Modular storage unit with charger for power tool battery packs

Abstract

The embodiments described herein provide a modular storage unit (100) for a power tool device, including a charging compartment (130) for a power tool battery pack. The modular storage unit (100) includes a housing (110), a storage compartment (120) within the housing (110), and a charger compartment (130) within the housing (110) including a battery pack interface (185) configured to accept a power tool battery pack (180). The modular storage unit (100) also includes an AC input for receiving AC power and an active power factor correction (PTC) converter configured to receive AC power from the AC input and convert the AC power to a high-voltage DC output. The modular storage unit (100) further includes a DC-DC converter electrically connected between the active PTC converter and the battery pack interface (185), the DC-DC converter including an active clamp flyback converter.

Description

[Technical field]

[0001] Related Applications This application claims the benefit of U.S. Provisional Patent Application No. 63 / 000,688, filed March 27, 2020, the entire contents of which are incorporated herein by reference. Summary of the Invention [Means for solving the problem]

[0002] The embodiments described herein provide modular storage for power tool devices, including a charging compartment for a power tool battery pack.

[0003] One embodiment provides a charger for a power tool battery pack including a battery pack interface configured to accept the power tool battery pack and an AC power input for receiving input AC power. The charger also includes a converter for converting AC power at the AC power input to a high-voltage DC output and a DC-DC converter connected between the converter and the battery pack interface. The DC-DC converter includes an active clamp (AC) flyback topology and is configured to convert the high-voltage DC output to charging DC power provided to the battery pack interface.

[0004] In some aspects, the DC-DC converter includes an active clamp flyback converter that receives the high voltage DC output, an active clamp flyback controller configured to control the active clamp flyback converter to convert the high voltage DC output to a corresponding voltage, a charge FET electrically connected between the AC flyback converter and the battery pack interface, and a charge FET control circuit configured to enable and disable the charge FET to charge the power tool battery pack using the corresponding voltage.

[0005] In some aspects, the charger includes a power cord configured to provide input AC power to the AC power input.

[0006] In some aspects, the charger includes an electromagnetic interference filter disposed between the AC power input and the battery pack interface.

[0007] In some aspects, the converter includes an active power factor correction (PFC) converter.

[0008] In some embodiments, the high voltage DC output is about 400 volts.

[0009] In some embodiments, the charger includes a DC bus that receives the high voltage DC output.

[0010] In some aspects, the charger includes a housekeeping power supply and a universal serial bus (USB) charging power supply. The DC bus delivers a high voltage DC output to the housekeeping power supply, the USB charging power supply, and the DC-DC converter.

[0011] In some aspects, the housekeeping power supply includes a quasi-resonant (QR) flyback converter for converting the high voltage DC output to a voltage level for use by the modular storage unit.

[0012] In some aspects, the charger includes one or more USB ports connected to a USB charging power supply that includes a quasi-resonant (QR) flyback converter for converting a high voltage DC output to a voltage level for powering the one or more USB ports.

[0013] In some aspects, the charger includes a housing, a storage compartment within the housing, and a charger compartment within the housing. The charger compartment includes a battery pack interface.

[0014] In some embodiments, the charger includes a handle disposed on a first side of the housing and pivotable relative to the housing.

[0015] In some embodiments, the charger includes a power cord receptacle disposed on a second side of the housing opposite the first side of the housing.

[0016] In some aspects, the charger includes a storage lid disposed over the storage compartment on the top surface of the housing, the storage lid being pivotable about a rear surface of the storage compartment, and a storage latch securing the storage lid to the housing about a front surface of the storage compartment.

[0017] In some embodiments, the charger includes a separation wall that separates the storage compartment from the charger compartment.

[0018] In some aspects, the charger includes a charger lid provided on a side of the housing such that the power tool battery pack is inserted into the charger compartment from the side of the housing, the charger lid is pivotable about a bottom surface of the housing and secured by a mechanism provided on a top surface of the housing.

[0019] In some aspects, the charger includes a storage lid disposed on a side of the housing such that one or more storable items are inserted into the storage compartment from the side of the housing, the storage lid being pivotable about a bottom surface of the housing and secured by a mechanism disposed on a top surface of the housing.

[0020] In some aspects, the charger includes a plurality of connection recesses disposed on a top surface of the housing and configured to receive and cooperate with protrusions from a complementary interface.

[0021] In some embodiments, the charger includes a plurality of protrusions configured to be received into a corresponding plurality of connection recesses in a complementary top surface of the second modular storage unit.

[0022] Another embodiment provides a charger for a power tool battery pack including a housing, a charging circuit within the housing, and a battery pack interface configured to receive the power tool battery pack. The charger also includes a power cord that receives an alternating current (AC) input, and an active power factor correction (PFC) converter configured to receive AC power from the power cord and convert the AC power to a high-voltage DC output. The charger further includes a DC-DC converter electrically connected between the active PFC converter and the battery pack interface, the DC-DC converter including an active clamp (AC) flyback converter.

[0023] In some aspects, the DC-DC converter includes an active clamp flyback converter that receives the high voltage DC output, an active clamp flyback controller configured to control the active clamp flyback converter to convert the high voltage DC output to a corresponding voltage, a charge FET electrically connected between the AC flyback converter and the battery pack interface, and a charge FET control circuit configured to enable and disable the charge FET to charge the power tool battery pack using the corresponding voltage.

[0024] In some aspects, the charger includes a DC bus that receives the high voltage DC output, a housekeeping power supply, and a Universal Serial Bus (USB) charging power supply. The DC bus delivers the high voltage DC output to the housekeeping power supply, the USB charging power supply, and the DC-DC converter.

[0025] In some aspects, the housekeeping power supply includes a quasi-resonant (QR) flyback converter for converting the high voltage DC output to a voltage level for use by the modular storage unit.

[0026] In some aspects, the charger includes one or more USB ports connected to a USB charging power supply that includes a quasi-resonant (QR) flyback converter for converting a high voltage DC output to a voltage level for powering the one or more USB ports.

[0027] Another embodiment provides a charger including a housing, a charging circuit within the housing, and a battery pack interface configured to receive a power tool battery pack. The modular storage unit also includes a power cord that receives an alternating current (AC) input, an active power factor correction (PFC) converter configured to receive AC power from the power cord and convert the AC power to a high-voltage DC output, and a DC bus that receives the high-voltage DC output. The modular storage unit further includes a housekeeping power supply, a universal serial bus (USB) charging power supply, and a DC-DC converter connected between the DC bus and the battery pack interface. The DC bus delivers the high-voltage DC output to the housekeeping power supply, the USB charging power supply, and the DC-DC converter.

[0028] In some aspects, the DC-DC converter includes an active clamp flyback converter that receives the high voltage DC output, an active clamp flyback controller configured to control the active clamp flyback converter to convert the high voltage DC output to a corresponding voltage, a charge FET electrically connected between the AC flyback converter and the battery pack interface, and a charge FET control circuit configured to enable and disable the charge FET to charge the power tool battery pack using the corresponding voltage.

[0029] In some aspects, the housekeeping power supply includes a quasi-resonant (QR) flyback converter for converting the high voltage DC output to a voltage level for use by the modular storage unit.

[0030] In some aspects, the charger includes one or more USB ports connected to a USB charging power supply that includes a quasi-resonant (QR) flyback converter for converting a high voltage DC output to a voltage level for powering the one or more USB ports.

[0031] Before describing each embodiment in detail, it should be understood that the embodiments are not limited in their application to the details of construction and arrangement of components set forth in the following description or illustrated in the accompanying drawings. The embodiments can be practiced or carried out in various ways. It should also be understood that the phrases and terms used herein are for purposes of description and should not be regarded as limiting. The use of "including," "comprising," or "having" and variations thereof is intended to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless otherwise expressly stated or limited, the terms "mounted," "connected," "supported," and "coupled," and variations thereof, are used in the broadest sense to encompass both direct and indirect mounting, connecting, supporting, and coupling.

[0032] In addition, it should be understood that the embodiments may include hardware, software, and electronic components or modules, which may be illustrated and described as if the majority of the components were implemented solely in hardware for purposes of discussion. However, based on reading this detailed description, one of ordinary skill in the art will recognize that in at least one embodiment, the electronic-based aspects may be implemented in software (e.g., stored in a non-transitory computer-readable medium) executable by one or more processing units, such as a microprocessor and / or an application-specific integrated circuit ("ASIC"). Thus, it should be noted that a number of hardware and software-based devices, as well as a number of different structural components, may be utilized to implement the embodiments. For example, a "server," "computing device," "controller," "processor," and the like, as described herein, may include one or more processing units, one or more computer-readable media modules, one or more input / output interfaces, and various connection means (e.g., a system bus) connecting the components.

[0033] Relative terms, such as "about," "approximately," "substantially," and the like, used in connection with a quantity or condition, will be understood by those of skill in the art to include the specified numerical value and to have the meaning dictated by the context (e.g., the terms include at least the degree of error associated with the precision of the measurement, the tolerances associated with the particular value [e.g., manufacturing, assembly, use, etc.], etc.). Such terms should also be understood to disclose a range defined by the absolute values ​​of the two endpoints. For example, the phrase "about 2 to about 4" also discloses the range "2 to 4." Relative terms may refer to plus or minus a certain percentage (e.g., 1%, 5%, 10%, or more) of the indicated value.

[0034] While certain figures illustrate hardware and software within certain devices, it should be understood that these depictions are for illustrative purposes only. Functions described herein as being performed by one component may be performed in a distributed manner by multiple components. Similarly, functions performed by multiple components may be integrated and performed by a single component. In some embodiments, the illustrated components may be combined or divided into separate software, firmware, and / or hardware. For example, logic or processing may be distributed among multiple electronic processors rather than being within and performed by a single electronic processor. Regardless of how they are combined or divided, the hardware and software components may be located on the same computing device or distributed among different computing devices connected by one or more networks or other suitable communication links. Similarly, components described as performing certain functions may also perform additional functions not described herein. For example, a device or structure that is "configured" in a certain way may be configured at least in that way, but may also be configured in ways not explicitly recited.

[0035] Other aspects of the embodiments will become apparent by consideration of the detailed description and accompanying drawings. [Brief description of the drawings]

[0036] [Figure 1] FIG. 1 illustrates a front perspective view of a modular storage unit with a charger lid open, according to some embodiments. [Diagram 2] 2 is a front perspective view of the modular storage unit of FIG. 1 according to some embodiments. [Diagram 3] FIG. 2 is a front perspective view of the modular storage unit of FIG. 1 with the charger lid removed, according to some embodiments. [Figure 4] 2 is a front perspective view of the modular storage unit of FIG. 1 with the upper housing removed, according to some embodiments. [Diagram 5] 2 is a rear perspective view of the modular storage unit of FIG. 1 according to some embodiments. [Figure 6] 2 is a rear plan view of the modular storage unit of FIG. 1 according to some embodiments. [Figure 7] 2 is a front plan view of the modular storage unit of FIG. 1 according to some embodiments. [Figure 8] FIG. 1 illustrates a front perspective view of a modular storage unit according to some embodiments. [Figure 9] FIG. 9 is a front perspective view of the modular storage unit of FIG. 8 with the charger lid removed, according to some embodiments. [Figure 10] 9 is a rear perspective view of the modular storage unit of FIG. 8 according to some embodiments. [Figure 11] 9 is a rear plan view of the modular storage unit of FIG. 8 according to some embodiments. [Figure 12] 9 is a front plan view of the modular storage unit of FIG. 8 according to some embodiments. [Figure 13] 9 is a perspective view of the modular storage unit of FIG. 8 with the upper housing removed, according to some embodiments. [Figure 14] FIG. 9 is a top view of the modular storage unit of FIGS. 1 and 8, according to some embodiments. [Figure 15] FIG. 9 is a bottom perspective view of the modular storage unit of FIGS. 1 and 8, according to some embodiments. [Figure 16] FIG. 9 is a perspective view of a charger compartment of the modular storage unit of FIGS. 1 and 8 according to some embodiments. [Figure 17] 9 is a cross-sectional view of a charger compartment of the modular storage unit of FIGS. 1 and 8 according to some embodiments. [Figure 18] 9 is a cross-sectional view of a charger compartment of the modular storage unit of FIGS. 1 and 8 according to some embodiments. [Figure 19]FIG. 9 is a block diagram of the storage module of FIGS. 1 and 8 according to some embodiments. [Figure 20] 10 illustrates a partial block diagram of the storage module of FIGS. 1 and 8 according to some embodiments. [Figure 21] FIG. 9 is a simplified circuit diagram of a power factor correction (PFC) converter used as a power converter in the encasement modules of FIGS. 1 and 8 according to some embodiments. [Figure 22] FIG. 9 is a simplified circuit diagram of an active clamp flyback converter used as a power converter in the encasement module of FIGS. 1 and 8 according to some embodiments. [Diagram 23] FIG. 9 is a simplified circuit diagram of a quasi-resonant flyback converter used as a power converter in the encasement modules of FIGS. 1 and 8 according to some embodiments. [Figure 24] FIG. 21 is a simplified block diagram of a DC-DC converter of the encasement module of FIGS. 1 and 8 including the active clamp flyback converter of FIG. 20 according to some embodiments. [Diagram 25] FIG. 9 is a simplified block diagram of a battery pack charging control circuit of the storage module of FIGS. 1 and 8 according to some embodiments. [Figure 26] FIG. 9 is a simplified block diagram of a battery pack charging control circuit of the storage module of FIGS. 1 and 8 according to some embodiments. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0037] 1-7, the modular storage unit 100 includes a housing 110 having a storage compartment 120 and a charger compartment 130. The storage compartment 120 is used to store power tool devices, tool bits, and power tool accessories. The charger compartment 130 is configured to receive and charge one or more power tool battery packs. The modular storage unit 100 includes a handle 140 disposed on a side of the housing 110. The handle 140 can be pivoted into the housing 100 when not in use and is pivotable from the housing 110 such that the handle 140 can be pivoted out of the housing 100 by a user to carry the modular storage unit 100. The modular storage unit also includes a power cord receptacle 145 disposed on a side of the housing 110 opposite the side on which the handle 140 is disposed.

[0038] The storage compartment 120 includes a storage lid 150 provided on the top of the housing 110 such that the storage lid 150 can pivot about the rear of the storage compartment 120 to place storable items into the storage compartment 120 from the top of the housing 110. The storage compartment 120 is formed by the side walls of the housing 110, a separation wall 125 (shown in FIG. 4 ) that separates the storage compartment 120 from the charger compartment 130, a bottom wall of the housing 110, and the storage lid 150. The storage lid 150 is secured to the housing 110 using a latch 160 to prevent the storage lid 150 from opening when the storage compartment 120 is being transported.

[0039] The charger compartment 130 includes a charger lid 170 provided on a side of the housing 110 so that the power tool battery pack 180 can be inserted into the charger compartment 130 from the side of the housing 110. The charger lid 170 can pivot around the housing 110 and be secured by a mechanism provided on a top wall of the housing 110. The charger compartment 130 can accept and charge different types of battery packs 180. The charger compartment 130 includes multiple battery pack interfaces 185 (e.g., a first battery pack interface, a second battery pack interface, and a third battery pack interface). In the illustrated embodiment, the charger compartment 130 accepts two 18 volt (V) battery packs 180 (e.g., a slidable battery pack) and one 12V battery pack 180 (e.g., a tower battery pack). The battery packs 180 are, for example, Milwaukee® REDLITHIUM M18™ and M12™ battery packs. In addition to charging the power tool battery pack 180, the charger section 130 may also include a DC outlet (e.g., a Universal Serial Bus (Type A or Type C) outlet) for charging other devices (e.g., smartphones, tablet computers, etc.).

[0040] Referring to Figures 8-13, another embodiment of a modular storage unit 190 is illustrated. The modular storage unit 190 is similar to the modular storage unit 100, but the storage lid 150 is located on the side of the housing, as is the charger lid 170. Storage items are received in the storage compartment 120 through the side of the housing 110. In Figures 1-13, a full stack embodiment is disclosed. However, the storage module 110 may also have a half stack configuration, with the charger compartment 130 located above the storage compartment, or vice versa. The half stack configuration may have half the footprint of the full stack configuration, but twice the height.

[0041] With reference to FIG. 14, the storage module 100 includes a number of connection recesses 205 on the top of the housing 110 that receive and cooperate with protrusions from a complementary interface (see FIG. 15). The connection recesses 205 include two rows of two small recesses 210 and one row of large recesses 215. In other embodiments, the top of the housing 110 may include a different number or pattern of connection recesses 205. An interference protrusion or wing 220 extends into each connection recess 205 from one end of the connection recess 205 on the opposite side of the connection recess 205. Each of the wings 220 has a length that spans approximately half of the connection recess 205 to define a first portion of the connection recess 205 and a second portion opposite the wings 220 that remain open. In some embodiments, each of the wings 220 has a length that spans less than half of the connection recess 205.

[0042] In relation to a storage module 100 having a bottom of the housing 110 as illustrated in FIG. 15, the second portion of each connection recess 205 is sized to receive a protrusion 225. When the protrusion 225 is received in the connection recess 205, the bottom surface of the housing 110 is positioned to contact and support the top surface of the housing 110. In the illustrated embodiment, each protrusion 225 extends from the bottom surface of the housing 110 and is configured to cooperate with the connection recess 205 to connect the storage module 100 to another storage module with or without a charger compartment. In the illustrated embodiment, each protrusion 225 is integrally formed with the bottom of the housing 110. Each protrusion 225 has a channel 230 on either side of the protrusion 225. Each channel 230 has a front open end and a rear closed end along an axis. Each protrusion 225 has a generally rectangular planar surface 235. In other embodiments, the planar surface 235 may be another shape (e.g., circular, triangular, etc.). Protrusions 225 are positioned such that storage module 100 can be supported on a surface by protrusions 225 through contact with flat surface 235 .

[0043] Each of the wings 220 of the connection recesses 205 is configured to correspond to and cooperate with a corresponding one of the channels 230 of the protrusions 225 received by the respective connection recesses 205. In the disconnected position, the protrusions 225 are oriented within the connection recesses 205 such that the open ends of the channels 230 are closer to the wings 220 than the closed ends. Once in the disconnected position, the bottom of the housing 110 can slide against the top of the housing 110 of another storage module in a first direction parallel to the longitudinal axis toward the wings 220 such that the wings 220 are received within the channels 230 in a second, interfaced or connected position. The wings 220 and the protrusions 225 engage within the connection recesses 205 to interface and connect the bottom of the housing 110 and prevent separation of the bottom of the housing 110 from the top of the housing 110 of another storage module except in a second direction opposite the first direction and generally parallel to the longitudinal axis. The wings 220 and the channels 230 engage one another perpendicular to the longitudinal axis.

[0044] 16-18, example configurations of the charger compartment 130 are illustrated. In a first configuration illustrated in FIG. 17, the slidable battery pack 180 and the tower battery pack 180 are received in the compartment along axes parallel to each other. In a second configuration illustrated in FIG. 18, the slidable battery pack 180 is received in the compartment along axes parallel to each other. However, the tower battery pack 180 is received along an axis that is at an angle to the axis of the slidable battery pack 180. For example, the tower battery pack 180 is received along an axis that is 45 degrees to the axis of the slidable battery pack 180.

[0045] FIG. 19 is a block diagram of the storage module 100, according to some embodiments. FIG. 20 illustrates a partial block diagram of the storage module 100, according to some embodiments. With reference to FIGS. 19-20, the storage module 100 includes a power cord for receiving a universal AC input, for example from a wall outlet. In some embodiments, the power cord may also be plugged into a portable power source powered by a gas engine or a high voltage battery pack. An electromagnetic interference filter is provided to reduce or prevent interference between the AC power input and the DC component of the storage module. The AC power from the power cord is provided to an active power factor correction (PFC) converter (shown in FIG. 21). The active PFC converter converts the AC power input to a high voltage DC output provided at a DC bus. In one example, the active PFC converter converts the AC power input to a 400V DC output provided at the DC bus. The DC bus delivers the 400V DC power to the various power converters of the storage module 100.

[0046] The storage module 100 includes a housekeeping power supply, a USB charging power supply, and a number of DC-DC power converters. In the illustrated embodiment, the storage module 100 includes three DC-DC power converters for charging three power tool battery packs as described above. 400V DC power from the DC bus is provided to the housekeeping power supply, the USB charging power supply, and each of the number of DC-DC power converters. Each of the housekeeping power supply, the USB charging power supply, and each of the number of DC-DC power converters includes a power converter that converts the 400V DC power from the DC bus to various power outputs at different voltages. In one example, the power converters may be implemented using an active clamp flyback topology as illustrated in FIG. 22.

[0047] The housekeeping power supply includes a quasi-resonant (QR) flyback converter (shown in FIG. 23) for converting the 400V DC voltage to a voltage level for use by the various controllers of the storage module 100. The flyback converter includes a flyback topology coupled to a flyback transformer and a rectifier. The flyback converter converts the 400V DC voltage to, for example, a 15V DC voltage for use by the various controllers of the storage module 100. The 15V DC voltage is provided to the DC-DC power converter controller, the USB charging power supply controller, and other microcontrollers of the storage module 100.

[0048] The USB charging power supply includes a QR flyback converter (shown in FIG. 23) or a synchronous step-down DC-DC converter for converting the 400V DC voltage to a voltage level that can be provided to the USB port of the storage module 100. The QR flyback converter includes a QR flyback topology coupled to a flyback transformer, a first rectifier, and a second rectifier. The QR flyback converter converts the 400V DC voltage to, for example, a 5V DC voltage for use by the various USB ports of the storage module 100. The first rectifier provides a 5V DC voltage to, for example, a USB Type A port, and the second rectifier provides a 5V DC voltage to, for example, a USB Type C port. The USB ports can be used to charge various home devices, for example, smartphones, tablet computers, wearable devices, and the like. In some embodiments, the output from the flyback transformer of the QR flyback converter can also be used to power the controller of the USB charging power supply. In some embodiments, the USB charging power supply receives its power supply from a housekeeping power supply rather than a 400V DC voltage from a DC bus. In other embodiments, the USB charging power supply receives its power supply from one of the DC-DC converters rather than the 400V DC voltage from the DC bus.

[0049] The DC-DC converter includes an active clamp (AC) flyback converter (shown in FIG. 22) for converting the 400V DC voltage to a voltage level that can be provided to the power tool battery pack 180 for charging the power tool battery pack 180. The AC flyback converter includes an AC flyback topology coupled to a flyback transformer and a synchronous rectifier. A charging field effect transistor (FET) or relay is coupled between the AC flyback converter and the battery pack 180 to control the charging of the battery pack 180. The AC flyback converter converts the 400V DC voltage to, for example, 3-21V DC voltage for charging the battery pack 180 received in the storage module 100. As discussed above, the storage module includes, for example, three AC flyback converters and three charging FETs for charging the three battery packs 180 received in the storage module 100.

[0050] 21 illustrates one example embodiment of a power factor correction (PFC) converter 800 that may be used with encasement module 100. PFC converter 800 includes a diode rectifier 810, an inductor 820, a converter FET 830, an output diode 840, an output capacitor 850, and a gate driver 260. Diode rectifier 810 receives an AC input voltage from an AC power source, such as power supply 200. Diode rectifier 810 rectifies the AC voltage to a rectified AC voltage at the output.

[0051] An inductor 820 is connected in series with diode rectifier 810 to receive the rectified voltage. An output diode 840 and an output capacitor 850 are connected in series with inductor 820. A load 250 is connected in parallel with output capacitor 850 and in series with output diode 840. A converter FET 830 is connected in series with inductor 820 and in parallel with output diode 840 and output capacitor 850.

[0052] The gate driver 260 drives the converter FET 830 to operate the PFC converter 800. The gate driver 260 receives control signals from the electronic processor 220 to control the operation of the converter FET 830. The electronic processor 220 implements a power factor control algorithm to drive the converter FET 830 and convert the AC voltage to a DC voltage at the load 250. Wide bandgap FETs can be used for the converter FET 830 to increase efficiency and reduce the size of the PFC circuit 800.

[0053] FIG. 22 illustrates one example embodiment of an active clamp flyback converter 600 that can be used in a DC-DC converter. The active clamp flyback converter 600 can be used as a step-up or step-down DC-DC converter. In the illustrated embodiment, the active clamp flyback converter 600 receives power from a power source 200 and includes a primary side circuit 610 (e.g., an AC flyback topology) and a secondary side circuit 620 coupled by a two-winding inductor 630 (e.g., a flyback transformer). The active clamp flyback converter 600 can include more or fewer components than those illustrated in FIG. 22.

[0054] The primary side circuit 610 includes a flyback switching FET 640 coupled in series with the primary side of the two-winding inductor 630, and an input capacitor 650 coupled in parallel with the flyback switching FET 640 and the two-winding inductor 630. The input capacitor 650 is coupled in parallel to the power supply 200. The secondary side circuit 620 includes an output diode 660 and an output capacitor 670. In some embodiments, the output diode is replaced with the output FET 660. When the output diode 660 is replaced with the output FET 660, the second side circuit 620 forms a synchronous rectifier. The output FET 660 is coupled in series with the positive side of the secondary side of the two-winding inductor 630 and is controlled by a synchronous rectifier controller (not shown). The output capacitor 670 is coupled in parallel with the secondary side of the two-winding inductor 630 downstream of the output diode 660. The load 250 is coupled in parallel with the output capacitor 670.

[0055] The primary side circuit 610 also includes an active clamp circuit 690 that includes a series-connected clamp FET 694 and a clamp capacitor 698. The clamp circuit 690 is connected in parallel with the primary side of the two-winding inductor 630 and in series with the flyback switching FET 640.

[0056] In operation, the flyback switching FET 640 is turned on to store energy from the power supply 200 in the two-winding inductor 630. During the on-time of the flyback switching FET 640, the output capacitor 670 provides operating power to the load 250. When the flyback switching FET 640 is turned off, the energy stored in the two-winding inductor 630 is transferred to the output capacitor 670 and the load 250. The clamp FET 694 is turned on during the off-state of the flyback switching FET 640 to reduce stress on the flyback switching FET 640. In the illustrated embodiment, wide bandgap FETs may be used for one or more of the flyback switching FET 640, the output FET 660, and the clamp FET 694 based on the desired characteristics of the DC-DC converter. In particular, the use of wide bandgap FETs can reduce the size of inductive and capacitor components compared to an active clamp flyback converter that uses MOSFETs for the flyback switching FET 640 and the clamp FET 694. The flyback switching FET 640, the clamp FET 694, and the output FET 660 (or synchronous rectifier) ​​are driven by gate drivers that are controlled by a DC-DC converter controller that provides control signals to the gate drivers to control the operation of the flyback switching FET 640 and the clamp FET 694.

[0057] FIG. 23 illustrates one example embodiment of a QR flyback converter 500 that can be used in a housekeeping power supply or a USB charging power supply. The QR flyback converter 500 can be used as a step-up or step-down DC-DC converter. In the illustrated embodiment, the QR flyback converter 500 receives power from a power source 200 and includes a primary side circuit 510 (e.g., flyback or QR flyback topology) and a secondary side circuit 520 coupled by a two-winding inductor 530 (e.g., flyback transformer). The flyback converter 500 can include more or fewer components than those illustrated in FIG. 23.

[0058] The primary side circuit 510 includes a flyback switching FET 540 coupled in series with the primary side of the two-winding inductor 530 and an input capacitor 550 coupled in parallel with the flyback switching FET 540 and the two-winding inductor 530. The input capacitor 550 is coupled in parallel to the power supply 200. A passive clamp resistor-capacitor diode (RCD) snubber circuit 580 may also be provided in series with the flyback switching FET 540 and in parallel with the primary side of the two-winding inductor 530. The passive clamp RCD snubber circuit limits voltage noise to the flyback switching FET 540. The secondary side circuit 520 includes an output diode 560 and an output capacitor 570. The output diode 560 is coupled in series with the positive side of the secondary side of the two-winding inductor 530. The output capacitor 570 is coupled in parallel with the secondary side of the two-winding inductor 530 downstream of the output diode 560. The load 250 is coupled in parallel with the output capacitor 570.

[0059] In operation, the flyback switching FET 540 is turned on to store energy from the power source 200 in the two-winding inductor 530. During the on-time of the flyback switching FET 540, the output capacitor 570 provides operating power to the load 250. When the flyback switching FET 540 is turned off, the energy stored in the two-winding inductor 530 is transferred to the output capacitor 570 and the load 250. In the illustrated embodiment, a wide bandgap FET is used as the flyback switching FET 540 to enable high frequency operation. The flyback switching FET 540 is driven by a gate driver 260 that is controlled by a controller of the housekeeping power supply or the USB charging power supply. The controller provides a control signal to the gate driver to control the operation of the flyback switching FET 540. In some embodiments, a wide bandgap FET can be used to replace the diode 560 to further increase the operating frequency of the flyback converter 500.

[0060] FIG. 24 is a simplified block diagram of a DC-DC converter of the storage module 100. The DC-DC converter includes an active clamp flyback controller, an active clamp flyback topology, a flyback transformer, a synchronous rectifier, and a charge FET. The active clamp flyback controller receives a supply voltage, for example, a DC voltage of 400V from a DC bus. The active clamp flyback controller controls the active clamp flyback topology to convert the DC input voltage to a corresponding voltage and provide a DC voltage output through the charge FET to the battery pack 180. A charge FET control circuit is provided to control the charge FET to enable and disable charging of the battery pack 180. The charge FET control circuit is controlled by a microcontroller, for example, the controller illustrated in FIG. 25.

[0061] The DC-DC converter also includes a gate driver for driving the FETs of the active clamp flyback topology. The gate driver is controlled by the active clamp flyback controller to drive the FETs of the active clamp flyback topology. A burst mode hysteresis circuit is provided to enable burst mode operation of the active clamp flyback converter. Additionally, an auxiliary winding fast discharge circuit and an auxiliary winding bias circuit are provided to control an auxiliary winding of the active clamp flyback converter.

[0062] Figures 25 and 26 illustrate battery pack charging control circuits of storage module 100. Figure 25 is a block diagram of a first battery pack charging control circuit, e.g., a control circuit for charging an 18V battery pack 180. Figure 26 is a block diagram of a second battery pack charging control circuit, e.g., a control circuit for charging a 12V battery pack 180.

[0063] Referring to FIG. 25, the first battery pack charging control circuit includes a first battery pack interface that accepts the first power tool battery pack 180. A first pack voltage measurement circuit is coupled to the first battery pack interface to measure the pack voltage of the first power tool battery pack 180. A supply output voltage measurement circuit is also provided to measure the voltage of the charging voltage supply, for example from an active clamp flyback converter. A first overvoltage and latch circuit is provided to latch the output when an overvoltage condition is detected. A first standby power mode interface is also included in the first battery pack charging control circuit to provide standby power. The first pack voltage measurement circuit, the supply output voltage measurement circuit, the first overvoltage and latch circuit, and the first standby power mode interface are controlled by a first battery pack charger controller. A voltage regulator provides operating power to the first battery pack charger controller and other components of the first battery pack charging control circuit.

[0064] Referring to FIG. 26, the second battery pack charging control circuit includes a second battery pack interface that accepts a second power tool battery pack 180. A supply output voltage measurement circuit is also provided to measure the voltage of the charging voltage supply, for example from an active clamp flyback converter. A second over-voltage and latch circuit is provided to latch the output when an over-voltage condition is detected. A second standby power mode interface is also included in the second battery pack charging control circuit to provide standby power. The supply output voltage measurement circuit, the second over-voltage and latch circuit, and the second standby power mode interface are controlled by the second battery pack charger controller. A voltage regulator provides operating power to the second battery pack charger controller and other components of the second battery pack charging control circuit.

Claims

1. 1. A charger for a power tool battery pack, comprising: Housing and a battery pack interface configured to receive a power tool battery pack; an AC power input for receiving input AC power; a converter for converting AC power at the AC power input to a high voltage DC output; a DC-DC converter connected between the converter and the battery pack interface, the DC-DC converter including an active clamp flyback topology and configured to convert the high voltage DC output to charging DC power provided to the battery pack interface; a DC bus receiving the high voltage DC output; Housekeeping power supply, Universal Serial Bus (USB) charging power supply; a storage compartment within the housing; a charger compartment within the housing, the charger compartment including the battery pack interface; a charger lid provided on a side of the housing such that the power tool battery pack is inserted into the charger compartment from the side of the housing; the DC bus delivers the high voltage DC output to the housekeeping power supply, the USB charging power supply, and the DC-DC converter; the charger lid is pivotable about a bottom surface of the housing and secured by a mechanism on a top surface of the housing; charger.

2. The DC-DC converter comprises: an active clamp flyback converter receiving the high voltage DC output; an active clamp flyback controller configured to control the active clamp flyback converter to convert the high voltage DC output to a corresponding voltage; a charge FET electrically connected between the active clamp flyback converter and the battery pack interface; a charge FET control circuit configured to enable and disable the charge FET to charge the power tool battery pack using the corresponding voltage. The charger of claim 1.

3. 10. The charger of claim 1, further comprising a power cord configured to provide the input AC power to the AC power input.

4. 10. The charger of claim 1, further comprising an electromagnetic interference filter disposed between the AC power input and the battery pack interface.

5. The charger of claim 1 , wherein the converter comprises an active power factor correction (PFC) converter.

6. 2. The charger of claim 1, wherein said high voltage DC output is approximately 400 volts.

7. 2. The charger of claim 1, wherein the housekeeping power supply includes a quasi-resonant (QR) flyback converter for converting the high voltage DC output to a voltage level for use by a modular storage unit.

8. further comprising one or more USB ports connected to said USB charging power supply; the USB charging power supply includes a quasi-resonant (QR) flyback converter for converting the high voltage DC output to a voltage level for powering the one or more USB ports; The charger of claim 1.

9. The charger of claim 1 , further comprising a handle disposed on a first side of the housing and pivotable relative to the housing.

10. 10. The charger of claim 9, further comprising a power cord receptacle on a second side of the housing opposite the first side of the housing.

11. a storage lid provided on an upper surface of the housing to cover the storage compartment, the storage lid being pivotable about a rear surface of the storage compartment; a storage latch for securing the storage lid to the housing around a front surface of the storage compartment. The charger of claim 1.

12. The charger of claim 1 , further comprising a separation wall separating the storage compartment from the charger compartment.

13. a storage lid provided on a side of the housing such that one or more storable items are inserted into the storage compartment from the side of the housing; The storage lid is pivotable about the bottom surface of the housing and is secured by a mechanism provided on the top surface of the housing. The charger of claim 1.

14. 10. The charger of claim 1, further comprising a plurality of connection recesses disposed on a top surface of the housing and configured to receive and cooperate with protrusions from a complementary interface.

15. 15. The charger of claim 14, further comprising a plurality of protrusions configured to be received into a corresponding plurality of connection recesses on a complementary top surface of the second modular storage unit.

16. 1. A charger for a power tool battery pack, comprising: Housing and a charging circuit within the housing for charging one or more power tool battery packs; a battery pack interface configured to receive a power tool battery pack; a power cord for receiving an alternating current (AC) input; an active power factor correction (PFC) converter configured to receive AC power from the power cord and convert the AC power to a high voltage DC output; a DC-DC converter electrically connected between the active PFC converter and the battery pack interface, the DC-DC converter including an active clamp flyback topology; a DC bus receiving the high voltage DC output; Housekeeping power supply, Universal Serial Bus (USB) charging power supply; a storage compartment within the housing; a charger compartment within the housing, the charger compartment including the battery pack interface; a charger lid provided on a side of the housing such that the power tool battery pack is inserted into the charger compartment from the side of the housing; the DC bus delivers the high voltage DC output to the housekeeping power supply, the USB charging power supply, and the DC-DC converter; the charger lid is pivotable about a bottom surface of the housing and secured by a mechanism on a top surface of the housing; charger.

17. The DC-DC converter comprises: an active clamp flyback converter receiving the high voltage DC output; an active clamp flyback controller configured to control the active clamp flyback converter to convert the high voltage DC output to a corresponding voltage; a charge FET electrically connected between the active clamp flyback converter and the battery pack interface; a charge FET control circuit configured to enable and disable the charge FET to charge the power tool battery pack using the corresponding voltage.

17. The charger of claim 16.

18. 17. The charger of claim 16, wherein the housekeeping power supply includes a quasi-resonant (QR) flyback converter for converting the high voltage DC output to a voltage level for use by a modular storage unit.

19. further comprising one or more USB ports connected to said USB charging power supply; the USB charging power supply includes a quasi-resonant (QR) flyback converter that converts the high voltage DC output to a voltage level for powering the one or more USB ports.

17. The charger of claim 16.

20. 1. A charger for a power tool battery pack, comprising: Housing and a charging circuit within the housing for charging a power tool battery pack; a battery pack interface configured to receive a power tool battery pack; a power cord for receiving an alternating current (AC) input; an active power factor correction (PFC) converter configured to receive AC power from the power cord and convert the AC power to a high voltage DC output; a DC bus receiving the high voltage DC output; Housekeeping power supply, Universal Serial Bus (USB) charging power supply; a DC-DC converter connected between the DC bus and the battery pack interface, the DC-DC converter including an active clamp flyback topology; a storage compartment within the housing; a charger compartment within the housing, the charger compartment including the battery pack interface; a charger lid provided on a side of the housing such that the power tool battery pack is inserted into the charger compartment from the side of the housing; the DC bus delivers the high voltage DC output to the housekeeping power supply, the USB charging power supply, and the DC-DC converter; the charger lid is pivotable about a bottom surface of the housing and secured by a mechanism on a top surface of the housing; charger.

21. The DC-DC converter comprises: an active clamp flyback converter receiving the high voltage DC output; an active clamp flyback controller configured to control the active clamp flyback converter to convert the high voltage DC output to a corresponding voltage; a charge FET electrically connected between the active clamp flyback converter and the battery pack interface; a charge FET control circuit configured to enable and disable the charge FET to charge the power tool battery pack using the corresponding voltage.

21. The charger of claim 20.

22. 22. The charger of claim 21, wherein the housekeeping power supply includes a quasi-resonant (QR) flyback converter for converting the high voltage DC output to a voltage level for use by a modular storage unit.

23. 22. The charger of claim 21, further comprising one or more USB ports connected to the USB charging power supply, the USB charging power supply including a quasi-resonant (QR) flyback converter for converting the high voltage DC output to a voltage level for powering the one or more USB ports.

24. 1. A charger for a power tool battery pack, comprising: a battery pack interface configured to receive a power tool battery pack; an AC power input for receiving input AC power; a converter for converting AC power at the AC power input to a high voltage DC output; a DC-DC converter connected between the converter and the battery pack interface, the DC-DC converter including an active clamp flyback topology and configured to convert the high voltage DC output to charging DC power provided to the battery pack interface; Housing and a storage compartment within the housing; a charger compartment within the housing, the charger compartment including the battery pack interface; a charger lid provided on a side of the housing such that the power tool battery pack is inserted into the charger compartment from the side of the housing; the charger lid is pivotable about a bottom surface of the housing and secured by a mechanism on a top surface of the housing; charger.

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