The present disclosure relates to portable electronic devices and, more particularly, to systems and methods for charging batteries and battery-powered portable electrical devices.
Rechargeable batteries and rechargeable battery packs used with electronic devices are well known in the art. These batteries and battery packs are generally required to be charged periodically, often via an external battery charger.
The typical configuration of rechargeable batteries or a rechargeable battery pack in an electronic device charger limits the end user to selecting preferences of a single, dual or six bay configuration, and thereby narrows the options available. This usually limits a charger configuration to be one device type, not allowing a mixture of different charging bays or a multi-bay charger.
There is a continuing need for a charging system that can accommodate multiple batteries or battery-powered electronic devices. Desirably, the charging system is modular to permit for simultaneous charging of a predetermined number of different portable devices and/or batteries.
In concordance with the instant disclosure, a charging system that can accommodate multiple batteries or battery-powered electronic devices, and which is modular to permit the simultaneous charging of a predetermined number of different portable devices and/or batteries, is surprisingly discovered.
In one embodiment, a charging system includes a primary single charging bay unit and at least one secondary single charging bay unit. The primary single charging bay unit has a main body with a first removable adapter cup for receiving a first electronic device for charging. The main body is configured to be placed in electrical communication with an external power supply. The at least one secondary single charging bay unit has a main body and a second removable adapter cup for receiving a second electronic device for charging. The at least one secondary single charging bay unit is in electrical communication with the primary single charging bay. Advantageously, the first electronic device and the second electronic device may be different, and the first removable adapter cup and the second removable adapter cup may likewise be configured to receive the different electronic devices. The first and second removable adapter cups may also be interchangeable.
In another embodiment, a method of forming a charging system includes placing the at least one secondary single charging bay unit in electrical communication with the primary single charging bay.
In a further embodiment, each of the units has an associated printed circuit board disposed beneath the adapter cup, and a primary printed circuit board disposed within the main body. The least one secondary single charging bay unit is in communication with the primary single charging bay unit via a user assembled backplane bus. The backplane bus is expandable to permit a gangable or build-out configuration of the charging system.
In an illustrative embodiment, the present disclosure includes a rechargeable battery pack or rechargeable batteries contained in an electronic device charging system. The charging system is modular and expandable in design, and can be easily field upgraded into any configuration the user may require without requiring an additional base frame.
The charging system can be configured from the ‘primary single bay’ charger, which charges one battery or electronic device containing a battery at a time using alternating current or direct current power inputs. The user can add one or more additional ‘secondary bays’ to make a multi-bay configuration using alternating current or direct current power inputs.
The charging system's primary single charging bay monitors the quantity of ‘secondary charging bays’ attached to the ‘primary single charging bay’ via I2C communication protocol, acting as a unique safety feature as to not over-burden the charging system's power supplies.
The charging system of the present disclosure also allows the user to charge multiple different makes and/or models of rechargeable batteries or rechargeable batteries contained in an electronic device in the same base unit, along with automatically identifying and charging different battery cell chemistries.
The charging system has an integral “user assembled backplane” which is unique in the battery charger industry. This “user assembled backplane” provides the power and I2C communication interconnects for the individual secondary charging bays back to the primary bay. The backplane consists of male/female connectors interlocking from the “primary single charging bay” to the secondary bays and in-between the secondary charging bays. The backplane also has an expansion monitoring failsafe line which monitors the number of bays connected on the backplane and allows the number to be limited according to the safe limits of the power supply, and/or connector limitations and circuit board limitations.
The charging system of the disclosure also has a unique method of ensuring that the power supply used is within the safe operating ratings of the power supply. When used as a primary single bay charger, a power supply with a lower operating voltage is provided. For example, a 12 VDC power supply is used for a single bay charger. However, for an expanded system a higher voltage supply, such as a 15 or 19 VDC, is used. This has an economic benefit due to a less expensive supply being used in the cost-sensitive “primary single bay” configuration.
An expanded system is also detected via the I2C and/or the “Bay Detect” line. The “primary single charging bay” module will not allow an expanded system to operate without the higher voltage supply. An added benefit of the higher voltage supply is that the power supply current demands are reduced slightly along the “user assembled backplane”, reducing I (Current) and R (Resistance) drops, inherent in printed circuit board traces, and in electrical connectors.
In certain embodiments, the charging system of the present disclosure can be configured from the ‘primary single bay’ charger, which charges one battery or electronic device containing a battery at a time using alternating current or direct current power inputs, and the user can add an additional ‘secondary bays’ to make a multi-bay configuration using alternating current or direct current power inputs.
In other embodiments, the charging system can electrically and mechanically accept multiple different makes and/or models of rechargeable batteries or rechargeable batteries contained in an electronic device in the same base unit along with automatically identifying and charging different battery cell chemistries.
In additional embodiments, the charging system uses a method of alignment and securing the mechanical interlock providing the mechanical and electrical interface from the “Primary Single Charging Bay” modules to one or more “Secondary Single Charging Bay” modules.
In yet further embodiments, a mechanical interconnection mechanism is formed into the ‘Primary Single charging bay’ and ‘Secondary Single Charging bay’ with the proper keyed orientation as to allow additional ‘Secondary Single Charging bays’ to be added and interlocked by the modules unique bottom plates.
In some embodiments, the charging system contains a “User Assembled Backplane” to provide power, communications, and a method of detecting the number of modules assembled into a single unit.
In yet more embodiments, the charging system contains circuitry and sensors for detecting the power capability of the connected power supply by measuring the input voltage whereas 12 VDC is used for one stand alone “Primary Single Charging Bay” module, and no “Secondary Single Charging Bay” modules connected.
In even further embodiments, when the “Primary Single Charging Bay” module detects a higher input voltage such as 15 VDC or 19 VDC, then the “Primary Single Charging Bay” module enables the power switch to allow charging in more than the “Secondary Single Charging Bay” modules.
In yet another embodiment, the charging system uses paralleled resistors to inform the “Primary Single Charging Bay” module via an I2C communication bus of the total number of modules assembled into a single functioning unit.
The above, as well as other advantages of the present disclosure, will become readily apparent to those skilled in the art from the following detailed description, particularly when considered in the light of the drawings described hereafter.
The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should also be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features. In respect of the methods disclosed, the order of the steps presented is exemplary in nature, and thus, is not necessary or critical unless otherwise disclosed.
The singular forms “a,” “an,” and “the” can include plural referents in the present disclosure unless the context clearly dictates otherwise. Thus, for example, reference to “a secondary single charging bay unit” can, but doesn't not necessarily, include reference to one or more of such units.
As used herein, relative terms, such as “top,” “bottom,” “upper,” “lower,” “front,” “rear,” etc., are used to refer to various components of the charging system discussed herein, as those terms would be readily understood by one of ordinary skill in the relevant art. It is to be understood that such terms in no way limit the present disclosure, but are used to aid in describing the components of the charging systems of the disclosure in the most straightforward manner.
Referring now to
In
A block representation of the primary single charging bay unit 102 is identified by reference number 204, and block representations of the secondary single charging bay unit 104 are identified by reference number 207, in
As shown in
The male or female electrical connectors 208 shown in
In
A schematic representation of a power switch 210, which controls the power to each secondary charging single bay unit 104, and which can also be enabled or disabled by an I2C command issued by the primary charging single bay unit 102, is also shown in
A schematic representation of an I2C slave communications interface 211 is further shown in
Although shown in
The primary single charging bay unit 102 and the second single charging bay units 104 are described in further detail herein below, with respect to
As non-limiting examples, the front end cap 302 and the rear end cap 303 may be formed from molded plastic, and the main body 304 may be formed from an extruded aluminum. One of ordinary skill in the art may also select other suitable materials and manufacturing methods for the front end cap 302, the rear end cap 303, and the main body 304 of the primary single charging bay unit 102, as desired.
The primary single charging bay unit 102 further has an adapter cup 307. The adapter cup 307 is configured to receive one of the portable electronic devices 106 (shown in
As shown in
The top plate 312 also has an LED display 316 formed therein. The LED display 316 is in communication with a control printed circuit board 313 (also shown in
With further reference to
With renewed reference to
As shown in
The adapter cup 307 of the primary single charging bay unit 102 is also shown in
It should be appreciated that many different types of the adapter cup 307, all receivable by the main body 304 but configured to accommodate differently sized and differently shaped electronic devices 106, may be provided or used in the system 100 of the present disclosure.
As further shown in
In one non-limiting example, the main body item 304 has the male features 305 and the female locking guides 306 situated on opposite sides of the main body 304. It should be appreciated that this configuration allows for the innovative ability of the primary single charging bay unit 102 to be expanded into a rugged and durable multi-bay charging system 100, by use one or more secondary single charging bay units 104, with many options available for the end user.
The secondary single charging bay unit 104 has the male features 305 and the female locking guides 306 disposed on opposite sides of the main body 304. The secondary single charging bay unit 104 also has the retaining holes 311 for mounting the top cover plate 312 and the bottom plate 315 to the secondary single charging bay unit 104. Fasteners such as screws, bolts, and the like may be used with the retaining holes 311 to mount top cover plate 312 and the bottom plate 315 to the main body 304 of the secondary single charging bay unit 104.
The secondary single charging bay unit 104 also has the adapter cup 307 for receiving the portable electronic device 106 or the rechargeable battery 106. In operation, the adapter cup 307 receives the portable electronic device 106 or the rechargeable battery 106, which is placed in contact with an associated printed circuit board 309 via the interface contacts 308. The adapter cup 307 further has the key feature 310 formed in an outer surface thereof for orientation of the adapter cup 307 by alignment with the cooperating channel feature into the main body 304 of the primary single charging bay unit 102.
As shown in
As one non-limiting example, the main body 304 has the male features 305 and the female locking guides 306 situated on opposite sides of the main body 304. This configuration allows for the innovative ability of the secondary single charging bay unit 104 to be expanded into a rugged and durable multi-bay charging system 100 with many options for the end user.
In operation, the end user first obtains the primary single charging bay unit 102, as shown in
By repeating the aforementioned assembly steps, and as shown in
Referring now to
With reference to
Advantageously, the charging system 100 of the present disclosure has a common backplane and multiple bays for receiving and charging both AC and DC chargeable batteries, in combination simultaneously. The multiple charging bays and a parallel resistor means are used to detect the number of modules or units in place. Additionally, the charging system 100 may have “slave” modules that will charge at higher voltages than the primary charging module upon demand. Furthermore, the charging system 100 is, in combination, gangable with an expandable backplane, and with each module containing a programmable AC/DC charger.
While certain representative embodiments and details have been shown for purposes of illustrating the invention, it will be apparent to those skilled in the art that various changes may be made without departing from the scope of the disclosure, which is further described in the following appended claims.
This application claims the benefit of U.S. Provisional Application No. 62/310,862, filed on Mar. 21, 2016. The entire disclosure of the above application is hereby incorporated herein by reference.
Number | Date | Country | |
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62310862 | Mar 2016 | US |