the position of the belt hook 144 can be adjustable and / or the belt hook 144 can be removable from the housing 104. In other embodiments, other types of fastening mechanisms or couplings can be used, such as magnets, clips, buttons, and the like.

[0012] With reference to Fig. In the embodiment shown, a heating device 156 surrounds the battery receptacles 120 and is configured to uniformly heat the batteries 124 held in the battery receptacles 120 to a chargeable temperature within 10 minutes at an ambient temperature of minus 20 degrees Celsius. The heating device 156 is a low-power heating device configured to consume no more than 10 watts of power. In the embodiment shown, the heating device 156 surrounds each battery receptacle 120a, 120b (e.g., substantially all of each battery receptacle 120a, 120b). In some embodiments, the heating device 156 may surround only sections of the battery receptacles 120a, 120b. The heating device 156 may comprise several discrete sections or be integrally formed as a single, unified piece.Additionally, the heating device 156 can comprise separate sections for each of the respective battery receptacles 120a, 120b, and each section can be activated separately. The heating device 156 can include heating elements for generating heat, such as a resistance heating element, an inductive heating element, an infrared element, etc. In some embodiments, the battery receptacles 120 can include a thermal interface between the heating device 156 and the batteries 124. The thermal interface 160 can be a thermal conductor (e.g., copper), a thermal conductor and electrical insulator (e.g., ceramic heat spreaders), or a combination thereof (e.g., a metal-plastic composite). In other embodiments, the heating device 156 can be in direct contact with the batteries 124. Additionally or alternatively, insulation or thermal shielding (e.g.,A heat-reflective lining is provided within the housing 108 to surround the heating device 156 and the battery receptacles 120. The inclusion of a thermal interface and / or additional insulation surrounding the heating device 156 allows more heat to be transferred from the heating device 156 to the batteries 124 housed in the battery receptacle 120.

[0013] With reference to Fig. In the embodiment shown, the charger 100 comprises a user interface 128 and a power interface 148, which are arranged on the housing 104. The user interface 128 includes a plurality of displays 132, which are configured to illuminate based on the charge level of the batteries 124 that are connected to it. In the embodiment shown, the plurality of displays 132 are divided into two subgroups of displays 132a, 132b. Each subgroup of displays 132a, 132b comprises a section of the plurality of displays 132 that corresponds to a respective battery receptacle 120a, 120b. Accordingly, the charge level (e.g., the state of charge) of each individual battery 124 connected to the battery receptacle 120 can be displayed separately on the respective set of displays 132. The user interface 128 also includes a user-operated power switch 136.In some embodiments, the power switch 136 is a push-button switch configured to control the charger's operating mode, e.g., enabling and disabling charging. The power interface 148 is configured to transfer power to and from the battery receptacles 120. The power interface 148 is used both to charge the batteries 124 arranged in the battery receptacles 120 and to draw power from the batteries 124 to charge a device connected to the power interface 148. In the illustrated embodiment, the power interface 148 includes a bidirectional connector 152a and an output connector 152b. The power connectors 152a and 152b are USB-C connectors and are configured to connect to USB-C compatible devices (e.g., a mobile phone). In other embodiments, different configurations may use more connectors and different connector types (e.g., USB-A, AC, etc.).) feature discrete input and output connections and output at a variety of voltages and wattages as understood in engineering.

[0014] Fig. 5, Fig. 6 to Fig. Figure 7 shows a portable battery charger 200 according to another example. The charger 200 is similar in some aspects to the charger 100 described above. The illustrated charger 200 comprises a housing 204, which defines a body 208 and a cover 212 that is pivotable relative to the body 208 about a hinge 240, a locking device 216, a belt hook 244, and battery receptacles 220. In the illustrated example, the hinge 240 and the locking device 216 are provided on opposite sides of the side surfaces of the housing 204. With reference to Fig. 7 The battery mounts 220 shown can accommodate two rechargeable single-cell batteries 224. Refer to the description in Fig. 1, Fig. 2, Fig. 3 to Fig. Reference is hereby made to the battery charger 100 shown in Figure 4 for the description of features and elements of the charger 200 that are not specifically included below.

[0015] With reference to Fig. Figure 6 shows that the charger 200 comprises a user interface 228 and a power interface 248, which are arranged on the body 208 opposite the cover 212. Similar to the charger 100, the illustrated charger 200 comprises a plurality of indicators 232, a power switch 236, and a plurality of power connections 252a, 252b. The power connection 252a is a bidirectional power connection, and the power connection 252b is a unidirectional power connection. In the illustrated embodiment, the user interface 228 and the power interface 248 are both arranged on the underside of the body 208.

[0016] In other embodiments, the user interface 228 can be separate from the power interface 248 and arranged on different surfaces of the housing 204.

[0017] Fig. 8 and Fig. Figure 9 shows a portable battery charger 500 according to another example. The charger 500 is similar in some aspects to the charger 200 described above, with identical parts being designated with the same reference numerals. The illustrated charger 500 comprises a housing 204, which defines a body 208 and a cover 212 that is pivotable about a hinge 240 relative to the body 208, as well as a belt hook 510. In the illustrated example, the belt hook 510 is provided on a rear side of the housing below the hinge 240.

[0018] With reference to Fig. Figure 9 shows that the charger 500 comprises a user interface 228 and a power interface 248, which are arranged on the body 208 opposite the cover 212. Similar to the charger 200, the illustrated charger 500 includes a plurality of indicators 232, a power switch 236, and a power connector 540. The power connector 540 is a bidirectional power connector. In the illustrated embodiment, the user interface 228 and the power interface 248 are both arranged on the underside of the housing 208.

[0019] A control unit 300 for the portable battery charger 100, 200, 500 is in Fig. Figure 10 shows the control unit 300, which is configured to control the distribution of power to and from power terminals 380 (e.g., power terminals 152a, 152b, 252a, and 252b) to batteries 124 and 224 connected to the battery interface 305. The control unit 300 is electrically and / or communicatively connected to a variety of modules or components of the charger 100, 200, or 500. For example, the control unit 300 shown is connected to the battery interface(s) 305 (e.g., battery receptacle 120) via a battery current control module 310. The control unit 300 may include or otherwise be connected to the user interface 128 and the displays 132, a power input / output circuit 315, at least one temperature sensor 320, and a heating circuit 325.The control unit 300 comprises combinations of hardware and software that serve, among other things, to control the operation of the battery charger 100, 200, 500, to activate the displays 132 (e.g. one or more LEDs), to estimate the temperature of a connected battery 124 and the environment, and to activate the heating circuit 325.

[0020] The control unit 300 comprises a variety of electrical and electronic components that power, control, and protect the components and modules within the control unit 300 and / or the battery charger 100, 200, 500. For example, the control unit 300 includes, among other things, a processing unit 330 (e.g., an electronic processor, a microprocessor, a microcontroller, or another suitable programmable device), a memory 335, input units 340, and output units 345. The processing unit 330 includes, among other things, a control unit 350, an ALU 355, and a variety of registers 360 and is implemented using a known computer architecture (e.g., a modified Harvard architecture, a von Neumann architecture, etc.).The processing unit 330, the memory 335, the input units 340, and the output units 345, as well as the various modules connected to the control unit 300, are connected via one or more control and / or data buses (e.g., a common bus 365). The control and / or data buses are shown in the diagram for illustrative purposes. Fig. 10 generally presented.

[0021] Memory 335 is a non-volatile, computer-readable medium and comprises, for example, a program memory area and a data memory area. The program memory area and the data memory area can include combinations of different memory types, such as ROM, RAM (e.g., DRAM, SDRAM, etc.), EEPROM, flash memory, a hard disk, an SD card, or other suitable magnetic, optical, physical, or electronic storage devices. The processing unit 330 is connected to Memory 335 and executes software instructions that may be stored in RAM of Memory 335 (e.g., during execution), in ROM of Memory 335 (e.g., on a generally permanent basis), or on another non-volatile, computer-readable medium such as another memory or a disk.The software included in the implementation of the battery charger 100, 200, 500 can be stored in memory 335 of the control unit 300. The software includes, for example, firmware, one or more applications, program data, filters, rules, one or more program modules, and other executable instructions. The control unit 300 is configured to retrieve and execute instructions relating to the control processes and procedures described herein from memory 335. In other embodiments, the control unit 300 includes additional, fewer, or different components.

[0022] The battery interface(s) 305 comprises a combination of mechanical and electrical components configured and operable to connect the battery charger 100, 200, 500 to a battery 124, 224 (e.g., mechanically, electrically, and communicatively). For example, the battery interface(s) 305 is configured to transfer power between the power control module 310 and the battery interface(s) 305 via a power line 370. The battery interface(s) 305 is also configured to communicate with the power control module 310 via a communication line 375.

[0023] The battery power control module 310 comprises a charging circuit 312 and a discharging circuit 314. Accordingly, the battery power control module 310 can control both the charging and discharging of the batteries 124 and 224 connected via the battery interface 305. The charging circuit 312 receives power from the power terminal 380 and supplies charging current to the battery interface 305 based on control signals from the control unit 300. The charging circuit 312 can implement constant voltage and / or constant current charging for charging the batteries 124 and 224. The battery power control module 310 receives power from the power terminal(s) 380 and / or sends power to the power terminal(s) 380 via the power input / output circuit 315.In some embodiments, the power connection input / output circuit 315 and the battery power control module 310 can charge a received battery 124, 224 and simultaneously output power via a power connection 380. That is, the power connection input / output circuit 315 and the battery power control module 310 can provide through-power. In some embodiments, more than one power connection 380 can be electrically and communicatively connected to the battery power control module 310 via the power connection input / output circuit 315.

[0024] The power terminal input / output circuit 315 controls the direction and allocation of power from the power terminal(s) 380 to the battery power control module 310 and the heating circuit 325. The power terminal input / output circuit 315 can also control the power from the battery power control module 310 to a specific power terminal 380. For example, in embodiments with multiple power terminals, a power terminal 380 can be used as an input to the power terminal input / output circuit 315, thereby supplying power to the battery power control module 310 to charge a battery 124, 224. Another power connection 380 can be used as an output from the power connection input / output circuit 315 and can draw power from another battery 124, 224 via the battery power control module 310 and the power connection input / output circuit 315.In another example, a power terminal 380 can be restricted to a pure output mode, and the power terminal input / output circuit 315 isolates the pure power output terminal 380 from any circuit that uses a power input to power the heating circuit 325 and / or charge a connected battery 124, 224. In some embodiments, the heating circuit 325 can be completely isolated from the battery interface 305 and the battery power control module 310. That is, the heating circuit 325 can only be powered via the power input through the power terminal 380. Consequently, the heating circuit 325 cannot operate if the power terminal 380 cannot supply sufficient power.Additionally, in such an embodiment, the power connection input / output circuit 315 can switch or split a power input from the power connection 380 between the heating circuit 325 and the battery power control module 310. In other embodiments, the heating circuit 325 can draw power from the battery 124, 224.

[0025] The temperature sensors 320 can comprise one or more temperature sensors distributed throughout the charger 100, 200, 500. The temperature sensors 320 can be any temperature sensors known in the art, including, for example, thermistors, infrared sensors, thermocouples, positive temperature coefficient (PTC) elements, negative temperature coefficient (NTC) elements, and the like. The temperature sensors 320 are configured to determine the temperature of a receiving battery 124, 224. In some embodiments, the thermal relationships or gradients between the temperature measured by the temperature sensors 320 and other components of the battery charger 100, 200, 500 can be stored in the memory 335 of the control unit 300.

[0026] Fig.Figure 11 shows a flowchart for an example procedure 400 for operating the charger 100. The procedure 400 can be implemented by the control unit 300 to activate the heating device 156 and the charging / discharging circuits arranged in the battery power control module 310. In step 410, the control unit 300 determines the temperature of a battery 124 using the temperature sensor 320. In some examples, the control unit 300 can continuously monitor the temperature. In other examples, the control unit 300 can monitor the temperature before charging / discharging begins. In some embodiments, the temperature sensor 320 can directly measure the temperature of a battery 124, 224. In some embodiments, the temperature sensor 320 can monitor a different section of the charger than the battery 124, 224 (e.g.,The control unit 300 can measure the temperature of the battery 124, 224 housed in the battery holder 120, based on the temperature measurement of the temperature sensor 320. In some embodiments, temperature sensors 320 can be located adjacent to the battery 124, 224, the heating device 156, and / or another component to determine the specific temperature of the respective component. Other temperature sensors 320 can also be located adjacent to the outer surface of the charger 100, 200, 500 to determine the ambient temperature. In still other embodiments, several temperature sensors 320 can be located in the same component (e.g., battery holder 120, 220) to improve the accuracy of a measurement instead of relying on a single measurement location.The control unit can also communicate with the battery power control module 310 to detect whether a battery is connected to the battery interface 305, and can additionally determine the number of batteries connected to the battery interface 305.

[0027] In step 420, the control unit 300 determines whether the battery temperature meets a low-temperature threshold. For example, the battery temperature meets the low-temperature threshold if it is less than or equal to zero degrees Celsius. To determine whether the battery temperature meets the lower temperature threshold, the control unit 300 compares the measured or extrapolated battery temperature value with an internal temperature limit stored in the memory 335. In some embodiments, the control unit 300 can also determine whether the battery temperature is below a predetermined maximum temperature or within a predetermined temperature range relative to the ambient environment.For example, the control unit 300 can return an error message if the temperature inside the charger 100, 200, 500 exceeds fifty degrees Celsius, or if the measured temperature on the outside of the charger 100, 200, 500 is more than thirty degrees Celsius above the ambient temperature. Upon detecting an error, the control unit 300 can interrupt the power supply to and from the power terminals 380 and display an error message (e.g., via the user interface 128, 228).

[0028] In response to the detection that the battery temperature meets the low temperature threshold, the control unit 300 deactivates the charging circuit 312 in step 430. In some embodiments, the control unit 300 can also deactivate the discharging circuit 314. Accordingly, the control unit 300 can communicate with the battery power control module 310 to deactivate both the charging circuit 312 and the discharging circuit 314 to ensure that no power is sent to the battery 124, 224 via the battery interface 305. In some embodiments, only one of the charging circuits 312 or the discharging circuits 314 can be deactivated within the battery power control module 310. For example, the control unit 300 can deactivate only the charging circuit 312 and activate only the discharging circuit 314 to output current below the lower temperature threshold (e.g., zero degrees Celsius).Conversely, the control unit can deactivate the discharge circuit 314 at a temperature above the lower temperature threshold. In short, the temperatures at which charging and discharging are permitted can differ.

[0029] Additionally or alternatively, the control unit 300 can communicate with the power connection input / output circuit 315 to disable power transmission (e.g., using a FET) to the battery power control module 310. In other embodiments, the battery power control module 310 can limit the battery output to the control unit to maintain operation and control the displays 132.

[0030] In step 440, the control unit 300 activates the heating device 156 to heat the battery 124, 224. The control unit 300 can activate the heating device 156 in response to the temperature meeting the low temperature threshold. The control unit 300 controls the power terminal input / output circuit 315 to provide a power flow from the power terminals 380 to the heating circuit 325, enabling the heating device 156 to heat the battery 124. The heating circuit 325 heats the heater 156. In some embodiments, the control unit 300 can use the indicators 132 to display an error to indicate that insufficient power is being supplied to the heating circuit 325. After activating the heater in step 440, the procedure 400 returns to step 410 and continues monitoring the battery temperature.

[0031] In step 450, if it is determined that the battery temperature does not reach the low temperature limit, the control unit 300 deactivates the heater 156. In some embodiments, the control unit 300 can enable battery current transfer without deactivating the heater up to a certain temperature. For example, the control unit 300 can include a delay or other parameter to activate the heating circuit 325 for a specific period or temperature range (e.g., up to ten degrees Celsius), so that the heater 156 continues to heat the battery 124 at temperatures above the temperature limit. In step 460, the control unit 300 activates the charging circuit 312. The control unit 300 activates the charging circuit 312 to charge the batteries 124 and 224.

[0032] Various features and advantages are listed in the following claims. 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 patent literature

[0000] US 63 / 674,934

[0001]

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