Power supply including control of thermal management system

Abstract

To provide a power supply device including control of a thermal management system.SOLUTION: A portable power supply device 100 includes an internal power supply 120, a thermal management system 122 that controls the temperature of one or more internal components of the portable power supply device, a power input unit 114 that charges the internal power supply, a power output unit 116 that supplies power output by the internal power supply, a first sensing circuit that detects a temperature of one or more internal components, a secondary power supply, and a controller, and the controller receives a first signal from the first sensing circuit, enables the thermal management system on the basis of the temperature of the one or more internal components, and enables charging of the internal power supply on the basis of the temperature of the one or more internal components.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Patent Application No. 63 / 347,884, filed June 1, 2022, and U.S. Provisional Patent Application No. 63 / 370,755, filed August 8, 2022, the entire contents of each of which are incorporated herein by reference.

[0002] SUMMARY OF THE DISCLOSURE The embodiments described herein relate to a portable power supply device. Summary of the Invention [Means for solving the problem]

[0003] The portable power supply disables power discharge and / or charging functions to the user when the power source reaches a predefined operating condition, such as end of discharge ("EOD") when the on-board battery voltage is too low to function adequately (e.g., the battery reaches a low voltage discharge threshold), end of charge when the on-board battery reaches 100% charge, over temperature (OT) when the portable battery is too hot to provide discharge power, or under temperature (UT) when the portable battery is too cold to provide discharge power or charge. When the power source reaches these predefined operating conditions, it is desirable to restore full functionality of the power supply as quickly as possible. The rate at which the unit can resume function may depend on the user's access to the power source. Additionally, the rate at which the unit can recharge and / or resume function may depend on the temperature of the on-board battery. Certain battery chemistries and user life cycle requirements require the battery to be at or below a temperature threshold in order to charge or discharge. The charging over temperature and / or under temperature threshold may be lower than the discharging over temperature and / or under temperature threshold. Additionally, the battery chemistry and life cycle requirements of on-board batteries may have a hierarchy of charging capabilities that dictates a reduced maximum charging rate depending on the cell and ambient temperature.

[0004] Various embodiments of the present disclosure recognize that challenges exist in enabling functionality of a portable battery unit at low ambient temperatures. These challenges result in the inability to charge and / or discharge at low ambient temperature conditions. Thus, there is a need for a portable battery power supply that can quickly heat up an on-board battery to begin discharging or charging and reach a maximum charge rate as quickly as possible when connected to a secondary power source when the on-board battery is too cold to charge (e.g., the minimum cell temperature is below the charge UT threshold). Some embodiments of the present disclosure utilize a secondary power source to power a thermal management system independent of the charge state of the portable battery power supply, thereby enabling charge / discharge functionality and / or minimizing charge and / or standby times in low ambient conditions.

[0005] A portable power supply described herein includes an internal power source configured to provide power to a device connected to the portable power supply, a thermal management system configured to control a temperature of the internal power source, a power input unit configured to charge the internal power source, a power output unit configured to provide power output by the internal power source, a first sensing circuit configured to detect a state of charge ("SOC") of the internal power source, a second sensing circuit configured to detect a temperature of the internal power source, a secondary power source, and a controller. The controller includes a processor and a memory. The controller is configured to receive a first signal related to the SOC of the internal power source from the first sensing circuit, receive a second signal related to the temperature of the internal power source from the second sensing circuit, disable charging of the internal power source based on one of the SOC of the internal power source and the temperature of the internal power source, and power the thermal management system using the secondary power source.

[0006] A portable power supply described herein includes an internal power source configured to provide power to a device connected to the portable power supply, a thermal management system configured to control a temperature of the internal power source, a power input unit configured to charge the internal power source, a power output unit configured to provide power output by the internal power source, a first sensing circuit configured to detect a state of charge ("SOC") of the internal power source, a second sensing circuit configured to detect a temperature of the internal power source, and a controller. The controller includes a processor and a memory. The controller is configured to receive a first signal related to the SOC of the internal power source from the first sensing circuit, receive a second signal related to the temperature of the internal power source from the second sensing circuit, disable charging of the internal power source based on one of the SOC of the internal power source and the temperature of the internal power source, and power the thermal management system using a rebound voltage of the internal power source after the internal power source is disabled due to reaching a low-voltage discharge threshold.

[0007] The portable power supply includes an internal power source, a thermal management system configured to control a temperature of one or more internal components of the portable power supply, a power input unit configured to charge the internal power source, a power output unit configured to provide power output by the internal power source, a first sensing circuit configured to detect a temperature of the one or more internal components, a secondary power source, and a controller, wherein the controller is configured to receive a first signal from the first sensing circuit, enable the thermal management system based on the temperature of the one or more internal components, and enable charging of the internal power source based on the temperature of the one or more internal components.

[0008] Before describing any embodiment in detail, it is to be understood that the embodiment is not limited to the details of construction and arrangement of elements disclosed in the following description or illustrated in the accompanying drawings. These embodiments can be practiced or carried out in various ways. It is also to be understood that the phraseology and terminology used herein is for descriptive purposes and should not be considered as limiting the invention. The use of "including", "including" or "having" and variations thereof is intended to encompass the items listed thereafter and equivalents thereof, as well as additional items. Unless otherwise specified or limited, the terms "mounted", "connected", "supported" and "coupled" and variations thereof are used broadly and include direct and indirect mounting, connecting, supporting, and coupling.

[0009] It should also be understood that while embodiments may include hardware, software, and electronic elements or modules, for purposes of explanation, the majority of elements may be shown and described as if they were implemented exclusively in hardware. However, upon reading and understanding this detailed description, one of ordinary skill in the art will recognize that in at least one embodiment, the electronic 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 the embodiments may be implemented using a number of hardware and software-based devices and a number of different structural elements. For example, the terms "server," "computing device," "controller," "processor," etc. described herein 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) connecting the elements.

[0010] Those skilled in the art will understand that relative terms used in connection with a quantity or condition, such as "about," "approximately," "substantially," etc., are inclusive of the declared value and have the meaning stated in the context (e.g., the term includes at least the error associated with the measurement precision, the tolerance associated with a particular value (e.g., manufacture, assembly, use, etc.)). Such terms should also be considered to indicate a range defined by the absolute values ​​of the two endpoints. For example, the phrase "about 2 to about 4" indicates a range of "2 to 4." Relative terms may refer to a percentage increase or decrease (e.g., 1%, 5%, 10% or more) of the indicated value.

[0011] Functions described herein as being performed by one element may be performed in a distributed manner by multiple components. Similarly, functions performed by multiple elements may be integrated and performed by a single element. Similarly, an element described as performing a particular function may also perform additional functions not described herein. For example, a device or structure "configured" in a particular way is configured in at least that way, but may be configured in multiple ways not explicitly recited.

[0012] Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings. [Brief description of the drawings]

[0013] [Figure 1] FIG. 1 is a perspective view of a portable power supply device. [Diagram 2] 2 illustrates an embodiment of an internal power supply included in the portable power supply of FIG. 1. [Diagram 3] 2 illustrates an embodiment of an internal power supply included in the portable power supply of FIG. 1. [Figure 4A] FIG. 2 illustrates a control system for the portable power supply device of FIG. [Figure 4B] FIG. 2 is a block circuit diagram of a network communication module of the portable power supply device of FIG. 1. [Figure 4C]FIG. 2 is a diagram showing a communication system between the portable power supply device and an external device of FIG. [Diagram 5] FIG. 2 is a schematic diagram of the portable power supply device of FIG. 1. [Figure 6A] FIG. 2 illustrates a situation where the thermal management system is disabled. [Figure 6B] FIG. 2 illustrates a situation where the thermal management system is disabled. [Figure 6C] FIG. 2 illustrates a situation where the thermal management system is enabled. [Figure 6D] FIG. 2 illustrates a situation where the thermal management system is enabled. [Figure 6E] FIG. 1 illustrates a thermal management system and a situation where charging is enabled. [Figure 7] FIG. 2 shows the voltage response of a battery during pulse discharge. [Figure 8] FIG. 2 shows the voltage response of a battery during continuous discharge. [Figure 9] 2 illustrates the power supply of FIG. 1 including a secondary power source. [Figure 10] 2 illustrates a process for charging the internal power supply of the power supply of FIG. 1. [Figure 11] 2 illustrates a process for powering additional features of the power supply device of FIG. 1. [Figure 12] FIG. 2 illustrates a process for controlling the thermal management system of the power supply of FIG. [Figure 13] FIG. 2 illustrates a process for controlling the thermal management system of the power supply of FIG. [Figure 14A] FIG. 2 illustrates a process for controlling the thermal management system of the power supply of FIG. [Figure 14B] FIG. 2 illustrates a process for controlling the thermal management system of the power supply of FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0014] FIG. 1 illustrates a portable power supply or power supply 100. The power supply 100 includes, among other things, a housing 102. In some embodiments, the housing 102 includes one or more wheels 104 and a handle assembly 106. In the illustrated embodiment, the handle assembly 106 is a telescoping handle movable between an extended position and a folded position. The handle assembly 106 includes an inner tube 108 and an outer tube 110. The inner tube 108 fits snugly inside and is slidable relative to the outer tube 110. The inner tube 108 is coupled to a horizontal gripping member 112. In some embodiments, the handle assembly 106 further includes a locking mechanism to prevent the inner tube 108 from accidentally moving relative to the outer tube 110. The locking mechanism may include a notch, a sliding catch pin, or another suitable locking mechanism to prevent the inner tube 108 from sliding relative to the outer tube 110 when the handle assembly 106 is in the extended and / or folded position. In practice, a user grasps gripping member 112 and pulls upward to extend handle assembly 106. Inner tube 108 slides relative to outer tube 110 until handle assembly 106 is locked in the extended position. The user can then pull power supply 100 by handle assembly 106 and guide it to a desired location. Wheels 104 on power supply 100 facilitate such movement.

[0015] The housing 102 of the power supply 100 further includes a power input unit 114, a power output unit 116, and a display 118. In the illustrated embodiment, the power input unit 114 includes a plurality of electrical connection interfaces configured to receive power from an external power source. In some embodiments, the external power source is a DC power source. For example, the DC power source can be one or more photovoltaic cells (e.g., solar panels), an electric vehicle (EV) charging station, or any other DC power source. In some embodiments, the external power source is an AC power source. For example, the AC power source can be a conventional wall outlet, such as a 120V or 240V outlet found in North America. As another example, the AC power source can be a conventional wall outlet, such as a 220V or 230V outlet found outside of North America. In some embodiments, the power input unit 114 is replaced with or additionally includes a cable configured to plug into a conventional wall outlet. In some embodiments, the power input unit 114 further includes one or more devices, such as an antenna or an inductive coil, configured to wirelessly receive power from an external power source. The power received by the power input unit 114 may be used to charge a core battery or internal power source 120 disposed within the housing 102 of the power supply 100. The power received by the power input unit 114 may also be used to power a thermal management system 122 disposed within the housing 102 of the power supply 100. The thermal management system 122 is configured to reduce the temperature of the internal power source 120 below a high temperature cutoff threshold, resulting in a cooling time duration that is shorter than the natural cooling time duration of the internal power source 120.

[0016] The power received by the power input unit 114 may also be used to provide power to one or more devices connected to the power output unit 116. The power output unit 116 includes one or more power outlets. In the illustrated embodiment, the power output unit 116 includes a number of AC power outlets 116A and DC power outlets 116B. It should be understood that the number of power outlets included in the power output unit 116 is not limited to the number of power outlets shown in FIG. 1. For example, in some embodiments of the power supply 100, the power output unit 116 may include more or fewer power outlets than the power outlets included in the illustrated embodiment of the power supply 100.

[0017] In some embodiments, the power output unit 116 is configured to provide power output by the internal power source 120 to one or more peripheral devices. In some embodiments, the power output unit 116 is configured to provide power provided by an external power source directly to one or more peripheral devices. The one or more peripheral devices may be a smartphone, a tablet computer, a laptop computer, a portable music player, a power tool, a power tool battery pack, a power tool battery pack charger, etc. The peripheral devices may be configured to receive DC and / or AC power from the power output unit 116.

[0018] In some embodiments, the DC power outlet 116B includes one or more sockets for receiving and charging a power tool battery pack. In such embodiments, a power tool battery pack received by or connected to the battery pack socket 116B is charged using power output by the internal power source 120 and / or power received directly from an external power source. In some embodiments, a power tool battery pack connected to the battery pack socket 116B is used to provide power to the internal power source 120, to the thermal management system 122, and / or to one or more peripheral devices connected to the outlets of the power output unit 116. In some embodiments, the power output unit 116 includes a tool specific power outlet. For example, the power output unit may include a DC power outlet used to power a welding tool.

[0019] Display 118 is configured to indicate to a user the status of power supply 100, such as the charging status and / or fault status of internal power source 120. In some embodiments, display 118 includes one or more light emitting diode ("LED") indicators configured to illuminate and indicate the current charging status of internal power source 120. In some embodiments, display 118 is, for example, a liquid crystal display ("LCD"), a light emitting diode ("LED") display, an organic LED ("OLED") display, an electroluminescent display ("ELD"), a surface conduction electron emitter display ("SED"), a field emission display ("FED"), a thin film transistor ("TFT") LCD, an electronic ink display, or the like. In other embodiments, power supply 100 does not include a display. In those embodiments, the display functions accomplished by the on-board display may be accomplished via external device 437 (see, for example, FIG. 4C).

[0020] FIG. 2 illustrates a block diagram of the internal power source 120 included in the power supply 100, according to some embodiments. As illustrated in FIG. 2, the internal power source 120 includes one or more sub-core modules 125A-125N. At least one sub-core module 125 is included in the internal power source 120. However, the internal power source 120 may include any desired number, N, of the sub-core modules 125A-125N. Although the sub-core modules 125A-125N are shown connected in series, they may be electrically connected in series, in parallel, and / or in combinations thereof. In some embodiments, the sub-core modules 125A-125N included in the internal power source 120 are implemented as rechargeable battery packs, such as power tool battery packs. As described in more detail below, the rechargeable battery packs included in the internal power source 120 may be relatively high voltage (e.g., 72V) battery packs used to power large power tools.

[0021] The following description of each sub-core module 125 is written with respect to sub-core module 125A. However, it should be understood that each of the individual sub-core modules 125 included in the internal power source 120 may include similar components and may include corresponding reference numbers (e.g., 125B, 126B, 127B, 125N, 126N, 127N, etc.). The sub-core module 125A includes a stack of battery cells 126A, or a plurality of battery cells 126A. The stack of battery cells 126A includes at least two battery cells electrically connected in series. However, the stack of battery cells 126A may include any desired number of battery cells. For example, the stack of battery cells 126A may include 2, 3, 4, 10, 20, 23, 28, 46, 70, or more battery cells electrically connected in series. In some embodiments, the stack of battery cells 126A includes battery cells electrically connected in parallel. In some embodiments, the stack of battery cells 126A includes battery cells electrically connected in series and parallel. For example, Figure 3 illustrates an embodiment of a sub-core module 125A in which the stack of battery cells 126A are electrically connected in a combination of parallel and parallel. In some embodiments, the sub-core module 125A includes multiple stacks of battery cells 126A electrically connected in parallel with each other.

[0022] The battery cells included in the stack of battery cells 126A are rechargeable battery cells having a lithium ion chemistry, such as lithium phosphate or lithium manganese. In some embodiments, the battery cells included in the stack of battery cells 126A may have lead acid, nickel cadmium, nickel metal hydride, and / or other chemistries. Each battery cell in the stack of battery cells 126A has an individual nominal voltage. The nominal voltage of the individual battery cells included in the stack of battery cells 126A may be, for example, 4.2V, 4V, 3.9V, 3.6V, 2.4V, or some other voltage value. For illustrative purposes, it is assumed that the nominal voltage of the individual battery cells included in the stack of battery cells 126A is equal to 4V. Thus, if the stack of battery cells 126A includes two battery cells connected in series, the nominal voltage of the stack of battery cells 126A or the sub-core module 125A is equal to 8.0V. Similarly, if the stack of battery cells 126A includes 23 battery cells connected in series, the nominal voltage of the sub-core module 125A will be 92V. As shown in Figure 3, the ampere-hour capacity, or capacity, of the sub-core module 125A can be increased by adding additional battery cells connected in parallel and series combinations to the stack of battery cells 126A. In some embodiments, supercapacitors are used in place of or in conjunction with the battery cells.

[0023] The sub-core module 125A further includes a battery or sub-core monitoring circuit 127A and a sub-core housing 128A. The sub-core monitoring circuit 127A is electrically connected to the stack of battery cells 126A and to a controller 200 (FIG. 4A) included in the power supply 100. The sub-core monitoring circuit 127A receives power from the stack of battery cells 126A during operation of the power supply 100. The sub-core monitoring circuit 127A is configured to sense a state of charge ("SOC") level or voltage value of the stack of battery cells 126A and transmit the voltage reading to the controller 200. The voltage level of the sub-core module 125A can be determined by measuring the total open circuit voltage of the stack of battery cells 126A or by summing the open circuit voltage measurements of each parallel string of battery cells in the stack of battery cells 126A. In some embodiments, the sub-core monitor circuits 127A-127N send voltage readings of the stack of battery cells 126A-126N to a separate master monitor circuit. The separate master monitor circuit can send a signal to the sub-core monitor circuits 127A-127N to begin sensing the state of charge ("SOC") level, i.e., voltage value, of the stack of battery cells 126A-126N. In some embodiments, the SOC level may be determined using various methodologies, such as, for example, open circuit voltage conversion, coulomb counting, highest cell voltage, lowest cell voltage, etc. In some embodiments, depending on the state of the power supply 100, various constraints, and SOC utilization, it may be advantageous to use one of the SOC level determination methods over other methodologies. Additionally, SOC is used throughout this disclosure and may refer to the calculation of SOC via any of the aforementioned methods. In some embodiments, the sub-core monitoring circuit 127A is further configured to sense the discharge current of the stack of battery cells 126A (e.g., using a current sensor) and / or the temperature of the sub-core module 125A (e.g., using a temperature sensor) and transmit the sensed current and / or temperature readings to the controller 200. The sub-core monitoring circuit 127A is further configured to receive commands from the controller 200 during operation of the power supply 100.

[0024] In some embodiments, the stack of battery cells 126A and the sub-core monitor circuitry 127A are disposed within a sub-core housing 128A of the sub-core module 125A. In some embodiments, the stack of battery cells 126A is disposed within the sub-core housing 128A and the sub-core monitor circuitry 127A is included as a component of the controller 200. In some embodiments, the sub-core module 125A does not include a sub-core housing 128A.

[0025] As described above, the internal power source 120 of the power supply device 100 may include a plurality of sub-core modules 125 electrically connected in series and / or in parallel. For example, if the internal power source 120 includes a first sub-core module 125A and a second sub-core module 125B electrically connected in series, and each of the first sub-core module 125A and the second sub-core module 125B has a nominal voltage of 92V, the combined voltage of the first sub-core module 125A and the second sub-core module 125B is equal to 184V. Thus, the voltage level at which the internal power source 120 outputs DC power is 184V. Similarly, if the internal power source 120 includes five sub-core modules 125A-125E connected in series, and each of the sub-core modules 125A-125E has a nominal voltage of 56V, the voltage level at which the internal power source 120 outputs DC power is 280V. Any number of sub-core modules 125A-125N can be electrically connected in series and / or parallel to achieve a desired nominal voltage and / or capacity of the internal power supply 120.

[0026] 4A is a generalized schematic diagram of a controller 200 included in the power supply 100. The controller 200 is electrically and / or communicatively connected to various modules or components of the power supply 100. For example, the controller 200 may be connected to the power input unit 114, the power output unit 116, the display 118, the internal power supply 120, and the thermal management system 122. Those skilled in the art will recognize that the electrical and / or communicative connections between the controller 200 and the internal power supply 120 include electrical and / or communicative connections between the controller 200 and components included in the internal power supply 120, such as, but not limited to, the multiple sub-cores 125A-125N and the components included therein (e.g., the battery cells 126A-125N and the sub-core monitoring circuits 127A-127B).

[0027] Controller 200 is further electrically and / or communicatively connected to input power conversion unit 400, DC bus 405, AC output power conversion unit 410, and DC output power conversion unit 415, a user interface 420, a network communication module 425, and a number of sensors 430. Input power conversion unit 400, DC bus 405, AC output power conversion unit 410, and DC output power conversion unit 415 are described in more detail below.

[0028] The network communication module 425 is connected to a network 435 to enable the controller 200 to communicate with peripheral devices in the network, such as a smartphone or a server. The sensors 430 include, for example, one or more voltage sensors, one or more current sensors, one or more temperature sensors, and / or one or more additional sensors used to measure electrical and / or other characteristics of the power supply 100. Each of the sensors 430 generates one or more output signals that are provided to the controller 200 for processing and evaluation. A user interface 420 is included to provide user control of the power supply 100. The user interface 420 may include any combination of digital and analog input devices needed to achieve a desired level of control of the power supply 100. For example, the user interface 420 may include knobs, dials, switches, buttons, etc. In some embodiments, the user interface 420 is integrated with the display 118 (e.g., as a touch screen display).

[0029] The controller 200 includes a combination of hardware and software operable to, among other things, control the operation of the power supply 100, communicate via a network 435, receive input from a user via a user interface 420, provide information to a user via a display 118, and the like. For example, the controller 200 includes, among other things, a processing unit 440 (e.g., a microprocessor, a microcontroller, an electronic processor, an electronic controller, or another suitable programmable device), a memory 445, an input unit 450, and an output unit 455. The processing unit 440 includes, among other things, a control unit 460, an arithmetic logic unit ("ALU") 465, and a number of registers 470 (shown as a group of registers in FIG. 4A ), and is implemented using a known computer architecture (e.g., a modified Harvard architecture, a von Neumann architecture, etc.). The processing unit 440, the memory 445, the input unit 450, and the output unit 455, as well as the various modules or circuits connected to the controller 200, are connected by one or more control buses and / or data buses (e.g., a shared bus 475). A control bus and / or data bus is generally shown in Figure 4A for purposes of illustration. Although controller 200 is shown in Figure 4A as a single controller, controller 200 may also include multiple controllers configured to work in concert to achieve a desired level of control of power supply 100. Thus, any control functions and processes described herein with respect to controller 200 may also be performed by two or more controllers acting in a distributed manner.

[0030] The memory 445 is a non-transitory computer-readable medium, including, for example, program storage and data storage. The program storage and data storage may include a combination of various types of memory, such as read-only memory ("ROM"), random access memory ("RAM") (e.g., dynamic RAM ["DRAM"], synchronous DRAM ["SDRAM"], etc.), electrically erasable programmable ROM ("EEPROM"), flash memory, a hard disk, an SD card, or other suitable magnetic, optical, physical, or electronic memory elements. The processing unit 440 is coupled to the memory 445 and is configured to execute software instructions, which may be stored in the RAM of the memory 445 (e.g., during execution), in the ROM of the memory 445 (e.g., typically permanently), or in another memory or another non-transitory computer-readable medium, such as a disk. Software included in the implementation of the power supply 100 and the controller 200 may be stored in the memory 445 of the controller 200. The software may include, for example, firmware, one or more applications, program data, filters, rules, one or more program modules, and other executable instructions. Controller 200 is configured to retrieve and execute instructions relating to, among other things, the control processes and methods described herein from memory 445. In other embodiments, controller 200 includes additional, fewer, or different components.

[0031] During operation of the power supply 100, the controller 200 is configured to monitor voltage, current, temperature, and / or other signals received from the various components described above. For example, the controller 200 is configured to monitor a voltage signal received from the internal power source 120 when the internal power source 120 is charged by an external power source connected to the power input unit 114. As another example, the controller 200 is configured to monitor a voltage signal received from the internal power source 120 when the internal power source 120 provides power to one or more peripheral devices connected to the power output unit 116. More generally, the controller 200 is configured to monitor and / or control the flow of power from and to the above-mentioned components of the power supply 100 that are electrically and communicatively coupled to the controller 200.

[0032] As shown in FIG. 4B, the network communication module or wireless communication controller 425 includes a processor 426, a memory 427, an antenna and transceiver 428, and a real-time clock (RTC) 429. The wireless communication controller 425 enables the power supply 100 to communicate with an external device 437 (see, e.g., FIG. 4C). The wireless antenna and transceiver 428 cooperate to send and receive wireless messages to the external device 437 and the processor 426. The memory 427 may store instructions to be performed by the processor 426 and / or may store data related to communications between the power supply 100 and the external device 437, etc. The processor 426 of the wireless communication controller 425 controls wireless communications between the power supply 100 and the external device 437. For example, the processor 426 associated with the wireless communication controller 425 may buffer incoming and / or outgoing data, communicate with the controller 200, and determine communication protocols and / or settings to use in wireless communications. Communications via wireless communication controller 425 may be encrypted to protect data exchanged between power supply 100 and external device 437 from third parties.

[0033] In the illustrated embodiment, the wireless communication controller 425 is a Bluetooth controller. The Bluetooth controller communicates with the external device 437 employing the Bluetooth protocol. Thus, in the illustrated embodiment, the external device 437 and the power supply 100 are within communication range (i.e., nearby) of each other when exchanging data. In other embodiments, the wireless communication controller 425 communicates using other protocols (e.g., Wi-Fi, ZigBee, proprietary protocols, etc.) over different types of wireless networks. For example, the wireless communication controller 425 may be configured to communicate via Wi-Fi over a wide area network or a local area network such as the Internet, or through a piconet (e.g., using infrared or NFC communication).

[0034] In some embodiments, the network is a cellular network, such as, for example, a Global System for Mobile Communications ("GSM") network, a General Packet Radio Service ("GPRS") network, a Code Division Multiple Access ("CDMA") network, an Evolution-Data Optimized ("EV-DO") network, an Enhanced Data Rates for GSM Evolution ("EDGE") network, a 3GSM network, a 4GSM network, a 4G LTE network, a 5G New Radio, a Digital Enhanced Cordless Telecommunications ("DECT") network, a digital AMPS (IS-136 / TDMA) network, or an Integrated Digital Enhanced Network ("iDEN") network.

[0035] The wireless communication controller 425 is configured to receive data from the controller 200 and relay that information to the external device 437 via the antenna and transceiver 428. Similarly, the wireless communication controller 425 is configured to receive information (e.g., configuration and programming information) from the external device 437 via the antenna and transceiver 428 and relay that information to the controller 200.

[0036] The RTC 429 increments and maintains time independent of other powered tool components. The RTC 429 receives power from the internal power supply 120. Having the RTC 429 as an independently powered clock allows for time stamping of operational data (stored in memory 427 for later export) and security features whereby a lockout time can be set by the user (e.g., via external device 437) and the tool is locked out if the time on the RTC 429 exceeds the set lockout time.

[0037] 4C illustrates a communication system 436. The communication system 436 includes at least one power supply 100 and an external device 437. Each power supply 100 and the external device 437 can communicate wirelessly while within communication range of each other. Each power supply 100 can communicate power supply status, power supply operation statistics, power supply identification information, power supply sensor data, stored power supply usage information, power supply maintenance data, etc.

[0038] Using the external device 437, a user can access parameters of the power supply 100. Using the parameters (e.g., power supply operational data or settings), a user can determine how the power supply 100 has been used, whether maintenance is recommended or has been performed in the past, and identify malfunctioning components or other causes for a particular performance problem. The external device 437 can also send data or send commands to the power supply 100 for power supply configuration, firmware updates, etc. The external device 437 also allows a user to configure the power supply 100's operating parameters, safety parameters, operating modes, etc.

[0039] The external device 437 may be, for example, a smart phone (as shown), a laptop computer, a tablet computer, a personal digital assistant (PDA), or another electronic device capable of wirelessly communicating with the power supply 100 and providing a user interface. The external device 437 provides a user interface to allow a user to access and interact with the power supply 100. The external device 437 may determine operating parameters and accept user inputs, such as turning features on or off. The user interface of the external device 437 provides an easy-to-use interface for the user to control and customize the operation of the power supply 100. Thus, the external device 437 provides a user interface that gives the user access to the power supply operational data of the power supply 100 and allows the user to interact with the controller 200 of the power supply 100.

[0040] In addition, as shown in FIG. 4C , the external device 437 can also share power supply operational data obtained from the power supply 100 with a remote server 438 connected via the network 435. The remote server 438 may be used to store tool operational data obtained from the external device 437, to provide additional functionality and services to the user, or a combination thereof. In some embodiments, storing information on the remote server 438 allows the user to access the information from multiple different locations. In some embodiments, the remote server 438 collects information from various users about their power supplies and provides statistics or statistical measures to the users based on information obtained from the different power supplies. For example, the remote server 438 may provide statistics regarding the efficiency of the power supply 100 gained from experience, typical usage of the power supply 100, and other relevant characteristics and / or measures of the power supply 100. Network 435 may include various network elements (routers 439A, hubs, switches, cellular towers 439B, wired connections, wireless connections, etc.) for connecting to, for example, the Internet, a cellular data network, a local network, or combinations thereof, as previously described. In some embodiments, power supply 100 is configured to communicate directly with remote server 438 through an additional wireless interface or over the same wireless interface that power supply 100 uses to communicate with external device 437.

[0041] In some embodiments, the power supply 100 is configured to provide output power (e.g., from the internal power source 120) until the internal power source 120 reaches a low-voltage cutoff threshold. In embodiments in which the power supply 100 receives a removable, rechargeable battery pack, the battery pack used to provide output power from the power supply 100 may be similarly discharged until the low-voltage cutoff threshold is reached. A user may also program the power supply 100 or select an operating mode for the power supply 100 such that the power supply 100 stops providing (e.g., stops outputting power to the power output unit 116) before the power supply 100 or a connected battery pack reaches the low-voltage cutoff threshold. For example, using the external device 437, a user may enable a power-down timer in the controller 200. A user can enable a power down timer so that if the output power from the power supply 100 falls below a threshold (e.g., power threshold, current threshold, etc.) for a selected time interval (e.g., 1 hour, 2 hours, 6 hours, 12 hours, etc.), the power supply 100 output is turned off. A user can set the threshold and time interval using an external device 437. As an example, a user can set a power threshold of 80 watts and a time interval of 1 hour. If the power supply 100 has not output 80 watts of power for an hour, the power supply 100 will be turned off. In some embodiments, the timer is used as an energy saving feature. Rather than powering a relatively low power device for an extended period of time, power is conserved for higher power applications (e.g., corded power tools). If the power down timer is not enabled, the power supply 100 will not shut down until the low voltage cutoff threshold is reached, and can power lower power devices until the low voltage cutoff is reached.

[0042] Figure 5 shows a general schematic diagram of a power supply 100, according to some embodiments. As shown in Figure 5, a power input unit 114 is configured to receive power from an external power source and provide the received power to an input power conversion unit 400. Although the power input unit 114 is illustrated as an electrical plug, the power input unit 114 may be implemented as any of the examples described above for the power input unit 114.

[0043] The input power conversion unit 400 includes a power factor correction (PFC) circuit 500 and an input DC-DC converter 505. The PFC circuit 500 is configured to convert, or rectify, AC power received from an external power source (e.g., a 120V wall outlet) to DC power. The PFC circuit 500 includes components configured to smooth, or improve, the power factor of the power rectified by the PFC circuit 500. Compared to a converter circuit that does not include a PFC component, the PFC circuit 500 operates with improved efficiency by reducing the amount of current drawn from the external power source during operation of the power supply 100. For example, if the power supply 100 demands 3.6 kilowatts (kW) during operation, the PFC circuit 500 will draw a smaller amount of current from the external power source to meet the demand for 3.6 kW, compared to the amount of current drawn by a converter circuit that does not include any PFC components. Additionally, the PFC circuit 500 reduces the electromagnetic interference (EMI) requirements of the power supply 100 by absorbing differential mode currents present in the first input DC-DC converter 505. For example, the PFC circuit 500 may include a capacitor bank connected to an output side of the PFC circuit 500 to provide a majority of the differential mode transient current to circuitry downstream of the PFC circuit 500.

[0044] As mentioned above, the input power conversion unit 400 further includes an input DC-DC converter 505. The input DC-DC converter 505 is configured to convert the DC power output by the PFC circuit 500 at a first voltage level (e.g., 120V) to a voltage level (e.g., 36V, 72V, 120V, 280V, etc.) used to charge the internal power source 120 and / or power the thermal management system 122. However, it should be understood that in some implementations, the internal power source 120 can alternatively or additionally power the thermal management system 122. In some embodiments, the input DC-DC converter 505 is a step-down converter configured to reduce the voltage level of the DC power output by the PFC circuit 500 to a voltage level used to charge the internal power source 120. In some embodiments, the input DC-DC converter 505 is a step-up converter configured to increase the voltage level of the DC power output by the PFC circuit 500 to a voltage level used to charge the internal power source 120. In some embodiments, the input DC-DC converter 505 is a step-down / step-up converter. In some embodiments, the input DC-DC converter 505 is a single converter circuit. In some embodiments, the input DC-DC converter 505 is implemented as two or more converter circuits.

[0045] The DC bus 405 is configured to transfer DC power between components included in the power supply 100. For example, the DC bus 405 delivers the DC power output by the input power conversion unit 400 to the internal power source 120 for charging the internal power source 120. As another example, the DC bus 405 delivers the DC power output by the internal power source 120 to the AC output power conversion unit 410 and / or the DC output power conversion unit 415. As another example, the DC bus 405 delivers the DC power output by the input power conversion unit 400 to the thermal management system 122 to reduce the temperature of the internal power source 120. However, it should be understood that in some implementations, the internal power source 120 can alternatively or additionally supply power to the thermal management system 122. In some embodiments, the DC bus 405 transfers DC power directly from the input power conversion unit 400 to the AC output power conversion unit 410 and the DC output power conversion unit 415. The DC bus 405 is implemented as a combination of one or more bus bars, circuits, wires, and / or terminals used to transfer DC power to and from the various components of the power supply 100.

[0046] The AC output power conversion unit 410 is configured to convert DC power provided by the internal power source 120 and / or the input power conversion unit 400 into AC power used to power one or more peripheral devices connected to the AC outlet 116A. The AC output power conversion unit 410 includes a first DC-DC converter 510 and an inverter 515. The first DC-DC converter 510 is configured to convert DC power from a voltage level used to charge the internal power source 120 (e.g., 36V, 72V, 120V, 280V, etc.) to a voltage level provided as an input to the inverter 515 (e.g., 120V, 240V, etc.). In some embodiments, the first DC-DC converter 510 is a boost converter configured to increase the voltage level of the DC power provided by the internal power source and / or the input power conversion unit 400. In some embodiments, the first DC-DC converter 510 is a step-down converter configured to step-down the voltage level of the DC power provided by the internal power supply 120 and / or the input power conversion unit 400. In some embodiments, the input DC-DC converter 505 is a step-down / step-up converter. In some embodiments, the input DC-DC converter 505 is a single converter circuit. In some embodiments, the input DC-DC converter 505 is implemented as two or more converter circuits.

[0047] 5, the DC power output by the first DC-DC converter 510 is provided as an input to an inverter 515. The inverter 515 is configured to convert the DC power output by the first DC-DC converter 510 to AC power that is used to power one or more peripheral devices connected to the AC outlet 116A. Various circuit configurations may be used to implement the inverter 515.

[0048] The DC output power conversion unit 415 is configured to convert a voltage level of the DC power provided by the internal power source 120 and / or the input power conversion unit 400 to one or more voltage levels of DC power used to power one or more peripheral devices connected to the DC outlet 116B. In FIG. 5, the DC outlet 116B is shown as a socket configured to charge a power tool battery pack. However, it should be understood that the DC outlet 116B is not limited to implementation in a battery pack charger. For example, the DC outlet 116B may additionally or alternatively include a DC power outlet, such as a USB outlet, a headphone jack (AUX cord port), a cigarette lighter, or any other type of DC output.

[0049] In particular, the DC output power conversion unit 415 includes a second DC-DC converter 520 configured to convert DC power from a voltage level (e.g., 36V, 72V, 120V, 280V, etc.) used to charge the internal power source 120 to a voltage level (e.g., 5V, 12V, 18V, 36V, 72V, etc.) used to power the thermal management system 122 or one or more peripheral devices connected to the DC power outlet 116B. For example, if the DC outlet 116B is a battery pack socket 116B configured to charge a power tool battery pack, the second DC-DC converter 520 converts the DC power from the voltage level used to charge the internal power source 120 to one or more voltage levels used to charge one or more power tool battery packs (e.g., 5V, 12V, 18V, 72V, etc.). In some embodiments, the second DC-DC converter 520 is implemented as one or more of the DC-DC converter configurations described herein. In some embodiments, the second DC-DC converter 520 is implemented as one or more converter configurations not explicitly described herein.

[0050] In some embodiments, the second DC-DC converter 520 is implemented using a single DC-DC converter. In such embodiments, the second DC-DC converter 520 may be a wide-output converter capable of outputting DC power at a wide range of voltage levels. In some embodiments, the second DC-DC converter 520 is implemented using multiple DC-DC converters, each of which outputs DC power at a different voltage level. For example, the second DC-DC converter 520 may include a first converter that outputs DC power at 12V to charge a 12V power tool battery pack, a second converter that outputs DC power at 18V to charge an 18V power tool battery pack, and a third converter that outputs DC power at 72V to charge a 72V battery pack.

[0051] In some embodiments, power supply 100 includes fewer power modules than the illustrated number of power modules. For example, in some embodiments, AC power output conversion unit 410 and DC power output conversion unit 415 are included within a single power module or housing. In some embodiments, power supply 100 includes more power modules than the illustrated number of power modules.

[0052] FIG. 6A illustrates a set of operating conditions for the power supply 100 according to some embodiments. As illustrated in FIG. 6A, the thermal management system 122 is configured to receive power from the internal power source 120 of the power supply 100. The controller 200 can disable the discharge and / or charge functions of the internal power source 120 based on a low-voltage cutoff threshold and / or a high-temperature cutoff threshold. In this example, the SOC of the internal power source 120 reaches the low-voltage cutoff threshold and the temperature reaches the high-temperature cutoff threshold. In this example, the internal power source 120 is the only power source for the thermal management system 122. The low-voltage cutoff threshold and / or the high-temperature cutoff threshold of the internal power source 120 limit the operation of the thermal management system 122 regardless of the availability of an external power source. As a result, the standby time associated with cooling and charging the internal power source 120 is extended.

[0053] FIG. 6B illustrates a set of operating conditions for the power supply 100 according to some embodiments. As illustrated in FIG. 6B, the thermal management system 122 is configured to receive power from the internal power source 120 of the power supply 100. The controller 200 can disable the discharge and / or charge functions of the internal power source 120 based on a low-voltage cutoff threshold and / or a low-temperature cutoff threshold. In this example, the SOC of the internal power source 120 reaches the low-voltage cutoff threshold and the temperature reaches the low-temperature cutoff threshold. In this example, the internal power source 120 is the only power source for the thermal management system 122. The low-voltage cutoff threshold and / or the low-temperature cutoff threshold of the internal power source 120 limit the operation of the thermal management system 122 regardless of the availability of an external power source. As a result, the standby time associated with heating and charging the internal power source 120 is extended.

[0054] FIG. 6C illustrates a set of operating conditions for the power supply 100 according to some embodiments. As illustrated in FIG. 6C, the power supply 100 includes an internal power source 120, a secondary power source 600, and a thermal management system 122. The secondary power source 600 may also be used to provide power to one or more devices or features of the power supply 100. In some implementations, the secondary power source 600 is the power input unit 114. For example, the secondary power source 600 is an external power source connected through an electrical connection interface of the power input unit 114. In some embodiments, the secondary power source 600 is a secondary power source internal to the power supply 100 (e.g., a secondary battery or battery pack, a capacitor bank, a hybrid supercapacitor, etc.). In this example, the thermal management system 122 is configured to receive power from the internal power source 120 and / or the secondary power source 600 of the power supply 100. In one scenario, the internal power source 120 reaches a low voltage cutoff threshold and / or a high temperature cutoff threshold. In this scenario, the secondary power source 600 is configured to power the thermal management system 122, thereby reducing the temperature of the internal power source 120 below the high temperature cutoff threshold, thereby reducing the cooling time associated with the internal power source 120 (e.g., as compared to natural cooling of the internal power source 120).

[0055] As mentioned above, the power supply 100 may disable all discharge and charge operations depending on the SOC (e.g., EOD state and fully charged, respectively) and temperature (e.g., discharge-OT state and charge-UT state, respectively) of the internal power source 120. If the internal power source 120 is the only power source for the thermal management system 122, the thermal management system 122 is also limited by the SOC and temperature of the internal power source 120. In one scenario, if the thermal management system 122 is powered only by the internal power source 120, which has reached the EOD state and is below the low temperature cutoff threshold, the internal power source 120 cannot power the thermal management system 122 and increase the temperature above the low temperature cutoff threshold (e.g., charge-UT threshold). As a result, the user would need to move the power supply 100 to a warmer environment or heat it by external means in order to raise the temperature above the low temperature cutoff threshold and begin charging the internal power source 120.

[0056] FIG. 6D illustrates a set of operating conditions for the power supply 100 according to some embodiments. As illustrated in FIG. 6D, the power supply 100 includes an internal power source 120, a secondary power source 600, and a thermal management system 122. The secondary power source 600 may also be used to provide power to one or more devices or features of the power supply 100. In some implementations, the secondary power source 600 is the power input unit 114. For example, the secondary power source 600 is an external power source connected through an electrical connection interface of the power input unit 114. In some embodiments, the secondary power source 600 is a secondary power source internal to the power supply 100 (e.g., a secondary battery or battery pack, a capacitor bank, a hybrid supercapacitor, etc.). In this example, the thermal management system 122 is configured to receive power from the internal power source 120 and / or the secondary power source 600 of the power supply 100. In one scenario, the internal power source 120 reaches a low voltage cutoff threshold and / or a low temperature cutoff threshold. In this scenario, the secondary power source 600 is configured to power the thermal management system 122, which causes the temperature of the internal power source 120 to rise above a low temperature cutoff threshold, thereby reducing the heating time associated with the internal power source 120 (e.g., as compared to natural warming of the internal power source 120 by moving the internal power source 120 to an area having a warmer temperature).

[0057] FIG. 6E illustrates a set of operating conditions for the power supply 100 according to some embodiments. As illustrated in FIG. 6E, the thermal management system 122 is configured to receive power from the internal power source 120 or the secondary power source 600 of the power supply 100. As described above, the secondary power source 600 may also be used to provide power to one or more devices or features of the power supply 100. In some implementations, the secondary power source 600 is the power output unit 116. For example, the secondary power source 600 is one or more peripheral devices connected to an outlet of the power output unit 116. In some embodiments, the secondary power source 600 is a secondary power source internal to the power supply 100 (e.g., a secondary battery or battery pack, a capacitor bank, a hybrid supercapacitor, etc.). In this example, the thermal management system 122 is configured to receive power from the internal power source 120 and / or the secondary power source 600 of the power supply 100. In another scenario, none of the low voltage cut-off threshold, the low temperature cut-off threshold, and the high temperature cut-off threshold of the internal power source 120 is reached. In such a scenario, using the secondary power source 600 to power the thermal management system 122 is still advantageous because it allows for faster charging times, as charging power is provided to the internal power source 120 (i.e., the charging power of the internal power source 120 is not utilized to power the thermal management system 122). Once the temperature of the internal power source 120 drops below the high temperature cutoff threshold or rises above the low temperature cutoff threshold, the internal power source 120 can be charged or discharged (e.g., resume operation) (e.g., using the secondary power source 600).

[0058] In some embodiments, it is advantageous to operate the thermal management system 122 using the secondary power source 600 once the internal power source 120 exceeds a low temperature cutoff threshold by making the heating duration and capabilities of the thermal management system 122 independent of the SOC, voltage, and capacity of the internal power source 120. In some embodiments, the thermal management system 122 may include heating and cooling modes that may be operated continuously once the low temperature cutoff threshold is exceeded, as it is desirable to maintain the internal power source 120 at an optimal temperature that allows maximum charging current.

[0059] In some embodiments, the controller 200 can optimize the heating operation of the internal power source 120. For example, in a low ambient temperature scenario, the controller 200 can utilize the heating mode of the thermal management system 122 in a blended approach to maximize the efficiency of the internal power source 120. Powering the thermal management system 122 in a heating mode via the internal power source 120 has the disadvantage of being dependent on the SOC of the internal power source 120, but has the benefit of having a higher overall heating efficiency. For example, resistive heating of the cells of the internal power source 120 from powering the thermal management system 122 also contributes to heating. In this example, the internal power source 120 first powers the thermal management system 122 for heating when the SOC is above the low voltage cutoff threshold and below the low temperature cutoff threshold, thereby allowing the highest heating efficiency at the beginning of the heating cycle. Once the SOC is depleted to a low voltage cutoff threshold (e.g., EOD) or the internal power source 120 exceeds a low temperature cutoff threshold and charging of the internal power source 120 begins, the controller 200 can utilize the secondary power source 600 to continue charging and terminate heating of the internal power source 120, allowing the advantages of both approaches to complement the disadvantages of both approaches. In these embodiments, the internal power source 120 can optimize charging operations by selectively powering the thermal management system 122 and charging the internal power source 120 using the secondary power source 600. In some embodiments, the maximum capacity of the secondary power source 600 may be limited when powering the thermal management system 122 and charging the internal power source 120. For example, the power supply 100 includes an on-board charger that includes a low voltage power source (LVPS) for powering the thermal management system 122 and a separate circuit for charging the internal power source 120. In this example, powering the LVPS will take power away from the charging circuitry for the internal power supply since the input utility power to the charger from the secondary power source 600 is fixed.

[0060] In some embodiments, the secondary power source 600 may also be the internal power source 120 (e.g., in addition to the separate secondary power source 600). For example, FIG. 7 shows a graph of the capacitive and resistive behavior of a lithium-ion (Li-ion) battery cell included in the internal power source 120. As shown in FIG. 7, the Li-ion battery cell exhibits resistive behavior, which is shown as a sudden drop and rise in voltage during pulse current discharge. Also, after the load is removed, the Li-ion battery cell exhibits capacitive behavior, which gradually rises to a stable no-load value after the load is removed. The difference between the open circuit voltage and the loaded voltage (e.g., the overpotential of the Li-ion battery cell) is based on ohmic losses in the Li-ion battery cell, charge transfer overpotentials at the interface, and mass transfer limitations. For example, when the Li-ion battery cell supplies a current, the operating voltage or the loaded voltage is displaced from the open circuit voltage due to electrochemical polarization. In this example, when the load is removed from the Li-ion battery cell, the voltage recovers (e.g., rebounds or relaxes) to the resting open circuit voltage at the current state of charge (SOC) of the Li-ion battery cell. Voltage recovery may occur after the internal power source 120 reaches its end of the discharge voltage threshold. During this recovery, the battery ions diffuse back to equilibrium. The diffusion process of the battery ions occurs over time (e.g., as a slow capacitive recovery of the battery's voltage). As a result, even after the internal power source 120 reaches its end of the discharge voltage threshold, there may still be available energy remaining in the internal power source (e.g., to power the thermal management system 122). Hereinafter, these phenomena will be referred to simply as resistive behavior and / or capacitive behavior for ease of understanding and redundancy.

[0061] FIG. 8 shows a graph of the voltage behavior Li-ion battery cell included in the power internal power source 120 during continuous discharge. The resistive and capacitive behavior of the Li-ion battery cell depends on several factors, such as the battery state of charge (SOC). For example, at low SOC, e.g., near the low voltage cutoff threshold, the resistance of the Li-ion battery cell increases significantly. In this example, at a given SOC, a large load will cause a large voltage deviation and a small load will cause a negligible voltage deviation. In one example, a medium to large load will cause a large voltage deviation from the open circuit / no load voltage (OCV) when the Li-ion battery cell is at a low SOC. Conversely, when the SOC of the Li-ion battery cell is high, a medium to large load will cause the voltage to deviate by a smaller amount. In this example, the amount by which this voltage deviation is a function of the magnitude of the applied load. If this voltage deviation causes the SOC of the internal power source 120 to reach the end of the discharge voltage threshold, the internal power source 120 can be disabled from further discharge. However, there may still be energy available in the internal power supply (eg, to power the thermal management system 122 or low-load applications).

[0062] In some implementations, the power supply 100 is configured to power the thermal management system 122 using a secondary power source 600 received from the internal power source 120 of the power supply 100 (e.g., using energy associated with the rebound voltage of the internal power source 120). In some implementations, the power supply 100 powers the thermal management system 122 during periods when there is no power access, such as during a transient transfer period to an external power source. Pre-cooling is the name associated with the feature of utilizing the capacitive and resistive behavior of Li-ion battery cells to power the thermal management system 122.

[0063] In some embodiments, the internal power source 120 reaches a low voltage cutoff threshold, effectively rendering the internal power source 120 "dead" from the user's perspective (i.e., all discharge activity stops until the internal power source 120 is recharged to a certain threshold above the low voltage cutoff threshold). As discussed above with respect to FIGS. 7-8, the amount of usable energy of the internal power source 120 is based on resistive and capacitive voltage recovery. In this scenario, the internal power source 120 may contain usable energy depending on the operating conditions (e.g., ambient temperature, number of battery discharge cycles, discharge load, etc.) during a previous discharge of the internal power source 120. However, because the battery resistance of the internal power source 120 is high at low SOC, the usable energy may be used by a small or light load (e.g., thermal management system 122). Additionally, because the power required to operate the thermal management system 122 is significantly less than the normal operating load of the power supply 100, there is no large voltage excursion of the internal power source 120 when the thermal management system 122 begins to operate, allowing the internal power source to use remaining energy (e.g., recovered voltage) to operate the thermal management system 122 even when the unit is effectively "OFF" to the user and while operating within the requirements and thresholds of the shelf-life energy requirements. In some instances, a heavy to moderate load would simply re-expose the voltage of the internal power source 120 to the low voltage cutoff threshold, risking over-discharging the internal power source 120 or violating the shelf-life energy requirements. In those instances, the pre-cooling firmware of the power supply 100 may be designed to ignore voltage excursions at transient start-up because the run-time power draw of the thermal management system 122 is controlled, consistent, and low.

[0064] 9 is a generalized schematic diagram of the power supply 100. The controller 200 is electrically and / or communicatively connected to the various modules or components of the power supply 100. For example, the controller 200 may be connected to the secondary power source 600, the internal power source 120, the thermal management system 122, a first feature 905, a second feature 910, and an Nth feature 915. The first feature 905, the second feature 910, and the Nth feature 915 may hereinafter be collectively referred to as "features." As discussed above, in some embodiments, the controller 200 uses power from the secondary power source 600 and / or the internal power source 120 to enable operation of the thermal management system 122 or features.

[0065] In some embodiments, the controller 200 uses an algorithm to assign priorities to the features of the power supply 100. For example, the controller can prioritize features based on function type, required voltage, or a combination thereof. In some embodiments, the controller 200 assigns the highest priority to features related to cooling the internal power source 120. In this example, the controller 200 determines the available energy in the secondary power source 600 and enables, for example, the thermal management system 122. If the available energy in the secondary power source 600 is sufficient to cool the internal power source 120, the controller 200 will not enable other features. In other examples, the controller 200 can disable features during operation to allow the internal power source 120 to cool to a desired temperature with the available SOC. For example, the controller 200 assigns a priority level of 1, 2, or 3 while operating the thermal management system 122 in a pre-cooling mode based on the determined available energy, and disables features with lower assigned priority levels first. In some embodiments, the features include a thermal management system 122, lighting (e.g., area or accent lighting), a human machine interface ("HMI") or user input, a personal device charger (e.g., a phone charger), connections to personal devices (e.g., phones), powered transportation capabilities (e.g., powered drive wheels, etc.), radio (e.g., AM, FM, Bluetooth, etc.), etc.

[0066] FIG. 10 illustrates a method 1000 performed by the controller 200 of the power supply 100. The controller 200 receives or measures the voltage of the internal power source 120, and the controller 200 determines the SOC of the internal power source 120 (step 1005). The controller 200 receives or measures the temperature of the internal power source 120 (step 1010). In some embodiments, the controller 200 determines the temperature of one or more components of the power supply 100. The controller 200 compares the SOC of the internal power source 120 to a low voltage threshold (step 1015). If the SOC of the internal power source 120 is above the low voltage threshold in step 1015, the controller 200 is configured to continue determining the SOC of the internal power source 120 (step 1005). If the SOC of the internal power source 120 is equal to or less than the low voltage threshold in step 1015, the controller 200 is configured to determine whether a high temperature threshold of the internal power source 120 has been reached. In some implementations, the controller 200 can also disable one or more features or functions of the power supply 100 based on the SOC of the internal power source 120 and a low voltage threshold.

[0067] The controller 200 compares the temperature of the internal power source 120 to a high temperature threshold (step 1020). If the temperature of the internal power source 120 is less than the high temperature threshold in step 1020, the controller 200 is configured to continue to determine the temperature of the internal power source 120 (step 1010). If the temperature of the internal power source 120 is equal to or greater than the high temperature threshold in step 1020, the controller 200 is configured to control one or more functions and / or features of the power supply 100. For example, the controller 200 disables the charging function of the power supply 100 (step 1025). In some embodiments, the controller 200 disables one or more other features of the power supply 100. The controller 200 enables the thermal management system 122 using the secondary power source 600 (step 1030). In some embodiments, the operation of the thermal management system 122 may not be directly related to disabling the charging function. One advantage of operating the thermal management system 122 before disabling the charging function of the internal power source 120 allows for reducing heat during operation as a preventative measure. In some embodiments, the controller 200 may use a power source (e.g., the internal power source 120) to enable the thermal management system 122. In some embodiments, the controller 200 may toggle the use of a power source (e.g., the internal power source 120) or a secondary power source 600 to allow the thermal management system 122 to efficiently charge and operate the power source. The controller 200 then proceeds to determine whether the temperature of the internal power source 120 is below the high temperature threshold. The controller 200 compares the temperature of the internal power source 120 to the high temperature threshold (step 1035). If the temperature of the internal power source 120 is above the high temperature threshold in step 1035, the controller 200 is configured to continue powering the thermal management system 122 using the secondary power source 600 (step 1030). If, at step 1035, the SOC of the internal power source 120 is below the high temperature threshold, the controller 200 enables the charging function of the power supply 100 (step 1040). The controller 200 is also configured to enable one or more other functions and / or features of the power supply 100.

[0068] FIG. 11 illustrates a method 1100 performed by the controller 200 of the power supply 100. The controller 200 receives or measures the voltage of the internal power source 120, and the controller 200 determines the SOC of the internal power source 120 (step 1105). The controller 200 receives or measures the temperature of the internal power source 120 (step 1110). In some embodiments, the controller 200 determines the temperature of one or more components of the power supply 100. The controller 200 compares the SOC of the internal power source 120 to a low voltage threshold (step 1115). If the SOC of the internal power source 120 is above the low voltage threshold in step 1115, the controller 200 is configured to continue determining the SOC of the internal power source 120 (step 1105). If the SOC of the internal power source 120 is equal to or less than the low voltage threshold in step 1115, the controller 200 is configured to determine whether a high temperature threshold of the internal power source 120 has been reached. In some implementations, the controller 200 may also disable one or more other features or functions of the power supply 100 based on the SOC of the internal power source 120 and a low voltage threshold.

[0069] The controller 200 compares the temperature of the internal power source 120 to the high temperature threshold (step 1120). If the temperature of the internal power source 120 is less than the high temperature threshold in step 1120, the controller 200 is configured to continue to determine the temperature of the internal power source 120 (step 1110). If the temperature of the internal power source 120 is equal to or greater than the high temperature threshold in step 1120, the controller 200 is configured to control one or more functions and / or features of the power supply 100. For example, the controller 200 disables the charging function of the power supply 100 (step 1125). In some embodiments, the controller 200 also disables one or more features of the power supply 100. The controller 200 receives or measures the voltage of the secondary power source 600, and the controller 200 determines the energy level of the secondary power source 600 (step 1130). In some embodiments, the controller determines the energy level of the secondary power source 600 using the methodology described above in connection with the sub-core module 125. Controller 200 then determines 1135 the power requirements of one or more features of power supply 100. For example, controller 200 receives 1135 the power requirements of thermal management system 122 from memory 445. In some embodiments, controller 200 also determines 1140 the power requirements of one or more other features / functions of power supply 100. Controller 200 selectively enables 1140 the one or more features of power supply 100 based on the SOC of secondary power source 600 and the power requirements for the one or more other features / functions of power supply 100. In some embodiments, features / functions of power supply 100 are selectively enabled with power from secondary power source 600 based on the determined priority of the features / functions.

[0070] 12 illustrates a method 1200 performed by the controller 200 of the power supply 100. The controller 200 receives or measures the temperature of the internal power source 120 (step 1205). In some embodiments, the controller 200 determines the temperature of one or more components of the power supply 100. The controller 200 compares the temperature of the internal power source 120 to a high temperature threshold (step 1210). If the temperature of the internal power source 120 is less than the high temperature threshold at step 1210, the controller 200 is configured to continue determining the temperature of the internal power source 120 (step 1205). If the temperature of the internal power source 120 is equal to or greater than the high temperature threshold at step 1210, the controller 200 is configured to control one or more functions and / or features of the power supply 100. For example, the controller 200 powers the thermal management system 122 of the power supply 100 to control a pre-cooling feature (e.g., using a rebound voltage of the internal power source 120). The controller 200 then enables the thermal management system 122 of the power supply 100 (step 1215).

[0071] The controller 200 compares the temperature of the internal power source 120 to a high temperature threshold (step 1220). If, at step 1220, the temperature of the internal power source 120 is equal to or greater than the high temperature threshold, the controller 200 is configured to continue enabling the thermal management system of the power supply 100 (step 1215). If, at step 1220, the temperature of the internal power source 120 is less than the high temperature threshold, the controller 200 is configured to control one or more functions and / or features of the power supply 100. For example, the controller 200 disables the thermal management system 122 of the power supply 100 (step 1225).

[0072] In various embodiments, the controller 200 controls the thermal management system 122 to perform a "pre-cooling" of the power supply 100 to reduce the temperature of the internal power supply 120 during a transient transfer to an external power source or in the absence of a separate power source (e.g., AC mains). As a result, once the power supply 100 is connected to an external power source, the power supply 100 resumes charging the internal power supply 120 in a shorter time compared to the natural cooling time because the power supply 100 has been "pre-cooled". The "pre-cooling" function is not limited to only cooling the internal power supply 120. In some implementations, the controller 200 can operate the thermal management system 122 via "pre-cooling" to reduce the temperature of on-board electronics, chargers, etc.

[0073] In some embodiments, controller 200 may be unable to reduce the temperature of internal power supply 120 below the high temperature threshold due to various conditions, such as, for example, the residual energy available via voltage restoration is not sufficient to operate thermal management system 122 for the required period of time. In such situations, the residual available energy is sufficient to operate thermal management system 122, but the ambient conditions (e.g., extreme hot weather in the summer) are not conducive to rapid cooling. In those embodiments, controller 200 can utilize an external secondary power source in addition to the internal secondary power source to reduce the temperature of internal power supply 120 below the high temperature threshold.

[0074] 13 illustrates a method 1300 performed by the controller 200 of the power supply 100. The controller 200 receives or measures the voltage of the internal power source 120, and the controller 200 determines the SOC of the internal power source 120 (step 1305). The controller 200 receives or measures the temperature of the internal power source 120 and / or other internal components of the power supply 100 (step 1310). In some embodiments, the controller 200 determines the temperature of one or more components of the power supply 100. The controller 200 compares the temperature of the internal power source 120 to an under-temperature threshold (step 1315). In step 1315, if the temperature of the internal power source 120 is equal to or below the under-temperature threshold (e.g., an under-temperature cutoff threshold), the controller 200 is configured to control one or more functions and / or features of the power supply 100. For example, the controller 200 provides power to the thermal management system 122 of the power supply 100 (step 1320). In some embodiments, the controller 200 powers the thermal management system 122 using the secondary power source 600. For example, the controller 200 enables a heating mode of the thermal management system to increase the temperature of one or more components of the power supply 100. In addition, the controller 200 can keep comparing the temperature to an under-temperature threshold to determine if operating conditions of the power supply 100 are met to enable a charging function. In some embodiments, the controller 200 can also enable one or more functions of the power supply 100 that generate heat.

[0075] If the temperature of the internal power source 120 is above the sub-temperature threshold at step 1315, the controller 200 is configured to control one or more functions and / or features of the power supply 100. For example, the controller 200 enables a charging function of the power supply 100 (step 1325). In some embodiments, the controller 200 may also enable one or more features of the power supply 100. The controller 200 continues to receive or measure the voltage of the internal power source 120 while the internal power source 120 is charging until the SOC of the internal power source 120 reaches the SOC threshold (step 1330).

[0076] FIG. 14A illustrates a method 1400 performed by the controller 200 of the power supply 100. The controller 200 determines that a secondary power source is present (step 1405). The controller 200 receives or measures the temperature of the internal power source 120 (step 1410). In some embodiments, the controller 200 determines the temperature of one or more components of the power supply 100. The controller 200 compares the temperature of the internal power source 120 to an under-temperature threshold (step 1415). In step 1415, if the temperature of the internal power source 120 is above the under-temperature threshold (e.g., an under-temperature cutoff threshold), the controller 200 is configured to control one or more functions and / or features of the power supply 100. For example, the controller 200 enables a charging function of the power supply 100 (step 1420). In some embodiments, the controller 200 can also enable one or more features of the power supply 100.

[0077] The controller 200 then selects a charge rate for the internal power source 120 of the power supply 100 (step 1425). In some embodiments, the controller selects the charge rate for the internal power source 120 based on the temperature of the power supply 100. For example, the controller 200 may select the charge rate for the power supply 100 from a set of charge rates (e.g., a first charge rate, a second charge rate, and a third charge rate). Each charge rate in the set of charge rates is different and is associated with a tier (e.g., tier 1, tier 2, and tier 3). Each tier may be defined by a minimum temperature threshold. In this example, the controller 200 may compare the temperature of the internal power source 120 to the minimum temperature threshold of each tier. In one scenario, the controller 200 determines that the temperature of the internal power source 120 is less than the minimum temperature threshold of tier 1 and selects the first rate associated with tier 1. In another scenario, controller 200 determines that the temperature of internal power source 120 is greater than or equal to the minimum temperature threshold for Tier 1 but less than the minimum temperature threshold for Tier 2 and selects a second rate associated with Tier 2. In yet another scenario, controller 200 determines that the temperature of internal power source 120 is greater than or equal to the minimum temperature threshold for Tier 2 and selects a third rate associated with Tier 3.

[0078] The controller 200 then controls the operation of the thermal management system 122 of the power supply 100 (step 1430). For example, the controller 200 may power the thermal management system 122 using the secondary power source 600. In this example, the controller 200 controls the heating and cooling modes of the thermal management system 122 to increase or decrease the temperature of one or more components of the power supply 100. The controller 200 may enable one or more modes of the thermal management system 122 using closed loop control to maintain a maximum charge rate (e.g., the third rate).

[0079] 14B illustrates a continuation of method 1400 performed by controller 200 of power supply 100. After comparing the temperature of internal power source 120 to the under-temperature threshold in step 1415, if the temperature of internal power source 120 is below the under-temperature threshold (e.g., an under-temperature cutoff threshold), controller 200 is configured to control one or more functions and / or features of power supply 100. In some embodiments, controller 200 receives or measures the voltage of internal power source 120, and controller 200 determines the SOC of internal power source 120.

[0080] The controller 200 compares the SOC of the internal power source 120 to a low-voltage threshold (step 1435). If the SOC of the internal power source 120 is above the low-voltage threshold in step 1435, the controller 200 is configured to power the thermal management system 122 using the internal power source 120 (step 1440). As discussed above, using the internal power source 120 to power the thermal management system 122 advantageously increases the heating efficiency of the power supply 100. If the SOC of the internal power source 120 is below the low-voltage threshold in step 1435, the controller 200 is configured to power the thermal management system 122 using the secondary power source 600 (step 1445).

[0081] In various embodiments, the internal power source 120 does not need to reach EOD for the controller 200 to enable the “pre-cool” feature and provide a benefit to the user. The controller 200 can activate the “pre-cool” feature, for example, when the user turns off the power supply 100 and the internal power source 120 rises above the charge OT threshold. This ensures that the power supply 100 is as ready as possible for a charging event across multiple scenarios. For example, if the user partially discharges the internal power source 120, the internal power source 120 reaches a temperature above the charge OT threshold, and the power supply 100 is turned off, the controller 200 can activate the “pre-cool” feature to accelerate the cooling of the power supply 100 to a temperature below the charge OT threshold. In this case, the runtime duration of the “pre-cool” feature is not limited to the small available energy present via rebound voltage (i.e., the battery did not reach EOD) because the internal power source 120 has sufficient remaining battery capacity for use.

[0082] Accordingly, the embodiments described herein provide, among other things, a power supply that includes a secondary power source for powering a thermal management system. Various features and advantages are set forth in the claims that follow. [Explanation of symbols]

[0083] 100 Power supply equipment 114 Power Input Unit 116 Power Output Unit 118 Display 120 Internal power supply 122 Thermal Management System (TMS) 127A Sub-core monitoring circuit 127B Sub-core monitoring circuit 127N Sub-core monitoring circuit 200 Controller 400 Input Power Conversion Unit 405 DC Bus 410 AC Output Power Conversion Unit 415 DC Output Power Conversion Unit 420 User Interface 425 Network Communication Module 426 processor 427 Memory 428 Antennas and Transmitters 429 RTC 430 Sensors 440 Processing Unit 445 Memory 450 Input Units 455 Output Unit 460 Control Unit 465 Arithmetic and Logic Unit 470 Register 500 PFC circuit 505 DC-DC Converter 510 First DC-DC Converter 515 Inverter 520 Second DC-DC Converter 600 Secondary power supply 905 First Feature 910 Second Feature 915 Nth Feature

Claims

1. 1. A portable power supply device, comprising: an internal power source configured to provide power to a device connected to the portable power supply; a thermal management system configured to control a temperature of the internal power supply; a power input unit configured to charge the internal power source; a power output unit configured to supply power output by the internal power source; a first sensing circuit configured to detect the temperature of the internal power supply; A secondary power source; A controller including a processor and a memory, receiving a first signal related to the temperature of the internal power supply from the first sensing circuit; enabling the thermal management system based on the temperature of the internal power supply; and enabling charging of the internal power source based on the temperature of the internal power source; It is configured as follows: the thermal management system is powered, at least in part, by the internal power source; A controller, Portable power supply device.

2. The portable power supply device of claim 1 , wherein the controller is further configured to enable charging of the internal power source based on the temperature of the internal power source and a temperature threshold.

3. 3. The portable power supply of claim 2, wherein the controller is further configured to power the thermal management system using the secondary power source.

4. a second sensing circuit configured to detect a state of charge (SOC) of the internal power source; The controller: receiving a second signal related to the SOC of the internal power supply from the second sensing circuit; responsive to determining that the SOC of the internal power source is above an SOC threshold, powering the thermal management system using the internal power source. The method is further configured as follows:

2. The portable power supply device of claim 1.

5. a second sensing circuit configured to detect a state of charge (SOC) of the internal power source; The controller: receiving a second signal related to the SOC of the internal power supply from the second sensing circuit; powering the thermal management system using the secondary power source in response to determining that the SOC of the internal power source is less than an SOC threshold. It is further structured as follows: the thermal management system reduces the temperature of the internal power supply.

2. The portable power supply device of claim 1.

6. 2. The portable power supply of claim 1, further configured: the controller selecting a charge rate for the internal power source based on the temperature of the internal power source and one or more temperature thresholds, each of the one or more temperature thresholds being associated with a different charge rate.

7. 7. The portable power supply of claim 6, wherein the controller is further configured to control operation of the thermal management system using the secondary power source based on the selected charge rate and a temperature of the internal power source.

8. 10. The portable power supply of claim 1, wherein the secondary power source of the portable power supply is a renewable energy source.

9. 2. The portable power supply of claim 1, wherein the secondary power source of the portable power supply is provided by the power input unit from an external power source.

10. 2. The portable power supply of claim 1, wherein the secondary power source of the portable power supply is provided by a peripheral device connected to the power output unit.

11. 1. A portable power supply device, comprising: an internal power source configured to provide power to a device connected to the portable power supply; a thermal management system configured to control a temperature of one or more internal components of the portable power supply; a power input unit configured to charge the internal power source; a power output unit configured to supply power output by the internal power source; a first sensing circuit configured to detect the temperature of the internal power supply; A secondary power source; A controller including a processor and a memory, receiving a first signal related to the temperature of the one or more internal components from the first sensing circuit; enabling the thermal management system based on the temperature of the one or more internal components; and enabling charging of the internal power source based on the temperature of the one or more internal components; It is configured as follows: the thermal management system is powered, at least in part, by the internal power source; A controller, Portable power supply device.

12. 12. The portable power supply of claim 11, wherein the controller is further configured to enable charging of the internal power source based on the temperature of the internal power source and a temperature threshold.

13. 13. The portable power supply of claim 12, wherein the controller is further configured to power the thermal management system using the secondary power source.

14. a second sensing circuit configured to detect a state of charge (SOC) of the internal power source; The controller: receiving a second signal related to the SOC of the internal power supply from the second sensing circuit; responsive to determining that the SOC of the internal power source is above an SOC threshold, powering the thermal management system using the internal power source. The method is further configured as follows:

12. A portable power supply device according to claim 11.

15. a second sensing circuit configured to detect a state of charge (SOC) of the internal power source; The controller: receiving a second signal related to the SOC of the internal power supply from the second sensing circuit; powering the thermal management system using the secondary power source in response to determining that the SOC of the internal power source is less than an SOC threshold. It is further structured as follows: the thermal management system reduces the temperature of the internal power supply.

12. A portable power supply device according to claim 11.

16. 12. The portable power supply of claim 11, wherein the controller is further configured to select a charge rate of the internal power source based on the temperature of the one or more internal components and one or more temperature thresholds, each of the one or more temperature thresholds being associated with a different charge rate.

17. 17. The portable power supply of claim 16, wherein the controller is further configured to control operation of the thermal management system using the secondary power source based on the selected charge rate and the temperature of the one or more internal components.

18. 12. The portable power supply of claim 11, wherein the secondary power source of the portable power supply is a renewable energy source.

19. 12. The portable power supply of claim 11, wherein the secondary power source of the portable power supply is provided by the power input unit from an external power source.

20. 12. The portable power supply of claim 11, wherein the secondary power source of the portable power supply is provided by a peripheral device connected to the power output unit.

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