US-12627250-B2 - Battery pack, power tool and battery pack charger system

Abstract

A battery pack including a first subset of battery cells and a second subset of battery cells, set of switches, a DC output port and an AC output port. The battery pack may provide both a DC output signal at the DC output port and an AC output signal at the AC output port by selectively activating the switches of the set of switches. The battery pack may couple the first subset of battery cells and the second subset of battery cells in a parallel configuration or a series configuration.

Inventors

• Andrew E. Seman, Jr.
• Matthew J. Velderman
• Daniel J. White

Assignees

• BLACK & DECKER INC.

Dates

Publication Date

20260512

Application Date

20220805

Claims (17)

1. 1 . A battery pack, comprising: a set of battery cells including a first subset of battery cells and a second subset of battery cells; a DC output port, the first subset of battery cells and the second subset of battery cells are coupled in series and to the DC output port to provide a DC output signal; an AC output port; and a set of switches, the set of switches may be controlled and configured such that the first subset of battery cells and the second subset of battery cells may be alternatively coupled to the AC output port to provide an AC output signal.
2. 2 . The battery pack, as recited in claim 1 , wherein each subset of battery cells includes forty-five battery cells and each battery cell has a nominal voltage of approximately 3.75 volts.
3. 3 . The battery pack, as recited in claim 1 , further comprising a pack control module wherein the set of switches is coupled to and controlled by the pack control module.
4. 4 . The battery pack, as recited in claim 3 , further comprising a user inverter switch coupled to the pack control module, wherein upon the user inverter on/off switch being placed in an on position, the pack control module controls the set of switches to provide the AC output signal to the AC output port.
5. 5 . The battery pack, as recited in claim 4 , wherein a first switch of the set of switches is coupled between a positive node of the first subset of battery cells and an AC line terminal of the AC output port and a second switch of the set of switches is coupled between the AC line terminal and a negative node of the second subset of battery cells and an AC neutral terminal of the AC output port is coupled to a node at a negative terminal of the first subset of battery cells and a positive terminal of the second subset of battery cells.
6. 6 . The battery pack, as recited in claim 2 , wherein the DC output signal is approximately 340 volts.
7. 7 . The battery pack, as recited in claim 1 , further comprising a first DC-DC converter and a first DC-DC converter switch and a second DC-DC converter and a second DC-DC converter switch, the first DC-DC converter and the first DC-DC converter switch coupled between a positive node of the first subset of battery cells and a line terminal of the AC output port and the second DC-DC converter and the second DC-DC converter switch coupled between the line terminal of the AC output port and a negative node of the second subset of battery cells.
8. 8 . The battery pack, as recited in claim 7 , further comprising a pack control module wherein the set of switches and the first DC-DC converter switch and the second DC-DC converter switch are coupled to and controlled by the pack control module to provide a modified sine-wave at the AC output port.
9. 9 . The battery pack, as recited in claim 8 , wherein during a first portion of a period a first switch of the set of switches, a second switch of the set of switches, and the second DC-DC converter switch are maintained open and the first DC-DC converter switch is maintained closed providing a constant relatively low positive voltage at the AC output port and during a second and a third portion of the period P, the second switch of the set of switches, the first DC-DC converter switch, and the second DC-DC converter switch are maintained open and the first switch of the set of switches is maintained closed providing a constant relatively high positive voltage at the AC output port equal to the voltage of the first subset of battery cells and during a fourth portion of the period P, the first DC-DC converter switch is maintained closed and the first switch of the set of switches, the second switch of the set of switches, and the second DC-DC converter switch are maintained open providing the constant relatively low positive voltage at the AC output port and during a fifth portion of the period P, the second DC-DC converter switch is maintained closed and the first and second switch of the set of switches and the first DC-DC converter switch are maintained open providing a constant relatively low negative voltage at the AC output and during the transition from the first DC-DC converter switch opening and the second DC-DC converter switch closing, there is a zero cross and during a sixth and a seventh portion of the period P, the first switch of the set of switches, the first DC-DC converter switch, and the second DC-DC converter switch are maintained open and the second switch of the set of switches is maintained closed providing a constant relatively high negative voltage at the AC output port equal to the voltage of the second subset of battery cells and during an eighth portion of the period P, the second DC-DC converter switch is maintained closed and the first switch of the set of switches, the second switch of the set of switches, and the first DC-DC converter switch are maintained open providing the constant relatively low negative voltage at the AC output.
10. 10 . A battery pack, comprising: a set of battery cells including a first subset of battery cells and a second subset of battery cells; a DC output port; an AC output port; and a converter switch, the converter switch may be controlled and configured such that in a first configuration the first subset of battery cells and the second subset of battery cells are coupled in parallel and to the DC output port to provide a DC output signal and in a second configuration the first subset of battery cells and the second subset of battery cells are coupled in series and to the AC output port to provide an AC output signal.
11. 11 . The battery pack, as recited in claim 10 , further comprising a pack control module and wherein the converter switch includes a first terminal coupled to the pack control module allowing the pack control module to control the converter switch, a second terminal coupled to a negative terminal of the first subset of battery cells and a third terminal coupled to a positive terminal of the second subset of battery cells.
12. 12 . The battery pack, as recited in claim 11 , wherein the pack control module controls the converter switch to the first configuration and the first subset of battery cells and the second subset of battery cells are coupled to the DC output port to provide two DC signals to the DC output port.
13. 13 . The battery pack, as recited in claim 12 , further comprising an inverter coupled to the set of battery cells, an inverter activation switch, and a user inverter on/off switch, the inverter, the inverter activation switch and the user inverter on/off switch coupled to the pack control module, wherein the user inverter on/off switch being in an on position, the pack control module controls the converter switch to the second configuration and closes the inverter activation switch to couple the inverter to the AC output port and provide the AC output signal to the AC output port.
14. 14 . The battery pack, as recited in claim 13 , wherein the inverter includes a first inverter transistor and a second inverter transistor, and wherein the inverter activation switch includes a first inverter activation switch and a second inverter activation switch and the first inverter activation switch is coupled between the first inverter transistor and a line terminal of the AC output port and the second inverter activation switch is coupled between the second inverter transistor and a neutral terminal of the AC output port.
15. 15 . The battery pack, as recited in claim 14 , further comprising a first DC-DC converter and a first DC-DC converter switch and a second DC-DC converter and a second DC-DC converter switch, the first DC-DC converter and the first DC-DC converter switch coupled between a positive node of the set of battery cells and the line terminal of the AC output port and the second DC-DC converter and the second DC-DC converter switch coupled between the neutral terminal of the AC output port and a negative node of the set of battery cells.
16. 16 . The battery pack, as recited in claim 10 , wherein the battery pack is alternatively couplable to a DC power driven device coupled to the DC output port and a AC power drive device coupled to the AC output port.
17. 17 . The battery pack, as recited in claim 10 , wherein each subset of battery cells includes forty-five battery cells and each battery cell has a nominal voltage of approximately 3.8 volts.

Description

CROSS-REFERENCE TO RELATED APPLICATION This application is a continuation of U.S. patent application Ser. No. 16/376,810, filed Apr. 4, 2019, entitled, “BATTERY PACK, POWER TOOL AND BATTERY PACK CHARGER SYSTEM,” which is a continuation of PCT Application No. PCT/US2017/055619, filed Oct. 6, 2017, entitled “BATTERY PACK, POWER TOOL AND BATTERY PACK CHARGER SYSTEM,” which claims priority to PCT Application No. PCT/US2017/054857, filed Oct. 3, 2017, entitled “BATTERY AND MOTOR SYSTEM FOR REPLACING INTERNAL COMBUSTION ENGINE,” together with U.S. Provisional Application No. 62/404,999, filed on Oct. 6, 2016, entitled, “BATTERY PACK, POWER TOOL AND BATTERY PACK CHARGER SYSTEM” and U.S. Provisional Application No. 62/405,118, filed on Oct. 6, 2016, entitled, “BATTERY AND MOTOR SYSTEM FOR REPLACING INTERNAL COMBUSTION ENGINE.” TECHNICAL FIELD This application relates to a system including a battery pack, a direct current (DC) power tool and a battery pack charger and a method of operating the battery pack, power tool and battery pack charger. In one implementation, the battery pack includes a high voltage battery bank, a DC output port and an alternating current (AC) output port, a switching network for generating an AC waveform from the battery bank and configured to simultaneously provide an AC output waveform at the AC output port and a DC output waveform at the DC output port. BACKGROUND When providing alternating current (AC) power to operate AC powered devices such as power tools (such as drills, table saws, miter saws), equipment (such as lawn mowers), and consumer products (such as refrigerators, television, lights) without being tied to a fixed utility power supply typically requires a generator (such as an internal combustion engine based generator) or a battery powered inverter. In order to meet power and runtime needs for these devices, a battery powered inverter must be relatively large and expensive. This simple fact prohibits their use in many environments. Referring to FIG. 1, common AC voltage in the US and elsewhere globally is approximately 120 volts AC. This value is a root-mean squared (RMS) value that will provide an equal value to that of a direct current (DC) power source powering a resistive load. The peaks of the 120V AC sine wave are a 170V. There are common methods for producing a waveform to run an AC product, including a pure sine wave, a square wave, and a modified sine wave. An inverter that produces a pure sine wave will attempt replicate the AC waveform produced by a utility power supply. It will likely run any product without issue. However, it requires expensive and large electronic components (i.e. inductors, transformers) to provide such a clean, consistent waveform. An inverter that produces a square wave will match the RMS of the 120V AC utility power supply but the shape of the waveform may cause issues with some AC products, such as products with particularly sensitive electronics, electronic drives, audio, and induction motors. This inverter uses inexpensive and small electronics relative to the pure sine wave inverter. An inverter that produces a modified sine wave will match the RMS of the 120V AC utility power supply and is generally able to run a wider range of AC products, but may have issue operating products with variable speed control and electronics that require a ‘zero-cross’ at line frequency (i.e. ‘60 Hz’). This inverter also uses inexpensive and small electronics relative to the pure sine wave inverter. Typical battery based inverters use low voltage batteries or a bank of battery cells or packs, such as a 12V DC battery pack or a plurality of cells strung together to produce 12V DC as compared to the 120V AC of a utility power supply. With reference to FIG. 2, to increase the battery voltage level to a level necessary to achieve the necessary higher AC voltage waveform, these inverters require a DC to DC converter (also known as a boost converter) between the battery and the inverter circuit. The converter electronics are also large, expensive, and add heat to the system. One system which utilizes a high voltage battery bank to achieve the necessary DC voltage level without a boost converter is disclosed in U.S. Pat. No. 8,994,336. This system then inverts the high voltage DC waveform to a high voltage AC waveform for use by AC powered devices. Thermal management of the boost converter and/or the inverter circuitry typically requires a significant increase in the physical size of the inverter. As such, conventional systems have either required a boost converter in conjunction with a low voltage battery to produce a high voltage DC signal and an inverter of some type to produce the high voltage AC signal to power AC powered devices or a high voltage battery bank and an inverter of some type to produce the high voltage AC signal to power AC powered devices. Typical inverters, whether using a low voltage DC battery and a boost converter or a high voltage battery