Patent ID: 12212169

DETAILED DESCRIPTION

Before any independent embodiments of the utility model are explained in detail, it is to be understood that the utility model is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The utility model is capable of other independent embodiments and of being practiced or of being carried out in various ways.

Use of “including” and “comprising” and variations thereof as used herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Use of “consisting of” and variations thereof as used herein is meant to encompass only the items listed thereafter and equivalents thereof.

Relative terminology, such as, for example, “about”, “approximately”, “substantially”, etc., used in connection with a quantity or condition would be understood by those of ordinary skill to be inclusive of the stated value and has the meaning dictated by the context (for example, the term includes at least the degree of error associated with the measurement of, tolerances (e.g., manufacturing, assembly, use, etc.) associated with the particular value, etc.). Such terminology should also be considered as disclosing the range defined by the absolute values of the two endpoints. For example, the expression “from about 2 to about 4” also discloses the range “from2to4”. The relative terminology may refer to plus or minus a percentage (e.g., 1%, 5%, 10% or more) of an indicated value.

Also, the functionality described herein as being performed by one component may be performed by multiple components in a distributed manner. Likewise, functionality performed by multiple components may be consolidated and performed by a single component. Similarly, a component described as performing particular functionality may also perform additional functionality not described herein. For example, a device or structure that is “configured” in a certain way is configured in at least that way but may also be configured in ways that are not listed.

Furthermore, some embodiments described herein may include one or more electronic processors configured to perform the described functionality by executing instructions stored in non-transitory, computer-readable medium. Similarly, embodiments described herein may be implemented as non-transitory, computer-readable medium storing instructions executable by one or more electronic processors to perform the described functionality. As used in the present application, “non-transitory computer-readable medium” comprises all computer-readable media but does not consist of a transitory, propagating signal. Accordingly, non-transitory computer-readable medium may include, for example, a hard disk, a CD-ROM, an optical storage device, a magnetic storage device, a ROM (Read Only Memory), a RAM (Random Access Memory), register memory, a processor cache, or any combination thereof.

Many of the modules and logical structures described are capable of being implemented in software executed by a microprocessor or a similar device or of being implemented in hardware using a variety of components including, for example, application specific integrated circuits (“ASICs”). Terms like “controller” and “module” may include or refer to both hardware and/or software. Capitalized terms conform to common practices and help correlate the description with the coding examples, equations, and/or drawings. However, no specific meaning is implied or should be inferred simply due to the use of capitalization. Thus, the claims should not be limited to the specific examples or terminology or to any specific hardware or software implementation or combination of software or hardware.

FIG.1illustrates a battery charger10operable to charge a battery14A,14B coupled to the charger10. In the illustrated construction, the battery charger10is operable to charge a first battery14A of a first type and a second battery14B of a second type. The illustrated battery charger10may be operable to charge a high output battery (e.g., having a current capacity of 12 amp-hours (Ah) or more), which requires about 3 times the power of typical chargers, in about 60 minutes.

The battery type may be defined by nominal voltage, current capacity, connection configuration (e.g., “tower” vs. “slide-on”), etc., of the battery14A,14B. For example, the first battery14A may include a high-power battery pack with a nominal voltage of about 12 volts (V) and having a tower-style configuration, and the second battery14A may include a high-power battery pack with a nominal voltage of 18V and a slide-on configuration. In other constructions (not shown), the batteries14A,14B may be the same type of battery.

Each battery14A,14B is connectable to and operable to power various motorized power tools (e.g., a cut-off saw, a miter saw, a table saw, a core drill, an auger, a breaker, a demolition hammer, a compactor, a vibrator, a compressor, a drain cleaner, a welder, a cable tugger, a pump, etc.), outdoor tools (e.g., a chain saw, a string trimmer, a hedge trimmer, a blower, a lawn mower, etc.), other motorized devices (e.g., vehicles, utility carts, a material handling cart, etc.), and non-motorized electrical devices (e.g., a power supply, a light, an AC/DC adapter, a generator, etc.).

The charger10includes a housing18providing support structure22A,22B (FIG.2) engageable with the respective batteries14A,14B, a power input port26for connection to a power supply (e.g., through a power cord30), charger electronics34(FIG.6), and a heat dissipating structure38. Air flow (e.g., green lines;FIG.9) is configured to flow though the housing18for dissipating heat generated by the charger10.

With reference toFIG.2, the charger housing18has a top portion42A and an opposite bottom portion42B coupled to the top portion42A (e.g., by fasteners (not shown)). The housing portions42A,42B may be formed of plastic with each molded as a single piece.

The top portion42A has a top wall46, a lower wall48, and an inclined wall50coupled between the walls46,48. The top wall46is spaced from the bottom portion42B, and the lower wall48is substantially perpendicular to the bottom portion42B. The top wall46provides the top of the housing18, and the bottom portion42B provides a bottom of the housing18opposite the top. The inclined wall50and the lower wall48provide a front of the housing18. The top portion42A further includes a back wall54opposite the front and opposite side walls56,60. The bottom portion42B has a raised wall62interfacing with one or more walls (e.g., the back wall54, the side walls56,60, etc.) of the portion42A.

The housing18provides the battery support structure22A,22B. Each support structure22A,22B is at least partially positioned substantially on the front of the housing (e.g., on the inclined wall50) and defines adjacent supporting sections64A,64B. The supporting sections64A,64B are configured to support the batteries14A,14B, respectively.

The illustrated supporting section64A defines a recess70, as a battery receiving port, defined by the top wall46and the inclined wall50. The recess70is configured to receive at least a portion (e.g., the tower) of the battery14A. A first set of charger terminals74(FIG.6) extend from within the housing18through holes into the recess70. The charger terminals74are configured to electrically connect to battery terminals of the battery14A received in the recess70for charging.

The illustrated supporting section64B includes rail members80A,80B and a charger terminal block84. The rail members80A,80B are spaced apart, substantially parallel and positioned on the inclined wall50. A groove88A,88B is defined between the inclined wall50and the associated rail member88A,88B. The rail members80A,80B and grooves88A,88B are engageable with corresponding structure on the battery14B. The charger terminal block84is positioned between the rail members80A,80B and includes a second set of charger terminals92configured to electrically connect to battery terminals of the battery14A for charging.

In some embodiments (seeFIGS.10A-10B), the rail members80A,80B include a reinforcement member82. The illustrated reinforcement member82(e.g., green member) is molded as a part of the housing18with the rail members80A,80B and with the supporting section64B. The illustrated reinforcement member82is formed as a single piece of reinforcing material, such as metal (e.g., a metal stamping), hard plastic, etc. In other embodiments (not shown), the reinforcement member82is formed by two or more pieces coupled together.

With reference toFIGS.2-4, the housing18defines an air inlet96in the inclined wall50and positioned below the first supporting section64A (e.g., the recess70). As such, the illustrated air inlet96is below the battery14A when coupled to the charger10. In addition, the illustrated inlet96is positioned on the front of the housing18and includes slots100(e.g., longitudinal slots) defined in the inclined wall50and, partially, by the lower wall48. The illustrated slots100extend through the inclined wall50into the interior of the housing18. The slots100extend from proximate the top wall46to the lower wall48. In other embodiments (not shown), the slots100may extend in a latitudinal direction, a combination longitudinal/latitudinal direction, etc. The slots100are configured to facilitate air flow into the housing18.

The housing18also defines an air outlet104positioned on the side56of the housing18and proximate the back54. The outlet104includes slots108(e.g., longitudinal slots) defined by the side56and extending from proximate the bottom portion42B to proximate the top portion42A (e.g., the top wall46). In other embodiments (not shown), the slots108may extend in a latitudinal direction, a combination longitudinal/latitudinal direction, etc. The slots108are configured to facilitate air flow exiting the housing18. The inlet96and the outlet104are positioned on different locations of the housing18(e.g., as illustrated, the outlet104is positioned on the side56oriented at 90 degrees relative to the front of the housing18).

The housing18may include more than one inlet and/or outlet. For example, as shown inFIG.4, the housing18further defines a second air inlet110(FIG.4) positioned on the bottom. The illustrated second air inlet110is defined by the bottom portion42B. The second air inlet110includes slots114proximate the front (e.g., the lower wall48) and the side56of the housing18. The second air inlet110may facilitate air flow to a bottom side118(FIG.6) of the charger electronics34, as further discussed below.

It should be understood that, in other constructions (not shown), the first inlet96, the second inlet110, and/or the outlet104may be positioned on any side of the housing18(e.g., the back54, the other side60, the bottom, etc.).

The slots100,108,114may have the same or different lengths. For example, the illustrated slots100of the first inlet96have different lengths. The illustrated slots114,108of each of the second inlet110and the outlet104, respectively, have the same length. Furthermore, the slots100,108,114may have any shape, such as, rectangular, triangular, trapezoidal, etc. For example,FIG.3illustrates the inlet96formed by rectangular and trapezoidal slots, whileFIG.4illustrates the outlet104being formed by generally rectangular slots.

With reference toFIG.4, feet members120extend from and are configured to position the bottom portion42B of the housing18at a distance (e.g., three millimeters (3 mm)) from a work surface (e.g., a table). Furthermore, the feet members120are configured to facilitate air flow to the second inlet110. The illustrated feet members120include an elastomeric material and to improve support (e.g., frictional, vibrational, etc.) of the charger10on the work surface.

With reference toFIGS.2-3, the top portion42A includes an indicia region126in which logos, images, brands, text, marks, etc., are displayed. The illustrated indicia region126is positioned on the top wall46and above the second supporting section64B. The housing18may include one or more indicia regions positioned on any of the sides (e.g., top, bottom, back54, etc.). Furthermore, the top wall46may include another indicia region above the first supporting section64A.

The top portion42A includes a plurality of openings130(e.g., two openings130A,130B) defined by the top wall46and positioned proximate the back54of the housing18. One opening130A is positioned opposite the first supporting section64A, and the other opening130B is positioned opposite the second supporting section64B. The openings130A,130B may be configured to receive a lens134(only one of which is shown inFIG.1). A light source (e.g., a light-emitting diode (LED)) may be provided within the housing18to illuminate the lens134. As such, the openings130A,130B and the lens134are configured to form indicators on the top portion42A. Each supporting section64A,64B has an indicator for indicating an operation (e.g., charging) of the charger10.

The illustrated power input port26is positioned on the front of the housing18, and below the second supporting section64B (FIG.2). More specifically, the power input port26is defined in the lower wall48. In other embodiments (not shown), the power input port26may be located on any side (e.g., back54, bottom, etc. of the housing18). The illustrated power cord30extends from the charger electronics34within the housing18(FIG.6) through the power input port26to the power source.

With reference toFIGS.6-7, the charger electronics34are supported by the bottom portion42B. The charger electronics34are operable to output a charging current to one or both of the batteries14A,14B to charge the batteries14A,14B. The charger electronics34include, among other things, a printed circuit board (PCB)140, a charger microcontroller (not shown), and a transformer144. The charger electronics34may include a charging circuit portion (not shown; e.g., on separate PCBs) for each of the batteries14A,14B so that each battery14A,14B may be charged simultaneously and independently. The charging current provided to each battery14A,14B may be the same or different.

The charger10further includes a heat sink150and a fan154within the housing18to provide the heat dissipating structure38. A temperature sensor (not shown) is disposed in the housing18and positioned near the charger electronics34(e.g., near the component(s) generating the most heat (e.g., the CPU, the transformer144, field effect transistors (FETs), etc.)) or the heat sink150. In the illustrated embodiment, the temperature sensor is positioned proximate a side of the heat sink150.

In the illustrated construction, the heat sink150is disposed in the housing18proximate the back54. In other constructions (not shown), the heat sink150may be positioned at other locations in the housing18(e.g., proximate the front, the sides56,60, etc.). The heat sink150is in heat transfer relationship with components of the charger electronics34(e.g., is mounted onto and in contact with the PCB140). In other words, heat transfers from the heat-generating components of the charger10to the heat sink150through conduction.

In the illustrated embodiment, the heat sink150is formed of heat-conducting material, such as, for example, aluminum, and extends between opposite ends158A,158B. Furthermore, the illustrated heat sink150is constructed of one or more hollow tubes162(three are shown inFIG.7), each having a rectangular shape and stacked above one another. The tubes162extend between the opposite ends158A,158B. As such, the illustrated heat sink150forms a tubular heat sink.

In other constructions (not shown), the hollow tube(s)162may have another shape, such as, for example, triangular, cylindrical, etc., and the heat sink150may have any number of tubes162(e.g., one, two, more than three). The charger10may include more than one heat sink150.

The first end158A forms an inlet of each tube162for air flow to enter the heat sink150, and the second end158B forms an outlet of each tube162for air flow to exit the heat sink150. As shown inFIG.7, the inlet of each tube162is angled toward the front of the housing18.

The illustrated fan154is positioned between the second end158B of the heat sink150and the outlet104. A baffle166extends between the second end158B and the fan154for directing air flow from the heat sink150to the outlet104. Projections170A,170B extend from the top portion42A (FIG.5) and the bottom portion42B (FIG.6). The fan154is positioned between (i.e., sandwiched between) the projections170A,170B to be secured within the housing18.

The illustrated fan154is a multi-speed fan operable to rotate at more than one speed and directs air flow from the inlet96through the housing18and to the outlet104. The speed at which the fan154rotates may be determined based on a temperature of one or more of the charger electronics34, the heat sink150, a supported battery14A,14B, etc. The temperature sensor (not shown) is configured to measure the temperature and transmit a signal output to the microcontroller for determining the temperature of the charger10. Subsequently, the microcontroller controls the speed of the fan154based on the temperature (e.g., of the heat sink150, as illustrated). In some embodiments, at full speed, the fan154generates an air flow of between about 13.6 m3/hour and about 25.5 m3/hour. Still further, in some embodiments, the fan154may generate an air flow of about 20.4 cubic feet per minute (CFM) and up to about 35 m3/hour or less.

With reference toFIG.5, the top portion42A of the housing18includes a plurality of wall members176extending from an inner surface180. The wall members176are integral with the top portion42A and are configured to form a fluid diverter within the housing18. The diverter may direct air (FIG.6) from the inlet96over the charger electronics34(e.g., the PCB140) to the heat sink150. Furthermore, the diverter is configured to create turbulent fluid flow and may, therefore, increase air flow through the housing18and/or facilitate dissipation of heat from the housing18. The bottom portion42B may also include similar integral wall members or diverters for further directing air flow through the housing18. The wall members176may further extend through the PCB140for directing air flow through the PCB140and through the housing18.

As shown inFIG.6, the charger10defines a flow path A through the housing18. In the illustrated embodiment, air flows along the flow path A from the inlet96, over the charger electronics34(e.g., the PCB140) to the inlet of the heat sink150, and through the heat sink150to the outlet104. The fan154directs air flow along the flow path A. Furthermore, the fan154directs air flow into the inlet and out of the outlet of each tube162. The air flow operates to dissipate heat generated by the charger electronics34from the housing18. In other embodiments (not shown), the fan154may be operated in reverse such that the flow path A through the housing18is reversed.

In one example (seeFIG.9in which the housing18and the heat sink150are shown as transparent to illustrate the air flow), air (e.g., green lines) flows from the inlet96to the outlet104through the housing18. Specifically, air flows from the inlet96, over the charger electronics34, and through the heat sink150to the outlet104. The inlet96, the heat sink150, and the outlet104are positioned to direct the air along this flow path for dissipating the heat generated by the charger10.

The charger10may further define a second flow path in fluid communication with the second inlet110. Specifically, air flows into the bottom of the housing18through the second inlet110and past components of the charger electronics34positioned on the bottom side118of the PCB140. Air flow in the second flow path may be combined with air flow in the first flow path from the first inlet96to exit the outlet104. As such, air flow within the housing18may be separated along at least a portion of the flow paths through the housing18.

The PCB140may further include a heat sink or copper (not shown) extending from a top side184through the PCB140to the bottom side118to dissipate heat generated by any of the components of the charger electronics34to the bottom side118. Air entering the housing18through the second inlet110is configured to flow past the bottom side118to further facilitate dissipation of heat of the charger electronics34from the housing18.

The heat sink150may include a slot (not shown) proximate one or some of the components of the charger electronics34, such as, for example, the transformer144. The slot may be configured to direct a portion of air flowing through the heat sink150over a specific component (e.g., the transformer144) on the PCB140. As such, air may flow at least partially through the heat sink150more than once.

With reference toFIGS.6-7, the charger10includes a plurality of light pipes190(e.g., two light pipes190A,190B), each extending to an opening130A,130B defined by the top portion42A. Each light pipe190A,190B directs light from an associated light source to each indicator. In one embodiment, a number (e.g., two shown) of light emitting diodes (LEDs) are positioned on and electrically connected to the PCB140. Each LED emits light, and the associated light pipe190A,190B is configured to direct the light to the indicator on the top portion42A of the housing18. The light pipes190A,190B are in heat transfer relationship ((e.g., mounted onto and in contact) with the heat sink150for transferring heat generated by the light pipes190A,190B to the heat sink150.

The light pipes190A,190B (i.e., the respective LEDs) are electrically connected to the charger electronics34for controlling illumination of the light pipes190A,190B. For example, the indicator of the first supporting section64A (i.e., the light pipe190A) may be operated when the first battery14A is electrically connected to the charger terminals74of the first supporting section64A. As such, the indicators may be configured to indicate to a user when the respective batteries14A,14B are connected and charging.

In operation, one or both of the batteries14A,14B are coupled to the respective battery support structure22A,22B (e.g., the supporting sections64A,64B) for charging. The first set of terminals74electrically connect with the battery terminals of the first battery14A, and/or the second set of terminals92electrically connect with the battery terminals of the second battery14B. The charger10supplies charging current to the first and/or second battery14A,14B. Each indicator indicates to the user the charging operation for the associated battery14A,14B (e.g., completion of charging (i.e., when the charging current is zero Amps (0 A)).

As mentioned above, in the illustrated construction, the fan154is a multi-speed fan. With reference toFIG.8, the microcontroller determines the charger temperature (e.g., of the heat sink(s)150, the charger electronics34, etc.) and, when the temperature reaches or exceeds a threshold, activates the fan154to operate at a corresponding fan speed. For example, if the microcontroller detects a temperature of X° C. (e.g., about 50% maximum operating temperature), then the fan154is activated at X % speed (e.g., about 50% speed). It should be understood that, in other embodiments, the fan154may be activated at a different speed (e.g., more than 50% (100%, 75%, etc.) or less than 50% (25%, 10%, etc.)). Also, the speed of the fan154may be based on the sensed temperature (e.g., higher for a higher temperature or lower for a lower temperature) and/or a duration the sensed temperature exceeds a threshold (e.g., higher for a longer duration or lower for a shorter duration).

If the fan154is not at the maximum speed, then the speed of the fan154may be increased by X % (e.g., about an additional 10%), and the loop starts over (i.e., measuring the battery temperature and the charger temperature). It should be understood that, in other embodiments, the speed of the fan154may be increased by a different amount (e.g., 5%, 15%, 25%, etc.)). Also, the increase in the speed of the fan154may be based on the sensed temperature and/or duration the sensed temperature exceeds a threshold.

If the fan154is at the maximum speed, the microcontroller may determine the charging current output of the charger10. If the charging current output is not 0 A, then the charge current may be reduced by X % (e.g., about 10%), and the loop may start over (i.e. measuring the battery temperature and the charger temperature). It should be understood that, in other embodiments, the charge current may be reduced by a different amount (e.g., 5%, 15%, 25%, 50%, etc.)). Also, the reduction in the charge current may be based on the sensed temperature and/or duration the sensed temperature exceeds a threshold.

The microcontroller determines the charger temperature and controls the speed of the fan154regardless whether either of the batteries14A,14B is coupled to the charger10. The microcontroller deactivates the fan154only if the sensed temperature is below a threshold (e.g., a lower limit of the charger10).

Thus, the utility model may provide, among other things, a charger10operable to charge different types of batteries14A,14B at the same time, and a method for dissipating heat regardless whether the batteries14A,14B are coupled to the charger10. The charger10may include structure (e.g., a diverter) integral with and positioned within the housing18and operable to direct air flow from the inlet96through the housing18to the outlet104. The inlet96and the outlet104may be defined by adjacent sides (e.g., the front and the side56) or on opposite sides (e.g., the front and the back).

FIGS.11A-11Billustrate a charger10and charger electronics34including a printed circuit board (PCB)140′ positionable within the housing18. A plurality of portions200A,200B form the PCB140,140′. Similar to the PCB140, the PCB140′ includes a transformer144′, positioned between the portions200A,200B. The PCB140′ is configured to facilitate charging of the one or more batteries14A,14B.

Alternating current (AC) electrical components202A, operable to receive AC power from a power source (e.g., line power through the cord30), are supported on the first portion200A, and direct current (DC) electrical components202B, operable to output DC power to charge the battery pack(s)14A,14B, are supported on the second portion200B. The AC electrical components include (seeFIG.11B), among other things, capacitors204A, a resistor206A, inductors, etc. The DC electrical components include, among other things, capacitors204B, an inductor206B, resistors, etc.

A heat sink assembly150′ is in heat transfer relationship with the AC and DC electrical components202A,202B of the charger electronics34. In the illustrated embodiment, the heat sink assembly150′ is mounted onto and in contact with the PCB140′. Heat transfers from the heat-generating electrical components202A,202B on the PCB140′ to the heat sink150′ through conduction. The heat sink150′ is configured to be disposed in the housing18proximate the rear54, similar to the heat sink150.

The illustrated heat sink assembly150,150′ includes a number (e.g., three shown) of portions208A,208B,208C extending across a width of the PCB140,140′, respectively. The first and second portions208A,208B are formed of the heat-conducting material, such as, for example, aluminum, which is also electrically conductive. The first portion208A of the heat sink150′ may be defined as the AC heat sink, and the second portion208B of the heat sink150′ may be defined as the DC heat sink. The third portion208C is formed of non-electrically-conducting material, such as, for example, plastic, and is positioned between and electrically insulates the AC and DC heat sink portions208A,208B. The heat sink portions208A,208B,208C are configured such that the air flow is directed through each of the portions208A,208B,208C as described above with respect to the heat sink150. Furthermore, in the illustrated embodiment, the third portion208C includes the slot (not shown) proximate the transformer144for directing a portion of the air flowing through the heat sink150′ over the transformer144.

With particular reference toFIG.7, the light source (e.g., the LED; not shown) for each light pipe190is positioned on the DC portion200B of the PCB140(e.g., proximate the DC heat sink208B). The LEDs are powered by DC power, and the light pipes190are constructed to direct the light to the respective indicators on the top portion42A of the housing18. In the illustrated embodiment, the light pipes190are bendable or flexible such that the desired position of the respective indicators on the top portion42A may be achieved.

With particular reference toFIGS.11A-11B, the PCB140′ includes an in-board trace210(FIG.11A) extending from the DC portion200B of the PCB140′ proximate the third heat sink portion208C along a rear edge212of the PCB140′ to proximate the AC heat sink208A and the AC portion200A. The illustrated in-board trace212extends between opposite ends214A,214B.

With reference toFIGS.11A and13, in the illustrated construction, a LED216A is positioned on and electrically connected to the in-board trace210. As such, the LED216A is powered by DC power from the DC portion200B of the PCB140′ but is positioned on the AC portion200A. In the illustrated construction, the position of the LED216A is adjustable along the trace210so that the LED216A may be appropriately positioned relative to the indicator defined by the opening130A within the housing18(e.g., directly below the indicator above the AC portion200A of the PCB140,140′). In the illustrated embodiment, the LED216A is positioned intermediate the first and second ends214A,214B of the in-board trace210. Specifically, the LED216A is positioned at a distance A from the first end214A. The distance is adjustable such that the position of the LED216A on the AC portion200A is adjustable as necessary to be positioned relative to the indicator.

Another LED216B is positioned proximate the DC heat sink208B for providing light to the indicator defined by the opening130B. A light directing member220A,220B extends between an associated LED216A,216B and an indicator lens134A′,134B′ positioned within each opening130A,130B. Due to the positioning of the LED216A,216B, the light directing members220A,220B have a substantially linear shape in a vertical direction from the PCB140′.

An isolating member228is positioned between the LED216A and the heat sink portion208A. The isolating member228is formed of non-conducting material, such as, for example, plastic, and is operable to isolate the LED216A on the AC portion200A from interference caused by proximity to the AC components202A and electrically-conductive components (e.g., the heat sink portion208A).

With reference toFIGS.12-13, the PCB140′ includes a slot224extending along a portion of the AC heat sink portion208A and the in-board trace212. The slot224is configured to receive the isolating member228(FIG.13). Specifically, in the illustrated embodiment, the isolating member228extends from the bottom housing portion42B through the slot224. In other embodiments (not shown), the isolating member228may extend from the top housing portion42A. Still further, in other embodiments (not shown), the isolating member228may be positioned on the PCB140′, and the PCB140′ may not include the slot224to receive the isolating member228. In such a construction, isolating material may be provided on the PCB140′ on which the isolating member228may be mounted.

The illustrated isolating member228has a generally box-like shape and is positioned between the LED216A and the AC heat sink portion208A. A lateral direction B of the charger10extends through opposite sides of the isolating member228(e.g., its thickness). In some embodiments, the thickness may be about 1 millimeter (mm) or more. Still further, in some embodiments, the thickness may be between about 1 mm and about 2.2 mm. In the illustrated embodiment, the thickness is about 1.6 mm.

The isolating member228is positioned at a distance E from the AC heat sink portion208A (e.g., about 2.6 mm in the illustrated construction). In addition, the LED216A is spaced from the isolating member228by a distance F along the lateral direction B (e.g., about 7.4 mm in the illustrated construction). Rather than being linear, in other constructions (not shown), the isolating member228may curve around the LED216A with a radius of curvature being equal to or greater than the distance F.

In the illustrated construction, a total distance G that the LED216A is spaced from the AC heat sink portion208A is about 10 mm. In other embodiments, the total distance G is at least about 8 mm, the minimum over-surface distance (creepage) between the LED216A and the AC heat sink portion208A. Still further in other embodiments, the total distance G is between about 10 mm and about 12 mm.

The opposite ends of the isolating member228are spaced from the LED216A by a distance H (e.g., about 18.6 mm or more). In some embodiments, the distance H is about 18.664 mm or more. Furthermore, in some embodiments, the distance is between about 18.664 mm and about 22.8664 mm. In the illustrated embodiment, the distance H is about 18.8664 mm. In the illustrated construction, the LED216A is positioned equidistant between the ends of the isolating member228. Furthermore, in other embodiments, the distance H is about 8 mm or more.

The isolating member228may be sized to facilitate adjustment of the LED216A on the trace212. The size of the isolating member228may be sufficient to maintain a minimum distance (e.g., about 18.8664 mm) between the LED216A and the proximate edge of the isolating member228in the various adjusted positions of the LED216A along the trace212. In other constructions, the isolating member228may also be adjusted to a position corresponding to the position of the LED216A.

The top of the isolating member228is spaced above the LED216A by a distance I which may be the same as or different than the distance H. In some embodiments, the distance I is about 14.8 mm or more (e.g., 14.8677 mm in the illustrated construction). In some embodiments, the distance is between about a. Furthermore, in other embodiments, the distance I is about 8 mm or more.

In other constructions (not shown), the isolating member228may have a different shape. For example, the isolating member228may be curved. With the curved isolating member228, a horizontal distance from the LED216A to the lateral edge of the isolating member228may be at least the minimum distance (e.g., 8 mm to each side), a vertical distance from the LED216A to the top of the isolating member228may be at least the minimum (e.g., about 8 mm), and the wall of the isolating member228may be curved therebetween. In still other constructions (not shown), portions of the isolating member228beyond the minimum distances may be removed (e.g., the corner portions removed to approximate the curved isolating member228).

Thus, the utility model may provide, among other things, a charger10with a LED216A supported on an AC side of a PCB140′ and isolated from electrical interference by AC components on the PCB140′. The charger10may include a LED that is adjustably positioned on the AC side of the PCB140′.

Although the utility model has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of one or more independent aspects of the utility model as described.

One or more independent features and/or independent advantages of the utility model may be set forth in the claims.