Charger having a Charging Electronics Unit and a Cooling-Air-Guiding Structure

Abstract

A charger includes a charger housing with at least one battery-charging space accessible from the outside for positioning of a rechargeable battery unit, a charging electronics unit in the charger housing for controlling an electrical charging operation for the battery unit positioned on the battery-charging space, and a cooling-air-guiding structure configured for guiding a cooling-air flow from an air inlet structure of the charger housing via the charging electronics unit to an air outlet structure of the charger housing. The cooling-air-guiding structure has a cooling housing arranged in the interior of the charger housing and has a cooling housing air inlet structure and a cooling housing air outlet structure, and is configured for guiding the cooling-air flow through the cooling housing from the cooling housing air inlet structure to the cooling housing air outlet structure and from the latter to the air outlet structure of the charger housing. The charging electronics unit has at least one electronic component which is arranged in the cooling housing. Use may be for electrically charging rechargeable battery packs for electrically operated garden and forestry working apparatus.

Claims

1. A charger, comprising: a charger housing having at least one battery-charging space which is accessible from outside for positioning of a rechargeable battery unit; a charging electronics unit in the charger housing for controlling an electrical charging operation for the battery unit positioned on the battery-charging space; and a cooling-air-guiding structure which is configured for guiding a cooling-air flow from an air inlet structure of the charger housing via the charging electronics unit to an air outlet structure of the charger housing, wherein the cooling-air-guiding structure comprises a cooling housing which is arranged in the interior of the charger housing and has a cooling housing air inlet structure and a cooling housing air outlet structure and is configured for guiding the cooling-air flow through the cooling housing from the cooling housing air inlet structure to the cooling housing air outlet structure and from the latter to the air outlet structure of the charger housing, and the charging electronics unit has at least one electronic component which is arranged in the cooling housing.

2. The charger according to claim 1, wherein the cooling housing air inlet structure and the cooling housing air outlet structure are each formed locally on two different side or corner regions of the cooling housing.

3. The charger according to claim 1, wherein the cooling housing is fireproof.

4. The charger according to claim 1, wherein the charging electronics unit comprises at least one further electronic component which is located outside the cooling housing.

5. The charger according to claim 1, wherein the charging electronics unit has a power electronics part and/or a switchover electronics part as the electronic component arranged in the cooling housing.

6. The charger according to claim 1, wherein the cooling housing adjoins with its cooling housing air outlet structure to the air outlet structure of the charger housing.

7. The charger according to claim 1, wherein the cooling housing air inlet structure comprises two air inlet zones on two mutually adjacent side regions of the cooling housing.

8. The charger according to claim 1, wherein the cooling housing has two opposite main sides and a narrow side circumference connecting them, and the cooling housing air inlet structure and the cooling housing air outlet structure are formed on the narrow side circumference.

9. The charger according to claim 1, wherein the electronic component which is arranged in the cooling housing is arranged on one of two opposite main sides of the cooling housing.

10. The charger according to claim 1, wherein the cooling-air-guiding structure comprises a fan which is arranged adjacent upstream or downstream to the cooling housing air outlet structure.

11. The charger according to claim 1, wherein the air inlet structure of the charger housing is designed as a delocalized air inlet structure and comprises a plurality of air inlets which are distributed on at least one side region of the charger housing throughout the extent of the area thereof.

12. The charger according to claim 1, wherein the air inlet structure of the charger housing is designed as a delocalized air inlet structure and comprises a plurality of air inlets which are formed on at least two opposite side regions of the charger housing.

13. The charger according to claim 11, wherein at least one of the air inlets is located on a bottom side of the charger housing in a use position of the charger housing and forms a water outlet opening.

14. The charger according to claim 12, wherein at least one of the air inlets is located on a bottom side of the charger housing in a use position of the charger housing and forms a water outlet opening.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0028] FIG. 1 shows a perspective view of a charger obliquely from above having a charger housing with a lower and an upper housing shell in a use position of the charger;

[0029] FIG. 2 shows a sectional view of the charger along a line II-II in FIG. 1;

[0030] FIG. 3 shows a perspective view of a charging electronics unit which is accommodated in the charger housing and has a cooling housing;

[0031] FIG. 4 shows a perspective view of the charger obliquely from below;

[0032] FIG. 5 shows a longitudinal sectional view of a battery-charging space of the charger housing;

[0033] FIG. 6 shows a top view of the battery-charging space with an inserted battery unit;

[0034] FIG. 7 shows a detailed sectional view of a lower region of a battery-charging space of the charger housing;

[0035] FIG. 8 shows a perspective view of the charger obliquely from below without the lower housing shell; and

[0036] FIG. 9 shows a perspective view of the charger obliquely from above with the upper housing shell half cut away and without the lower housing shell.

DETAILED DESCRIPTION OF THE DRAWINGS

[0037] The charger according to the invention which is shown by way of example in a possible embodiment in the figures includes a charger housing 1 having at least one battery-charging space which is accessible from the outside for the positioning of a rechargeable battery unit, in the example shown four battery-charging spaces 2.sub.1, 2.sub.2, 2.sub.3, 2.sub.4, and a charging electronics unit 3 for controlling an electrical charging operation for the battery unit positioned at the respective battery-charging space 2.sub.1 to 2.sub.4. FIG. 1 shows the charger having four battery units 14 fitted into the four battery-charging spaces 2.sub.1 to 2.sub.4. A charging electronics unit 3 for controlling an electrical charging operation for the battery unit 14 positioned on the respective battery-charging space 2.sub.1 to 2.sub.4 is located in the charger housing 1.

[0038] Furthermore, the charger includes a cooling-air-guiding structure 4 which is configured for guiding a cooling-air flow 5 from an air inlet structure 6 of the charger housing 1 via the charging electronics unit 3 to an air outlet structure 7 of the charger housing 1. The cooling-air-guiding structure 4 includes a cooling housing 8 which is arranged in the interior of the charger housing 1 and has a cooling housing air inlet structure 9 and a cooling housing air outlet structure 10.

[0039] In the example shown, the charger housing is configured in cuboid form, i.e. with a square cross section, in particular is approximately cube-shaped. In alternative embodiments, the charger housing 1 has a different configuration, for example with a round or oval cross section or with a polygonal cross section with more than four corners. In the example shown, the four battery-charging spaces 2.sub.1 to 2.sub.4 are arranged in a square constellation, as is apparent, for example, from FIGS. 1 and 8. The cooling housing 8 is positioned approximately centrally in the charger housing 1 between in each case two of the four battery-charging spaces 2.sub.1 to 2.sub.4 and extends substantially over virtually the entire length and at least in sections over virtually the entire height of the charger housing 1, as is apparent in particular from FIGS. 8 and 9. Outer sides of the cooling housing 8 run approximately parallel here to outer sides of the charger housing 1.

[0040] The cooling-air-guiding structure 4 is configured for guiding the cooling-air flow 5 through the cooling housing 8 from the cooling housing air inlet structure 9 to the cooling housing air outlet structure 10 and from the latter to the air outlet structure 7. The charging electronics unit 3 has at least one electronic component 11.sub.1 which is arranged in the cooling housing 8, as illustrated schematically in FIG. 2.

[0041] In corresponding realizations, the cooling housing air inlet structure 9 and the cooling housing air outlet structure 10, as in the example shown, are each formed locally on two different side or corner regions of the cooling housing 8. In the example shown, the air inlet structure 9 of the cooling housing 8 is formed in the cooling housing 8 on a left upper side/corner region 8.sub.3 in FIGS. 2 and 3 and the air outlet structure 10 opposite on a right lower side/corner region 8.sub.4 in FIGS. 2 and 3. The cooling-air flow 5 can thereby flow optimally as it were longitudinally or diagonally through the entire cooling housing 8.

[0042] In advantageous embodiments, the cooling housing 8, as in the example shown, is fireproof, i.e. the material used for the cooling housing 8 is resistant to temperatures of at least 850° C. without catching fire. This avoids the charger catching fire if the electronic component 11.sub.1 accommodated in the cooling housing 8 heats up excessively, for example because of a defect or an overload situation.

[0043] In corresponding realizations, the charging electronics unit 3, as in the example shown, has at least one further electronic component 11.sub.2 which is located outside the cooling housing 8 and can be seen schematically, for example, in FIGS. 2, 3 and 9. Said electronic component 11.sub.2 outside the cooling housing 8 can be, for example, a microcontroller which only generates a small amount of heat during operation and therefore does not necessarily need to be cooled by the cooling-air flow 5. In alternative embodiments, the microcontroller is also located inside the cooling housing 8.

[0044] In corresponding embodiments, the charging electronics unit 3 comprises a power electronics part and/or a switchover electronics part as the at least one electronic component 11.sub.1 which is arranged in the cooling housing 8. In the example shown, both a power electronics part 12 and a switchover electronics part 13 each of conventional design are located in the cooling housing 8, as can be seen schematically in FIG. 2.

[0045] In advantageous embodiments, the cooling housing 8 adjoins by means of its cooling housing air outlet structure 10 to the air outlet structure 7 of the charger housing 1, as is also the case in the example shown and can be seen in particular from FIG. 2. In alternative embodiments, the air outlet structures 10, 7 of cooling housing 8 and charger housing 1 are arranged spaced apart from each other such that the cooling-air flow 5 after emerging from the cooling housing 8 first of all still flows in the charger housing 1 as far as its air outlet structure 7 before it leaves the charger housing 1.

[0046] In corresponding realizations, the cooling housing air inlet structure 9 includes at least two air inlet zones on two mutually adjacent side regions of the cooling housing 8. This permits an air entry, which is favorable in corresponding applications, into the cooling housing 8 on two adjacent housing sides. In the example shown, it includes one air inlet zone 9.sub.1, 9.sub.2 on each of two adjacent narrow side regions 8.sub.1, 8.sub.2 of the cooling housing 8. In alternative embodiments, the two adjacent side regions are different sides of the cooling housing 8.

[0047] In corresponding embodiments, the cooling housing 8, as in the example shown, has two opposite main sides 8a, 8b and a narrow side circumference 8c connecting them, wherein the cooling housing air inlet structure 9 and the cooling housing air outlet structure 10 are formed on the narrow side circumference 8c, i.e. at suitable points of the circumference around the cooling housing 8 between the two opposite main sides 8a, 8b. As a result, the cooling-air flow 5, as is apparent from FIG. 2, can flow over its entire flow length in the cooling housing 8 substantially parallel to the main sides 8a, 8b without having to be deflected in a direction perpendicular to the main sides 8a, 8b. This is of advantage for the cooling efficiency of the cooling-air flow 5 in many applications. Alternatively, it can be provided, for example, that the air inlet structure 9 or the air outlet structure 10 of the cooling housing 8 is formed on one of its two main sides 8a, 8b.

[0048] In advantageous embodiments, the electronic component 11.sub.1 which is arranged in the cooling housing 8 is arranged on one of two opposite main sides of the cooling housing 8. Specifically, in the example shown, it is arranged on the rear main side 8b in FIG. 3. This is of advantage in particular if, as in the example shown, the charging electronics unit 3 has a printed circuit board constructional form, i.e. has one or more printed circuit boards 16.sub.1, 16.sub.2 which is or are populated with the diverse components of the charging electronics unit 3 since, in this case, the one or more printed circuit boards 16.sub.1, 16.sub.2 can simultaneously contribute in the form of a wall for the relevant main side of the cooling housing 8. In most cases, it is favorable in this connection if the one or more printed circuit boards 16.sub.1, 16.sub.2, as in the example shown, are mounted on a carrier plate 17 which closes off the cooling housing 8 on the relevant main side 8b completely or at any rate in an airtight manner to an extent such that the entry of air takes place primarily as desired via the air inlet structure 9 with the relevant air inlet zone or air inlet zones 9.sub.1, 9.sub.2 and is not disturbed by relatively large air leaks on this printed circuit board side of the cooling housing 8. The components of the charging electronics unit 3 that are mounted on the inner side on the printed circuit board or the printed circuit boards 16.sub.1, 16.sub.2 can then be effectively cooled by the cooling-air flow 5 if said components are located in the interior of the cooling housing 8. In this case, the remaining part of the cooling housing 8 forms a type of housing hood which is connected, preferably releasably, to the printed circuit board or the printed circuit boards 16.sub.1, 16.sub.2 and/or to the carrier plate 17 thereof.

[0049] In corresponding embodiments, the cooling-air-guiding structure 4, as in the example shown, has a fan 15 which is arranged upstream or downstream adjacent to the cooling housing air outlet structure 10. In the example shown, the fan 15 specifically sits in the air outlet region of the cooling housing 8, i.e. directly upstream of the cooling housing air outlet structure 10, as is apparent from FIGS. 2 and 8. In alternative embodiments, the fan can be positioned on the charger housing 1 in the region of the air outlet structure 7 thereof or in the air entry region of the cooling housing 8, i.e. upstream or downstream adjacent to the air inlet structure 9 thereof.

[0050] In corresponding realizations, the air inlet structure 6 of the charger housing 1 is designed, as in the example shown, as a delocalized air inlet structure and has a plurality of air inlets 18 which are distributed on at least one side region, in the example shown on a lower side 1a and on an upper side 1b, of the charger housing 1 over and throughout the extent of the area of this side region and/or are formed on at least two opposite side regions, in the example shown the lower side 1a and the upper side 1b, of the charger housing 1. By contrast, in the example shown, the air outlet structure 7 of the charger housing 1 is designed as a localized air outlet structure by being formed by a single air outlet slot structure with a plurality of closely adjacent parallel outlet slots.

[0051] In this embodiment, cooling air consequently enters the charger housing 1 in a correspondingly delocalized manner at the relatively large number of air entries 18 distributed over the charger housing 1, which results in a correspondingly undirected, diffuse cooling-air flow from the air inlet structure 6 of the charger housing 1 as far as the cooling housing air inlet structure 9, while the cooling air emerges out of the charger housing 1 as a directed cooling-air flow via the air outlet structure 7 with its localized air outlet slot structure. In alternative embodiments, the air inlet structure 6 of the charger housing 1, for example similarly as the air outlet structure 7 in the example shown, has a localized air inlet structure in the form of one or more spaced-apart air inlet zones or air inlet slot structures.

[0052] In addition, the air inlet structure 6 of the charger housing 1 can comprise air leaks which are consciously retained between mutually adjacent housing walls or housing parts of the charger housing 1. In the example shown, the charger housing 1 is composed of a lower housing shell 19.sub.1 and an upper housing shell 19.sub.2, and said two housing shells 19.sub.1, 19.sub.2 can be assembled with such air leaks being retained, for example with wall gaps or labyrinth seal regions being retained between the two housing shell walls.

[0053] In corresponding realizations, at least one of the air inlets, in the example shown these are a plurality of air inlets 18.sub.1, is located on a bottom side, in the example shown the bottom side la, of the charger housing 1 in a use position of the charger housing 1, wherein said respective air inlet 18.sub.1 at the same time forms a water outlet opening, i.e. water can flow out of the charger housing 1 via said air inlet 18.sub.1 if the charger housing 1 is in its use position shown, for example, in FIG. 1. For this additional function as a water outlet opening, the relevant air inlet 18.sub.1 is suitably configured, in particular by it being arranged on the bottom housing side 1a in the use position of the charger housing 1 at a water outlet point, which is preferably located as low down as possible, to which water which has penetrated the charger housing 1 or is formed therein can pass by means of corresponding water-conducting housing structures, in order to be able to be removed there.

[0054] In the example shown, further air inlets 18.sub.2 are formed at gap regions in the entry region of the respective battery-charging space 2.sub.1 to 2.sub.4 on the upper side 1b of the charger housing 1, as is apparent from FIGS. 5 and 6, for example in the region of a locking lever mechanism for releasably locking the battery unit 14 inserted into the respective battery-charging space 2.sub.1 to 2.sub.4. In the example shown, the battery-charging spaces 2.sub.1 to 2.sub.4 are formed by corresponding battery chambers of the charging housing 1. Furthermore, in the example shown, air inlets 18.sub.3 are configured in the form of gap regions in contact plates 20 on the bottom side of the respective battery-charging space 2.sub.1 to 2.sub.4 or battery shaft, as can be seen specifically from FIG. 7.

[0055] As the exemplary embodiments which have been shown and the further exemplary embodiments explained above make clear, the invention provides a charger which advantageously has a cooling-air-guiding structure which makes it possible to accommodate one or more electronic components of a charging electronics unit in a dedicated cooling housing inside the charger housing and to effectively subject same there to a cooling-air flow. The charger which is optimized in terms of cooling in such a manner can be used, for example, for electrically charging battery units or rechargeable battery packs for garden and forestry working apparatus and for DIY devices or hand-held tool devices.