Portable vehicle battery crossover starter with air pump

文档序号：958152 发布日期：2020-10-30 浏览：19次中文

阅读说明：本技术 具有气泵的便携式车辆电池跨接启动器 (Portable vehicle battery crossover starter with air pump ) 是由乔纳森·里维斯·努克威廉·奈特·努克詹姆斯·理查德·斯坦菲尔德德里克·迈克尔·昂德希尔于 2018-12-14 设计创作，主要内容包括：一种便携式或手持式跨接启动和空气压缩装置,用于跨接启动汽车引擎以及给物品诸如轮胎充气。该装置可包括可再充电锂离子电池或电池组和微控制器。锂离子电池通过由微控制器驱动的FET智能开关耦接到设备的电源输出端口。与正极性输出和负极性输出电路连接的车辆电池隔离传感器检测在正极性输出和负极性输出之间连接的车辆电池的存在。与正极性输出和负极性输出电路连接的反极性传感器检测连接在正极性输出和负极性输出之间的车辆电池的极性。(A portable or hand-held jump start and air compression device for jump starting an automobile engine and inflating articles such as tires. The device may include a rechargeable lithium ion battery or battery pack and a microcontroller. The lithium ion battery is coupled to the power output port of the device through a FET smart switch driven by the microcontroller. A vehicle battery isolation sensor connected to the positive polarity output and the negative polarity output circuit detects the presence of a vehicle battery connected between the positive polarity output and the negative polarity output. A reverse polarity sensor connected to the positive polarity output and the negative polarity output circuit detects a polarity of the vehicle battery connected between the positive polarity output and the negative polarity output.)

1. A vehicle battery jump starter device having an air pump, the device comprising:

a cover;

an internal power source disposed within the lid;

a vehicle battery crossover starter disposed within the cover, the crossover starter configured to crossover start a vehicle battery; and

an air pump disposed within the lid, the air pump configured to provide a supply of pressurized air,

wherein the internal power supply provides power to the jump starter device and/or the air pump device.

2. The apparatus of claim 1, wherein the internal power source is a rechargeable battery.

3. The apparatus of claim 2, wherein the rechargeable battery is a lithium-ion rechargeable battery.

4. The device of claim 1, further comprising an air hose.

5. The device of claim 1, wherein the lid includes an air supply port for connecting the air hose.

6. The device of claim 5, wherein the cap and air pump provide an air supply port for connecting the hose.

7. The apparatus of claim 5, further comprising an internal air hose connecting the air pump to the air supply port.

8. The device of claim 1, wherein the internal power source is a single battery that powers the vehicle battery cross-starter and the air pump.

9. The device of claim 1, wherein the internal power source comprises a first battery for powering the vehicle battery cross-starter and a second battery for powering the air pump.

10. The apparatus of claim 1, further comprising a switch for selectively powering the vehicle battery cross-starter or the air pump.

11. The apparatus of claim 10, wherein the switch is configured to also power both the vehicle battery cross-over initiator and the air pump.

12. The device of claim 1, further comprising an internal fan for cooling the device.

13. The apparatus of claim 1, wherein the air pump comprises an air compressor.

14. The apparatus of claim 13, wherein the air compressor is a rotary air compressor.

15. The apparatus of claim 13, wherein the air pump further comprises an air tank connected to the air supply port.

16. The apparatus of claim 13, wherein the air pump is connected to the air supply port.

17. The apparatus of claim 1, further comprising:

at least one output port providing a positive polarity output and a negative polarity output;

a vehicle battery isolation sensor in circuit connection with the positive polarity output and the negative polarity output, the vehicle battery isolation sensor configured to detect the presence of a vehicle battery connected between the positive polarity output and the negative polarity output;

a reverse polarity sensor connected to the positive polarity output and the negative polarity output circuit, the reverse polarity sensor configured to detect a polarity of a vehicle battery connected between the positive polarity output and the negative polarity output;

a power FET switch connected between the internal power supply and the output port; and

A microcontroller configured to receive input signals from the vehicle isolation sensor and the reverse polarity sensor and provide an output signal to the power FET switch such that the power FET switch conducts to connect the internal power source and the output port in response to signals from the vehicle battery isolation sensor and the reverse polarity sensor indicating the presence of a vehicle battery at the output port and signals that the positive and negative terminals of the vehicle battery are connected with the correct polarity of the positive polarity output and the negative polarity output.

Technical Field

The present invention relates to a vehicle battery jump starter having a battery-powered air pump (e.g., an air compressor) for providing jump starting of a vehicle (e.g., cars, trucks, vans, motorcycles, boats, aircraft, and other vehicles or equipment having a starting battery) and for providing a supply of pressurized air, such as for inflating vehicle tires. A vehicle battery jump starter generally relates to a device or apparatus for jump starting a vehicle battery having a depleted or discharged battery.

Background

Vehicles such as automobiles, trucks, and buses require an air pump to provide pressurized air, for example, to inflate vehicle tires. Advances in battery technology have allowed portable crossover starters with air pumps to be developed in a single stand-alone product.

Currently, portable vehicle air pumps typically have a high noise air compressor that vibrates violently, and have a DC power cord that must be wired and plugged into a vehicle accessory port (e.g., cigarette lighter port). Furthermore, the power cord and air hose need to be long enough to contact the tires of the vehicle.

In addition, jump starting a car can be difficult because the user needs to have jumper cables and access to other vehicles. Safety is also an issue because improperly connecting clips is always a hazard.

The jump starting device with air pump provides a basic function which may be critical, since without such a device with two functions the vehicle and its driver may get stuck on the highway.

Furthermore, it is known in the prior art to provide either a pair of electrical connector cables for connecting the fully charged battery of another vehicle to the engine starter circuit of a vehicle with the battery dead, or a portable booster device comprising a fully charged battery connectable to the engine starter circuit of a vehicle by means of a pair of cables.

Problems with prior art devices arise when the jumper terminals or cable clamps inadvertently contact each other while the other end is connected to a rechargeable battery, or when the positive and negative terminals are connected to opposite polarity terminals in the vehicle to be jumped, causing short circuits that result in sparking and potential damage to the batteries and/or personal injury.

Disclosure of Invention

In order to solve the above problems, it is necessary to manufacture a product that provides both a convenient and safe portable jump start for a vehicle and a portable, stand-alone battery powered air compressor. Lithium battery technology already exists and can support both functions in a single product.

A hand-held portable device, powered by its internal battery source, for inflating tires and cross-over starting a vehicle engine may include a rechargeable lithium ion (Li-ion) battery pack, a dc motor, and a microcontroller.

A lithium ion (Li-ion) battery is coupled to the dc motor and to a smart switch driven by the microcontroller. A vehicle battery isolation sensor connected to the positive polarity output and the negative polarity output circuit detects the presence of a vehicle battery connected between the positive polarity output and the negative polarity output.

A reverse polarity sensor connected to the positive and negative polarity output circuits detects the polarity of the vehicle battery connected between the positive and negative polarity outputs so that the microcontroller will enable power to be delivered from the lithium ion power supply pack to the output port only when a good battery is connected to the output port.

The dc motor is coupled to the lithium ion battery pack to provide the sole power source for the motor without the need to connect to an a/C or secondary power source. The microcontroller allows the dc motor to inflate the tire to a set limit using the auto-off sensor without over-inflating the tire and allows an internal memory storage device to record and display the last known value.

Power transmission technology is incorporated to allow the tires to be pumped while charging the lithium battery. Noise dampening technology is built in to reduce decibel levels of tire pumps and vibration dampening technology is incorporated to achieve stable tire pumping.

Further, according to an aspect of the present invention, there is provided an apparatus for cross-over starting an engine of a vehicle, including: an internal power supply; an output port having a positive polarity output and a negative polarity output; a vehicle battery isolation sensor in circuit connection with the positive polarity output and the negative polarity output, the vehicle battery isolation sensor configured to detect the presence of a vehicle battery connected between the positive polarity output and the negative polarity output; a reverse polarity sensor connected to the positive polarity output and the negative polarity output circuit, the reverse polarity sensor configured to detect a polarity of a vehicle battery connected between the positive polarity output and the negative polarity output; a power FET switch connected between the internal power supply and the output port; and a microcontroller configured to receive input signals from the vehicle isolation sensor and the reverse polarity sensor and to provide an output signal to the power FET switch such that the power FET switch conducts to connect the internal power source to the output port in response to signals from the vehicle battery isolation sensor and the reverse polarity sensor indicating the presence of a vehicle battery at the output port and signals that the positive and negative terminals of the vehicle battery are connected with the correct polarity of the positive polarity output and the negative polarity output.

According to another aspect of the invention, the internal power source is a rechargeable lithium ion battery pack.

According to yet another aspect of the present invention, there is provided a jumper cable arrangement having: a plug configured to plug into an output port of a handheld battery charger booster device having an internal power source; a pair of cables integrated with the plug at respective one ends thereof; the pair of cables is configured to be individually connected to terminals of the battery at respective other ends thereof.

The presently described subject matter is directed to a new battery crossover start-up and air compression device.

The presently described subject matter is directed to an improved battery crossover start-up and air compression device. The presently described subject matter is directed to a heavy crossover start and air compression device.

The presently described subject matter is directed to a battery jump starting and air compression device that includes or consists of one or more batteries connected to an electrically conductive frame.

The presently described subject matter is directed to a battery crossover start-up and air compression device that includes or consists of one or more lithium ion batteries ("Li-ions") connected to an electrically conductive frame.

The presently described subject matter is directed to a battery cross-over start and air compression device that includes or consists of one or more lithium ion batteries ("Li-ions") connected to a high conductivity and high ampere (amp) current capacity framework.

The presently described subject matter is directed to a battery cross-over start and air compression device that includes or consists of two or more batteries connected to an electrically conductive frame.

The presently described subject matter is directed to a battery crossover start-up and air compression device that includes or consists of two or more Li-ion batteries connected to a highly conductive frame.

The presently described subject matter is directed to a battery crossover start-up and air compression device that includes two or more Li-ion batteries connected to a highly conductive frame.

The presently described subject matter is directed to a battery cross-over start and air compression device that includes or consists of one or more batteries connected to an electrically conductive frame configured to at least partially surround the one or more batteries.

The presently described subject matter is directed to a battery cross-over starting and air compressing device that includes or consists of one or more batteries connected to an electrically conductive rigid frame configured to at least partially surround the one or more batteries.

The presently described subject matter is directed to a battery crossover start-up and air compression device that includes or consists of one or more Li-ion batteries connected to an electrically conductive frame configured to at least partially surround the one or more batteries.

The presently described subject matter is directed to a battery cross-over activation and air compression device that includes or consists of one or more batteries connected to a rigid electrically conductive frame.

The presently described subject matter is directed to a battery crossover activation and air compression device that includes or consists of one or more batteries connected to a rigid electrically conductive frame that includes one or more electrically conductive frame members.

The presently described subject matter is directed to a battery cross-over start and air compression device that includes or consists of one or more batteries connected to an electrically conductive frame that includes one or more electrically conductive frame members.

The presently described subject matter is directed to a battery crossover activation and air compression device that includes or consists of one or more batteries connected to an electrically conductive frame that includes one or more conductors, such as electrically conductive wires, rods, bars, and/or tubes.

The presently described subject matter is directed to a battery crossover activation and air compression device that includes or consists of one or more batteries connected to an electrically conductive frame that includes one or more conductors, such as copper (Cu) wires, rods, bars, and/or tubes.

The presently described subject matter is directed to a battery crossover activation and air compression device that includes or consists of one or more batteries connected to a highly conductive rigid frame that includes one or more rigid conductors, such as copper (Cu) wires, rods, bars, and/or tubes.

The presently described subject matter is directed to a highly conductive cam lock electrical connection.

The presently described subject matter is directed to a highly conductive cam lock electrical connection according to the present invention for use in combination with a battery crossover start and air compression device.

The presently described subject matter is directed to a highly conductive cam lock electrical connection according to the present invention in combination with a battery jump start and air compression device according to the present invention.

The presently described subject matter is directed to a highly conductive cam lock electrical connection that includes or consists of a male cam lock end removably connected to a female cam lock end.

The presently described subject matter is directed to a highly conductive cam lock electrical connection comprising or consisting of: a highly conductive male cam lock end; a highly conductive female cam lock end; and a highly conductive connection arrangement between the male and female cam lock ends for conducting electrical power therebetween when coupled together, wherein the male and female cam lock are made of a highly conductive material, wherein the male cam lock end comprises a pin with teeth and the female cam lock end comprises a socket provided with a slot, wherein the socket is configured to receive the pin and teeth of the male cam lock end, wherein the socket of the female cam lock end is provided with an internal thread for cooperation with the teeth of the male cam lock end, wherein the male cam lock end comprises an end face portion and the female cam lock end comprises an end face portion, wherein the end face portions engage each other when the cam lock connection is fully tightened.

The presently described subject matter is directed to a highly conductive cam lock electrical connection comprising or consisting of: a highly conductive male cam lock end; a highly conductive female cam lock end; and a highly conductive connection arrangement between the male and female cam lock ends for conducting electrical power therebetween when coupled together, further comprising a cable connected to the male cam lock end, wherein the cable is a battery cable including a battery jump starting and air compression device, wherein the female cam lock end is connected to the battery jump starting and air compression device, wherein the battery jump start and air compression device comprises a highly conductive rigid frame connected to one or more batteries, and wherein the female cam lock is connected to the highly conductive frame, wherein the battery jump start and air compression device comprises a highly conductive rigid frame connected to one or more batteries, and wherein the female cam lock is connected to the highly conductive frame, wherein the battery jump start and air compression device comprises a positive battery cable having a positive battery clamp, the positive battery cable connected to the highly conductive rigid frame; and a negative battery cable having a negative battery clamp, the negative battery cable connected to the highly conductive rigid frame.

The presently described subject matter is directed to an improved electrically controlled switch.

The presently described subject matter is directed to an improved electrically controlled switch having a control knob provided with a backlight.

The presently described subject matter is directed to an electrically controlled switching backlight system comprising or consisting of: an electrical control switch having a control knob, the control knob having an optical window; and a backlight positioned behind the control knob for illuminating the light window of the control switch when the backlight is turned on, and an electronic device on which the control switch is mounted, wherein the cross-over activation device comprises a cover; a first 12V battery disposed within the cover; a second 12V battery disposed within the cover; a highly conductive rigid frame connected to the first 12V battery and the second 12V battery; a backlight LED for lighting the transparent part or the see-through part of the control knob, the backlight LED being mounted on the printed circuit board; a positive cable having a positive clamp, the positive cable connected to the battery; a negative cable having a negative clamp, the negative cable connected to the highly conductive rigid frame; and a printed circuit board disposed within the cover, wherein a control switch extends through the cover, the control switch is electrically connected to the highly conductive rigid frame, the control knob is configured to selectively rotate between a 12V operating position and a 24V operating position, the control switch is configured to selectively operate the device in either a 12V mode or a 24V mode.

The presently described subject matter is directed to an electrically controlled switching backlight system comprising or consisting of: an electrical control switch having a control knob, the control knob having an optical window; and a backlight positioned behind the control knob for illuminating the light window of the control switch when the backlight is turned on, and an electronic device on which the control switch is mounted, the electronic device being a battery cross-over charging device comprising a cover; a first 12V battery disposed within the cover; a second 12V battery disposed within the cover; a positive cable having a positive clamp, the positive cable connected to the battery; and a negative cable having a negative clamp, the negative cable connected to the highly conductive rigid frame, wherein the control switch extends through the cover, the control switch is electrically connected to the first 12V battery and the second 12V battery, the control knob is configured to selectively rotate between a 12V operational position and a 24V operational position, the control switch is configured to selectively operate the device in either the 12V mode or the 24V mode, further comprising the highly conductive rigid frame electrically connected to the first 12V battery, the second 12V battery, and the control switch, and configured to selectively operate the device in either the 12V mode or the 24V mode.

The presently described subject matter is directed to an electrically controlled switching backlight system comprising or consisting of: an electrical control switch having a control knob, the control knob having an optical window; and a backlight positioned behind the control knob for illuminating the light window of the control switch when the backlight is turned on, and an electronic device on which the control switch is mounted, the electronic device being a battery cross-over charging device comprising a cover; a first 12V battery disposed within the cover; a second 12V battery disposed within the cover; a positive cable having a positive clamp, the positive cable connected to the battery; and a negative cable having a negative clamp, the negative cable connected to the highly conductive rigid frame, wherein the control switch extends through the cover, the control switch is electrically connected to the first 12V battery and the second 12V battery, the control knob is configured to selectively rotate between a 12V operational position and a 24V operational position, the control switch is configured to selectively operate the device in either the 12V mode or the 24V mode, further comprising a highly conductive rigid frame electrically connected to the first 12V battery, the second 12V battery, and the control switch and configured to selectively operate the device in either the 12V mode or the 24V mode, and further comprising an interface disposed between the control knob and the cover of the device.

The presently described subject matter is directed to an electrically controlled switching backlight system comprising or consisting of: an electrical control switch having a control knob, the control knob having an optical window; and a backlight positioned behind the control knob for illuminating the light window of the control switch when the backlight is turned on, and an electronic device on which the control switch is mounted, the electronic device being a battery cross-over charging device comprising a cover; a first 12V battery disposed within the cover; a second 12V battery disposed within the cover; a positive cable having a positive clamp, the positive cable connected to the battery; and a negative cable having a negative clamp, the negative cable connected to the highly conductive rigid frame, wherein the control switch extends through the cover, the control switch is electrically connected to the first 12V battery and the second 12V battery, the control knob is configured to selectively rotate between a 12V operational position and a 24V operational position, the control switch is configured to selectively operate the device in either the 12V mode or the 24V mode, further comprising the highly conductive rigid frame, electrically connected to the first 12V battery, the second 12V battery, and the control switch, and configured to selectively operate the device in either the 12V mode or the 24V mode, and further comprising an interface disposed between the control knob and a cover of the device, wherein the interface includes a 12V backlight indicator and a 24V backlight indicator, the apparatus being configured to selectively turn on either the 12V backlight indicator or the 24V backlight indicator when either the 12V or 24V operating mode is selected by rotating a control knob of the control switch.

The presently described subject matter is directed to an electro-optical position sensing switch system comprising a first 12V battery; a second 12V battery; an electronically controlled switch electrically connected to the first 12V battery and the second 12V battery, the electronically controlled switch having a parallel switch position for connecting the first 12V battery and the second 12V battery in parallel, the electronically controlled switch having a series switch position for connecting the first 12V battery and the second 12V battery in series; a microcontroller electrically connected to the electrical control switch; and an optocoupler electrically connected to the microcontroller, the optocoupler providing a signal to the microcontroller for indicating a position of the electrically controlled switch, further comprising an enabling circuit configured to reduce parasitic current when the system is in an "off" state, wherein the circuit comprises a transistor that acts as an electrical switch when the system is in the "on" state.

The presently described subject matter is directed to an electro-optical position sensing switch system comprising a first 12V battery; a second 12V battery; an electronically controlled switch electrically connected to the first 12V battery and the second 12V battery, the electronically controlled switch having a parallel switch position for connecting the first 12V battery and the second 12V battery in parallel, the electronically controlled switch having a series switch position for connecting the first 12V battery and the second 12V battery in series; a microcontroller electrically connected to the electrical control switch; and an optocoupler electrically connected to the microcontroller, the optocoupler providing a signal to the microcontroller for indicating a position of the electrically controlled switch, wherein the circuit is configured such that when there is or is no current flowing, this allows the optocoupler to provide a signal to the microcontroller indicating to the microcontroller which position the control switch is in.

The presently described subject matter is directed to an electro-optical position sensing switch system comprising a first 12V battery; a second 12V battery; an electronically controlled switch electrically connected to the first 12V battery and the second 12V battery, the electronically controlled switch having a parallel switch position for connecting the first 12V battery and the second 12V battery in parallel, the electronically controlled switch having a series switch position for connecting the first 12V battery and the second 12V battery in series; a microcontroller electrically connected to the electrical control switch; and an optocoupler electrically connected to the microcontroller, the optocoupler providing a signal to the microcontroller for indicating a position of the electrically controlled switch, wherein the circuit is configured such that when there is or is no current flowing, this allows the optocoupler to provide a signal to the microcontroller indicating to the microcontroller which position the control switch is in, wherein the circuit is configured such that an opposite signal is provided as a separate input to the microcontroller such that the microcontroller can determine when the control switch is in a "neutral" position between the 12V position and the 24V position.

The presently described subject matter is directed to a portable battery jump starting and air compression device comprising or consisting of: a first 12V battery; a second 12V battery; a conductive frame connected to the first 12V battery and the second 12V battery; an electrically controlled switch electrically connected to the conductive frame, the first 12V battery, and the second 12V battery, the electrically controlled switch having a parallel switch position for connecting the first 12V battery and the second 12V battery in parallel, the electrically controlled switch having a series switch position for connecting the first 12V battery and the second 12V battery in series; a microcontroller electrically connected to the conductive frame; and a two-cell diode bridge connected to the conductive frame, the two-cell diode bridge having two diode channels that support the first 12V battery and the second 12V battery to prevent reverse charging after the vehicle is jump started, wherein the two-cell diode bridge is a reverse charging diode module.

The presently described subject matter is directed to a portable battery jump starting and air compression device comprising or consisting of: a first 12V battery; a second 12V battery; a conductive frame connected to the first 12V battery and the second 12V battery; an electrically controlled switch electrically connected to the conductive frame, the first 12V battery, and the second 12V battery, the electrically controlled switch having a parallel switch position for connecting the first 12V battery and the second 12V battery in parallel, the electrically controlled switch having a series switch position for connecting the first 12V battery and the second 12V battery in series; a microcontroller electrically connected to the conductive frame; and a two-cell diode bridge connected to the electrically conductive frame, the two-cell diode bridge having two diode channels supporting a first 12V battery and a second 12V battery to prevent reverse charging after the vehicle is cross-over started, wherein the reverse charging diode module includes an upper diode channel supporting current through the first 12V battery and a lower diode channel supporting current through the second 12V battery.

The presently described subject matter is directed to a portable battery jump starting and air compression device comprising or consisting of: a first 12V battery; a second 12V battery; a conductive frame connected to the first 12V battery and the second 12V battery; an electrically controlled switch electrically connected to the conductive frame, the first 12V battery, and the second 12V battery, the electrically controlled switch having a parallel switch position for connecting the first 12V battery and the second 12V battery in parallel, the electrically controlled switch having a series switch position for connecting the first 12V battery and the second 12V battery in series; a microcontroller electrically connected to the conductive frame; and a two-cell diode bridge connected to the electrically conductive frame, the two-cell diode bridge having two diode channels supporting a first 12V battery and a second 12V battery to prevent reverse charging after the cross-over start vehicle, wherein the reverse charging diode module includes an upper diode channel supporting current through the first 12V battery and a lower diode channel supporting current through the second 12V battery, wherein the upper diode channel and the lower diode channel are connected to strips of the electrically conductive frame leading to a positive output of the battery cross-over start and air compression device for combining current from the upper diode channel and the lower diode channel.

The presently described subject matter is directed to a portable battery jump starting and air compression device comprising or consisting of: a first 12V battery; a second 12V battery; a conductive frame connected to the first 12V battery and the second 12V battery; an electrically controlled switch electrically connected to the conductive frame, the first 12V battery, and the second 12V battery, the electrically controlled switch having a parallel switch position for connecting the first 12V battery and the second 12V battery in parallel, the electrically controlled switch having a series switch position for connecting the first 12V battery and the second 12V battery in series; a microcontroller electrically connected to the conductive frame; and a bi-cell diode bridge connected to the conductive frame, the bi-cell diode bridge having two diode channels that support a first 12V battery and a second 12V battery to prevent reverse charging after the vehicle is cross-connected started, wherein the bi-cell diode bridge is a reverse charging diode module, wherein the reverse charging diode module includes an upper conductive strip electrically connected to the upper diode channel, a lower conductive strip electrically connected to the lower diode channel, and a central conductive strip located between the upper conductive strip and the lower conductive strip and electrically connected to both the upper diode channel and the lower diode channel.

The presently described subject matter is directed to a portable battery jump starting system comprising or consisting of: a first 12V battery; a second 12V battery; a conductive wiring assembly or conductive frame connected to the first 12V battery and the second 12V battery; an electronically controlled switch electrically connected to the conductive connection or frame, the first 12V battery, and the second 12V battery, the electronically controlled switch having a parallel switch position for connecting the first 12V battery and the second 12V battery in parallel, the electronically controlled switch having a series switch position for connecting the first 12V battery and the second 12V battery in series; and a charger connected to the conductive wiring assembly or the conductive frame, the charger configured to sequentially charge the first 12V battery and the second 12V battery, wherein the charger is configured to incrementally charge the first 12V battery and the second 12V battery to maintain the first 12V battery and the second 12V battery near the same potential during a charging sequence.

The presently described subject matter is directed to a portable battery jump starting system comprising or consisting of: a first 12V battery; a second 12V battery; a conductive wiring assembly or conductive frame connected to the first 12V battery and the second 12V battery; an electronically controlled switch electrically connected to the conductive connection or frame, the first 12V battery, and the second 12V battery, the electronically controlled switch having a parallel switch position for connecting the first 12V battery and the second 12V battery in parallel, the electronically controlled switch having a series switch position for connecting the first 12V battery and the second 12V battery in series; and a charger connected to the conductive wiring assembly or the conductive frame, the charger configured to sequentially charge the first 12V battery and the second 12V battery, wherein the charger is operated to charge the first 12V battery or the second 12V battery first, whichever has the lowest voltage or charge.

The presently described subject matter is directed to a portable battery jump starting system comprising or consisting of: a first 12V battery; a second 12V battery; a conductive wiring assembly or conductive frame connected to the first 12V battery and the second 12V battery; an electronically controlled switch electrically connected to the conductive connection or frame, the first 12V battery, and the second 12V battery, the electronically controlled switch having a parallel switch position for connecting the first 12V battery and the second 12V battery in parallel, the electronically controlled switch having a series switch position for connecting the first 12V battery and the second 12V battery in series; and a charger connected to the conductive wiring assembly or the conductive frame, the charger configured to sequentially charge the first 12V battery and the second 12V battery, wherein the charger is configured to incrementally charge the first 12V battery and the second 12V battery to keep the first 12V battery and the second 12V battery near the same potential during a charging sequence, wherein the charger is operated to charge the first 12V battery or the second 12V battery first, whichever has the lowest voltage or charge.

The presently described subject matter is directed to a portable battery jump starting system comprising or consisting of: a first 12V battery; a second 12V battery; a conductive wiring assembly or conductive frame connected to the first 12V battery and the second 12V battery; an electronically controlled switch electrically connected to the conductive connection or frame, the first 12V battery, and the second 12V battery, the electronically controlled switch having a parallel switch position for connecting the first 12V battery and the second 12V battery in parallel, the electronically controlled switch having a series switch position for connecting the first 12V battery and the second 12V battery in series; and a charger connected to the conductive wiring assembly or the conductive frame, the charger configured to sequentially charge the first 12V battery and the second 12V battery, wherein the charger is configured to sequentially incrementally charge the first 12V battery and the second 12V battery at fixed voltage increments.

The presently described subject matter is directed to a portable battery jump starting system comprising or consisting of: a first 12V battery; a second 12V battery; a conductive wiring assembly or conductive frame connected to the first 12V battery and the second 12V battery; an electronically controlled switch electrically connected to the conductive connection or frame, the first 12V battery, and the second 12V battery, the electronically controlled switch having a parallel switch position for connecting the first 12V battery and the second 12V battery in parallel, the electronically controlled switch having a series switch position for connecting the first 12V battery and the second 12V battery in series; and a charger coupled to the conductive wiring assembly or the conductive frame, the charger configured to sequentially charge the first 12V battery and the second 12V battery, wherein the charger is configured to sequentially incrementally charge the first 12V battery and the second 12V battery at varying voltage increments.

The presently described subject matter is directed to a portable battery jump starting system comprising or consisting of: a first 12V battery; a second 12V battery; a conductive wiring assembly or conductive frame connected to the first 12V battery and the second 12V battery; an electronically controlled switch electrically connected to the conductive connection or frame, the first 12V battery, and the second 12V battery, the electronically controlled switch having a parallel switch position for connecting the first 12V battery and the second 12V battery in parallel, the electronically controlled switch having a series switch position for connecting the first 12V battery and the second 12V battery in series; and a charger connected to the conductive wiring assembly or the conductive frame, the charger configured to sequentially charge the first 12V battery and the second 12V battery, wherein the charger is configured to sequentially incrementally charge the first 12V battery and the second 12V battery at random voltage increments.

The presently described subject matter is directed to a portable battery jump starting system comprising or consisting of: a first 12V battery; a second 12V battery; a conductive wiring assembly or conductive frame connected to the first 12V battery and the second 12V battery; an electronically controlled switch electrically connected to the conductive connection or frame, the first 12V battery, and the second 12V battery, the electronically controlled switch having a parallel switch position for connecting the first 12V battery and the second 12V battery in parallel, the electronically controlled switch having a series switch position for connecting the first 12V battery and the second 12V battery in series; and a charger connected to the conductive wiring assembly or the conductive frame, the charger configured to sequentially charge the first 12V battery and the second 12V battery, wherein the charger is configured to sequentially incrementally charge the first 12V battery and the second 12V battery in fixed voltage increments, wherein the charger is configured to sequentially incrementally charge the first 12V battery and the second 12V battery in 100 millivolt (mV) increments.

The presently described subject matter is directed to a portable battery jump starting system comprising or consisting of: a first 12V battery; a second 12V battery; a conductive wiring assembly or conductive frame connected to the first 12V battery and the second 12V battery; an electronically controlled switch electrically connected to the conductive connection or frame, the first 12V battery, and the second 12V battery, the electronically controlled switch having a parallel switch position for connecting the first 12V battery and the second 12V battery in parallel, the electronically controlled switch having a series switch position for connecting the first 12V battery and the second 12V battery in series; and a charger connected to the conductive wiring assembly or the conductive frame, the charger configured to sequentially charge the first 12V battery and the second 12V battery, wherein the charger is operated to charge the first 12V battery or the second 12V battery first, whichever has the lowest voltage or charge, wherein the voltage charge increment is a fraction or fraction of a total voltage charge required to fully charge the first 12V battery or the second 12V battery.

The presently described subject matter is directed to a portable battery jump starting system comprising or consisting of: a first 12V battery; a second 12V battery; a conductive wiring assembly or conductive frame connected to the first 12V battery and the second 12V battery; an electronically controlled switch electrically connected to the conductive connection or frame, the first 12V battery, and the second 12V battery, the electronically controlled switch having a parallel switch position for connecting the first 12V battery and the second 12V battery in parallel, the electronically controlled switch having a series switch position for connecting the first 12V battery and the second 12V battery in series; and a charger connected to the conductive wiring assembly or the conductive frame, the charger configured to sequentially charge the first 12V battery and the second 12V battery, further comprising a programmable microcontroller electrically connected to the charger for controlling operation of the charger.

The presently described subject matter is directed to a portable battery jump starting system comprising or consisting of: a first 12V battery; a second 12V battery; a conductive wiring assembly or conductive frame connected to the first 12V battery and the second 12V battery; an electronically controlled switch electrically connected to the conductive connection or frame, the first 12V battery, and the second 12V battery, the electronically controlled switch having a parallel switch position for connecting the first 12V battery and the second 12V battery in parallel, the electronically controlled switch having a series switch position for connecting the first 12V battery and the second 12V battery in series; and a charger connected to the conductive wiring assembly or the conductive frame, the charger configured to sequentially charge the first 12V battery and the second 12V battery, and further comprising a peak voltage cut-off to prevent overcharging the first 12V battery and the second 12V battery.

The presently described subject matter is directed to a portable battery jump starting system comprising or consisting of: a first 12V battery; a second 12V battery; a conductive wiring assembly or conductive frame connected to the first 12V battery and the second 12V battery; an electronically controlled switch electrically connected to the conductive connection or frame, the first 12V battery, and the second 12V battery, the electronically controlled switch having a parallel switch position for connecting the first 12V battery and the second 12V battery in parallel, the electronically controlled switch having a series switch position for connecting the first 12V battery and the second 12V battery in series; and a charger connected to the conductive wiring assembly or the conductive frame, the charger configured to sequentially charge the first 12V battery and the second 12V battery, wherein the charger is configured to sequentially incrementally charge the first 12V battery and the second 12V battery at varying voltage increments, wherein the programmable microcontroller is configured to provide a charge timeout.

The presently described subject matter is directed to a skip-step charging system and method for an electronic device having at least a first rechargeable battery and a second rechargeable battery, comprising or consisting of: the first rechargeable battery and the second rechargeable battery are selectively charged in a certain charging sequence.

The presently described subject matter is directed to a skip-step charging method for an electronic device having at least a first rechargeable battery and a second rechargeable battery, comprising or consisting of: selectively charging the first rechargeable battery and the second rechargeable battery in a charging sequence, wherein the charging sequence is an incremental charging sequence, wherein the incremental charging sequence charges the first 12V battery or the second 12V battery in increments that are less than a total increment of charging for fully charging the first 12V battery or the second 12V battery.

The presently described subject matter is directed to a skip-step charging method for an electronic device having at least a first rechargeable battery and a second rechargeable battery, comprising or consisting of: the first rechargeable battery and the second rechargeable battery are selectively charged in a charging sequence, wherein the charging sequence is a back-and-forth charging sequence between the first 12V battery and the second 12V battery.

The presently described subject matter is directed to a skip-step charging method for an electronic device having at least a first rechargeable battery and a second rechargeable battery, comprising or consisting of: the first rechargeable battery and the second rechargeable battery are selectively charged in a charging sequence, wherein the charging sequence includes two or more consecutive charges to the same one of the first 12V battery and the second 12V battery before turning to the other battery.

The presently described subject matter is directed to a skip-step charging method for an electronic device having at least a first rechargeable battery and a second rechargeable battery, comprising or consisting of: the first rechargeable battery and the second rechargeable battery are selectively charged in a charging sequence, wherein the sequence is a programming sequence in which a charging time increment, a voltage increment, and a charging rate are all adjustable in the programming sequence.

The presently described subject matter is directed to a portable battery jump starting and air compression device comprising or consisting of: a first 12V battery; a second 12V battery; and a highly conductive frame connected to the first 12V cell and the second 12V cell, wherein the highly conductive frame is semi-rigid.

The presently described subject matter is directed to a battery assembly for use in an electronic device, the battery assembly comprising or consisting of: at least one battery cell having a positive foil end and a negative foil end; a positive electrode highly conductive member connected to the positive electrode foil; and a positive highly conductive member connected to the positive foil, wherein the positive highly conductive member and the negative highly conductive member are each oriented transversely with respect to the length of the positive foil and the negative foil, respectively.

The presently described subject matter is directed to a battery assembly for use in an electronic device, the battery assembly comprising or consisting of: at least one battery cell having a positive foil end and a negative foil end; a positive electrode highly conductive member connected to the positive electrode foil; and a positive highly conductive member connected to the positive foil, wherein the positive highly conductive member and the negative highly conductive member are each oriented transversely with respect to a length of the positive foil and the negative foil, respectively, wherein the highly conductive members are wider than the positive foil and the negative foil, respectively.

The presently described subject matter is directed to a battery assembly for use in an electronic device, the battery assembly comprising or consisting of: at least one battery cell having a positive foil end and a negative foil end; a positive electrode highly conductive member connected to the positive electrode foil; and a positive electrode highly conductive member connected to the positive electrode foil, wherein the highly conductive member is provided with a through hole for connecting an electronic device using a bolt and nut fastener.

The presently described subject matter is directed to a battery assembly for use in an electronic device, the battery assembly comprising or consisting of: at least one battery cell having a positive foil end and a negative foil end; a positive electrode highly conductive member connected to the positive electrode foil; and a positive highly conductive member connected to the positive foil, wherein the positive foil is at least partially wrapped around the positive highly conductive member and the negative foil is at least partially wrapped around the negative highly conductive member.

The presently described subject matter is directed to a battery assembly for use in an electronic device, the battery assembly comprising or consisting of: at least one battery cell having a positive foil end and a negative foil end; a positive electrode highly conductive member connected to the positive electrode foil; and a positive highly conductive member connected to the positive foil, wherein the positive foil is at least partially wrapped around the positive highly conductive member, and the negative foil is at least partially wrapped around the negative highly conductive member, wherein the positive foil and the negative foil are completely wrapped around the positive highly conductive member and the negative highly conductive member, respectively.

The presently described subject matter is directed to a battery assembly for use in an electronic device, the battery assembly comprising or consisting of: at least one battery cell having a positive foil end and a negative foil end; a positive electrode highly conductive member connected to the positive electrode foil; and a positive electrode highly conductive member connected to the positive electrode foil, wherein the positive electrode foil is soldered or welded to the positive electrode highly conductive member, and the negative electrode foil is soldered or welded to the negative electrode highly conductive member.

The presently described subject matter is directed to a vehicle battery jump starter device having an air pump, the device comprising or consisting of: a cover; an internal power source disposed within the lid; a vehicle battery crossover starter disposed within the cover, the crossover starter configured to crossover start a vehicle battery; and an air pump disposed within the lid, the air pump configured to provide a supply of pressurized air, wherein the internal power source provides power to the jump starter device and/or the air pump device, and wherein the internal power source is a rechargeable battery.

The presently described subject matter is directed to a vehicle battery jump starter device having an air pump, the device comprising or consisting of: a cover; an internal power source disposed within the lid; a vehicle battery crossover starter disposed within the cover, the crossover starter configured to crossover start a vehicle battery; and an air pump disposed within the lid, the air pump configured to provide a supply of pressurized air, wherein the internal power source provides power to the jump starter device and/or the air pump device, wherein the internal power source is a rechargeable battery, and wherein the rechargeable battery is a lithium ion rechargeable battery.

The presently described subject matter is directed to a vehicle battery jump starter device having an air pump, the device comprising or consisting of: a cover; an internal power source disposed within the lid; a vehicle battery crossover starter disposed within the cover, the crossover starter configured to crossover start a vehicle battery; and an air pump disposed within the lid, the air pump configured to provide a supply of pressurized air, wherein the internal power source provides power to the jumper activator device and/or the air pump device, and wherein the lid includes an air supply port for connecting the air hose.

The presently described subject matter is directed to a vehicle battery jump starter device having an air pump, the device comprising or consisting of: a cover; an internal power source disposed within the lid; a vehicle battery crossover starter disposed within the cover, the crossover starter configured to crossover start a vehicle battery; and an air pump disposed within the lid, the air pump configured to provide a supply of pressurized air, wherein the internal power source provides power to the jumper activator device and/or the air pump device, wherein the lid includes an air supply port for connecting the air hose, and wherein the lid and air pump provide an air supply port for connecting the hose.

The presently described subject matter is directed to a vehicle battery jump starter device having an air pump, the device comprising or consisting of: a cover; an internal power source disposed within the lid; a vehicle battery crossover starter disposed within the cover, the crossover starter configured to crossover start a vehicle battery; and an air pump disposed within the lid, the air pump configured to provide a supply of pressurized air, wherein the internal power source provides power to the jumper activator device and/or the air pump device, wherein the lid includes an air supply port for connecting the air hose, and the device further includes an internal air hose connecting the air pump to the air supply port.

The presently described subject matter is directed to a vehicle battery jump starter device having an air pump, the device comprising or consisting of: a cover; an internal power source disposed within the lid; a vehicle battery crossover starter disposed within the cover, the crossover starter configured to crossover start a vehicle battery; and an air pump disposed within the lid, the air pump configured to provide a supply of pressurized air, wherein the internal power source provides power to the crossover initiator device and/or the air pump device, and wherein the internal power source is a single battery that powers the vehicle battery crossover initiator and the air pump.

The presently described subject matter is directed to a vehicle battery jump starter device having an air pump, the device comprising or consisting of: a cover; an internal power source disposed within the lid; a vehicle battery crossover starter disposed within the cover, the crossover starter configured to crossover start a vehicle battery; and an air pump disposed within the lid, the air pump configured to provide a supply of pressurized air, wherein the internal power source provides power to the crossover initiator device and/or the air pump device, and wherein the internal power source comprises a first battery for powering the vehicle battery crossover initiator and a second battery for powering the air pump.

The presently described subject matter is directed to a vehicle battery jump starter device having an air pump, the device comprising or consisting of: a cover; an internal power source disposed within the lid; a vehicle battery crossover starter disposed within the cover, the crossover starter configured to crossover start a vehicle battery; and an air pump disposed within the cover, the air pump configured to provide a supply of pressurized air, wherein the internal power source provides power to the crossover actuator device and/or the air pump device, and the device further comprises a switch for selectively powering the vehicle battery crossover actuator or the air pump.

The presently described subject matter is directed to a vehicle battery jump starter device having an air pump, the device comprising or consisting of: a cover; an internal power source disposed within the lid; a vehicle battery crossover starter disposed within the cover, the crossover starter configured to crossover start a vehicle battery; and an air pump disposed within the cover, the air pump configured to provide a supply of pressurized air, wherein the internal power source provides power to the crossover activator device and/or the air pump device, the device further comprising a switch for selectively powering either the vehicle battery crossover activator or the air pump, and the switch is configured to also power both the vehicle battery crossover activator and the air pump.

The presently described subject matter is directed to a vehicle battery jump starter device having an air pump, the device comprising or consisting of: a cover; an internal power source disposed within the lid; a vehicle battery crossover starter disposed within the cover, the crossover starter configured to crossover start a vehicle battery; and an air pump disposed within the lid, the air pump configured to provide a supply of pressurized air, wherein the internal power source provides power to the jump starter device and/or the air pump device, and the device further comprises an internal fan for cooling the device.

The presently described subject matter is directed to a vehicle battery jump starter device having an air pump, the device comprising or consisting of: a cover; an internal power source disposed within the lid; a vehicle battery crossover starter disposed within the cover, the crossover starter configured to crossover start a vehicle battery; and an air pump disposed within the lid, the air pump configured to provide a supply of pressurized air, wherein the internal power source provides power to the jump starter device and/or the air pump device, wherein the air pump comprises an air compressor, and wherein the air compressor is a rotary air compressor.

The presently described subject matter is directed to a vehicle battery jump starter device having an air pump, the device comprising or consisting of: a cover; an internal power source disposed within the lid; a vehicle battery crossover starter disposed within the cover, the crossover starter configured to crossover start a vehicle battery; and an air pump disposed within the lid, the air pump configured to provide a supply of pressurized air, wherein the internal power source provides power to the crossover activator device and/or the air pump device, wherein the air pump comprises an air compressor, and wherein the air pump further comprises an air tank connected to the air supply port.

The presently described subject matter is directed to a vehicle battery jump starter device having an air pump, the device comprising or consisting of: a cover; an internal power source disposed within the lid; a vehicle battery crossover starter disposed within the cover, the crossover starter configured to crossover start a vehicle battery; and an air pump disposed within the lid, the air pump configured to provide a supply of pressurized air, wherein the internal power source provides power to the crossover activator device and/or the air pump device, and wherein the air pump is connected to the air supply port.

Further, the battery jump starter with an air pump according to the present invention is configured to maximize the amount of power transfer from one or more batteries (e.g., Li ions) to the battery being jump started. This requires the power circuit to have a high or extremely high conductive path from the battery or batteries to the battery clip. This physically requires the use of high or very high conductivity conductors such as copper bars, plates, rods, tubes and cables.

The "rigidity" and "strength" of the highly conductive rigid frame provide structural stability during battery cross-over start-up and storage and use of the air compression device. This is important, especially during use, when high currents are flowing through the highly conductive rigid frame, which may heat and soften the rigid frame. It is highly desirable that the highly conductive rigid frame maintain structural stability and configuration during such use in order to avoid the risk of contact and electrical shorting with the battery crossover activation and other electrical components of the air compression device. This is particularly true when a compact and portable configuration of the battery jump starting and air compression device is made to allow for minimizing the distance between the electrical components.

Drawings

FIG. 1 is a functional block diagram of a hand-held vehicle battery booster device or jump starter according to one aspect of the present invention.

Fig. 2A-1-2C-3 are schematic circuit diagrams of exemplary embodiments of a hand-held vehicle battery booster device or portable vehicle battery jump starter, according to an aspect of the present invention.

Fig. 3 is a perspective view of a handheld crossover starter booster device or portable vehicle battery crossover starter in accordance with an exemplary embodiment of the present invention.

Fig. 4 is a plan view of a jumper cable that may be used with a hand-held jumper enable booster device according to another aspect of the invention.

Fig. 5 is a block diagram of a portable vehicle battery jump starter having an air pump according to the present invention.

Fig. 6 is a perspective view of the portable vehicle battery jump starter with air pump shown in fig. 3.

Fig. 7 is a front perspective view of another hand-held vehicle battery booster device or portable vehicle battery jump starter in accordance with the present invention.

Fig. 8 is a front view of the portable vehicle battery jump starter shown in fig. 7.

Fig. 9 is a rear view of the portable vehicle battery jump starter shown in fig. 7.

Fig. 10 is a left side view of the portable vehicle battery jump starter of fig. 7.

Fig. 11 is a right side view of the portable vehicle battery jump starter of fig. 7.

Fig. 12 is a top plan view of the portable vehicle battery jump starter shown in fig. 7.

Fig. 13 is a bottom plan view of the portable vehicle battery jump starter shown in fig. 7.

Fig. 14 is a perspective view of the portable vehicle battery jump starter of fig. 7 with a removable battery cable attached to the battery jump starter and air compression device.

FIG. 15 is a top view of the internal component layout of the portable vehicle battery jumper shown in FIG. 7 with a removable battery cable.

Fig. 16 is a top view of the internal component layout of the portable vehicle battery jump starter of fig. 7 with a non-removable battery cable.

Fig. 17 is a top view of the connection end of the removable battery cable shown in fig. 15.

Fig. 18 is an exploded perspective view of the control switch mounted in front of the portable vehicle battery jump starter shown in fig. 7.

FIG. 19 is a front view of a switch plate of the control switch shown in FIG. 18 that is operable between a first position and a second position.

Fig. 20 is a rear perspective view of the switch plate shown in fig. 19.

Fig. 21 is a perspective view of the control switch shown in fig. 18.

Fig. 22 is a rear and left side perspective view of a portable vehicle battery jump starter according to the present invention with the cover removed.

Fig. 23 is a front and left side perspective view of the portable vehicle battery jump starter of fig. 7 with the cover removed.

Fig. 24 is a rear and right side perspective view of the portable vehicle battery jump starter of fig. 7 with the cover removed.

Fig. 25 is a front view of the portable vehicle battery jump starter of fig. 7 with the cover removed.

Fig. 26 is a rear view of the portable vehicle battery jump starter of fig. 7 with the cover removed.

Fig. 27 is a top plan view of the portable vehicle battery jump starter illustrated in fig. 7 with the cover removed.

Fig. 28 is a bottom plan view of the portable vehicle battery jump starter illustrated in fig. 7 with the cover removed.

Fig. 29 is a left side view of the portable vehicle battery jump starter of fig. 7 with the cover removed.

Fig. 30 is a right side view of the portable vehicle battery jump starter of fig. 7 with the cover removed.

Fig. 31 is a front and top perspective view of the portable vehicle battery jump starter of fig. 7 with the cover removed.

Fig. 32 is an exploded front perspective view of a third embodiment of a portable vehicle battery cross-over starter according to the present invention with the cover removed.

Fig. 33 is an exploded partial front perspective view of the portable vehicle battery jump starter illustrated in fig. 32 with the cover removed.

Fig. 34 is an exploded, partial right side perspective view of the portable vehicle battery jump starter illustrated in fig. 32 with the cover removed.

Fig. 35 is a partial rear perspective view of the portable vehicle battery jump starter of fig. 32 with the cover removed.

Fig. 36 is a partial rear perspective view of the portable vehicle battery jump starter of fig. 32 with the cover removed.

Fig. 37 is an exploded, partial, left side perspective view of the portable vehicle battery jump starter illustrated in fig. 32, with the cover removed.

Fig. 38 is a perspective view of a cam lock connection according to the present invention, shown with the male cam lock end separated from the female cam lock end, for use with, for example, a portable vehicle battery crossover starter according to the present invention.

FIG. 39 is a perspective view of the cam lock connection shown in FIG. 38 with the male cam lock end partially connected to the female cam lock end.

FIG. 40 is a perspective view of the male cam lock end of the cam lock connection shown in FIG. 38.

FIG. 41 is an exploded perspective view of the male cam lock end of the cam lock connection shown in FIG. 38.

FIG. 42 is a partially assembled perspective view of the male cam lock end of the cam lock connection shown in FIG. 38.

FIG. 43 is a partially assembled perspective view of the male cam lock end of the cam lock connection shown in FIG. 38.

FIG. 44 is a fully assembled perspective view of the male cam lock end of the cam lock connection shown in FIG. 38.

FIG. 45 is a partially assembled perspective view of the male cam lock end of the cam lock connection shown in FIG. 38.

FIG. 46 is an exploded perspective end view of the female cam lock end of the cam lock connection shown in FIG. 38.

FIG. 47 is an exploded perspective end view of the female cam lock end of the cam lock connection shown in FIG. 38.

FIG. 48 is an exploded perspective end view of the female cam lock end of the cam lock connection shown in FIG. 38.

FIG. 49 is a partially assembled perspective end view of the female cam lock end of the cam lock connection shown in FIG. 38.

FIG. 50 is an assembled perspective end view of the female cam lock end of the cam lock connection shown in FIG. 38.

Fig. 51 is an assembled perspective end view of the female cam lock end of the cam lock connection device shown in fig. 38, along with a bolt for connection to a conductor, such as a highly conductive frame of a vehicle battery crossover starter according to the present invention.

Fig. 52 is a front perspective view of the portable vehicle battery jump starter of fig. 7 with the cover removed showing the main control switches and interface backlighting system in accordance with the present invention.

Fig. 53 is a partial front perspective view of the portable vehicle battery jump starter shown in fig. 7 with the backlight of the control knob for the 12V control switch turned "on".

Fig. 54 is a partial front perspective view of the portable vehicle battery jump starter shown in fig. 7 with the backlight of the control knob for the 12V control switch turned "off.

FIG. 55 is a partial front perspective view of the portable vehicle battery jump starter shown in FIG. 7 with the backlight of the control knob of the control switch for 12V turned "on", the backlight indicator for 12V on the interface turned "on", showing the variable backlight indicator on the 12.7V indicator turned "on", and the backlight for power supply turned "on".

Fig. 56 is a partial front perspective view of the portable battery jump starter of fig. 7 with the backlight of the control knob for the 24V control switch turned "on".

Fig. 57 is a block diagram illustrating the 12V or 24V portable battery cross starter mode of operation.

FIG. 58 is a block diagram illustrating an electro-optical position sensing system according to the present invention.

FIG. 59 is an electrical schematic of a 12V/24V master switch reader.

Fig. 60 is a schematic diagram illustrating a single or double connection arrangement of the battery jump starter shown in fig. 7.

Fig. 61 is a rear view of the portable vehicle battery jump starter of fig. 7 with the cover removed showing a dual cell diode bridge according to the present invention.

Fig. 62 is a front perspective view of a highly conductive frame according to the present invention.

Fig. 63 is a front view of the highly conductive frame shown in fig. 62.

Fig. 64 is a rear view of the highly conductive frame shown in fig. 62.

Fig. 65 is a top plan view of the highly conductive frame shown in fig. 62.

Fig. 66 is a bottom plan view of the highly conductive frame shown in fig. 62.

Fig. 67 is a left side view of the highly conductive frame shown in fig. 62.

Fig. 68 is a right side view of the highly conductive frame shown in fig. 62.

Fig. 69 is a top plan view of an assembled Li-ion battery assembly according to the invention.

Fig. 70 is a perspective view of the Li-ion battery assembly shown in fig. 69 with the lid removed.

Fig. 71 is a perspective view of the Li-ion battery assembly shown in fig. 69 with the cover removed.

Fig. 72 is a perspective view of the Li-ion battery assembly shown in fig. 69 with the lid removed.

Fig. 73 is a functional block diagram of a portable vehicle battery booster device or portable vehicle battery jump starter, according to an aspect of the present invention.

Fig. 74A-1-74F-3 are schematic circuit diagrams of an exemplary embodiment of another portable vehicle battery booster device or portable vehicle battery cross-over starter, in accordance with an aspect of the present invention.

Fig. 75 is a detailed front view of the front display of the portable vehicle battery jump starter shown in fig. 7.

Fig. 76 is an electrical schematic of the skip-step charging system.

Fig. 77 is an electrical schematic of a modified battery detection system.

FIG. 78 is an electrical schematic of the improved battery detection system.

Fig. 79 is a front perspective view of the portable vehicle battery jump starter of fig. 7 with an air pump.

Fig. 80 is a block diagram of a portable vehicle battery jump starter with an air pump in accordance with the present invention.

Fig. 81 is another block diagram of a portable vehicle battery jump starter having an air pump in accordance with the present invention.

Detailed Description

FIG. 1 is a functional block diagram of a handheld battery booster in accordance with an aspect of the present invention. At the center of the hand-held battery booster is a lithium polymer battery pack 32 that stores sufficient energy to be cross-over started by a conventional 12 volt lead acid battery or a valve-regulated lead acid battery powered vehicle engine. In one exemplary embodiment, the high surge lithium polymer battery includes three 3.7V, 2666mAh lithium polymer cells in a 3S1p configuration. The resulting battery provided 11.1V, 2666Ah (8000 Ah at 3.7V, 29.6 Wh). The continuous discharge current was 25C (or 200 amps) and the burst discharge current was 50C (or 400 amps). The maximum charging current for the battery pack is 8000 milliamps (8 amps).

The hand-held or portable battery booster shown in fig. 1 is provided with an air pump (e.g., an air compressor device) to provide a crossover initiator/air pump having a crossover initiator device for crossover starting of the vehicle and an air pump for providing a source of pressurized air for filling items such as vehicle tires. The jumper actuator/air pump device will be described in detail below.

A programmable microcontroller unit (MCU)1 receives various inputs and generates information and control outputs. The programmable MCU 1 further provides flexibility to the system by allowing updates of functions and system parameters without requiring any changes in hardware. According to one exemplary embodiment, an 8-bit microcontroller with a 2K 15 bit flash memory is used to control the system. One such microcontroller is HT67F30, which is commercially available from Holtek Semiconductor Inc.

When the hand-held battery booster device is connected to the vehicle's electrical system, the automotive battery reversal sensor 10 monitors the polarity of the vehicle battery 72. As described below, the booster device prevents the lithium battery pack from being connected to the vehicle battery 72 when a terminal of the battery 72 is connected to the wrong terminal of the booster device. The automotive battery isolation sensor 12 detects whether the vehicle battery 72 is connected to the booster device and prevents the lithium battery pack from being connected to the output terminal of the booster device unless there is a good (e.g., rechargeable) battery connected to the output terminal.

The smart switch FET circuit 15 electrically switches the hand-held battery boost lithium battery to the vehicle's power system only when the MCU 1 determines that the vehicle battery is present (in response to the detection signal provided by the isolation sensor 12) and is connected to the correct polarity (in response to the detection signal provided by the reverse sensor 10). The lithium battery temperature sensor 20 monitors the temperature of the lithium battery pack 32 to detect overheating during jump start due to high ambient temperature conditions and excessive current consumption. The lithium battery voltage measurement circuit 24 monitors the voltage of the lithium battery pack 32 to prevent the voltage potential from rising too high during a charging operation and from falling too low during a discharging operation.

The lithium battery reverse charge protection diode 28 prevents any charging current delivered to the vehicle battery 72 from flowing from the vehicle electrical system back to the lithium battery pack 32. The flashlight LED circuit 36 is provided to provide a flashlight function for enhancing under-hood light of the vehicle in dark conditions, and SOS and flashlight illumination functions for safety purposes when the vehicle may be disabled in a potentially hazardous location. A voltage regulator 42 provides regulation of the internal operating voltage for the microcontroller and sensors. The on/off manual mode and flashing light switch 46 allows the user to control the energization of the hand-held battery booster device to control manual override operations in the absence of the battery of the vehicle, as well as to control the flashing light function. The manual push button is only active when the booster device is energized. This button allows the user to jump-start a vehicle with a missing battery or a battery that is too low in voltage to be automatically detected by the MCU. When the user presses and holds the manual override button for a predetermined period of time (e.g., 3 seconds) to prevent accidental activation of the manual mode, the internal lithium ion battery power source is switched to the vehicle battery connection port. The only exception to the manual override is the automotive battery reverse connection. If the reverse battery is connected in reverse, the internal lithium battery power supply must not be switched to the vehicle battery connection port.

The USB charging circuit 52 converts power from any USB charger power source to a charging voltage and current to charge the lithium battery pack 32. The USB output 56 provides a USB portable charger for charging smartphones, tablets and other rechargeable electronic devices. The operation indicator LED60 provides a visual indication of the status of the capacity of the lithium battery as well as an indication of the activation status of the smart switch (indicating that power is being supplied to the vehicle electrical system).

The detailed operation of the hand-held booster device will now be described with reference to the schematic diagrams of fig. 2A-2C. As shown in fig. 2A, the microcontroller unit 1 is the center of all inputs and outputs. The reverse battery sensor 10 comprises an opto-isolator phototransistor (4N27) connected to the vehicle battery 72 at the terminals of the input pins 1 and 2 and having a diode D8 in the lead of pin 1 (associated with the negative terminal CB-) so that if the battery 72 is connected to the terminal of the booster device with the correct polarity, the opto-coupler LED 11 will not conduct current and therefore be turned off, providing a "1" or high output signal to the MCU 1. The automotive battery isolation sensor 12 includes an optically coupled isolator phototransistor (4N27) connected to the vehicle battery 72 on the terminals of input pins 1 and 2 and having a diode D7 (associated with positive terminal CB +) in the lead of pin 1 so that if the battery 72 is connected to the terminals of the booster device with the correct polarity, the opto-coupler LED 11A will conduct current and thus be turned on, providing a "0" or low output signal to the MCU indicating the presence of a battery on the cross-over output terminal of the hand-held booster device.

If the car battery 72 is connected to the hand-held booster device in the opposite polarity, the opto-coupler LED 11 of the reverse sensor 10 will conduct current, providing a "0" or low signal to the microcontroller unit 1. Furthermore, if no battery is connected to the hand-held booster device, the opto-coupler LED 11A of the isolated sensor 12 will not conduct current and is therefore turned off, providing a "1" or high output signal to the MCU 1, indicating that there is no battery connected to the hand-held booster device. With these specific inputs, the microcontroller software of the MCU 1 can determine when it is safe to turn on the smart switch FET 15 to connect the lithium battery pack to the jumper terminals of the boost device. Therefore, if the car battery 72 is not connected to the booster device at all, or is connected in the opposite polarity, the MCU 1 can prevent the smart switch FET 15 from being turned on, thereby preventing sparking/shorting of the lithium battery pack.

As shown in fig. 2B, FET smart switch 15 is driven by the output of microcontroller 1. The FET smart switch 15 includes three FETs in parallel (Q15, Q18, and Q19) that distribute the power from the lithium battery pack across the FETs. When the microcontroller output is driven to logic low, the FETs 16 are all in a high resistance state, thus not allowing current to flow from the internal lithium battery negative contact 17 to the vehicle battery 72 negative contact. When the microcontroller output is driven to logic high, FET 16(Q15, Q18, and Q19) is in a low resistance state, allowing current to flow freely from the internal lithium battery pack negative contact 17 (LB-) to the vehicle battery 72 negative contact (CB-). Thus, the microcontroller software controls the connection of the internal lithium battery pack 32 to the vehicle battery 72 for cross-starting the vehicle engine.

Returning to fig. 2A, the internal lithium battery pack voltage may be accurately measured using one of the analog to digital inputs of circuit 24 and microcontroller 1. Circuit 24 is designed to sense when the voltage of the main 3.3V regulator 42 is on and turn on transistor 23 when the voltage of regulator 42 is on. When transistor 23 is turned on, it turns on FET 22, thereby providing a conductive path to voltage divider 21 to the positive contact (LB +) of the internal lithium battery, allowing a lower voltage range to be brought to the microcontroller for reading. Using this input, the microcontroller software can determine whether the lithium battery voltage is too low during a discharge operation or too high during a charge operation and take appropriate action to prevent damage to the electronic components.

Still referring to fig. 2A, the temperature of the internal lithium battery pack 32 may be accurately measured by two Negative Temperature Coefficient (NTC) devices 20. As the temperature of these devices increases, they decrease their resistance. This circuit is a voltage divider that brings the result to two analog-to-digital (a/D) inputs on the microcontroller 1. Microcontroller software can then determine when the internal lithium battery is too hot to allow jump starting, adding safety to the design.

The main voltage regulator circuit 42 is designed to convert the internal lithium battery voltage to a regulated 3.3 volts for use by the microcontroller 1 and other components of the booster device for internal operating power. The three lithium battery reverse charge protection diodes 28 (see fig. 2B) are in place so that current flows only from the internal lithium battery pack 32 to the automotive battery 72 and not from the automotive battery to the internal lithium battery. Thus, if the automotive electrical system is being charged from its alternator, it cannot reverse charge (and thus damage) the internal lithium battery, thereby providing another level of security. The main power-on switch 46 (fig. 2A) is a combination that allows for double pole, double throw operation so that the product can be turned on in the off state or turned off in the on state for as long as one push is required. The circuit also uses the microcontroller output 47 to "remain powered" when activated by the power-on switch. When the switch is depressed, the microcontroller transitions this output to a high logic level to remain energized when the switch is released. In this way, the microcontroller maintains control over when power is turned off when the on/off switch is again active or when the lithium battery voltage is too low. The microcontroller software also includes a timer that turns off power after a predetermined period of time (such as, for example, 8 hours) if not used.

The strobe LED circuit 45 shown in fig. 2B controls the operation of the strobe LED. The two outputs of the microcontroller 1 are dedicated to two separate LEDs. Thus, the LEDs can be software controlled independently for strobe and SOS modes, providing yet another safety feature for the booster device. The LED indicators provide feedback that the operator needs to know what is happening with the product. Four individual LEDs 61 (fig. 2A) are controlled by respective individual outputs of microcontroller 1 to provide an indication of the remaining capacity of the internal lithium battery. These LEDs are controlled in the form of "fuel gauge" with capacity indications of 25%, 50%, 75% and 100% (red, yellow, green). When the vehicle battery 72 has been connected in the opposite polarity, the LED indicator 63 (fig. 2B) provides a visual warning to the user. The "boost" and on/off LEDs 62 provide visual indications when the booster device is providing cross-over start-up power and when the booster device is on, respectively.

A USB output 56 circuit (fig. 2C) is included to provide a USB output for charging a portable electronic device, such as a smartphone, from the internal lithium battery pack 32. The control circuit 57 from the microcontroller 1 allows to switch the USB output 56 on and off by software control to prevent the capacity of the internal lithium battery from becoming too low. The USB output is brought outside the device on a standard USB interface 58, the standard USB interface 58 including a standard voltage divider for enabling charging of some smart phones that require it. The USB charging circuit 52 allows the internal lithium battery pack 32 to be charged using a standard USB charger. This charging input uses a standard micro-USB connector 48 (allowing for the use of a standard cable). The 5V potential provided from the standard USB charger is up-converted to the 12.4VDC voltage required to charge the internal lithium battery pack using the DC-DC converter 49. The DC-DC converter 49 may be switched on and off by the output of the microcontroller 1 via a circuit 53.

Thus, if the A/D input 22 measures that the battery voltage is too high, the microcontroller software can shut down the charge. Additional security is provided to help eliminate overcharging of the internal lithium battery using lithium battery charge controller 50, which lithium battery charge controller 50 provides charge balancing for internal lithium battery cell 51. The controller also provides safety redundancy to eliminate over-discharge of the internal lithium battery.

Fig. 3 is a perspective view of a handheld device 300 according to an exemplary embodiment of the present invention. 301 is a power-on switch. 302 denotes an LED "fuel gauge" indicator 61. 303 represents a 12 volt output port connectable to a cable arrangement 400, as will be further described below. And 304, a strobe control switch for activating the strobe LED 45. 305 is a USB input port for charging an internal lithium battery, and 306 is a USB output port for providing charging from the lithium battery to other portable devices such as a smart phone, a tablet computer, and a music player. 307 is a "power on" indicator indicating that power is being supplied to the 12V output port. 308 is a "reverse" indicator that the vehicle battery is not properly connected in polarity. Reference numeral 309 is a "power on" indicator that the device is powered on.

Fig. 4 shows a jumper cable arrangement 400 specifically designed for use with the hand-held device 300. The device 400 has a plug 401 configured to plug into the 12 volt output port 303 of the handheld device 300. A pair of cables 402a and 402b are integrated with the plug 401 and connected to battery terminal clamps 403a and 403b via ring terminals 404a and 404b, respectively. The output port 303 and the plug 401 may be sized such that the plug 401 will mate with the output port 303 only in a particular orientation, thus ensuring that the clip 403a will correspond to a positive pole and the clip 403b will correspond to a negative pole, as shown. Further, the ring terminals 404a and 404b may be disconnected from the clip and directly connected to terminals of the vehicle battery. This feature may be used, for example, to permanently attach the cables 302a-302b to a battery of a vehicle. In the event of a battery voltage drain, the handheld booster device 300 can be properly connected to the battery as long as the plug 401 is plugged into the output port 303.

Fig. 5 is a schematic diagram showing a crossover activator/air pump device 400 including a crossover activator or crossover charger 410a with an air pump or air compressor 410 b. The crossover activator or crossover charger 410a and the air pump or air compressor 410b may be located within a single cover 420 (e.g., a housing or casing), or alternatively in separate covers (e.g., covers connected together, one nested within the other, with one resting within the other). For example, an air pump or air compressor 410b can be removably mounted within the crossover starter or crossover charger 410 a. The air pump may for example comprise one or more selected from: a group of air compressors, rotary air compressors, reciprocating air compressors, air tanks, electric motors, hydraulic motors, pneumatic motors, controls, conduits and air hoses. Other known air pump structures, arrangements or systems may be used for the combined cross-over initiator/air pump 400. The control of the air pump or air compressor 410b may be incorporated in the MCU 1 shown in fig. 1 and/or a separate control may be provided, for example by the MCU 1. The crossover starter or crossover charger 410a and the air pump or air compressor 410b may be powered by the same battery (e.g., rechargeable battery, rechargeable lithium ion battery, inside or outside the cover 420 shown in fig. 5). Alternatively, the crossover starter or crossover charge 410a and the air pump or air compressor may be powered using separate batteries (e.g., separate rechargeable batteries, separate lithium ion batteries).

Fig. 6 shows a jump starter/air pump device 400 according to the invention. For example, the vehicle battery crossover initiator shown in fig. 3 is provided with an air pump 410 to provide components and features of both the crossover initiator and the air pump within the same cover 420 (e.g., cover, housing, or enclosure). Crossover activator/air pump device 400 includes all of the components and features of crossover activator device 300 shown in fig. 1-4, and, as described above, is combined with components and features of an air pump (e.g., air pump 410b shown in fig. 5) to supply pressurized air. For example, the crossover activator/air pump device 400 includes an air hose 411, an air supply port 412, an air hose connector 413 having a connection end 414, an external air hose 415, and an air valve connector 416 (e.g., a tire valve connector). The air hose connection 413, the external air hose 415, and the air valve connection 416 are connected together. For example, these components are connected together and removably connected as a unit from the cross-over activator/air pump device 400. The air supply port may extend through the cover, the display, and/or the cover/display.

The crossover starter/air pump device 400 may have a single battery (e.g., a lithium ion battery) for supplying power to a crossover starter or crossover charger 410a (fig. 5) and/or an air pump or air compressor 410 b. A manual or electrical switch may be incorporated to allow for simultaneous or selective power to both the jumper starter or jumper charger 410a and the air pump or air compressor 410 b. Additionally, optionally, the crossover activator/air pump device 400 includes two or more batteries for independently powering the crossover activator or crossover charger 410a and the air pump or air compressor 410 b.

The crossover activator/air pump device 400 may include a fan for cooling before, during, and/or after use. Alternatively, or in addition, the crossover actuator/air pump device 420 may use an air pump or air compressor 410b to supply cooling air internally to cool the combined crossover actuator/air compressor 400. For example, the internal high pressure air hose 411 (fig. 6) may have an exhaust port and/or valve to controllably release air within the lid 420 and out the exhaust port for cooling.

The crossover activator/air pump device 400 may be controlled (e.g., manual or electrically powered switches) and operated (e.g., using controls and control circuitry and/or the MCU1) to utilize, for example, one or more batteries (e.g., rechargeable batteries, rechargeable lithium ion batteries) located within the crossover activator/air pump device 400 to power the crossover activator or crossover charger 410a and the air pump or air compressor 410 b. Alternatively, one or more batteries located within the cross-over starter/air pump device 400 in combination with an external battery (e.g., a vehicle battery) may also be used to power the cross-over power starter/air pump device 400. For example, the jumper initiator/air pump device 400 may be electrically connected to the vehicle battery using a cable assembly with a clip, and/or to a cigarette lighter port using a power cable. The crossover activator/air pump device 400 may include the following additional features:

1) A digital air pressure (e.g., psi) gauge or display (e.g., digital air pressure gauge, located on the front display (located on the combined crossover activator/air pump 400 cover));

2) a switch for presetting a target air pressure (for example, a switch on a front display or a cover in addition to a display);

3) power (e.g., a manual and/or automatic switch connected to a power circuit) to the jumper activator/air pump device 400, respectively;

4) providing a battery mode of operation (e.g., a lithium ion battery powering both the crossover starter or crossover charger 410a and the air pump or air compressor 410 b);

5) providing a plurality of batteries that provide multiple modes of operation (e.g., using one or two batteries to operate a jump starting device and/or an air compressor device;

6) charging the battery using a dc or ac power source with an appropriate charger or converter and/or powering a jumper starter or jumper charger 410a and an air pump or air compressor 410b (e.g., integrated electrical and air supply ports (e.g., a single port on the lid and configured to provide power and air supply connections);

7) operating the cooling fan in various modes (e.g., the cooling fan only operates when the cross-over initiator/air pump device 400 is operational; the cooling fan works after the cross-over starter runs; an internal temperature sensor having a preset temperature level controls the operation of the cooling fan; and

8) A cooling fan powered by a separate battery (e.g., a separate battery is provided to power the cooling fan when the combined cross-over starter/air pump 400 is operated simultaneously).

Another vehicle battery jump starter 1010 in accordance with the present invention is shown in fig. 7-14. The battery cross-over initiator 1010 may be provided with an air pump to provide a cross-over initiator/air pump arrangement.

The battery jump starting device 1010 may be equipped with an air pump to provide a jump starting feature and an air pump feature. The crossover activation feature is provided by a crossover activator for crossover activation of the vehicle, and the air pump feature is provided by an air pump to provide pressurized air for filling items such as vehicle tires. The detailed arrangement or configuration of the combination jump starter and air pump will be described in detail below. The vehicle battery crossover initiator 1010 includes a cover 1012, the cover 1012 carrying a handle 1014, as shown in fig. 7-14, and having the particular design shown.

The vehicle battery cross-over starter 1010 includes a front interface 1016, a power button 1017 for turning power on or off, and an electronically controlled switch 1018, the electronically controlled switch 1018 having a control knob 1018a for operating controls located internally. The control switch 1018 is configured such that the control knob 1018a may be rotated between a first position (12V mode) to a second position (24V mode) depending on the particular voltage system (e.g., 12V, 24V) of the vehicle being cross-activated.

The interface 1016 may be provided with the following features as shown in fig. 7, including:

1) a power button 1017;

2) power LEDs (e.g., white LEDs);

3)12V mode LEDs (e.g., white LEDs);

4)24V mode LED 16d (e.g., blue LED);

5) a wrong LED (e.g., a red LED);

6) cold error LEDs (e.g., blue LEDs);

7) thermal error LEDs (e.g., red LEDs);

8) internal battery fuel gauge LEDs (e.g., red, amber, green LEDs);

9) a flash mode button;

10) flash LEDs (e.g., white LEDs);

12)12V input LEDs (e.g., white/red LEDs);

13) a 12V output LED (e.g., white/red LED);

14) a USB output LED (e.g., white LED);

15) a manual override button;

16) override LED red manually;

17) a voltmeter displaying an LED (e.g., a white LED);

18)12V mode LEDs (e.g., white LEDs);

19)24V mode LEDs (e.g., blue LEDs); and

20) a boost LED (e.g., a white LED).

The above-described features may be modified with different colors and/or arrangements on the surface of the interface 1016.

The vehicle battery crossover starter 1010 also includes a port 1020 having a left port 1020a and a right port 1020b, as shown in fig. 8. Port 1020 is configured to extend through a through-hole 1016t located to the lower right of interface 1016. The left port 1020a receives dual 2.1 amp (a) USB output ports 1020c, 1020d, and the right port 1020b receives 1018a 12VXGC output port 1020e and 5a 12V XGC input port 1020f, as shown in fig. 8.

The cover 1012 is provided with resilient sealing caps 1022, including a left sealing cap 1022a for sealing the left port 1020a during non-use of the vehicle battery crossover initiator 1010 and a right sealing cap 1022b for sealing the right port 1020b during non-use of the vehicle battery crossover initiator 1010.

The left side of the vehicle battery cross-over starter 1010 is also fitted with a pair of light emitting diodes 1028 (LEDs) for using the vehicle battery cross-over starter 1010 as a work light. For example, the LED 1028 is a dual 1100 lumen high intensity LED floodlight, as shown in fig. 7, 10 and 14. The LED 1028 is configured to have seven (7) operating modes including 100% intensity, 50% intensity, 10% intensity, SOS (emergency protocol), blink, strobe, and off.

The vehicle battery cross-starter 1010 is fitted with a heat sink 1029 (fig. 7) for dissipating heat from the LED 1028. For example, heat sink 1029 is made of a thermally conductive material (e.g., a molded or die cast aluminum heat sink). The rib design shown (fig. 7) facilitates heat sink 1029 to transfer heat to the surrounding atmosphere, thereby preventing LED 1028 from overheating.

Vehicle battery jump starter 1010 is shown in fig. 7 without a battery cable having a battery clip for connecting vehicle battery jump starter 1010 to the battery of the vehicle to be jump started. Vehicle battery cross-over starter 1010 may be configured to removably connect to a set of battery cables each having a battery clip (e.g., a positive battery cable having a positive clip, a negative battery cable having a negative clip). Alternatively, the battery jump start and air compression device may be fitted with a battery cable that is hardwired directly to the device and is not removable.

In the vehicle battery cross-over starter 1010 shown in fig. 7 and 10, a positive (+) cam lock 1024a and a negative (-) cam lock 1024b are provided on the left side of the vehicle battery cross-over starter 1010. Cam locks 1024a, 1024b include receptacles 1025a, 1025b (fig. 10) configured to removably connect with connection end 1056a (fig. 11) of positive battery cable 1056 and connection end 1058a of negative battery cable 1058, respectively. The cam locks 1024a, 1024b are fitted with sealing caps 26 (fig. 7) for closing and sealing the receptacles 1025a, 1025b of the cam locks 1024a, 1024b, respectively, during periods when the vehicle battery crossover starter 1010 is not in use.

A power circuit 1030 for the vehicle battery jump starter 1010 is shown in fig. 15.

The power supply circuit 1030 includes two (2) separate lithium ion (Li-ion) batteries 1032 (e.g., two (2) 12VLi ion batteries) that are respectively connected to a control switch 1018 via a pair of cable sections 1034, 1036 (e.g., insulated copper cable sections). The control switch 1018 is connected to a reverse current diode array 1048 (i.e., a reverse flow protection device) via a cable section 1044 and to a smart switch 1050 (e.g., a 500A solenoid device) via a cable section 1040, as shown in fig. 15.

The reverse current diode array 1048 is connected to one battery 1032 via a cable section 1044 and to another battery 1032 via a cable section 1046 as shown in fig. 15.

A positive battery cable 1056 having a positive battery clamp 1060 is removably or detachably connected to the positive cam lock 1024a (fig. 15), the positive cam lock 1024a being connected to the reverse current diode array 1048 via a cable section 1052.

A negative battery cable 1058 having a negative battery clip 1062 is removably connected to the negative cam lock 1024b (fig. 15), the negative cam lock 1024b being connected to the smart switch 1050 via a cable section 1054.

In the above-described first embodiment of the power supply circuit 1030, the electrical components of the power supply circuit 1030 are connected together via a cable portion (e.g., a heavy duty flexible insulated copper cable portion). The ends of the cable sections are soldered and/or mechanically secured to the respective electrical components to provide a highly conductive electrical connection between the electrical components.

In the modified first embodiment shown in fig. 16, the battery cables 1056, 1058 are directly hardwired to the reverse current diode array 1048 and the smart switch 1050, respectively, thereby eliminating the cam locks 1024a, 1024b so that the battery cables 1056, 1058 are no longer detachable.

In a second embodiment of the power supply circuit, which will be described below, the cable portions 1036, 1040, 1042, 1044, which are located between the Li-ion battery 1032 and the reverse current diode array 1048 and the smart switch 1050, respectively, are replaced by a highly conductive rigid frame.

The control switch 1018 assembly is shown in fig. 18-18. The control switch 1018 includes the following components:

1) a control knob 1018 a;

2) a front housing 1072;

3) a rear housing 1074;

4) a rotor 1076 having a collar 1076a, legs 1076b and 1076 c;

5) a spring 1078;

6) pivot contacts 1080, each having two (2) contact points (e.g., slots 1080 c);

7) separate terminals 1082, 1084, 1086, 1088;

8) connected terminals 1090, 1092;

9) a conductive strip 1094;

10) an O-ring 1096;

11) an O-ring 1098; and

12) o-ring 10100.

The control knob 1018a includes rear extension portions 1018b, 1018 c. Extension 1018c has a T-shaped cross-section to connect into a T-shaped groove 1076e (fig. 18) in rotor 1076 when assembled. The rotor 1076 is provided with a flange 1076a, the flange 1076a configured to receive a rear extension portion 1018b (e.g., circular cross-section) therein.

A pair of legs 1076c (e.g., U-shaped legs) of the rotator 1076 each partially house a spring 1078, and the springs 1078 exert a force against the pivot contacts 1080 to maintain it in highly conductive contact with selected contacts 1082b through 1092c of the terminals 1082 through 1092.

The pivot contacts 1080 each have a pivot contact plate 1080a, the pivot contact plate 1080a having a central slot 1080b configured to receive an end of each leg 1076b of the rotor 1076. As the rotor 1076 is rotated, each leg 1076b actuates and pivots each pivoting contact plate 1080 a.

Further, the pivoting contact plates 1080a each have a pair of spaced apart through holes 1080c (e.g., oval through holes) that serve as two (2) points of contact with selected contacts 1082c through 1092c of the terminals 1082 through 1092.

The terminals 1082-1092 have threaded posts 1082 a-1092 a, spacers 1082 b-1092 b, and bus bars 1094, respectively, that are configured such that the contacts 1082 c-1092 c all lie in the same plane (i.e., a plane transverse to the longitudinal axis of the control switch 1018) to allow selective pivotal movement of the pivot contact 1080. The threaded posts 1082a to 1092a of the terminals 1082 to 1092, respectively, are inserted through the through holes 74a of the rear housing 1074.

As shown in fig. 18, O- rings 1096, 1098, 1100 seal and separate the various components of control switch 1018 as shown. After assembly of the control switch 1018, a set of screws 1075 are connected with the anchors 1074b of the rear housing 1074 to secure the front housing 1072 to the rear housing 1074, as shown in fig. 18.

The control switch 1018 is a 12V/24V selection type switch as shown in fig. 19. The configuration of the pivot contacts 1080 in the first position or position 1 (i.e., parallel position) is shown on the left side of fig. 19, and the second position or position 2 (i.e., series position) is shown on the right side of fig. 19.

The rear side of the control switch 1018 is shown in fig. 20. Another high conductive strip 1094 is disposed on the rear outer surface of the rear housing 1074. A fully assembled control switch 1018 is shown in fig. 21.

A second embodiment of a vehicle battery cross-over starter 1110 is shown in fig. 20-25 with the cover 1112 removed. The cover for the battery jump starting and air compression device 1110 is the same as the cover 1012 of the vehicle battery jump starting and air compression device 1010 shown in fig. 7-14.

In the second embodiment of the battery crossover starter 1110, the cable portions 1034, 1036, 1040, 1042, 1044, 1046 (fig. 15) of the first embodiment are replaced by a highly conductive frame 1170 in comparison to the vehicle battery crossover and air compression device 1010 (fig. 7-14).

The battery crossover starter 1110 includes a pair of 12V Li-ion batteries 1132 directly connected to a highly conductive rigid frame 1170. Specifically, the Li-ion battery's keys (not shown) are welded to the highly conductive rigid frame 1170.

The vehicle battery crossover starter 1110 is equipped with an air compressor arrangement to provide a crossover start and air compression arrangement having a crossover starter arrangement for crossover starting the vehicle and an air compressor arrangement for providing a source of high pressure air for filling items such as vehicle tires. The crossover start and air compressor assembly, the crossover start assembly, and the air compressor assembly will be described in detail below.

The highly conductive rigid frame 1170 is comprised of a plurality of highly conductive rigid frame members 1134, 1136, 1140, 1144, 1146, 1152, 1154 that are connected together by mechanical fasteners (e.g., copper nut and/or bolt fasteners) and/or welding. For example, the highly conductive rigid frame member is made of a highly conductive rigid copper bar. Alternatively, the highly conductive rigid copper rod may be replaced with a highly conductive rigid copper plate, strip, tube, or other suitably configured highly conductive copper material (e.g., copper stock). The highly conductive rigid frame members 1134, 1136, 1140, 1144, 1146, 1152, 1154 may also be insulated (e.g., heat shrunk) at least in critical areas to prevent any internal short circuits.

The highly conductive rigid frame members may be configured with flattened ends (e.g., flattened by pressing), each end having a through hole to provide a portion of a mechanical connection for connecting successive or adjacent highly conductive rigid frame members and/or electrical components together using highly conductive nut and bolt fasteners (e.g., copper bolts and nuts). Furthermore, the highly conductive rigid frame member may be formed as a base (e.g. a plate or strip portion) for the electrical component. For example, the reverse diode assembly 1148 has three (3) bases, including (1) an upper highly conductive rigid strip 1148a (fig. 22) with a flat end 1148aa, which flat end 1148aa is connected to a flat end 1144a of the highly conductive rigid frame member 1144 using a highly conductive fastener 1206 (e.g., made of copper) with a highly conductive bolt 1206a and a highly conductive nut 1206 b; (2) a lower highly conductive rigid strip 1148b made of a flat end of the highly conductive rigid frame member 1144; and (3) a central highly conductive rigid strip 1148c made from the flat ends of the highly conductive rigid frame member 1152.

As another example, smart switch 1150 (fig. 22) includes a highly conductive rigid plate 1150a that serves as a base to support solenoid 1150 b. The highly conductive rigid plate 1150a is provided with through holes for connecting the highly conductive rigid frame member to the smart switch 1150 (highly conductive rigid frame member 1142) using highly conductive fasteners 1206.

The raw materials (e.g., copper or aluminum bars, plates, strips, tubes) selected for construction of the highly conductive rigid frame 1170 have substantial gauge to provide high conductivity and substantial rigidity. The "rigid" nature of the highly conductive rigid frame 1170 provides the advantage that the highly conductive rigid frame 1170 remains structurally rigid and stable during battery cross-over activation and storage and use of the air compression device 1110.

For example, the highly conductive rigid frame 1170 is designed and configured to be sufficiently resistant to flexing, moving, bending, and/or displacement during storage or use to prevent the highly conductive rigid frame from contacting other internal electrical components or parts of the electronic assembly for electrical shortage. This "rigid" nature is important because of the highly conductive path for electrical energy from the Li-ion battery to flow through the power supply circuit and reach the battery clip. One desirable object and feature of the present invention is to reduce or minimize any resistance by using the disclosed heavy and highly conductive rigid frame 1170 arrangement to conduct as much power as possible from the Li-ion battery to the battery being cross-battery started and air compression device cross-started.

Alternatively, the highly conductive rigid frame 1170 may be constructed as a single piece without mechanical fastening tabs. For example, the highly conductive rigid frame may be made from a single piece of raw material and then formed into the highly conductive rigid frame. For example, a highly conductive copper billet may be machined (e.g., milled, lathed, drilled) into a highly conductive rigid frame. As another example, a copper sheet or plate may be bent and/or machined into a highly conductive rigid frame. As another alternative, the highly conductive rigid frame may be metal molded (e.g., a lost wax process).

As another alternative, the highly conductive rigid frame 1170 is made of multiple highly conductive rigid frame members that are connected together to form a unitary structure. For example, the highly conductive rigid frame 1170 is made of highly conductive portions of raw material (e.g., copper rods, plates, bars, tubes) that are bent and welded and/or soldered together.

The vehicle battery cross-over starter 1110 also includes a resistor array 1202 (e.g., 12V 5A XGC), the resistor array 1202 including a Printed Circuit Board (PCB)1202a, the PCB 1202a serving as a base to support an array of individual resistors 1202b, as shown in fig. 23 and 25. The PCB 1202a also supports dual 2.1 ampere (a) USB output ports 1120c, 1120d, 1018a 12VXGC output port 1020e and 5a 12V XGC input port 1020 e.

The left side of the vehicle battery cross-starter 1110 is also fitted with a pair of light emitting diodes 1128 (LEDs) for using the vehicle battery cross-starter 1110 as a work light. For example, the LED 1128 is a dual 1100 lumen high intensity LED floodlight, as shown in FIG. 22. The LEDs 1128 are configured to have seven (7) operating modes including 100% intensity, 50% intensity, 10% intensity, SOS (emergency protocol), blinking, strobing, and off.

The vehicle battery jump starter 1110 is equipped with a heat sink 1129 (fig. 16) for dissipating heat from the LED 1128. For example, heat sink 1129 is made of a thermally conductive material (e.g., a molded or die-cast metal plate). The heat sink 1129 is provided with ribs 1129a, the ribs 1129a transferring heat to the surrounding atmosphere to prevent overheating of the LEDs 1128.

The vehicle battery jump starter 1110 is shown in fig. 16 without any battery cable having a battery clip for connecting the battery jump starter and air compressor 1110 to the battery of the vehicle to be jump started. Battery crossover actuator 1110 may be configured to removably connect to a set of battery cables having battery clips (e.g., a positive battery cable having a positive clip, a negative battery cable having a negative clip). For example, referring to the removable battery cables 1056, 1058 and battery clips 1060, 1062 of FIG. 15, they may be removably connected to the cam locks 1124a, 1124b of the battery crossover activation and air compression device 1110. Alternatively, the vehicle battery jump starter 1110 may be fitted with a non-removable battery cable having a clip that is hard wired to the device, which is the same or similar to the battery cable shown in fig. 16.

For example, the vehicle battery crossover starter 1110 is provided with a positive (+) cam lock 1124a and a negative (-) cam lock 1124b on the left side thereof, as shown in fig. 22. Cam locks 1124a, 1124b include sockets 1125a, 1125b configured to removably connect with connection end 1156a (fig. 17) of positive battery cable 1056 and connection end 158a of negative battery cable 158, respectively. Cam locks 1124a, 1124b may be fitted with sealing caps identical or similar to sealing cap 26 (fig. 1) for closing and sealing receptacles 1125a, 1125b of cam locks 1124a, 1124b, respectively, during periods when the battery crossover activation and air compression device 1110 is not in use.

The vehicle battery crossover and air compression device 1010 includes a main printed circuit board 1208 that serves as a base for the control knob 1018a and the LEDs of the interface 1016, and for supporting the other electrical components of the vehicle battery crossover and air compression device 1010.

A third embodiment of a vehicle battery jump starter 210 is shown in fig. 32 to 37. In this embodiment, the highly conductive rigid frame is made from a flat copper bar stock material having a rectangular cross-sectional profile. The flat copper strip is bent to at least partially wrap and encapsulate the Li-ion battery.

Cam lock connector

Likewise, battery cables 1056, 1058 (fig. 16) may be removably connected to battery crossover and air compression device 1010 via cam locks 1024a, 1024b (fig. 7) or cam locks 1124a, 1124b (fig. 16).

Cam locks 1024a, 1124a, 1024b, 1124b and cables 1056, 1058 (fig. 9) having conductive ends 1056a, 1056b (fig. 17) may each have the configuration of cam lock connector 1027, as shown in fig. 38-51.

Cam lock connector 1027 may be used to removably connect a conductive cable to other applications of an electronic device other than a battery crossover and air compression device according to the present invention.

Cam lock connector 1027 includes male cam lock end 1027a and female cam lock end 1027b for detachably connecting battery cables 1056, 1058 (fig. 16), respectively, to vehicle battery cross-over starter 1010.

Male cam lock end 1027a includes a pin 1027aa having teeth 1027 ab. Female cam lock end portion 1027b includes a socket 1027ba, socket 1027ba having slots 1027bb located together in hexagonal portion 1027 bc. The socket 1027ba is configured to receive the pin 1027aa and the teeth 1027ab of the male cam lock end portion 1027 a. Specifically, pin 1027aa and teeth 1027ab of male cam lock end 1027a may be inserted (fig. 39) into socket 1027ba and slot 1027bb a fixed distance until teeth 1027ab contact an inner surface of an internal thread of female cam lock 1027b, described below. The male cam lock end 1027a may be rotated (e.g., clockwise) to tighten within the female cam lock end 1027b until an end face portion 1027ac of the male cam lock end 1027a engages an end face portion 1027bc of the female cam lock end 1027 b. The tighter the cam lock 1024, the better the electrical connection between the male cam lock end 1027a and the female cam lock end 1027 b.

As shown in fig. 40, the male cam lock end 1027a is fitted with a rubber molded cover 1031 to insulate and improve grip on the male cam lock end 1027 a. The highly conductive cable 1033 is electrically and mechanically connected to the male cam lock end 1027a and fits through a passage in the rubber molded cover 1031.

The assembly of the male cam lock 1027a is shown in FIG. 41. The male cam lock 1027a is provided with a threaded bore 1037 for receiving an allen head fastener 1039. One end of the male cam lock 1027a is provided with a socket 1027ad for receiving a copper bushing 1041 fitted onto the end of the inner conductor 1056a of the battery cable 1056. The copper bushing 1041 is soldered to the inner conductor 1056a using solder 1043.

The copper bushing 1041 is fitted into the socket 1027ad of the male cam lock end portion 1027a as shown in fig. 42. When the copper bushing 1041 is fully inserted into the socket 1027 of the male cam lock end 1027a, as shown in fig. 42, the allen head fastener is then threaded into the threaded bore 1037 and tightened, as shown in fig. 43.

Note that the inner end of the allen head fastener, when sufficiently tightened, forms a notch 1045 to securely anchor the copper sleeve 1041 and inner conductor 1056a of the battery cable 1056 to mechanically and electrically connect the cable 1056 to the male cam lock end 1027 a.

The rubber molded cover 1031 is provided with one or more inwardly extending protrusions 1031a (fig. 32) that cooperate with one or more slots 1027ae (fig. 44) in the outer surface of the male cam lock end 1027 a.

Likewise, the male cam lock end 1027a and the female cam lock end 1027b are configured to be screwed together when rotating the male cam lock end 1027a while inserted into the female cam lock end 1027 b.

As shown in fig. 46, female cam lock end 1027b is provided with a socket 1027ba and a slot 1027bb for receiving an end of male cam lock end 1027 a. Slot 1027bb is provided with a surface 1027bba, surface 1027bba serving as a stop for tooth 1027ab of male cam lock end 1027 a. The socket 1027ba is provided with internal threads 1027baa for cooperating with teeth 1027ab of the male cam lock end 1027a to provide a threaded connection therebetween. Specifically, teeth 1027ab engage surface 1027bba and are prevented from further insertion into socket 1027ba of female cam lock end 1027 b. As male cam lock end 1027a is rotated, teeth 1027ab engage and cooperate with internal threads 1027baa of socket 1027ba of female cam lock end 1027b to begin tightening male cam lock end 1027a within female cam lock end 1027b, with teeth 1027ab abutting against the edges of internal threads 1027 baa. The male cam lock end 1027a is further rotated to further tighten the connection with the female cam lock end 1027 b. When face 1027ac (fig. 38) of male cam lock end 1027a engages face 1027bd of female cam lock end 1027b, then cam lock ends 1027a, 1027b are fully engaged and rotation is stopped.

The female cam lock end 1027b receives a rubber molded cover 1051 having cover portions 1051a, 1051b, as shown in fig. 48-51.

Female cam lock end 1027b (fig. 46 and 47) is provided with internal threads 1027bf (fig. 46) to receive bolt 47 and lock washer 49 (fig. 47) for connecting female cam lock end 1027b to vehicle battery crossover activator 1010 (e.g., to a substrate for smart switch 1050 (fig. 9)).

Female cam lock end 1027b is received within molded rubber cover portions 1051a, 1051b, as shown in fig. 47-49. The molded rubber cover portions 1051a, 1051b are fitted onto the threaded portion 1027be of the female cam lock end 1027b (fig. 51) and then secured in place using a nut 1053 and lock washer 1055. The molded rubber cover portion 1051a includes an outwardly extending protrusion 1051 aa.

Backlight system of electric control switch

The vehicle battery cross-over charger 1010 or 1110 may be provided with an electronically controlled switching backlighting system 1200, for example, as shown in fig. 52-56.

For example, the electronically controlled switch backlighting system 200 includes a control switch 1018 having a control knob 1018a, an interface 1016 (e.g., a thin film label), and a main printed circuit board 1208.

The control knob 1018a is made of plastic (e.g., black injection molded plastic part). For example, the control knob 1018a is primarily made of a colored opaque plastic material selected to prevent light transmission therethrough, and a slot 1018b provided with a light transmissive plastic molded (e.g., insert molded) therein has a transparent or see-through embedded portion. The light transmissive plastic slot 1018b acts as a light window to allow light from one or more backlight LEDs mounted on the printed circuit board 1208 to pass through the interface 1016 and through the light window when the power button 1017 of the interface 1016 is turned on (e.g., touching the power switch) to illuminate the one or more LEDs. The LED 408a or 408b is selectively illuminated. Alternatively, the light-transmissive plastic slot 1018b may be replaced by an open slot in the control knob 1018b that serves as a light window.

The control switch 1018 may be rotated between a first position (position 1) for a 12V mode of operation of the battery jump start and air compression device 1010 and a second position (position 2) for a 24V mode of operation of the battery jump start and air compression device 1010. The power supply is shown as "on" in fig. 53 and "off" in fig. 54.

Interface 1016 is provided with 12V backlight indicator 1016a, 24V backlight indicator 1016b, 12V backlight indicator 1016c, 24V backlight indicator 1016d, variable display backlight indicator 1016e for indicating the actual operating voltage of battery cross-over charging device 1010, and power "on" indicator 1016f, as shown in fig. 55.

The electronically controlled switching backlight system 1200 may be configured to turn on the white LEDs mounted on the printed circuit board 1208 when the control switch 1018 is in position 1 for the 12V mode of operation of the battery cross-over start and air compression apparatus 1010, and to turn on the blue LEDs mounted on the printed circuit board 1208 when the control switch 1018 is in position 2 for the 24V mode of operation of the battery cross-over start and air compression apparatus 1010. As shown in fig. 53, when the control knob 1018 is in position 1, the light window provided on the control knob 1018 by slot 1018b lights up with the 12V backlight indicators 1016a, 1016c on the interface 1016. When control knob 1018b is in position 2, 24V backlight indicator 1016b lights up along with 24V backlight indicator 1016 d.

Electro-optical position sensing switch system

The portable crossover start and air compression device 1010 or 1110, for example, may be configured as a dual-purpose lithium ion crossover start to allow crossover start of 12V or 24V heavy vehicles or piece equipment. The lightweight portable unit utilizes a manually rotatable control switch 1018 having a control knob 1018a to switch between 12V or 24V cross-over start or operating modes. Any of the above-described portable jump starting devices according to the invention may be provided with an electro-optical position sensing system 1300, as shown in fig. 57-59.

The portable crossover start device 1010 uses two 12V Li-ion batteries in parallel for 12V crossover start and in series for 24V crossover start. Series or parallel connection is achieved by a rotary control switch 1018 (e.g., a main switch), as shown in fig. 57.

An electro-optical position sensing system 1300 is shown in FIG. 58. The optical position sensing system 1300 is configured as a safe and effective method of allowing the system microcontroller to read the position of the control switch 1018. The optical position sensing system 1300 includes a sensor 1302 (fig. 58) that uses optical coupling to ensure integrity of isolation on a 12V to 24V rotary control switch 1018.

A schematic diagram of the circuitry of the optical position sensing system 1300 is shown in fig. 59. The upper left portion of the schematic includes transistor Q1028 and resistors R165, R168, R161, and R163. This circuit acts as an electrical enable when the main system 3.3V power supply is "on". The purpose of this activation is to reduce parasitic currents when the portable jump starting device 10 is in the "off" state. When "on," this enables current from battery a + to flow through Q1027, Q1027 acting as an electrical switch.

If Q27 is "ON," it allows current to flow from battery A + to battery B-when the batteries are connected in parallel. When they are connected in series, no current flows because A + and B-are connected together by control switch 1018.

The result of the current flow or lack thereof allows the optocoupler to provide a signal to the microcontroller until it is told which position the main switch is in.

The second part of the schematic (i.e. the schematic directly below the first) allows the opposite signal to be provided to a separate input of the microcontroller. The result is to provide an efficient way for the microcontroller to determine when the switch is "in the middle", i.e. it is not in the 12V position or the 24V position, but in between these two positions. This allows the microcontroller to provide diagnostics in the event that the user places the switch in an unavailable position.

Dual cell diode bridge system

The vehicle battery cross-over starter 1010 or 1110 may be provided, for example, with a two-diode battery bridge, for example, in the form of a reverse charging diode module 1148 configured to prevent reverse charging after the vehicle battery has been cross-over charged, as shown in fig. 60.

The reverse charging diode module 1148 is configured to provide two (2) diode channels 1148a, 1148b to support two battery systems (e.g., two (2) batteries of the battery jump starting device 1110), and to be bridged together to provide peak current output during jump starting.

The single and double wire connections of the vehicle battery jump starter 1110 are shown in fig. 60. These components are connected together by a highly conductive rigid frame 1170 (including copper bar elements 1152). The copper strip members that make up the highly conductive rigid frame 1170 are more conductive than the 2/0 copper cable. Further, the connection points between the copper bar members of the highly conductive rigid frame 1170 are configured to reduce power loss as compared to copper cables. The copper bar member of the highly conductive rigid frame 1170 may be replaced with other highly conductive metals (e.g., aluminum, nickel, plated metal, silver plated metal, gold plated metal, stainless steel, and other suitable highly conductive metal alloys).

A two-diode battery bridge in the form of a reverse charging diode module 1148 is shown in fig. 61. The top diode channel 1148a supports current through one 12V battery 1132, and the bottom diode channel 1148b supports current through a second 12V battery 1132. The combined current from the two batteries 1132, 1132 through the two (2) diode channels exits the reverse charging diode module 1148 through the copper bar member 1152 to the positive output (i.e., positive cam lock 124a) of the battery crossover start-up and air compression device 1010.

Reverse charging diode module 1148 includes an upper highly conductive plate 1149e, a lower highly conductive plate 1149b, and a central highly conductive plate 1149c connected together by diode channels 1148a, 1148b, respectively.

Jumping charging system

The vehicle battery jump starter 1010 or 1110, for example, uses two (2) 12V lithium batteries for jump starting the vehicle and other system functions. Both of these separate batteries are used in series or in parallel depending on whether the operator has a 12V vehicle or a 24V vehicle at cross-over start.

The vehicle battery cross-over starter 1010, 1110, 1210 may be charged using a charging device (e.g., a 114V to 126V (rms) AC charger) having a patch cord and a charge control device (e.g., a programmable microcontroller). Each cell is independently charged from the other by the cell crossover start and air compression devices 1010, 1110, but the cells are kept close in potential during the charging process using a technique known as "skip charging". This charging method ensures that both batteries are close to the same potential even if the vehicle battery cross-over starter device 1010 or 1110 prematurely stops charging. This provides equal power transfer during cross-over start-up and other system functions.

The vehicle battery cross-over starter 1010, 1110, 1210 is provided with a charging device. For example, the circuit board 408 shown in fig. 32 may be provided with a charging member and a charging circuit for recharging two (2) Li-ion batteries. These components include, for example, a programmable microcontroller for controlling a recharging circuit for recharging the Li-ion battery.

This method is implemented by: starting with the lowest charged battery, one battery is charged until it is about 100mv higher than the other battery, and then a switch is made to charge the other battery. This process continues until both batteries are fully charged.

Protective measures are provided in the vehicle battery cross-over starters 1010, 1110 to prevent any batteries from being overcharged and to sense whether a battery cell is shorted. These include peak voltage shutdown and charge timeout in software.

The skip-charging system and method may be designed or configured to charge a rechargeable battery (e.g., a Li-ion battery) in a certain charging sequence. The charging sequence may be designed or configured to ensure that both batteries are fully charged regardless of the battery cross-over start and operation of the air compression device 1010, 1110, 1210. In this way, the battery is periodically fully charged to maximize the use and life of the battery.

Furthermore, the charging sequence may be tailored to most efficiently charge a particular type of rechargeable battery, particularly a Li-ion battery, in view of the particular charging characteristics of the battery (e.g., reducing battery heating over a time interval, applying an optimal charging rate to the battery, charging in sequence increasing the life of the battery). For example, the charging sequence may be to partially charge the battery, one at a time, and charge back and forth. For example, the charging sequence may be configured to incrementally charge the batteries in a back and forth sequence until both batteries are fully charged. For example, a voltage increase increment (e.g., 100mV) may be selected to charge the battery in a back-and-forth sequence.

In addition, the charging sequence between two batteries may be selected or programmed to provide two or more increments of continuous charging of one battery before switching to another battery for charging. Further, the charging sequence may include one or more pauses to prevent the rechargeable battery from becoming too hot (e.g., temperature extremes), or to match the charging sequence to the charging chemistry of the rechargeable battery.

High-conductivity frame

Details of the highly conductive frame 1470 are shown in fig. 62-68. The highly conductive frame 1470 may replace the conductive wiring pattern 16 of the portable battery crossover activation and air compression device 1010, the highly conductive frame 1170 (fig. 22) of the vehicle battery crossover activator 110, and the highly conductive frames of the portable battery crossover activation and air compression device 1210 (fig. 26) and the portable vehicle battery crossover activator 1310 (fig. 35).

For example, highly conductive frame 1470 may be a highly conductive semi-rigid or rigid frame made of a semi-rigid or rigid highly conductive material (e.g., copper, aluminum, plated metal, gold plated metal, silver plated metal, steel, coated steel, stainless steel). The highly conductive frame 1470 is structurally stable (i.e., does not move or flex) so that it does not contact and electrically short to components or parts of the portable jump starting device. The more rigid the highly conductive frame, the more stable the structure of the highly conductive frame. The highly conductive frame 1470 is connected to two (2) batteries, such as Li-ion battery 1032 (fig. 16) or battery 1132 (fig. 22), to, for example, cam locks 1024a, 1024b or cam locks 1124a, 1124 b. The cam lock is connected to a removable battery cable, such as battery cables 1056, 1058 (fig. 15).

Highly conductive frame 1470 includes a plurality of highly conductive frame members. For example, highly conductive frame members 1470a, 1470b, 1470c, 1470d are connected to control switches, such as terminals 1082a, 1084a, 1086a, 1088a (fig. 20) of control switch 1018 (fig. 18). Highly conductive frame members 1470d, 1470e, 1470f form part of a reverse flow diode assembly 1148 (fig. 24). The highly conductive frame member 1470f is connected to positive cam locks, such as positive cam lock 1024a (fig. 7 and 15) and positive cam lock 1124a (fig. 26). The highly conductive frame member 1470g is connected to a negative cam lock, such as negative cam lock 1024b (fig. 7) or negative cam lock 1124b (fig. 25). Highly conductive frame member 1470h is connected to smart switch 1150 (fig. 22).

The highly conductive frame 1470 is a three-dimensional (3D) structure configured to enclose a Li-ion battery, such as Li-ion battery 1132 (fig. 22-31). This arrangement provides the shortest conductive path from the electric Li-ion battery 1132 to the other internal electrical components of the portable crossover activation device 1110 to maximize the power output between the positive cam-lock 1024a and the negative cam-lock 1024 b.

The highly conductive frame members 1470 a-1470 h are provided with ends having through holes to receive highly conductive fasteners 1206 (e.g., bolts and nuts), as shown in fig. 22-31. Further, highly conductive frame members 1470 a-1470 h are made of flat strips that are bent at one or more locations so as to wrap a Li-ion battery, such as Li-ion battery 1132. For example, the highly conductive frame members 1470a to 1470h are bent at a plurality of positions to form a three-dimensional (3D) frame structure. For example, the highly conductive frame members 1470a to 1470h may have bent ends provided with annular through holes. Alternatively, highly conductive frame 1470 may be made as a single piece (e.g., a single piece plate that is bent into shape, multiple pieces that are welded or soldered together, machined from one piece of raw material).

The highly conductive frame 1470 is made from flat, highly conductive sheet stock (e.g., flat strip of copper stock cut to length, bent and drilled).

Battery pack

A Li-ion battery assembly 1133 in accordance with the present invention is shown in fig. 69 to 72.

The Li-ion battery assembly 1133 includes a Li-ion battery 1132, a positive electrode high-conductivity battery member 1132a, and a negative electrode high-conductivity battery member 1132 b. The Li-ion battery includes a plurality of lithium-ion battery cells 1132c, layer-by-layer.

The positive foil end 1135d of the Li-ion battery cell 1132c is connected (e.g., soldered, welded, and/or mechanically fastened) to the positive highly conductive battery member 1132 a. The negative foil end 1135e of the Li-ion cell 1132c is connected (e.g., soldered, welded, and/or mechanically fastened) to the negative highly conductive cell member 1132 b.

The positive highly conductive battery member 1132a and the negative highly conductive battery member 1132b are made of a highly conductive flat plate or bar raw material (e.g., copper plate, aluminum plate, steel plate, coated plate, gold-plated plate, silver-coated plate). The positive high-conductivity cell member 1132a is provided with a through-hole 1132aa at an end portion extending outward from the Li-ion cell 1132 by a distance and oriented transversely with respect to the Li-ion cell 1132. The negative very high conductive battery member 1132b is provided with a through-hole 1132ba, and the through-hole 1132c is located at an end portion extending outwardly a distance from the rechargeable battery cell 1135 and the rechargeable Li-ion battery 1132 and oriented transversely with respect to the Li-ion battery 1132.

The highly conductive cell members 1132a, 1132b are made of a relatively thick plate or strip material. The foil ends 1132d, 1132e of the battery cells 1132c may at least partially or completely wrap around the highly conductive battery members 1132a, 1132 b. In the assembled Li-ion battery assembly 1133 shown in fig. 69, the highly conductive battery components are each oriented flat against opposite ends of the Li-ion battery and covered with a protective heat shrink material until installed in an electronic device, such as a portable battery jump starter 1110.

For example, the highly conductive battery members 1132a, 1132b are connected to a highly conductive frame, such as the highly conductive frame 1170 (fig. 22-31) or the highly conductive frame 1470 (fig. 62-68) of any of the portable jump starters 1010, 1110, 1210, 1310, by highly conductive fasteners (e.g., nuts and bolts). The heat shrink material is wrapped over the assembled battery 1132 and highly conductive members 1132a, 1132b to complete the assembly.

Vehicle battery cross-over starting device with air pump

Fig. 79 is a schematic diagram showing a crossover initiator/air pump device 2010 including a crossover initiator or crossover charger 2010a, an air pump or air compressor 2010b, and a rechargeable battery 2010c (e.g., a lithium ion rechargeable battery). The crossover activator or crossover charger 2010a, air pump or air compressor 2010b, and rechargeable battery 2010c may be located within a single cover 2012 (e.g., a housing or shell), or alternatively in separate covers (e.g., covers connected together, one nested within the other, with one resting within the other). For example, an air pump or air compressor 2010b can be removably mounted within the crossover initiator or crossover charger 2010 a. In fig. 79, a jumper actuator or jumper charger 2010a is placed alongside an air pump or air compressor 2010 b.

The air pump may for example comprise one or more selected from: a group of air compressors, rotary air compressors, reciprocating air compressors, air tanks, electric motors, hydraulic motors, pneumatic motors, controls, conduits and air hoses. Other known air pump structures, arrangements or systems may be used for the cross-over initiator/air pump device 2010.

The control of the air pump or air compressor 2010b may be incorporated into the MCU 1 shown in fig. 1 and/or a separate control may be provided, for example by the MCU 1. The crossover initiator or crossover charger 2010a and the air pump or air compressor 2010b may be powered by the same battery (e.g., a rechargeable battery, a rechargeable lithium ion battery, inside or outside the cover 20120 shown in fig. 795). Alternatively, the crossover starter or crossover charge 2010a and the air pump or air compressor may be powered using separate batteries (e.g., separate rechargeable batteries, separate lithium ion batteries).

Fig. 80 is a schematic diagram showing a crossover initiator/air pump device 2010 'including a crossover initiator or crossover charger 2010 a', an air pump or air compressor 2010b ', and a rechargeable battery 2010 c' (e.g., a lithium ion rechargeable battery). The crossover activator or crossover charger 2010a ', air pump or air compressor 2010b ', and rechargeable battery 2010c ' may be located within a single cover 2012 (e.g., a housing or shell) or alternatively in separate covers (e.g., covers connected together, one nested within the other, with one resting within the other). For example, an air pump or air compressor 2010b can be removably mounted within the crossover initiator or crossover charger 2010 a. In fig. 80, an air pump or air compressor 2010b 'and a rechargeable battery 2010 c' are located with the crossover actuator 2010a "itself.

FIG. 81 illustrates a jump initiator/air pump device 2010 in accordance with the present invention. For example, the vehicle battery crossover initiator shown in fig. 7 is provided with an air pump 2410 to provide components and features of both the crossover initiator and the air pump within the same lid 2012 (e.g., lid, housing, or enclosure). The cross-over initiator/air pump device 2010 includes all of the components and features of the cross-over initiator device 1010 shown in FIGS. 7-78 and, as described above, in combination with the components and features of an air pump (e.g., air pump 2410b shown in FIG. 79) to supply pressurized air, an air supply port 2412, an air hose connector 2413 having a connection end 24124, an external air hose 2415, and an air valve connector 2416 (e.g., a tire valve connector). Air hose connection 2413, external air hose 2415 and air valve connection 2416 are connected together, e.g., removably connected as a unit, from jumper initiator/air pump device 2010.

The crossover initiator/air pump device 2010 may have a single battery (e.g., a lithium ion battery) for supplying power to the crossover initiator or crossover charger 2010a (fig. 79) and/or the air pump or air compressor 2010 b. A manual or electrical switch may be incorporated to allow for simultaneous or selective power to both the jumper actuator or jumper charger 2010a and the air pump or air compressor 2010 b. Additionally, optionally, the crossover activator/air pump device 2010 includes two or more batteries for independently powering the crossover activator or crossover charger 2010a and the air pump or air compressor 2010 b.

Cross-over initiator/air pump device 2010 may include a fan for cooling before, during, and/or after use. Alternatively, or in addition, the crossover actuator/air pump device 420 may use an air pump or air compressor 2010b to supply cooling air internally to cool the combined crossover actuator/air compressor 2010. For example, the internal high pressure pump 2410 may have an exhaust port and/or valve to controllably release air within the lid 2012 and out the exhaust port for cooling.

The crossover activator/air pump device 2010 may be controlled (e.g., manual or electrically powered switches) and operated (e.g., using controls and control circuitry and/or MCU1) to utilize, for example, one or more batteries (e.g., rechargeable batteries, rechargeable lithium ion batteries) located within the crossover activator/air pump device 2010 to power the crossover activator or crossover charger 2010a and the air pump or air compressor 2010 b. Alternatively, one or more batteries located within cross-over initiator/air pump device 2010 in combination with an external battery (e.g., a vehicle battery) may also be used to power cross-over powered initiator/air pump device 2010. For example, the jumper initiator/air pump device 2010 may be electrically connected to the vehicle battery using a cable assembly with a clip, and/or to the cigarette lighter port using a power cable. The cross-over initiator/air pump device 20100 may include the following additional features:

1) A digital air pressure (e.g., psi) gauge or display (e.g., a digital air pressure gauge, located on the front display (located on the lid of the combination jumper actuator/air pump 2010));

2) a switch for presetting a target air pressure (for example, a switch on a front display or a cover in addition to a display);

3) power (e.g., a manual and/or automatic switch connected to a power circuit) is provided to the jumper actuator/air pump device 2010, respectively;

4) providing a battery mode of operation (e.g., a lithium ion battery powering both the crossover starter or crossover charger 2010a and the air pump or air compressor 2010 b);

5) providing a plurality of batteries that provide multiple modes of operation (e.g., using one or two batteries to operate a jump starting device and/or an air compressor device;

6) charging the battery and/or powering a jumper starter or jumper charger 2010a and an air pump or air compressor 2010b using a dc or ac power source with an appropriate charger or converter (e.g., an integrated electrical and air supply port (e.g., a single port on the lid and configured to provide both a power supply connection and an air supply connection);

7) operating the cooling fan in various modes (e.g., the cooling fan only operates when the cross-over initiator/air pump device 2010 is operating; the cooling fan works after the cross-over starter runs; an internal temperature sensor having a preset temperature level controls the operation of the cooling fan; and

8) A cooling fan powered by a separate battery (e.g., a separate battery is provided to power the cooling fan when the combination jump starter/air pump 2010 is simultaneously operated).

Having thus described the invention, it will be apparent to those skilled in the art that the same may be varied in many ways without departing from the spirit or scope of the invention. Any and all such variations are intended to be included within the scope of the following claims.

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Portable vehicle battery crossover starter with air pump

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