阅读说明：本技术 用于电池供电设备的模块化电池组件 (Modular battery assembly for battery powered devices ) 是由 杰夫·蔡勒 凯尔·哈维 基思·丹德里奇 瑞恩·哈恩 瑞恩·贾斯科维奇 尼克·蔡德勒 雅各 于 2020-03-26 设计创作，主要内容包括：一种用于动力设备的动力系统,其包括电池和接收器,所述电池具有至少300瓦时的容量并包括基本上包围所述电池的电池壳体,所述接收器包括设置在所述接收器上的电端子,所述电端子选择性地和电地连接至所述电池。所述接收器被配置为与所述电池壳体的一部分选择性地连接。所述接收器被配置为在不使用工具的情况下与所述电池壳体的部分分离。所述接收器包括平面安装表面,所述平面安装表面包括至少一个用于接收螺纹紧固件的孔。所述接收器通过螺纹紧固件被连接至动力设备。(A power system for a power plant comprising a battery having a capacity of at least 300 watt-hours and including a battery housing substantially enclosing the battery and a receiver including electrical terminals disposed on the receiver, the electrical terminals selectively and electrically connected to the battery. The receiver is configured to selectively connect with a portion of the battery housing. The receiver is configured to be separated from a portion of the battery housing without the use of tools. The receiver includes a planar mounting surface including at least one aperture for receiving a threaded fastener. The receiver is connected to the power plant by a threaded fastener.)

1. A power system for a power plant, comprising:

a battery having a capacity of at least 300 watt-hours and comprising a battery housing substantially enclosing the battery; and

a receiver including electrical terminals disposed on the receiver, the electrical terminals selectively and electrically connected to the battery;

wherein the receiver is configured to selectively connect with a portion of the battery housing, and wherein the receiver is configured to detach from a portion of the battery housing without the use of tools;

wherein the receiver further comprises a planar mounting surface comprising at least one hole for receiving a threaded fastener; and

wherein the receiver is connected to the power plant by a threaded fastener.

2. The power system according to claim 1 wherein the battery further comprises:

a battery pack having a pack case;

a first modular housing portion connected to a battery housing at a first end of the battery housing;

a second modular housing portion connected to a battery housing at a second end of the battery housing;

a handle formed as part of the first modular housing portion; and

a plurality of battery cells located within the battery pack housing.

3. The power system of claim 2, wherein the battery further comprises a first slot formed on the first modular housing portion and a second slot formed on the second modular housing portion, the first slot and the second slot together forming an alignment slot configured to receive one of the plurality of protrusions of the receptacle.

4. The power system according to claim 2 wherein the handle includes a release mechanism configured to releasably connect the battery assembly to at least one of a power plant and a charging station when the release mechanism is in a release position.

5. The powered system of claim 4, wherein the release mechanism is located on an interior surface of the handle and extends along at least a portion of the handle.

6. The power system of claim 2, wherein the battery includes a heat sink located within the battery pack housing and configured to dissipate heat from the battery.

7. The power system of claim 2, wherein the battery further comprises a mating component comprising a plurality of ports electrically connected to the plurality of battery cells and configured to supply power from the plurality of battery cells through the ports and configured to selectively connect the battery with a receptacle of at least one of a power device and a charging station, wherein the mating component is located on the first modular housing portion.

8. The power system of claim 7, wherein the mating member includes a slot configured to engage with a protrusion on the charging station to releasably connect the battery to the charging station.

9. The power system of claim 2, wherein the battery further comprises a battery management system located within the battery pack housing and configured to monitor a status of the battery and control operation of the battery, and further configured to wirelessly communicate information with at least one of a remote server and a personal computer, wherein the information communicated with at least one of the remote server and the personal computer is at least one of information regarding a status and a command of the battery.

10. A battery assembly, comprising:

a housing comprising a first portion, a second portion, and a third portion connecting the first portion to the second portion, wherein the second portion is opposite the first portion;

a handle located above the first portion;

a plurality of battery cells located within the housing;

a mating component comprising a plurality of ports electrically connected to the plurality of battery cells and configured to provide power from the plurality of battery cells through the ports and configured to selectively connect the battery assembly with a receptacle of at least one of a power device and a charging station:

wherein the mating component is located on the first portion of the housing.

11. The battery assembly of claim 10, further comprising a plurality of bumpers on the first portion and the second portion, the plurality of bumpers configured to align the battery assembly to a receptacle of at least one of the power plant and the charging station.

12. The battery assembly of claim 10, further comprising a user interface that displays a battery status indication using a Light Emitting Diode (LED) and a Liquid Crystal Display (LCD), the user interface being located on a third portion of the housing.

13. The battery assembly of claim 10, wherein the battery further comprises a first slot formed on a first modular housing portion and a second slot formed on a second modular housing portion, the first slot and the second slot together forming an alignment slot configured to receive one of the plurality of protrusions of the receptacle.

14. The battery assembly of claim 10, wherein the handle includes a release mechanism configured to releasably connect the battery assembly to at least one of a power device and a charging station when the release mechanism is in a release position.

15. The battery assembly of claim 14, wherein the release mechanism is located on an inner surface of the handle and extends along at least a portion of the handle.

16. A battery assembly, comprising:

a housing comprising a handle;

a plurality of battery cells located within the housing; and

a mating component comprising a plurality of ports electrically connected to a plurality of battery cells and configured to provide power from the plurality of battery cells through the ports and configured to selectively connect the battery assembly with a receptacle of at least one of a power plant and a charging station;

wherein the handle includes a release mechanism configured to selectively disengage the battery assembly from at least one of the power device and the charging station when the release mechanism is in a release position; and

wherein the housing contains a plurality of channels configured to engage with a plurality of protrusions of the receptacle.

17. The battery assembly of claim 16, further comprising:

a lower housing modular portion; and

an upper housing modular portion;

wherein a first slot is formed on the lower housing modular portion and a second slot is formed on the upper housing modular portion, the first and second slots together forming an alignment slot configured to receive one of the plurality of projections of the receptacle.

18. The battery assembly of claim 16, wherein the release mechanism is located on an inner surface of the handle and extends along at least a portion of the handle.

19. The battery assembly of claim 16, further comprising a controller configured to monitor a status of the battery assembly and control operation of the battery assembly, and further configured to wirelessly communicate information with at least one of a remote server and a personal computer, wherein the information communicated with at least one of the remote server and the personal computer is at least one of information regarding the status and commands of the battery assembly.

20. The battery assembly of claim 16, further comprising:

-a cell assembly located within the housing, the cell assembly comprising:

-a plurality of battery cells; and

-a first current collecting plate and a second current collecting plate, wherein the plurality of battery cells are electrically connected together through the first current collecting plate and the second current collecting plate;

-wherein the plurality of battery cells are located between the first current collector plate and the second current collector plate;

-a plurality of sleeves located between the housing and the first collection plate; and

-a second plurality of bushings located between the housing and the second current collector plate.

Background

The present invention relates generally to the field of indoor and outdoor power equipment, and more particularly to the field of battery powered indoor and outdoor power equipment.

Summary of The Invention

One embodiment of the present invention includes a power system for a power plant. The power plant includes a battery having a capacity of at least 300 watt-hours. The battery also includes a battery housing substantially enclosing the battery. The power plant includes a receiver including an electrical terminal disposed on the receiver that is selectively and electrically connected to the battery. The receiver is configured to selectively connect with a portion of the battery housing. The receiver is configured to be separated from a portion of the battery housing without the use of tools. The receiver includes a planar mounting surface including at least one aperture for receiving a threaded fastener. The receiver is connected to the power plant by a threaded fastener.

Another embodiment of the invention is a battery assembly that includes a housing, a handle, a plurality of battery cells, and a mating component. The housing includes a first portion, a second portion, and a third portion connecting the first portion to the second portion. The second portion is opposite the first portion. The handle is located above the first portion. A plurality of battery cells are located within the housing. The mating member includes a plurality of ports electrically connected to the plurality of battery cells. The mating component is configured to be powered from the plurality of battery cells through the port. The mating component is configured to selectively connect the battery assembly with a receptacle (receptacle) of at least one of the power device and the charging station. The mating member is located on the first portion of the housing.

Another embodiment of the invention is a battery assembly that includes a housing, a plurality of battery cells, and a mating component. The housing includes a handle. A plurality of battery cells are located within the housing. The mating component includes a plurality of ports electrically connected to the plurality of battery cells. The mating component is configured to be powered from the plurality of battery cells through the port. The mating component is configured to selectively connect the battery assembly with a receptacle of at least one of a power device and a charging station. The handle includes a release mechanism configured to selectively disengage the battery assembly from at least one of the power device and the charging station when the release mechanism is in a release position. The housing includes a plurality of channels configured to engage with the plurality of protrusions of the receptacle.

Another embodiment of the invention is a battery assembly that includes a housing, a plurality of battery cells, and a mating component. The housing includes a handle. A plurality of battery cells are located within the housing. The mating component includes a plurality of ports electrically connected to the plurality of battery cells. The mating component is configured to be powered from the plurality of battery cells through the port. The mating component is configured to selectively connect the battery assembly with a receptacle of at least one of a power device and a charging station. The handle includes a release mechanism configured to selectively disengage the battery assembly from at least one of the power device and the charging station when the release mechanism is in a release position. The housing includes a plurality of channels configured to engage with the plurality of protrusions of the receptacle.

Another embodiment of the present invention is a battery charging system that includes a charging station and a plurality of battery assemblies. The charging station includes a plurality of receptacles. Each of the battery assemblies includes: a housing having a handle; a plurality of battery cells located within the housing; and a fitting member integrally formed with the housing. The mating component is configured to selectively connect the battery assembly with a receptacle of a charging station and includes a plurality of ports electrically connected to the plurality of battery cells. The mating component is configured to receive power from a charging station to charge the plurality of battery cells. The handle includes a release mechanism configured to selectively disengage the battery assembly from the plurality of receptacles of the charging station.

Another embodiment of the present invention is a battery assembly comprising: a battery pack having a pack case; and a cell assembly located within the battery housing. The cell assembly includes a plurality of battery cells, a first collecting plate, and a second collecting plate. The plurality of battery cells are electrically connected together by the first collecting plate and the second collecting plate. The plurality of battery cells are located between the first collecting plate and the second collecting plate. A plurality of sleeves are positioned between the pack housing and the first current collector plate. A plurality of bushings are also located between the stack housing and the second current collector plate.

Alternative exemplary embodiments relate to other features and combinations of features, as may be generally recited in the claims.

Drawings

The present invention will become more fully understood from the detailed description given herein below, taken in conjunction with the accompanying drawings, wherein:

FIG. 1A is a perspective view of a battery assembly for various types of indoor and outdoor power equipment according to one exemplary embodiment;

FIG. 1B is a perspective view of a battery assembly for various types of indoor and outdoor equipment according to one exemplary embodiment;

FIG. 2A is a front view of the battery assembly of FIG. 1A;

FIG. 2B is a front view of the battery assembly of FIG. 1B;

FIG. 3A is a perspective view of a portion of the battery assembly of FIG. 1A;

FIG. 3B is a perspective view of a portion of the battery assembly of FIG. 1B;

FIG. 4 is a perspective view of the battery system of FIG. 1A;

FIG. 5 is a front view of the battery assembly of FIG. 1A;

FIG. 6 is a perspective view of a portion of the battery assembly of FIG. 1A;

FIG. 7 is an exploded perspective view of the battery system of FIG. 1A;

FIG. 8 is a perspective cross-sectional view of the battery system of FIG. 1A;

FIG. 9 is a perspective view of a battery pack of the battery system of FIG. 1A;

fig. 10 is a front view of the battery pack of fig. 1A;

FIG. 11 is a perspective view of a portion of the battery pack of FIG. 9;

fig. 12 is an exploded perspective view of the battery pack of fig. 9;

FIG. 13 is a perspective view of a cell assembly of the battery pack of FIG. 9;

FIG. 14 is a top view of the cell assembly of FIG. 13;

FIG. 15 is a perspective view of the cell assembly of FIG. 13;

FIG. 16 is an exploded perspective view of the cell assembly of FIG. 13;

FIG. 17 is an exploded perspective view of the battery assembly of FIG. 1A;

FIG. 18A is a front view of components of the battery assembly of FIG. 1A;

FIG. 18B is a perspective cross-sectional view of the battery assembly of FIG. 1A;

FIG. 18C is a front cross-sectional view of the battery assembly of FIG. 1A;

FIG. 19 is a perspective view of the battery assembly of FIG. 1A used with a portable charger according to an exemplary embodiment;

fig. 20 is a perspective view of the portable charger of fig. 19;

FIG. 21 is a perspective view of the battery assembly of FIG. 1A used with a portable charger according to an exemplary embodiment;

fig. 22 is a perspective view of the portable charger of fig. 21;

FIG. 23 is a perspective view of the battery pack of FIG. 9 with a power connector;

fig. 24A is a perspective view of a plurality of battery assemblies stored in a vehicle;

FIG. 24B is a perspective view of a plurality of battery packs used as a backup power source in a home or business;

FIG. 25 is a schematic diagram of a battery and fleet management system (fleet management system) according to an exemplary embodiment;

FIG. 26 is a perspective view of a compact charger for the battery assembly of FIG. 1A according to an exemplary embodiment;

FIG. 27 is a perspective view of the compact charger of FIG. 26 used with the battery assembly of FIG. 1A according to an exemplary embodiment;

fig. 28 is a perspective view of the compact charger of fig. 26;

FIG. 29 is a schematic view of an environment in which the compact charger of FIG. 26 is used;

FIG. 30 is a perspective view of a quick charger for the battery assembly of FIG. 1A according to an exemplary embodiment;

FIG. 31 is a perspective view of the quick charger of FIG. 30 used with the battery assembly of FIG. 1A according to an exemplary embodiment;

FIG. 32 is a perspective view of the quick charger of FIG. 30 used with the battery assembly of FIG. 1A according to an exemplary embodiment;

FIG. 33 is a schematic diagram of an environment in which the rapid charger of FIG. 30 is used;

FIG. 34 is a perspective view of a triple bay charger (triple bay charger) for the multiple battery assembly of FIG. 1A, according to an exemplary embodiment;

figure 35 is a perspective view of the tri-bay charger of figure 34 used with the plurality of battery packs of figure 1A, according to one exemplary embodiment; and

fig. 36 is a schematic diagram of an environment in which the three bay charger of fig. 34 is used.

Detailed Description

Before turning to the figures, which illustrate exemplary embodiments in detail, it should be understood that the application is not limited to the details or methodology set forth in the description or illustrated in the figures. It is also to be understood that the terminology is for the purpose of description and should not be regarded as limiting.

Referring generally to the drawings, the battery assembly described herein is a removable and replaceable battery assembly that may be used with various types of indoor and outdoor power equipment and portable worksite field devices. Outdoor power equipment includes mowers, riding tractors, snow throwers, high pressure cleaners, tillers (tillers), log splitters, zero-turn mowers, walk-behind mowers, riding mowers, upright mowers, pavement surface preparation equipment, industrial vehicles (e.g., forklifts), utility vehicles, commercial turf equipment (e.g., blowers), vacuum cleaners, chip loaders, seed loaders, power rakes, ventilation, turf cutters (sod cutters), bush mowers (brush mowers), portable generators, and the like. Indoor power equipment includes floor sanders, floor bumpers and polishers, vacuum cleaners and the like. The portable worksite field device includes a portable lighthouse, a mobile industrial heater, and a portable light fixture.

Referring to fig. 1A-1B, a battery assembly 100 is shown according to an exemplary embodiment. Battery assembly 100 is removable and rechargeable. Battery assembly 100 is configured to be inserted (e.g., lowered, placed) into a receiver integral with a device and/or charging station. The battery assembly 100 can be mounted into a device vertically, horizontally, and at any angle. As described below, the battery assembly 100 includes a battery pack 105 and optionally one or more modular sections. The battery pack 105 is a lithium ion battery. However, other types of batteries are contemplated, such as nickel-cadmium (NiCD), lead-acid, nickel metal hydride (NiMH), lithium polymer, and the like. The battery assembly 100 produces a voltage of approximately 48 volts (V) and 1400 watt-hours (Wh) of energy. It is contemplated that other sizes of battery packs may be used. The battery assembly 100 may have a capacity of at least 300 Wh. The total weight of battery assembly 100 is less than about 20 pounds for ease of carrying, removal, and replacement. The battery assembly 100 is also hot-swappable, which means that a depleted battery assembly 100 can be replaced with a new battery assembly 100 without completely disconnecting the power supply of the connected device. Thus, down time between battery assembly 100 replacements is eliminated.

As described further herein, an operator may remove the battery assembly 100 from the device (e.g., from a receiver of the device) and recharge it using a charging station without the use of tools. In this way, the operator can use the second rechargeable battery with sufficient charge to power the device while allowing the first battery to recharge. In addition, battery assembly 100 can be used on various types of equipment, including indoor, outdoor, and portable worksite field devices. Due to its consistency among devices, the battery assembly 100 can also be used as part of a rental system, and rental companies that conventionally rent devices can also rent battery assemblies 100 to be used on such devices. An operator may rent the battery assembly 100 for use on various types of equipment that the operator may own and/or rent, and then return the battery assembly 100 for use by other operators as needed. Furthermore, multiple battery assemblies 100 may be used in conjunction with one another to provide sufficient power to devices that may require more than a single battery assembly.

The battery assembly 100 is configured to be selectively and electrically connected to a device and/or a charging station. The device or charging station includes a receiver having electrical terminals that selectively and electrically connect to the battery assembly 100 without the use of tools. For example, an operator may insert (and electrically connect) and remove (and electrically disconnect) the battery assembly 100 from a device (e.g., from a terminal of a receptacle) without the use of tools. The receiver may include a planar mounting surface having at least one hole for receiving a threaded fastener, and the receiver may be connected to the device by the threaded fastener.

Still referring to fig. 1A-1B, the battery pack 105 includes an upper portion 150, a lower portion 155, a left side 160, and a right side 165. Battery assembly 100 further includes an upper modular portion 115 connected to an upper portion 150 of battery pack 105, and lower modular portions 120, 125 connected to a lower portion 155 of battery pack 105 on each of a left side 160 and a right side 165. Upper modular portion 115 and lower modular portions 120, 125 are connected to battery pack 105 using fasteners 180 (e.g., bolts, screws). The lower modular portions 120, 125 provide protection for the battery pack 105 and function to absorb or limit forces experienced by the battery pack 105 when dropped, etc. In some embodiments, battery assembly 100 may not include upper modular portion 115 and/or lower modular portions 120, 125, and may be permanently mounted to a device. Upper modular portion 115 and lower modular portions 120, 125 are interchangeable and customizable so that an operator or original equipment manufacturer can select different designs and/or colors based on the type or make and model of equipment to be used with battery assembly 100. Upper modular portion 115 and lower modular portions 120, 125, including handle 110, may be removed from battery pack 105. The upper, handle 110 and lower modular portions 120, 125 connect to the battery pack 105 using a mechanical interface and do not include any electrical connections. In this manner, the battery pack 105 may be used without the modular section and handle 110, or the original equipment manufacturer may specifically select the modular section and handle to create their own unique platform.

Referring to fig. 1A-5, upper modular portion 115 includes a housing 117 and a handle 110 extending from the housing. The housing 117 surrounds the upper portion 150 of the battery pack 105. The housing 117 includes a mating portion 140 located near the left side 160 of the battery pack 105. The mating portion 140 includes an opening 170 having one or more ports 175 (fig. 6) therein. Port 175 is configured to mate with a charging connector (e.g., charging connector 198 in fig. 20, 22) on a charger (e.g., charger 192 in fig. 20-22). Upper modular portion 115 includes an upper modular portion slot 130 located on mating portion 140 and configured to guide corresponding components on the charger onto battery assembly 100 and/or the device.

Referring to FIG. 1A, upper modular portion 115 includes a slot or channel 181 formed in housing 117. Lower modular portions 120, 125 each include a slot or channel 183 formed thereon. One of slots 181 formed on upper modular portion 115 is aligned with slot 183 formed on lower modular portion 120 and a second of slots 181 formed on upper modular portion 115 is aligned with second slot 183 formed on lower modular portion 125. As shown in fig. 1A and 2A, aligned slots 181, 183 form two aligned slots 185 when upper and lower modular sections 115, 120, 125 are connected to battery pack 105. As further described herein, the aligned slots 185 are used to guide the battery assembly 100 onto a charging station or device. Alternatively, as shown in fig. 1B and 2B, upper modular portion 115 additionally includes an upper modular portion protrusion or bumper 191 and lower modular portions 120, 125 include a lower modular portion protrusion or bumper 171. The buffers 171, 191 allow buffering when the battery assembly 100 is toppled over, and double as alignment members when the battery assembly 100 is inserted into or connected to a device. The bumpers 171, 191 guide the battery assembly 100 onto the device so that an operator can easily align the battery assembly 100 with a receiver interface on the tool.

The handle 110 includes an outer surface 111 and an inner surface 113 positioned closer to the battery pack 105 than the outer surface 111. As shown in fig. 1-3, the inner surface 113 includes a release mechanism or movable member 135 configured to be operable by an operator to unlock and separate the battery assembly 100 from the charging station and/or device. When depressed, the movable member 135 moves inwardly toward the inner surface 113 and unlocks the battery assembly 100 out of engagement with the corresponding components on the charging station and/or device. In this manner, when the operator grasps the handle 110, the operator can easily press down the movable member 135 to disengage the battery assembly 100 from the device or charging station simultaneously and with the same hand.

Referring to fig. 3A-3B, the battery pack 105 further includes a user interface 122 configured to display various status and fault indications of the battery assembly 100. The user interface 122 displays various colors or other indications using Light Emitting Diodes (LEDs) (on the LED display 121), a liquid crystal display (on the LCD display 123), and the like. The LED display 121 can provide battery charge status and can flash or flash battery fault codes. The LCD display 123 can provide additional information about the battery assembly 100, including status, tool specific data, usage data, faults, and the like. For example, the battery indication may include, but is not limited to, state of charge, fault, battery health, battery life, battery mode, unique battery identifier, link system, and the like.

Referring to fig. 7-8, an exploded view and a cross-sectional view of a battery assembly 100 according to an exemplary embodiment are shown. The fasteners 180 are inserted through the front 101 and rear 103 of the battery pack 105 as further described herein. The battery assembly 100 includes a spacer 109 inserted through the battery pack 105 and extending from the front 101 to the rear 103 of the battery pack 105. In some embodiments, each end of the spacer 109 is threaded to receive a fastener 180 on each side of the battery pack 105.

Referring to fig. 9-11, a battery pack 105 according to an exemplary embodiment is shown. The battery pack 105 includes a front 101, a rear 103, a left side 131 and a right side 133. The battery pack 105 includes an aperture 107 extending from the front 101 (e.g., through the aperture) to the rear 103. As described above, the spacer 109 is inserted through the aperture 107 and extends through the battery pack 105 from the front 101 to the rear 103.

The battery pack 105 includes a connector portion 142 that includes one or more ports 175 configured to mate with a charging connector on a charger or charging station. When the upper modular portion 115 is connected to the battery pack 105, the connector portion 142 is located within the mating portion 140 of the upper modular portion 115. Thus, as described above, the port 175 is accessible through the mating portion 140 of the battery assembly 100. In this manner, upper modular portion 115 may serve to protect port 175 from damage from impact when installed on a charging station and/or power plant, or to limit the amount of debris and/or liquid that reaches or contacts port 175. The connector portion 142 includes a connector portion slot 144 configured to help guide and/or position the connector portion 142 into the mating portion 140 of the upper modular portion 115. As further described herein, the battery pack 105 also includes an insertion portion 177 at the left side 131 that includes an aperture 179 (e.g., threaded aperture) configured to receive a fastener 162 (e.g., threaded fastener, bolt) to connect to a power connector 178 (shown in fig. 23).

Referring to fig. 12-18C, the battery pack 105 includes a cell assembly 156 having a top cell holder 151, a bottom cell holder 153, and one or more battery cells 152 positioned therebetween. The battery pack 105 includes a top collector plate 149 located on or near the top cell holder 151 and a bottom collector plate 159 located on or near the bottom cell holder 153. Collector plates 149, 159 electrically connect battery cells 152 together. As further described herein, the collector plates 149, 159 make both parallel and series electrical connections, and are electrically connected to the BMS 167. The illustrated battery cells 152 are oriented vertically (i.e., each battery cell 152 has an axis extending longitudinally through the entire length of each battery cell 152 perpendicular to the cross-sectional area of each battery cell 152). The battery cells 152 can be stacked to increase or decrease the capacity of the battery assembly 100. In some embodiments, battery cells 152 are oriented horizontally. As shown in fig. 12, when the battery pack 105 is assembled, the spacers 109 are located outside the cell assemblies 156 and extend between the front 101 and rear 103 sides of the battery pack 105. The configuration of the spacer 109 relative to the cell assembly 156 allows the cell assembly 156 to be separated from the case of the battery assembly 100. In addition, the cell assembly 156 is isolated from the battery housing by a plurality of sleeves and foam cushions. As shown in fig. 18C, one or more corner sleeves 187 are positioned around each corner spacer 109. One or more center bushings 157 are located near the center of the battery pack 105. One or more foam pads are located between the top cell support 151 (e.g., top collector plate 149) and the battery pack housing, and one or more foam pads are located between the bottom cell support 153 (e.g., bottom collector plate 159) and the battery pack housing. In this manner, the cell assembly 156 is protected during use of the battery pack 105 (e.g., installation, shipping, potential dropping, storage in a truck bed or trailer, knocking, etc.) such that shock or vibration if dropped or on the device limits or eliminates injury to the battery pack 105. In addition, the inner surface of the battery pack 105 may be filled with additional foam material to protect the cell assembly 156 and other internal components of the battery assembly 100.

A Battery Management System (BMS) 167 is located within the battery pack 105 and is electrically connected to the unit assembly 156. When the battery assembly 100 is assembled, the BMS 167 is located near the upper portion 150 of the battery assembly 100 (e.g., below the user interface 122) (as shown in fig. 1A-1B). Referring to fig. 18B, the BMS 167 is connected to the unit assembly 156 and is electrically connected to the top and bottom collector plates 149 and 159. The electrical connection between BMS 167 and top collector plate 149 and bottom collector plate 159 allows for voltage reading across all parallel strings. Typically, this type of connection is accomplished by laying wires throughout the battery pack 105. By using collector plates 149, 159, wires that are typically used to make such connections are eliminated, thereby reducing the use of wires within assembly 105. BMS 167 is configured to manage the power output of battery cells 152. BMS 167 can be configured to allow battery cell 152 to provide full power output to port 175 to power the powered device connected to battery assembly 100. In some embodiments, the BMS 167 can allow the battery cells 152 to be charged when the battery assembly 100 is connected to a charging station. According to some embodiments, BMS 167 can also be configured to cut off power output from battery cells 152 to port 175. In some embodiments, the BMS 167 can also be configured to record and store data regarding usage, cycling, power levels, rental durations, etc. of the battery assembly 100. The BMS 167 can also be configured to wirelessly connect to a remote database, a remote network, or a remote device, according to some embodiments. In some embodiments, the BMS 167 can be further configured to control the user interface 122. As described above, the user interface 122 may display information to the operator, such as battery level, remaining rental time, error messages, and the like.

The battery assembly 100 includes an electrical connector 173 located within the connector portion 142 of the battery pack 105. The electrical connector 173 includes a port 175 and is electrically connected to the cell assembly 156. The electrical connector 173 transmits power from the cell assembly 156 to the port 175. The electrical connector 173 is located on the left side 131 of the battery pack 105, although it may be located in other locations (e.g., the right side 133). The electrical connector 173 is also communicatively and operatively connected to a Metal Oxide Semiconductor Field Effect Transistor (MOSFET) board 147. The battery pack 105 further includes a heat sink 145 located near the left side 131 (fig. 11) of the battery pack 105. The heat sink 145 regulates the temperature of the battery pack 105 by transferring heat generated by the battery pack 105 to a fluid medium (e.g., air) and then dissipating the heat from the battery pack 105.

Referring to fig. 19-22, a portable charger 192 for use with the battery assembly 100 is shown according to one embodiment. A portable charger 192 is plugged into port 175 and a wall outlet (e.g., via line 197) to provide charging to battery assembly 100. The portable charger 192 includes two longitudinal walls 189 with a receptacle 193 therebetween. The battery assembly 100 is configured to slide into the receptacle 193 and lock into place on the portable charger 192. As shown in fig. 20 and 22, the portable charger 192 includes two male (male) connectors 198 configured to mate with the ports 175 on the battery assembly 100 in the installed position of the portable charger 192. Portable charger 192 also includes a horizontal member 195 and a movable member 196 that operate together to connect portable charger 192 to mating portion 140 of battery assembly 100. In some embodiments, using portable charger 192, battery assembly 100 will be fully charged in approximately 4 hours.

Referring to fig. 23, a battery pack 105 and a power connector 178 are shown according to an exemplary embodiment. The power connector 178 slides onto the connector portion 142 of the battery pack 105 and connects with the port 175. To connect the power connector 178 to the battery pack 105, the fastener 162 is inserted through the aperture 172 on the power connector 178 and fastened to an aperture 179 (e.g., a threaded aperture) on the battery pack 105. In this manner, lateral movement of power connector 178 is limited, reducing the pressure exerted on port 175.

Referring to fig. 24A-24B, battery assembly 100 is shown in environments 200 and 250 using multiple battery systems 210 having multiple battery assemblies 100. Each battery assembly 100 is connected to a power bank 215 through a power connector 178. As shown in fig. 24A, a plurality of battery systems 210 can be easily transported in, for example, a truck bed 202 and serve as a backup power source 220 for home or business use. The multiple battery system 210 is relatively compact in size.

Referring to fig. 25, in some embodiments, a battery assembly 100 in a connection environment 300 is shown according to an example embodiment. As further described herein, the battery assembly 100 can be connected to and communicate with various types of charging systems or charging stations 304. Battery assembly 100 is also configured to connect (e.g., by near field communication of device 306) to various types of powered devices 302. Battery assembly 100 is connected to network 308. Network 308 allows for connection and communication between battery assembly 100 and various other devices. In some embodiments, the battery assembly 100 is connected to other battery assemblies 100, charging stations, or other devices via Wi-Fi, bluetooth, or other data communication systems. In some embodiments, an operator and/or employee communicates with the battery assembly 100 through a personal or mobile device 312 (e.g., a smartphone, a handheld computer, a desktop computer, a tablet computer, etc.) using the network 308. Thus, one or more mobile devices 312 are also connected to the network 308. In some embodiments, the fleet management system 310 is communicatively and operatively connected to the battery assembly 100 via the network 308.

In some embodiments, battery assembly 100 includes a network interface. In some arrangements, the network interface includes the hardware and logic necessary to communicate over multiple channels of data communication. For example, the network interface may include a Wi-Fi interface, a cellular modem, a bluetooth transceiver, a bluetooth beacon, an RFID transceiver, an NFC transceiver, or a combination thereof. The network interface facilitates data communication with the battery assembly 100 (and thus the device 302 using the battery assembly 100). The battery assembly 100 is capable of wirelessly communicating with a plurality of other devices including another battery assembly 100 in a mesh network. In this manner, the battery assembly 100 is able to communicate status and usage information as well as configuration data.

Network 308 may facilitate data communication between various combinations of battery assemblies 100 and mobile devices 312. In some arrangements, the network 308 includes a cellular transceiver. In another arrangement, the network 308 comprises the Internet. In yet another arrangement, the network 308 comprises a local area network or a wide area network. The network 308 may be facilitated by short-range and/or long-range communication techniques, including bluetooth transceivers, bluetooth beacons, RFID transceivers, NFC transceivers, Wi-Fi transceivers, cellular transceivers, wired network connections, and the like. As such, in one embodiment, communication between the mobile device 312 and the battery assembly 100 can be facilitated through RFID and Wi-Fi connections on the battery assembly 100 and connected to a cloud-based system. In another embodiment, communication is facilitated only by Wi-Fi and connected to a cloud-based system. In another embodiment, communication is facilitated by a cellular transceiver and connected to a cloud-based system. In yet another embodiment, the communication is facilitated by bluetooth and cellular transceivers and connected to a cloud-based system. In all such embodiments, a third party (e.g., a consumer and/or a rental company) can access the cloud-based system. To communicate over a cloud-based system, a gateway is included. The gateway may be a dedicated device, a charger, or another battery pack 100.

According to some embodiments, battery assembly 100 (e.g., battery management system 167, other circuitry) includes a communication interface. In some embodiments, the communication interface may be an interface that communicatively connects the battery assembly 100 to an external device. For example, the communication interface may allow battery assembly 100 to communicate serially with external devices via SPI (serial peripheral interface), I2C (integrated circuit bus), USB (universal serial bus), etc., or any other serial communication protocol. In some embodiments, the external device in communication with the battery assembly 100 is a charging station (e.g., the bay charger system 600 as shown in fig. 34). According to some embodiments, the battery assembly 100 may communicate information about the status of the battery assembly 100 (e.g., currently charged, fully charged, ready for use, predetermined, etc.) with the charging station.

Battery assembly 100 may include one or more circuits configured to monitor the status of battery assembly 100 or other aspects of a device used with battery assembly 100. The circuit may be further configured to monitor the state of the battery to predict the number of times the battery can be started. For example, the circuitry may monitor the state of charge of the battery, the average amount of power consumed to start and operate the device, and/or other characteristics of the device (e.g., operating state, RPM, etc.). The average amount of power consumed to start the device and/or characteristics of the device may be communicated to the circuit by one or more terminals connecting the battery assembly 100 to the receiver. The number of times battery assembly 100 can be activated can then be shown on a display integrally formed with the battery (e.g., user interface 122 shown in fig. 3A-3B) or provided elsewhere (e.g., on a control panel of the power device). The number of times the battery assembly 100 can be started may also be transmitted to the mobile device 312 and displayed on the user interface of the mobile device 312. The number of times battery assembly 100 can be started may be calculated based on characteristics of the device, for example, for one type of outdoor power equipment (e.g., a high pressure washer), a battery with a particular charge may be able to perform more starts than another type of outdoor power equipment (e.g., a lawn mower). The battery assembly 100 may also determine (e.g., by various circuitry) the type of device that uses the battery assembly 100. In this manner, battery assembly 100 is able to determine customized inputs and outputs based on the device type. In some embodiments, the battery assembly 100 is capable of wirelessly identifying the tool via an NFC tag mounted on the tool interface. Thus, the battery assembly 100 can include an NFC reader. Once the battery assembly 100 is inserted into the tool interface, the battery assembly 100 reads information from the NFC tag and can associate usage data of the battery assembly 100 with the particular tool or device. The battery assembly 100 is also capable of specifically reconfiguring data pins (data pins) to the tool. If the tool has multiple battery slots, the NFC tag can also be used to identify the slot into which the battery assembly 100 is inserted.

The circuitry may be further configured to monitor other characteristics of the device by communicating with sensors and monitoring devices (e.g., level sensors, temperature sensors, pressure sensors, timers, etc.). The circuitry may output data related to information received from the sensors and monitoring devices to a display, such as a user interface 122 (fig. 3A-3B) integrally formed with the battery assembly 100 or a display displayed on a user interface of the mobile device 312. Thus, the display may communicate various operational data related to the device and the battery assembly 100 to an operator of the device. For example, the circuit may output information such as operating time, battery level, or battery temperature to the display. In addition, the circuitry may monitor the temperature of the battery assembly 100 through input from a temperature sensor. If the battery temperature is too low for normal use of the battery, temperature monitoring may be used to alert an operator (e.g., via user interface 122, a user interface of mobile device 312). Powering these circuits using battery assembly 100 may provide information to an operator (e.g., battery temperature, battery charge level) prior to device start-up, so that any problems may be addressed prior to attempting to start-up the device.

Referring to fig. 26-29, a compact charger according to an exemplary embodiment is shown. The compact charger 400 is configured to connect to the battery assembly 100 and charge the battery assembly 100. In some embodiments, the compact charger 400 is a 400 watt (W) charger. The compact charger 400 can charge the battery assembly 100 in about 3-4 hours. The compact charger 400 includes a charger main body 402 and a receptacle 408. The compact charger 400 is configured to slide or otherwise connect to the battery assembly 100 (e.g., at the mating portion 140) and electrically connect to the port 175 (fig. 4). The wire 406 is connected to the compact charger 400 at one end and to a wall outlet at the other end. The wire 406 supplies power to the compact charger 400 and then the compact charger 400 supplies power to the battery assembly 100. In some embodiments, the compact charger 400 stores electrical energy to power the battery assembly 100 without the patch cord 406 or a wall outlet. In some embodiments, the compact charger 400 includes an indicator light 404 that can provide a status indication to an operator. For example, when the indicator light 404 is illuminated, an indication is provided to the operator that the compact charger 400 is charging the battery assembly 100. As another example, when the indicator light 404 is a certain color (e.g., green), the compact charger 400 is powered, and when the indicator light 404 is another color (e.g., red), the compact charger 400 is depleted of power. Referring to fig. 28, the wire 406 may be wrapped around the charger 400 in a storage position.

Referring to fig. 30-33, a fast charger according to an exemplary embodiment is shown. The quick charger 500 is configured to be connected to the battery assembly 100 and charge the battery assembly 100. In some embodiments, the fast charger 500 is a 1000W charger. The quick charger 500 can charge the battery pack 100 in about 1.5 hours. The quick charger 500 includes a charger main body 502 and a receptacle 508. The quick charger 500 is configured to slide or otherwise connect to the battery assembly 100 (e.g., at the mating portion 140) and electrically connect to the port 175 (fig. 4). A cord can be plugged into a charging port 506 (e.g., a USB port) to charge the fast charger 500. The fast charger 500 is configured to be used without connection to a wall outlet. The operator can select to use the fast charge mode (e.g., by pressing a fast charge mode option) or to use a lower rate charge mode, which may be the default mode. As shown in fig. 31-32, the quick charger 500 may be connected to the battery assembly 100 and be in a vertical or horizontal position. The quick charger 500 also includes a handle 512 and two wall portions 510. In the installed position, two wall portions 510 are located on either side of the battery assembly 100. An operator can grasp the handle 512 to manipulate the charger 500 (e.g., connect and disconnect the charger 500 from the battery assembly 100). In some embodiments, the quick charger 500 includes an indicator light 504 that can provide a status indication to an operator. Referring to fig. 33, a fast charger 500 is shown for use in a use environment 550. For example, the quick charger 500 is shown inside the vehicle 520, on the floor of the vehicle 520, and suspended from the interior walls of the vehicle 520.

Referring to fig. 34-36, a bay charger (bay charger) 600 is shown according to an exemplary embodiment. The bay charger 600 is configured to be connected to a plurality of battery packs 100 and to charge the plurality of battery packs 100 at the same time. In some embodiments, the bay charger is a 400W bay charger, providing 400W of power to each battery assembly 100 connected thereto. The bay charger 600 includes a charger body 602 and a plurality of receptacles 608 defined by a plurality of wall portions 610. Each receptacle 608 is configured to receive or otherwise connect to each battery assembly 100 and to electrically connect to a port 175 (fig. 4) of the battery assembly 100. The wire 606 is connected to the bay charger 600 at one end and to a wall outlet at the other end. In some embodiments, the bay charger 600 includes an indicator light 604 for each battery receptacle 608. Indicator light 604 provides an indication to the operator of the status of battery assembly 100 connected to receptacle 608. As shown in fig. 36, a plurality of battery assemblies 100 are plugged into and connected to the receptacle 608 and stored on shelves in a storage space or display environment 650. When an operator wishes to remove one of the battery assemblies 100, he grasps the handle 110 of the battery assembly 100, engages (e.g., squeezes, pushes in) the movable member 135, and removes the battery assembly 100 by sliding the battery assembly 100 out of the receptacle 608. The bay charger 600 may include one or more controllers configured to ensure proper charging of all battery assemblies 100.

In some embodiments, the bay charger 600 charges in sequence as the plurality of battery assemblies 100 are charged. Sequential charging includes charging different battery assemblies 100 at different times so that not all of the battery assemblies 100 are charged simultaneously, thereby not overloading the utility service system. Sequential charging may be accomplished by monitoring the charge levels of all connected battery assemblies 100 to determine which battery assemblies 100 need to be charged more than others, and charging those assemblies 100 when the power to a battery assembly 100 that may have been fully charged is shut down. The sequential charging may also determine the order in which the battery packs 100 are inserted into the bay charger 600 and charge the battery packs according to the order.

In addition to the charging system described above, the battery assembly 100 can also be charged when inserted into a device or tool in which the battery assembly 100 is used. An operator can insert the battery assembly 100 and insert a device or tool into the receptacle to charge the battery assembly 100. In this embodiment, the charging system is included in the tool or device such that an external charger is not required.

While this specification contains many specific implementation details, these should not be construed as limitations on the scope of what may be claimed, but rather as descriptions of specific features of particular implementations. Certain features that are described in this specification in the context of separate embodiments can also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments separately or in any suitable subcombination. Furthermore, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination.

It should be understood that while words such as "suitable" or "appropriate" have been used in the description above to indicate that the function so described may be more appropriate, they may not be necessary, and embodiments lacking the same may be contemplated as within the scope of the invention, the scope being defined by the claims that follow. In reading the claims, it is intended that when words such as "a," "an," or "at least one" are used, there is no intention to limit the claim to only one unless specifically stated to the contrary in the claim.

It should be noted that certain paragraphs of the invention may refer to terms such as "first" and "second" in relation to sides and ends or the like, for identifying or distinguishing one from another or from another. These terms are not intended to relate entities (e.g., first side and second side) only in time or according to an order, although in some cases, these entities may include such relationships. Nor are these terms limiting the number of possible entities (e.g., sides or ends) that may operate in a system or environment.

As used herein, the terms "coupled" and "connected," and the like, refer to two members being joined to one another either directly or indirectly. Such engagement may be fixed (e.g., permanent) or movable (e.g., removable or releasable). Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being connected to one another.

As used herein, the term "circuitry" may include hardware configured to perform the functions described herein. In some embodiments, each respective "circuit" may include a machine-readable medium for configuring hardware to perform the functions described herein. The circuitry may be embodied as one or more circuit components including, but not limited to, processing circuitry, network interfaces, peripherals, input devices, output devices, sensors, and the like. In some embodiments, the circuitry may take the form of one or more analog circuits, electronic circuits (e.g., Integrated Circuits (ICs), discrete circuits, system-on-chip (SOC) circuits, etc.), telecommunications circuits, hybrid circuits, and any other type of "circuit. In this regard, "circuitry" may include any type of component for implementing or facilitating the operations described herein. For example, the circuitry described herein may include one OR more transistors, logic gates (e.g., NAND, AND, NOR, OR, XOR, NOT, XNOR, etc.), resistors, multiplexers, registers, capacitors, inductors, diodes, wiring, etc.

"circuitry" may also include one or more processors communicatively connected to one or more memories or storage devices. In this regard, one or more processors may execute instructions stored in memory, or may execute instructions accessible to another one or more processors. In some embodiments, one or more processors may be implemented in various ways. One or more processors may be constructed in a manner sufficient to perform at least the operations described herein. In some embodiments, one or more processors may be shared by multiple circuits (e.g., circuit a and circuit B may contain or share the same processor, which in some example embodiments may execute instructions stored or otherwise accessed through different regions of memory). Alternatively or additionally, one or more processors may be configured to perform or otherwise perform certain operations independently of one or more coprocessors. In other exemplary embodiments, two or more processors may be connected via a bus (bus) to enable independent, parallel, pipelined, or multi-threaded instruction execution. Each processor may be implemented as one or more general-purpose processors, Application Specific Integrated Circuits (ASICs), Field Programmable Gate Arrays (FPGAs), Digital Signal Processors (DSPs), or other suitable electronic data processing components configured to execute instructions provided by the memory. The one or more processors may take the form of single-core processors, multi-core processors (e.g., dual-core processors, three-core processors, four-core processors, etc.), microprocessors, and the like. In some embodiments, the one or more processors may be external to the device, e.g., the one or more processors may be remote processors (e.g., cloud-based processors). Alternatively or additionally, the one or more processors may be internal and/or local to the device. In this regard, a given circuit or component thereof may be provided locally (e.g., as part of a local server, local computing system, etc.) or remotely (e.g., as part of a remote server (e.g., a cloud-based server)). To this end, a "circuit" as described herein may include components distributed over one or more locations.