A charger assembly

Abstract

The present invention relates to a charger assembly (100). The charger assembly (100) has a charger unit (102) and a charger cover (104). The charger unit (102) is configured to charge one or more battery packs. The charger cover (104) is configured to accommodate the charger unit (102). The charger assembly (100) further has a plurality of air paths (106). The plurality of air paths (106) is provided on the charger cover (104) and configured to enable air flow from the charger unit (102), thereby providing a thermal cooling of the charger unit (102).

Description

[0001] TITLE OF INVENTION

[0002] A CHARGER ASSEMBLY

[0003] FIELD OF THE INVENTION

[0004]

[0001] The present invention generally relates to charging. More particularly, the present invention relates to a charger assembly.

[0005] BACKGROUND OF THE INVENTION

[0006]

[0002] With the advancement in vehicle technologies, there is greater focus on the development of electric vehicles. To improve the overall experience of an electric vehicle, the need for improving the charging experience is also there. For charging one or more battery packs of the electric vehicle, a charger is required. The charger is configured to charge the one or more battery packs by routing a charging current from a power source to the one or more battery packs.

[0007]

[0003] There are certain problems associated with charging the one or more battery packs with the help of the existing and known charger. For example, the internal parts of the charger such as wires, connectors, circuits, and the like are exposed. This poses a risk of electrical circuit failure and other failures, if the charger comes in contact with moisture and other objects. Furthermore, the charger generates a significant amount of heat during the charging process and therefore, the heat dissipation from the charger is essential. The existing and known charger may overheat easily due to poor heat dissipation, thereby reducing the efficiency of the charger and increasing the risk of using the charger. Also, the charger needs protection from various safety hazards and physical damage.

[0008]

[0004] Thus, there is a need in the art for a charger assembly, which addresses at least the aforementioned problems.SUMMARY OF THE INVENTION

[0009]

[0005] In one aspect, the present invention is directed towards a charger assembly. The charger assembly has a charger unit and a charger cover. The charger unit is configured to charge one or more battery packs. The charger cover is configured to accommodate the charger unit. The charger assembly further has a plurality of air paths. The plurality of air paths is provided on the charger cover and configured to enable air flow from the charger unit, thereby providing a thermal cooling of the charger unit.

[0010]

[0006] In an embodiment of the invention, the charger unit is configured to convert an Alternating Current (AC) to a Direct Current (DC) for charging the one or more battery packs.

[0011]

[0007] In a further embodiment of the invention, the charger unit has one or more cooling fins configured to dissipate heat from the charger unit.

[0012]

[0008] In a further embodiment of the invention, the one or more cooling fins are made of at least aluminum.

[0013]

[0009] In a further embodiment of the invention, the charger cover has a handle integrated with the charger cover, thereby assisting in handling the charger assembly.

[0014]

[0010] In a further embodiment of the invention, the charger unit is provided with a fan, thereby cooling the charger unit.

[0015]

[0011] In a further embodiment of the invention, the charger assembly is configured to be accommodated inside a battery box.

[0016] BRIEF DESCRIPTION OF THE DRAWINGS

[0017]

[0012] Reference will be made to embodiments of the invention, examples of which may be illustrated in accompanying figures. These figures are intended to be illustrative, not limiting. Although the invention is generally described in context of these embodiments, it should be understood that it is not intended to limit the scope of the invention to these particular embodiments.Figure 1 illustrates a side view of a charger assembly, in accordance with an embodiment of the present invention.

[0018] Figure 2 illustrates another side view of the charger assembly, in accordance with an embodiment of the present invention.

[0019] Figure 3 illustrates another side view of the charger assembly, in accordance with an embodiment of the present invention.

[0020] Figure 4 illustrates a top view of the charger assembly, in accordance with an embodiment of the present invention.

[0021] DETAILED DESCRIPTION OF THE INVENTION

[0022]

[0013] Various features and embodiments of the present invention here will be discernible from the following further description thereof, set out hereunder.

[0023]

[0014] The present invention generally relates to charging. More particularly, the present invention relates to a charger assembly. The charger assembly of the present invention is typically used in a vehicle such as a two-wheeled vehicle, or a threewheeled vehicle including trikes, or a four-wheeled vehicle, or other multi-wheeled vehicles as required. The charger assembly of the present invention is typically used in the vehicle such as electric vehicles or hybrid vehicles as required.

[0024]

[0015] Figure 1 illustrates the charger assembly 100, in accordance with an embodiment of the present invention. As used herein, the ‘charger assembly’ 100 refers to an assembly configured for providing a charging current from a power source to one or more battery packs for charging. In a non-limiting embodiment, the charger assembly 100 may be used to charge the one or more battery packs of an electric vehicle. In an embodiment, the charger assembly 100 may be configured to be accommodated inside a battery box (not shown). Therefore, the charger assembly 100 is packaged in such a way so that the charger assembly 100 is easily accommodated inside the battery box, thereby ensuring that an entire system is efficient and compact.Moreover, the purpose of integrating the charger assembly 100 inside the battery box is to simplify the overall process of charging the one or more battery packs.

[0025]

[0016] As further illustrated in Figure 1 and Figure 2, the charger assembly 100 includes a charger unit 102. The charger unit 102 is configured to charge the one or more battery packs. As disclosed herein, each battery pack comprises one or more batteries connected together in a series connection, a parallel connection, or a seriesparallel connection as per requirement. In an embodiment, the one or more battery packs are configured to be disposed in the electric vehicle. The one or more battery packs are further configured to provide the desired power output for the functioning of the electric vehicle.

[0026]

[0017] In an embodiment, the charger unit 102 is configured to convert an Alternating Current (AC) supply to a Direct Current (DC) supply for charging the one or more battery packs. The charger unit 102 is connectable to the one or more battery packs and to the power source. The charger unit 102, upon electrically connecting the charger unit 102 to the power source and the one or more battery packs, is adapted to provide a charging current to the one or more battery packs from the power source. In an embodiment, the charger unit 102 comprises one or more electrical components that are configured to convert or modulate the power received from the power source for charging the one or more battery packs.

[0027]

[0018] In a non-limiting embodiment, the one or more electrical components are configured to receive Alternating Current (AC) power (or current) from the power source and convert it into Direct Current (DC) power. In a non-limiting embodiment, the charger unit 102 is configured to convert the AC supply to the DC supply to enable charging of the one or more battery packs such as 48V battery packs. For converting the AC supply to DC supply, the charger unit 102 consists of the one or more electrical components. The one or more electrical components are configured to convert the AC supply to the DC supply to enable smooth and efficient charging of the one or more battery packs.

[0019] During charging of the one or more battery packs, the charger unit 102 generates heat due to the conversion and charging process. Hence, it becomes essential to monitor the heat generation during the charging process for improving the efficiency of the charging process and the charger unit 102.

[0028]

[0020] Therefore, for monitoring and dissipating the heat, as depicted in Figure 1 and Figure 3, the charger unit 102 has one or more cooling fins 108. The one or more cooling fins 108 are configured to dissipate heat from the charger unit 102. The one or more cooling fins 108 are designed to effectively and efficiently manage the heat dissipation during the charging process. In an embodiment, the one or more cooling fins 108 are made of one or more materials with high thermal conductivity to efficiently dissipate heat, for example, the material preferred may be aluminum. Aluminum is generally preferred because it is lightweight, cost-effective, and has excellent thermal conductivity, which helps in effectively transferring heat away from the charger components. In an embodiment, the one or more cooling fins 108 are provided on a charger casing. The one or more cooling fins 108 are configured for dissipating the heat generated from the charging process, thereby enhancing the overall switching efficiency and avoiding the failure of the one or more electrical components.

[0029]

[0021] In an embodiment and as depicted in Figure 1 and Figure 2, the charger unit 102 is provided with one or more fans such as a fan 112. The fan 112 is configured for cooling the charger unit 102 i.e., the fan 112 helps to keep the internal components cool, especially during the charging process. While the one or more cooling fins 108 helps in providing a passive cooling of the charger unit 102 by increasing a surface area for heat dissipation, the fan 112 helps in enhancing the airflow around the components of the charger unit 102, thereby expelling the heat from the charger unit more effectively and efficiently and preventing overheating and extending the lifespan of the components.

[0030]

[0022] As illustrated in Figure 1 and Figure 3, the charger assembly 100 further comprises a charger cover 104. The charger cover 104 is configured to accommodatethe charger unit 102, thereby enclosing the charger unit 102 from all the sides. As disclosed herein, the ‘charger cover’ 104 is a protective housing or a casing configured to shield the internal components of the charger unit 102 from wear and tear, environmental factors, damage, and the like. In an embodiment, the charger cover 104 is configured to cover the one or more cooling fins 108, thereby enhancing the aesthetics of the charger assembly 100.

[0031]

[0023] In an embodiment, the charger cover 104 further comprises a handle 110, as shown in Figure 1, Figure 2, Figure 3, and Figure 4. The handle 110 is integrated with the charger cover 104, thereby assisting in handling the charger assembly 100. In a non-limiting embodiment, the handle 110 is integrated with the charger cover 104 with the help of one or more fasteners (not shown). The handle 110 further enhances the ergonomics of the charger assembly 100. The handle 110 integrated with the charger cover 104 enhances the ease of handling the charger assembly 100 and further helps in packaging the charger assembly 100 inside the battery box.

[0032]

[0024] As further shown in Figure 4, the charger assembly 100 has been provided with a plurality of air paths 106. In a non-limiting embodiment, the plurality of air paths 106 are holes or openings provided on the charger cover 104 for efficiently dissipating the heat from the charger unit 102. In an embodiment, the plurality of air paths 106 are provided on the charger cover 104. The plurality of air paths 106 are configured to enable air flow from the charger unit 102, thereby providing an enhanced thermal cooling of the charger unit 102.

[0033]

[0025] In a non-limiting embodiment, the present invention discloses the charger cover 104 for a portable electric vehicle (EV) charger unit 102. The EV charger unit 102 converts the AC supply to the DC supply to enable battery charging for the EV. The charger unit 102 has the one or more cooling fins 108 made of the aluminium which help in dissipating heat. As the one or more cooling fins 108 may not be aesthetically pleasing to the eye, an additional charger cover 104 is provided on the charger unit 102 to make it visually appealing. The charger cover 104 is provided with the plurality ofair paths 106 to enable air flow and improve the thermal efficiency of the one or more cooling fins 108. The charger cover 104 is also provided with the integrated handle 110 to improve ergonomic handling of the charger assembly 100.

[0034]

[0026] Advantageously, the present invention provides for a charger assembly. The charger assembly is provided with a charger unit and a charger cover, wherein the charger cover is configured to act as a housing for accommodating the charger unit. The present invention improves the overall thermal cooling of the charger unit with the help of one or more cooling fins provided on the charger unit and the plurality of air paths on the charger cover. The present invention also improves the aesthetics of the charger assembly by providing the charger cover, thereby covering the one or more cooling fins of the charger unit. Additionally, the present invention also provides a handle on the charger cover, wherein the handle is configured to enhance the ergonomics of the charger assembly. The handle provided on the charger cover helps in easy handling of the charger assembly.

[0035]

[0027] Moreover, the present invention further helps with easy packaging of the charger assembly inside a battery box, thus making the assembly easier and less sophisticated. The present invention provides for efficient cooling of the charger unit, thereby increasing the life of the charger assembly. The efficient cooling of the charger unit allows for better performance and durability of the charger unit, which lowers servicing and replacement costs of the charger unit. Furthermore, the charger cover helps in providing an enclosure to the charger unit, thereby eliminating the problems related to wear and tear of the charger unit and other potential damage to the charger unit as well.

[0036]

[0028] While the present invention has been described with respect to certain embodiments, it will be apparent to those skilled in the art that various changes and modification may be made without departing from the scope of the invention as defined in the following claims.List of Reference Numerals 100: Charger Assembly 102: Charger Unit

[0037] 104: Charger Cover

[0038] 106: Plurality of Air Paths 108: Cooling Fins

[0039] 110: Handle

[0040] 112: Fan

Claims

WE CLAIM:

1. A charger assembly (100), comprising:a charger unit (102), the charger unit (102) being configured to charge one or more battery packs;a charger cover (104), the charger cover (104) being configured to accommodate the charger unit (102); anda plurality of air paths (106), the plurality of air paths (106) being provided on the charger cover (104), and the plurality of air paths (106) being configured to enable air flow from the charger unit (102), thereby providing a thermal cooling of the charger unit (102).

2. The charger assembly (100) as claimed in claim 1, wherein the charger unit (102) being configured to convert an Alternating Current (AC) to a Direct Current (DC) for charging the one or more battery packs.

3. The charger assembly (100) as claimed in claim 1, wherein the charger unit (102) comprises one or more cooling fins (108), the one or more cooling fins (108) being configured to dissipate heat from the charger unit (102).

4. The charger assembly (100) as claimed in claim 3, wherein the one or more cooling fins (108) are made of at least aluminum.

5. The charger assembly ( 100) as claimed in claim 1 , wherein the charger cover ( 104) comprises a handle (110), the handle (110) being integrated with the charger cover (104), thereby assisting in handling the charger assembly (100).

6. The charger assembly (100) as claimed in claim 1, wherein the charger unit (102) being provided with a fan (112), thereby cooling the charger unit (102).

7. The charger assembly (100) as claimed in claim 1, wherein the charger assembly (100) being configured to be accommodated inside a battery box.

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