BATTERY CHARGER

A battery charger includes a housing, electronic components, a longitudinal plane, a first fan, a second fan, and a lateral plane. The housing includes a connection interface to slidably receive a rechargeable battery. The electronic components are disposed in the housing. The longitudinal plane extends through the connection interface and the electronic components. The first fan is disposed laterally from the longitudinal plane in a first direction. The second fan is disposed laterally from the longitudinal plane in a second direction. The second direction is opposite the first direction. The lateral plane intersects the longitudinal plane. The lateral plane extends through the connection interface, the electronic components, the first fan, and the second fan.

FIELD

The present disclosure relates to battery chargers for battery packs commonly used with power tools.

SUMMARY

In one aspect, the present disclosure includes a battery charger according to embodiments disclosed herein. The battery charger includes a housing, electronic components, a longitudinal plane, a first fan, a second fan, and a lateral plane. The housing includes a connection interface to slidably receive a rechargeable battery. The electronic components are disposed in the housing. The longitudinal plane extends through the connection interface and the electronic components. The first fan is disposed laterally from the longitudinal plane in a first direction. The second fan is disposed laterally from the longitudinal plane in a second direction. The second direction is opposite the first direction. The lateral plane intersects the longitudinal plane. The lateral plane extends through the connection interface, the electronic components, the first fan, and the second fan.

In another aspect, the battery charger includes a housing, electronic components, and a fan. The housing includes a connection interface to slidably receive a rechargeable battery. The electronic components are disposed in the housing. The fan is disposed in the housing between the connection interface and the electronic components. The fan includes a centrifugal blower having an axis of rotation that extends through the connection interface and the electronic components.

In another aspect, the battery charger includes a housing, electronic components, and a fan. The housing includes a connection interface to slidably receive a rechargeable battery. The housing further includes a side wall. The connection interface extends along a longitudinal axis. The electronic components are disposed in the housing. The fan is disposed in the housing adjacent the side wall. The fan includes a centrifugal blower having an axis of rotation that extends transverse to the longitudinal axis. The axis of rotation extends between the connection interface and the electronic components.

Features and aspects of the disclosure will become apparent by consideration of the following detailed description and accompanying drawings.

DETAILED DESCRIPTION

With reference toFIG.1, an embodiment of a battery charger100is shown. The battery charger100is illustrated with a rechargeable battery102configured to be removably coupled thereto. The battery charger100includes a housing104. The housing104includes a connection interface105having a connection rail106. The connection rail106allows the rechargeable battery102to slidably couple to the battery charger100in a direction such as along a longitudinal battery sliding axis A1.

The battery charger100further includes charging terminals108configured to electrically couple with corresponding battery terminals110of the rechargeable battery102. Upon sliding the rechargeable battery102along the connection rail106, the battery terminals110of the rechargeable battery102contact the charging terminals108of the battery charger100when the rechargeable battery102is in an installed position. The rechargeable battery102is moved from a position remote from the battery charger100to the installed position by first entering a battery entry end112of a battery receiving area114.

The battery receiving area114is defined by the housing104. In the illustrated embodiment, the battery receiving area114is bordered on one side by the connection rail106. Also, in the illustrated embodiment, the battery receiving area114is open in two perpendicular directions D1, D2away from the housing104. Engagement of the connection rail106with rechargeable battery102, in the installed position, restricts movement of the rechargeable battery102relative to the housing104in the D2direction. In some embodiments, the charging terminals108are disposed in the battery receiving area114opposite the battery entry end112.

With reference toFIG.2, the battery charger100includes electronic components116disposed in the housing104. The electronic components116include a circuit board116aand at least one other electronic component116disposed on the circuit board116a. In the illustrated embodiment, the electronic components116also include a second electronic component116b, a third electronic component116c, a fourth electronic component116d, a fifth electronic component116e, and a plurality of additional electronic components116. The electronic components116may include resistors, transistors, inductors, capacitors, or other electronic components. In the illustrated embodiment, a longitudinal plane P1extends through the connection interface105and the electronic components116. The plane P1is an imaginary plane and generally divides the battery charger100into two symmetrical portions. Fans120are disposed within the housing104and are disposed laterally from the plane P1and above the electronic components116. In other words, the fans120are disposed in the housing104opposite the electronic components116. The fans120are disposed between inner walls122of the connection interface105and side walls124of the housing104. The fans120are also disposed adjacent side ducts126, which are configured to guide air between the fans120and outside of the housing104. The housing104includes side vents128on the side walls124and top vents130on a side142opposite the electronic components116. The side vents128are located adjacent the side ducts126, such that air flows between the side vents128and the side ducts126. In some embodiments, the side vents128include a single vent on each of the side walls124. In other embodiments, the side vents128include a plurality of vents disposed on each of the side walls124. The side vents128may be aligned generally parallel with the longitudinal sliding axis A1, generally perpendicular to the longitudinal sliding axis A1, or in any other direction. The top vents130are located adjacent the fans120and the rechargeable battery102, such that air flows between the fans120and the rechargeable battery102through the top vents130to cool the rechargeable battery102. In one embodiment, the top vents130include a single vent. In other embodiments, the top vents130include a plurality of vents. The top vents130may be aligned generally parallel with the longitudinal sliding axis A1, generally perpendicular to the longitudinal sliding axis A1, or in any other direction.

In some embodiments, the fans120, which may be axial fans as illustrated, are configured to direct air from the rechargeable battery102, through the top vents130in a direction toward the electronic components116, and into the fans120. From the fans120, the air is directed by the side ducts126in a direction away from the plane P1and then exhausted through the side vents128. In other embodiments, the fans120are configured to direct air into the housing104through the side vents128in a direction toward the plane P1through the side ducts126, and into the fans120in a direction away from the electronic components116. From the fans120, the air is then directed through the top vents130and into the rechargeable battery102. In other embodiments, there are additional ducts between the fans120and the top vents130. In any case, the fans120, side ducts126, side vents128, and top vents130are configured in a cooling arrangement to cool the rechargeable battery102.

In some embodiments, air may be guided through the rechargeable battery102as well as the battery charger100when the rechargeable battery102is connected to the battery charger100. As illustrated inFIG.3, air may be directed into the rechargeable battery102through top battery vents103on a side of the rechargeable battery102opposite a connection interface of the rechargeable battery102. The air may flow through the rechargeable battery102and then be directed through bottom battery vents107on the rechargeable battery102adjacent the top vents130in a direction toward the electronic components116, and into the battery charger100through the top vents130. The air may then flow out of the battery charger100in similar ways as in previous embodiments.

As illustrated inFIG.4, air may enter the rechargeable battery102from the battery charger100through the top vents130and the bottom battery vents107in a direction away from the electronic components116. The air may then flow through the rechargeable battery102and exit the rechargeable battery102through the top battery vents103.

With reference toFIGS.5and6, air may flow in a first side wall124aof the battery charger100, through the rechargeable battery102, and then out a second side wall124bof the battery charger100opposite the first side wall124a. In some embodiments, air is drawn into the housing104through side vents128on the first side wall124ain a direction toward the plane P1through the side ducts126adjacent the first side wall124a, and into the fans120adjacent the first side wall124a. From the fans120adjacent the first side wall124a, the air is directed through the top vents130adjacent the first side wall124a, through the bottom battery vents107adjacent the first side wall124ain a direction away from the electronic components116, and into the rechargeable battery102. The air is then directed through the rechargeable battery102and toward the bottom battery vents107opposite the first side walls124aand adjacent the second side wall124b. The air then flows through the bottom battery vents107adjacent the second side wall124b, through the top vents130adjacent the second side wall124bin a direction toward the electronic components116, and into the fans120adjacent the second side wall124b. From the fans120adjacent the second side wall124b, the air is directed by the side ducts126adjacent the second side wall124bin a direction away from the plane P1and then exhausted through the side vents128on the second side wall124b.FIG.5illustrates the airflow path in a first direction, andFIG.6illustrates the airflow path in a second direction opposite the first direction.

With reference toFIG.7, the battery charger100includes two fans120that may be described as a first fan120aand a second fan120b. The first and second fans120a,120bare disposed on opposite sides of the plane P1. At least a portion of the connection interface105is disposed between the first and second fans120a,120b. The first fan120ais disposed laterally from the plane P1in a first direction D1, and the second fan120bis disposed laterally from the plane P1in a second direction D2. In the illustrated embodiment, D1and D2are perpendicular to the plane P1, and the direction D1is opposite the direction D2, such that the connection of D1and D2defines a 180-degree angle. In other embodiments, the connection of D1and D2defines an angle different from 180-degrees. A lateral plane P2intersects the first and second fans120a,120b, the connection interface105, the electronic components116, and the plane P1. The plane P2is an imaginary plane. In the illustrated embodiment, the plane P2perpendicularly intersects the plane P1. In other embodiments, the plane P2intersects the plane P1at a non-perpendicular angle.

With reference toFIG.8, the battery charger100includes four fans120that may be described as the first fan120a, the second fan120b, a third fan120c, and a fourth fan120d. The first fan120ais disposed laterally from the plane P1in the first direction D1, the second fan120bis disposed laterally from the plane P1in the second direction D2, the third fan120cis disposed laterally from the plane P1in a third direction D3, and the fourth fan120dis disposed laterally from the plane P1in a fourth direction D4. In the illustrated embodiment, the first direction D1extends from the same side of plane P1as the third direction D3, and the second direction D2extends from the same side of the plane P1as the fourth direction D4. In the illustrated embodiment, the first direction D1is also parallel with the third direction D3, and the second direction D2is parallel with the fourth direction D4. In other embodiments, the first direction D1is not parallel with the third direction D3, and the second direction D2is not parallel with the fourth direction D4. In the illustrated embodiment, the first fan120ais aligned with the third fan120cin a direction parallel to the plane P1. Similarly, the second fan120bis aligned with the fourth fan120din a direction parallel to the plane P1. Though this embodiment includes four fans120, the battery charger100may include any number of fans120.

With reference toFIG.9, the battery charger100includes four side ducts126that may be described as a first side duct126a, a second side duct126b, a third side duct126c, and a fourth side duct126d. The first side duct126ais configured adjacent and fluidly coupled to the first fan120a, such that the first side duct126guides air between the first fan120aand outside of the housing104. The other side ducts126b-dare configured adjacent and fluidly coupled to the other fans120b-d, respectively, to guide air between the fans120b-dand the outside of the housing104. In other embodiments, there are a plurality of fans120and a plurality of side ducts126configured to guide air between the plurality of fans120and the outside of the housing104.

FIG.10illustrates another embodiment of the disclosure, with terms similar toFIGS.1-5labeled similarly plus a value of one hundred. The battery charger200may include any combination of features, dimensions, or range of dimensions from the preceding or subsequent embodiments, but only features of the battery charger200not yet discussed with respect to the previous embodiments are detailed below.

The battery charger200includes one fan220disposed between the connection interface205and the electronic components216. The fan220includes a centrifugal blower232having an axis of rotation A232extending through the connection interface205and the electronic components216. The axis of rotation A232is transverse to a side234of the housing204opposite the connection interface205. In the illustrated embodiment, the axis of rotation A232is also transverse to the circuit board216a. In some embodiments, the axis of rotation A232is perpendicular to the side234of the housing204opposite the connection interface205, the circuit board216a, or both. The centrifugal blower232is disposed adjacent a top duct236configured to direct air between the rechargeable battery202and the centrifugal blower232. The top duct236may include a single duct or a plurality of ducts. In some embodiments, air flows into the housing204through top vents230in a direction toward the electronic components216. The air is then guided by the top duct236into the centrifugal blower232. From the centrifugal blower232, air flows in a direction away from the axis of rotation A232and exits the housing204through the side vents228disposed on the side walls224. In other embodiments, air flows into the housing204through the side vents228in a direction toward the axis of rotation A232. The air then flows through the centrifugal fan232and flows out of the housing204in a direction away from the electronic components216through top vents230.

FIG.11illustrates another embodiment of the disclosure, with terms similar toFIGS.1-5labeled similarly plus a value of two hundred. The battery charger300may include any combination of features, dimensions, or range of dimensions from the preceding or subsequent embodiments, but only features of the battery charger300not yet discussed with respect to the previous embodiments are detailed below.

The battery charger300includes one fan320disposed in the housing adjacent the side wall324of the housing304. The fan320may be disposed adjacent any side wall324of the housing304. The axis of rotation A332of the centrifugal blower332extends transverse to the plane P1. In some embodiments, the axis of rotation A332extends perpendicular to the plane P1. The axis of rotation A332extends between the connection interface305and the electronic components316, such that the axis of rotation A332does not intersect the connection interface305or the electronic components316. The fan320defines a perimeter338, and a projection340from the perimeter338extends parallel to the axis of rotation A332. The projection340is an imaginary projection and intersects the electronic components316and the connection interface305. In some embodiments, air flows through the top vents330past the connection interface305, in a direction toward the electronic components316, and into the centrifugal blower332. The air then flows out of the centrifugal blower332in a direction along the axis of rotation A332and through side vents328. In other embodiments, air flows from outside the housing304through side vents328in a direction along the axis of rotation A332and into the centrifugal blower332. The air then flows out of the centrifugal blower332in a direction away from the axis of rotation A332and through top vents330.

FIGS.12and13illustrate another embodiment of the disclosure, with terms similar toFIGS.1-5labeled similarly plus a value of three hundred. The battery charger400may include any combination of features, dimensions, or range of dimensions from the preceding or subsequent embodiments, but only features of the battery charger400not yet discussed with respect to the previous embodiments are detailed below.

Air flows through top vents430in the housing404past the connection interface405and toward the axis of rotation A432. Air then flows into the centrifugal blower432along the axis of rotation A432. The air then exits the centrifugal blower432in a direction away from the axis of rotation A432. The air may then exit the housing404through side vents428, bottom vents450, or a combination thereof. In some embodiments, the centrifugal blower432may be oriented such that air exits the housing404in any direction away from the axis of rotation A432, and the air is exhausted through vents on any side of the housing404.

FIG.14illustrates another embodiment of the disclosure, with terms similar toFIGS.1-5labeled similarly plus a value of four hundred. The battery charger500may include any combination of features, dimensions, or range of dimensions from the preceding or subsequent embodiments, but only features of the battery charger500not yet discussed with respect to the previous embodiments are detailed below.

In this embodiment, the centrifugal blower532is disposed in a flow pathway of a duct system552. The duct system552includes the side duct526and the top duct536. The centrifugal blower532is oriented in the duct system552such that the axis of rotation A532of the centrifugal blower532intersects the connection interface505. The side duct526is disposed between the centrifugal blower532and the side534of the housing504opposite the connection interface505. The top duct536is disposed between the centrifugal blower532and the connection interface505. In some embodiments, the top duct536may be disposed between the centrifugal blower532and the side wall524. As shown in the illustrated embodiment, the duct system552is a single unitary part, but other embodiments may include an assembly of ducts to form the duct system552.

With reference toFIG.15, the centrifugal blower532is disposed above the electronic components516. Said another way, the projection540from the perimeter538of the centrifugal blower532does not extend through any of the electronic components516. In some embodiments, the projection540extends through one or a plurality of the electronic components516.

The disclosed embodiments are not limited in application to battery chargers. The same configurations may be applied to any number of power tools, equipment, power supplies, inverters, or lighting arrangements.