Abstract:
An apparatus for charging multiple rechargeable devices is disclosed. The apparatus includes a hub or multiple T-connectors connected between a power source, preferably a Zinc-air battery, and several chargers, the hub/T-connectors configured to provide electrical and mechanical connectivity between the power source and the chargers. The apparatus includes housings configured to encase the chargers and to conformally receive each of the corresponding devices containing rechargeable batteries. The apparatus further includes pouches configured to removably receive chargers, devices, and the power source. When the power source voltage falls below a certain threshold, then a charger associated with a device having the smallest difference between its rated voltage and its measured voltage discontinues charging before other chargers. The apparatus is wearable by a user.

Description:
GOVERNMENT RIGHTS IN THIS INVENTION 
     This invention was made with U.S. government support under Army contract number BAA W15P7T-07-R-P042. The U.S. government has certain rights in this invention. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to power systems, and more particularly, to a system and a method for continuously charging a plurality of original equipment manufacturer (OEM) batteries carried in equipment worn by a soldier on the battlefield. 
     BACKGROUND OF THE INVENTION 
     There has been a proliferation of electronic equipment employed in the battlefield. More particularly, a soldier carries a plurality of electronic devices that require battery power. These electronic devices may include one or more radios, a GPS receiver, a laser target designator, and a battlefield computer. Mission profiles have increased the number of handheld devices and the time that the devices need to operate. In certain conditions, a soldier may need to carry up to 72 batteries of varying voltage and current requirements and size, the total number of batteries having a weight in excess of 20 pounds. Moreover, many batteries, such as lithium-ion batteries, have the potential to catch fire or even explode when in use. 
     Hence, there is a need in the art to reduce battery weight and the types of batteries carried by a soldier. 
     Conventional portable power solutions have reduced total battery count and weight by replacing the batteries with so-called battery eliminators. When battery eliminators are employed, the various batteries associated with the plurality of electronic devices are removed and the resulting empty battery compartments are retrofitted with adapters that directly supply power. Power is continuously supplied from a wearable battery via cables configured to be integrally attached to each of the adapters incorporated into the body armor of the soldier. As a result, when/if the soldier removes any electronic equipment from his body armor, power is lost to the removed electronic equipment. Further, battery eliminators continue to supply power at about 100% capacity, which produces inefficiencies. 
     Accordingly, what would be desirable, but has not yet been provided, is a system and a method for continuously charging a plurality of original equipment manufacturer (OEM) batteries carried in equipment worn by a soldier on the battlefield that is ergonomic to use, that reduces the cost and complexity of controlling centralized power to the multiple devices carried by the soldier, that supplies power to multiple devices using a charging method that provides a maximum device charge with a minimum consumption of energy in a minimal amount of time, where power is not lost when/if the electronic equipment from the body armor is removed. 
     SUMMARY OF THE INVENTION 
     The above-described problems are addressed and a technical solution is achieved in the art by providing an apparatus and method for charging a plurality of devices, comprising: a power source; a plurality of chargers in signal communication with the power source, a plurality of housings configured to encase each of the plurality of chargers and to conformally receive a corresponding one of the plurality of devices; and a plurality of pouches configured to receive the plurality of chargers, devices, and housings, wherein a corresponding one of the plurality of devices is removably insertable into a corresponding pouch and charger, and wherein the apparatus is configured to be worn by a user. 
     According to an embodiment of the present invention, a charger associated with a device having the smallest difference between its rated voltage and its measured voltage discontinues charging before other chargers of the plurality of chargers. 
     According to an embodiment of the present invention, each of the plurality of chargers is configured to: (a) charge a corresponding device; and (b) when a voltage of the power source falls below a low threshold: (c) count a predetermined voltage step with a predetermined time delay between a rated voltage of the corresponding device and a measured voltage of the corresponding device; (d) discontinue charging the corresponding device when the voltage of the power source remains below the low threshold; (e) repeat (a)-(d) when the voltage of the power source remains between the low threshold and a recovered threshold greater than the low threshold; and (f) repeat (a)-(e) when the voltage of the power source is equal to or exceeds the recovered threshold. 
     According to an embodiment of the present invention, each of the plurality of chargers is further configured to discontinue charging its corresponding device when the measured voltage of the corresponding device exceeds a predetermined charged threshold. The predetermined charged threshold may be a predetermined voltage below the rated voltage of the corresponding device or a predetermined percentage of the rated voltage. 
     According to an embodiment of the present invention, each of the plurality of chargers may be further configured to: (g) re-measure a voltage of its corresponding device; (h) re-start charging the corresponding device when the re-measured voltage of the corresponding device falls below the predetermined charged threshold; and (i) repeat (g) and (h) when the re-measured voltage of the corresponding device is equal to or exceeds the predetermined charged threshold. Each of the plurality of chargers may be further configured to repeat (a)-(f) when the re-measured voltage of its corresponding device falls below the predetermined charged threshold. 
     According to an embodiment of the present invention, the plurality of chargers may be connected in parallel with the power source. The power source is a battery, preferably, but not limited to, a zinc-air battery (the power source may be any 12 volt battery in the Defense Logistics Agency (DLA) Inventory—DLA is a logistics combat support agency whose primary role is to provide supplies and services to America&#39;s military forces worldwide). 
     According to an embodiment of the present invention, the apparatus may further comprise a hub connected between the battery and the plurality of chargers, wherein the hub is configured to provide electrical and mechanical connectivity between the battery and the plurality of chargers. The apparatus may further comprise a plurality of T-connectors connected between the battery and each of the plurality of chargers, wherein the plurality of T-connectors is configured to provide electrical and mechanical connectivity between the battery and the plurality of chargers. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present invention will be more readily understood from the detailed description of exemplary embodiments presented below considered in conjunction with the attached drawings in which like reference numerals refer to similar elements and in which: 
         FIG. 1  is an exploded view of the components of a portable multiple battery rapid charging system, according to an embodiment of the present invention; 
         FIG. 2  shows the portable multiple battery rapid charging system of  FIG. 1  as it may be worn by a soldier, according to an embodiment of the present invention; 
         FIG. 3  is a perspective view of a zinc-air battery assembly, according to an embodiment of the present invention; 
         FIG. 4  is a cutaway view if the internal workings of the zinc air battery of  FIG. 3 , according to an embodiment of the present invention; 
         FIG. 5A  is a top down view of an exemplary power distribution hub of  FIG. 1 , according to an embodiment of the present invention; 
         FIG. 5B  shows a “hub-less” alternative embodiment of the system of  FIG. 5A , according to an embodiment of the present invention; 
         FIG. 6  is an internal wiring diagram of the power distribution hub of  FIG. 5A , according to an embodiment of the present invention; 
         FIG. 7  is an internal wiring diagram showing wiring connections and electrical circuitry of a fully assembled system, according to an embodiment of the present invention; 
         FIG. 8  is an electrical block diagram of an exemplary equipment charger, according to an embodiment of the present invention; and 
         FIG. 9  is a process flow diagram exhibiting exemplary steps of a method for operating the equipment charger of  FIG. 8 , according to an embodiment of the present invention. 
     
    
    
     It is to be understood that the attached drawings are for purposes of illustrating the concepts of the invention and may not be to scale. 
     DETAILED DESCRIPTION OF THE INVENTION 
       FIG. 1  is an exploded view of the components of a portable multiple battery rapid charging system  10 , according to an embodiment of the present invention.  FIG. 2  shows the portable multiple battery rapid charging system  10  of  FIG. 1  as it may be worn by a soldier on his body armor system. The system  10  includes a light weight power source  12 , preferably, but not limited to, a high capacity charging battery, a multi-port power distribution hub  14  removably connectable to the power source  12 , one or more chargers  18  removably connectable to the multi-port power distribution hub  14 , and one or more cable adapters  20  removably connectable to the multi-port power distribution hub  14 . The adapters  20  are configured to be removably connectable to a device  21  having a direct charging port  22 , and/or to a removable battery pack  24 , such as an AA-type battery pack. Each of the chargers  18  is configured to include variable-shaped housings  26  configured to conformally receive rechargeable electronic devices  28  in their entirety (as opposed to the stand-alone removable battery pack  24 ) worn by the soldier for charging the internal batteries of the electronic devices  28  without removing their respective batteries. 
     A given housing  26  is compatible with a plurality of types of rechargeable electronic devices  28  typically carried by the soldier. Each of the housings  26  includes a cable  30  that is fixedly attached to the housing  22  on one end  23  and removably attachable with a connector  32  to a corresponding mating connector  33  that is fixedly attached via a cable  34  to the multi-port power distribution hub  14 . Each of the housings  26  includes an internal charger  18  to be described in connection with  FIG. 8  hereinbelow. Each of the chargers  18  is configured to be removably insertable into one of a plurality of pouches  38  for receiving and charging an electronic device  28  to be described hereinbelow in connection with  FIGS. 8 and 9 . 
     Referring now to  FIG. 2 , a soldier wears the system  10  with the a light weight power source  12  fitted to the back of their body armor system and the pouches  38 , the direct charging port  22 , and the removable battery pack  24  fitted to their body armor system, with cabling affixed to their body armor system preferably over their shoulders. Electronic devices having a corresponding conformal housing  26  are operable to be inserted and left in their respective pouch  38  to be continuously charged. Other devices may be removably connected to the direct charging port  22 , and/or to the removable battery pack  24 . At all times, the soldier may remove a device from its pouch/adapter when needed and return the device to its pouch/adapter when the device is not in use. 
     In a preferred embodiment, the power source  12  is a zinc-air battery, such as the BA-8140/U battery manufactured by Electric Fuel Battery Corporation (EFB) of Auburn, Ala., although other light-weight high power sources may be employed, such as, but not limited to, other battery types, a solar cell-based charging device, an AC-to-DC power supply, and a movement-to-charge transducer (converter), or a centralized inductive charging system. 
       FIG. 3  is a perspective view of a zinc-air battery assembly, according to an embodiment of the present invention.  FIG. 4  is a cutaway view if the internal workings of the zinc air battery of  FIG. 3 , according to an embodiment of the present invention. The zinc-air battery  40  is contained within a housing  42  configured to operate under military environmental standards. A fixedly attached coaxial cable  44  having a connector  46  extends from the housing  42 . The zinc-air battery  40  encased in the housing  42  may have, but is not limited to, a nominal output voltage of about 14 VDC and a capacity of about 30 Ah. Referring now to  FIG. 4 , the zinc-air battery  40  includes a zinc anode  50  and an air electrode  52 . The zinc-air battery  40  provides electrical power through the electrochemical oxidation of the zinc anode  50  by atmospheric oxygen according to the overall chemical reaction:
 
2Zn+O2=2ZnO
 
     Since the Zinc-air battery  40  possesses an electrochemistry similar to an alkaline manganese battery, it has similar safety and environmental properties, and additional advantageous properties of high energy density, light weight, low cost, and inherent safety. 
       FIG. 5A  is a top down view of the power distribution hub  14 , while  FIG. 6  shows internal wiring connectivity within the power distribution hub  14 , according to an embodiment of the present invention. The power distribution hub  14  is adapted to provide passive electrical and mechanical connectivity between active devices to be described hereinbelow. Referring now to  FIG. 5A , the power distribution hub  14  includes a central wiring distribution chamber  60 , an input power supply port  62  comprising a fixedly attached input power supply cable  64  and corresponding connector  66 , and a plurality of fixedly attached output power charger ports  68  each associated with an output cable  70  and corresponding support connector  72 . In a preferred embodiment, the number of output cables  70  is four: two configured to be connected to corresponding a housing charger  26 , one associated with cable a direct charging port  22 , and one associated with the removable battery pack  24 . 
       FIG. 5B  shows a “hub-less” alternative embodiment of the system  10  of  FIG. 5A , according to an embodiment of the present invention. To bypass the limited connectivity (i.e., the number of connectable chargers  26 ) of the hub  14 , the system  10 ′ dispenses with the power distribution hub  14  of  FIG. 5A  altogether. The hub  14  is replaced with one or more T-connectors  77  which may be fitted together as shown to permit a relatively unlimited number of chargers  26  to be connected to the power source  12  in a “parallel” configuration. 
     Referring now to  FIGS. 5A and 6 , the input power supply port  62  associated with the input power supply cable  64  of the power distribution hub  14  is electrically connected in parallel to each of the output power charger ports  68  associated with each of the output cables  70  via a BLK lead for providing a return and a RED lead for providing a high potential. Over-current protection is provided in series with each of the RED leads by a re-usable fuse-like device  78 . In a preferred embodiment, re-usable fuse-like device  78  is a positive temperature coefficient (PTC) resistor. The nominal input-output voltage of the power distribution hub  14  is about 12V in-12V out, with an operating range of between −20° C. to +60° C. The dimensions of the central wiring distribution chamber  60  are on the order of about 20 cm×67 cm by 67 cm, with a weight of about 0.13 kg. 
       FIG. 7  is an internal wiring diagram showing wiring connections and electrical circuitry of a fully assembled system  10 , according to an embodiment of the present invention. The zinc-air battery  40  is electrically connected to the power distribution hub  14  by the high potential RED lead and the low potential BLK lead which pass power directly within the power distribution hub  14  via each of the re-usable fuse-like devices  78  to the direct charging port  22  and the removable battery pack  24 , or pass power to each of the housings  26 . Each of the housings  26  includes a built-in charger  18 . In a preferred embodiment, the chargers  18  receive a nominal 12 V input at varying levels of current, and supply various values of output voltages/current to the electronic devices  28  removably insertable into the housings  26 . 
       FIG. 8  is an electrical block diagram of an exemplary charger  18 , according to an embodiment of the present invention. The charger  18  comprises a charging circuit  92  and a charger controller  94 . The charger  18  is operable to charge a rechargeable application battery according to a powering algorithm to be described hereinbelow in connection with  FIG. 9 . 
     The charger controller  94  includes an over-voltage protection circuit  100  operable to protect against voltage surges that may be applied or induced between the high potential RED lead and the low potential BLK lead inputs of the charger  18 . These over-voltage surges may originate from the charging source such as zinc-air battery  40  or be induced on inputs from the external environment (e.g., lightning). A current monitor  102  and a current limiter  104  are electrically connected in series with an output of the over-voltage protection circuit  100 . The current monitor  102  measures the input current emanating from the externally connected zinc-air battery  40  and provides a measured parameter for decisions made in a charging algorithm programmed into a micro-controller  106  electrically connected to the current monitor  102 . In a preferred embodiment, the input current is limited by the current limiter  104  to 0.5 amps and 1.5 amps for clamping DC output current originating from the charger  18  and surge currents that accompany induced voltages surges from the external environment, respectively. 
     An input voltage monitoring circuit  108  and a voltage regulator  110  flank the input and output of the over-voltage protection circuit  100 , respectively, and are likewise electrically connected as inputs to the micro-controller  106 . Similarly to the current monitor  102 , the input voltage monitoring circuit  108  monitors the charging voltage of the externally-connected zinc-air battery  40  and provides a second measured parameter for decisions made in a charging algorithm programmed into a micro-controller  106 . The voltage regulator  100  steps down the output voltage of the zinc-air battery  40  to a predetermined level suitable for powering digital circuitry, including the micro-controller  106 . 
     The micro-controller  106  further receives measurement parameters that monitor the output charging current and voltage associated with current and voltage outputs of the charging circuit  92  via an output current monitor  112  and an output voltage monitor  114 , respectively. The current and voltage outputs of the charging circuit  92  are representative of the charging current and voltage applied to the external removable battery pack  24 . The micro-controller  106  also receives at least an indication of ambient temperature from a temperature measuring device (not shown) that is operable to set a temperature dependent minimum and maximum zinc-air battery charging voltage to be described in connection with the powering algorithm of  FIG. 9  hereinbelow. 
     The microcontroller  106  is configured to receive the indicated currents, voltages, and temperature inputs to render a decision as to whether to power and therefore activate the charging circuit  92  according to the powering algorithm of  FIG. 9 . The microcontroller  106  may be, but is not limited to, the PIC16F91X manufactured by Microchip Corporation. Power is applied or removed from the charging circuit  92  via a power switch  116 , which may be, but is not limited to, a p-type FET, such as the Si4401BDY manufactured by Vishay/Siliconix. 
     The charging circuit  92  may be, for example, a complete off-the-shelf constant current source-type battery charger board, such as, but not limited to, the MIBTR or FALCON III manufactured by EFB, or it may comprise, but is not limited to, a programmable battery charger IC, such as, but not limited to, the CY8C27243-24PVI manufactured by Cypress Semiconductor, Inc., or the LT3652DFN13 manufactured by Linear Technologies, Inc. For the latter programmable battery charger IC, maximum charge current and maximum compliance voltage may be preset by external analog circuitry as outlined in the latter&#39;s datasheet. In a preferred embodiment, the maximum (constant) charging current is set to about 2 amps and peak maximum compliance voltage to about 17 volts. 
       FIG. 9  is a process flow diagram exhibiting exemplary steps of a method for operating the charger  18  of  FIG. 8 , according to an embodiment of the present invention. Initially, the charger  18  is “asleep” (i.e., no rechargeable electronic device  28  to be charged is attached and the charger  18  is switched off). In step S 1 , when the rechargeable electronic device  28  is attached, it presents a non-infinite resistive load to the charger  18 . As a result, current may be drawn and sensed on either an input side and/or an output side of the charger  18 . Further, the charger  18  “awakens” and in step S 2 , the ambient temperature (e.g., T) is measured and employed to set a power source threshold off voltage (e.g., ZnLowVoltageOff) and a power source threshold on voltage (e.g., ZnLowVoltageOn). The power source threshold off voltage is a predetermined voltage level below which the power source  12  cannot charge the rechargeable electronic device  28  and needs to recover. In such circumstances, it is necessary to reduce the total load on the power source  12  by “disconnecting” one or more of the rechargeable electronic devices  28  to be described hereinbelow. Hysteresis is built into the power source threshold on voltage, which is set to a predetermined voltage level greater than power source threshold off voltage above which the power source  12  is considered to have recovered and charging the rechargeable electronic device  28  may resume. 
     For example, assuming current is sensed and the charger  18  “awakens,” Table 1 illustrates the resulting power source threshold off voltages and the power source threshold on voltages: 
     
       
         
               
               
               
             
               
               
               
               
             
           
               
                 TABLE 1 
               
               
                   
               
               
                   
                 ZnLowVoltageOff 
                 ZnLowVoltageOn 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                   
                 T &gt; 10 C 
                   11 volts 
                  11.5 volts 
               
               
                   
                 −10 C &lt; T &lt; 10 C 
                 10.75 volts 
                 11.25 volts 
               
               
                   
                 T &lt; −10 C 
                  10.5 volts 
                   11 volts 
               
               
                   
               
             
          
         
       
     
     At step S 3 , the voltage of the power source (e.g., Zn voltage) is measured. At step S 3 A, if the voltage of the power source  12  (e.g., Zn voltage) is greater than the power source threshold off voltage (e.g., ZnLowVoltageOff), then at step S 4 A, if the charger has not been turned on, then at step S 5 , the charger  18  is turned on to charge the rechargeable electronic device  28 . In step S 6 , the voltage of the rechargeable electronic device  28  is measured. If, in step S 7 , the voltage of the rechargeable electronic device  28  is above the battery charged threshold voltage, then in step S 8 , the charger  18  is turned off, and the rechargeable electronic device  28  is considered charged. In a preferred embodiment, the battery charged threshold voltage is set to a predetermined percentage/level below the full voltage rating of the rechargeable electronic device  28  (e.g., if the battery rating is 12 volts, then the battery charged threshold voltage may be set to about 10 volts). 
     If, in step S 4 , the voltage of the power source  12  (e.g., Zn voltage) falls below the power source threshold off voltage (e.g., ZnLowVoltageOff), then the power source  12  is assumed to be depleted of charge, and needs to recover. In such circumstances, in step S 9 , the charger  18  begins a count down from the battery charged threshold voltage to the current voltage of the rechargeable electronic device  28  (i.e., the actual application battery voltage) in steps corresponding to a predetermined time delay. 
     For example, in a preferred embodiment, if the battery charged threshold voltage is 10 volts and the actual application battery voltage is 6 volts, then the charger  18  counts down from 10 volts to 6 volts in decrements of 100 mV (e.g., 8.0 V, 7.9 V, 7.8 V, . . . 6.2 V, 6.1 V, 6.0 V) wherein the time between counts is set to 100 msec (e.g., 8.0 V at time 0 msec, 7.9 V at time 100 msec, 7.8 V at time 200 msec, . . . 6.2 V at time 3800 msec, 6.1 V at time 3900 msec, 6.0 V at time 4000 msec). In other embodiments, counting may be performed in increments of 100 msec from 6 V to 10 V. In other embodiments, certain chargers  18  may have greater or lesser priority for being charged than other chargers  18 . In such circumstances, the voltage and/or time increment may be set to other values to count in a shorter or larger time/voltage interval (e.g., 20 mV decrements/increments in 10 msec increments or 200 mV increments/decrements at 200 msec increments). In the limiting case, the priority of one or more chargers may be so great that the time increment is infinite (equivalent to always charging the rechargeable electronic device  28 ). 
     When the count reaches the voltage of the rechargeable electronic device  28 , in step S 10 , the voltage of the power source  12  is re-measured. If, in step S 11 , the voltage of the power source  12  is still below the power source threshold off voltage (e.g., ZnLowVoltageOff), then in Step S 12 , the charger  18  is turned off; otherwise, the charger  18  continues to charge the rechargeable electronic device  28  in step S 6 . In step S 13 , the charger sleeps for a predetermined time delay to allow the power source  12  to recover. If in step S 14 , the voltage of the power source  12  is now above the power source threshold on voltage (e.g., ZnLowVoltageOn), then in Step S 15 , the charger  18  “sleeps” a predetermined amount of time, and then the method returns to step S 1 , ad infinitum. 
     Since all connected chargers  12  follow have the same method of steps S 3 -S 16 , the most fully charged rechargeable electronic device  28  is associated with the charger  18  that switches off first, allowing the power source  12  to recover so it can continue charging the other rechargable electronic device  28 . When the voltage of the power source  12  rises again above the power source threshold on voltages (e.g., ZnLowVoltageOn), the rechargeable electronic device  28  whose associated charger was switched off may be switched on again to charge that rechargeable electronic device  28 . If a particular rechargeable electronic device  28  is deemed to always be more important than others, as described above the charger  18  can count more slowly (i.e., have a larger predetermined time delay), or not at all. 
     The main advantage of the method outlined in  FIG. 9  is that a central expensive control box/processor is not needed to prioritize which rechargeable electronic device  28  is switched off first. In addition, as illustrated in the “hub-less” embodiment of  FIG. 5B , no central hub is needed. As a result, a nearly unlimited number of rechargeable electronic devices  28  may be strung together in a parallel network. 
     It is to be understood that the exemplary embodiments are merely illustrative of the invention and that many variations of the above-described embodiments may be devised by one skilled in the art without departing from the scope of the invention. It is therefore intended that all such variations be included within the scope of the following claims and their equivalents.