Portable Vehicle Battery Jump Start Apparatus With Safety Protection

Abstract

A handheld jump starter device includes a rechargeable lithium battery pack comprising at least three lithium battery cells, a housing for enclosing the rechargeable lithium battery pack, and a jumper cable assembly removably attachable to the housing, the jumper cable assembly comprising a plug and a pair of cables, wherein the plug is configured to attach to the housing in a specific orientation.

Claims

1. A handheld jump starter device, comprising: a rechargeable lithium battery pack comprising at least three lithium battery cells; a housing for enclosing the rechargeable lithium battery pack; and a jumper cable assembly removably attachable to the housing, the jumper cable assembly comprising a plug and a pair of cables, wherein the plug is configured to attach to the housing in a specific orientation; wherein the jump starter device is configured to detect at least: (1) an over-temperature condition of the rechargeable lithium battery pack; (2) an over-charge condition of the rechargeable lithium battery pack; and (3) an over-discharge condition of the rechargeable lithium battery pack.

2. The handheld jump starter device of claim 1, a power switch coupled between the rechargeable lithium battery pack and an output port, the power switch allowing jump starter current to flow from the rechargeable lithium battery pack to the output port when activated.

3. The handheld jump starter device of claim 1, wherein the plug has a substantially uniform width.

4. The handheld jump starter device of claim 2, further comprising a control circuit coupled to the power switch and configured to control activation of the power switch to allow jump starter current to flow from the rechargeable lithium battery pack to the output port.

5. The handheld jump starter device of claim 4, further comprising a vehicle battery presence sensor coupled to the output port for detecting the presence of a vehicle battery and for providing a detection signal to the control circuit.

6. The handheld jump starter device of claim 5, wherein the control circuit responds to the detection signal and activates the power switch when a vehicle battery is detected at the output port.

7. The handheld jump starter device of claim 4, further comprising a battery temperature sensor for detecting a temperature of the rechargeable lithium battery pack.

8. The handheld jump starter device of claim 7, wherein the control circuit prevents discharging of the rechargeable lithium battery pack when the battery temperature sensor detects a temperature above a high temperature threshold.

9. The handheld jump starter device of claim 1, wherein the housing comprises an LED light assembly configured to operate in at least three modes, a first mode being a flashlight mode, a second mode being an SOS mode, and a third mode being a strobe mode.

10. The handheld jump starting device of claim 1, wherein the housing is rectangular in shape, having a series of raised indentations on both long sides of the rectangular-shaped housing in order for the handheld jump starting device to be grasped by a hand.

11. The handheld jump starting device of claim 1, wherein the housing includes a user interface comprising an LED fuel gauge indicating a battery capacity of the rechargeable lithium battery pack, the fuel gauge comprising at least 4 LED indicator lights that indicate, respectively, 25% charge, 50% charge, 75% charge and 100% charge of the rechargeable lithium battery pack.

12. The handheld jump starting device of claim 1, further comprising: a manual override button for forcing the handheld jump starting device to apply jump starter current from the rechargeable lithium battery pack through the jumper cable assembly, the manual override button enabling jump starting of a vehicle attached to the jumper cable assembly when a vehicle battery is either missing or deeply depleted so as to be undetectable by the jump starter device, wherein the manual override button must be pressed for a predetermined period of time in order to prevent inadvertent actuation of the forcing function.

13. A handheld jump starter device, comprising: a rechargeable lithium battery pack comprising at least three lithium battery cells; a housing for enclosing the rechargeable lithium battery pack; and a jumper cable assembly removably attachable to the housing, the jumper cable assembly comprising a plug and a pair of cables, wherein the plug is configured to attach to the housing in a specific orientation, wherein the housing comprises an LED light assembly configured to operate in at least three modes, a first mode being a flashlight mode, a second mode being an SOS mode, and a third mode being a strobe mode.

14. A handheld jump starter device, comprising: a rechargeable lithium battery pack comprising at least three lithium battery cells; a housing for enclosing the rechargeable lithium battery pack; and a jumper cable assembly removably attachable to the housing, the jumper cable assembly comprising a plug and a pair of cables, wherein the plug is configured to attach to the housing in a specific orientation; wherein the housing is rectangular in shape, having a series of raised indentations on both long sides of the rectangular shaped housing in order for the handheld jump starter device to be grasped by a hand.

15. A handheld jump starter device, comprising: a rechargeable lithium battery pack comprising at least three lithium battery cells; a housing for enclosing the rechargeable lithium battery pack; and a jumper cable assembly removably attachable to the housing, the jumper cable assembly comprising a plug and a pair of cables, wherein the plug is configured to attach to the housing in a specific orientation; wherein the housing includes a user interface comprising an LED fuel gauge indicating the battery capacity of the rechargeable lithium battery pack, the fuel gauge comprising at least 4 LED indicator lights that indicate, respectively, 25% charge, 50% charge, 75% charge and 100% charge of the rechargeable lithium battery pack.

16. A handheld jump starter device, comprising: a rechargeable lithium battery pack comprising at least three lithium battery cells; a housing for enclosing the rechargeable lithium battery pack; and a jumper cable assembly removably attachable to the housing, the jumper cable assembly comprising a plug and a pair of cables, wherein the plug is configured to attach to the housing in a specific orientation; and a manual override button for forcing the jump starter to apply jump starter current from the rechargeable lithium battery pack through the jumper cable assembly, the manual override button enabling the jump starting of a vehicle attached to the jumper cable assembly when the vehicle's battery is either missing or deeply depleted so as to be undetectable by the handheld jump starter device, wherein the manual override button must be pressed for a predetermined period of time in order to prevent inadvertent actuation of the forcing function.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0019] FIG. 1 is a functional block diagram of a handheld vehicle battery boost apparatus in accordance with one aspect of the present invention;

[0020] FIGS. 2A-DC are schematic circuit diagrams of an example embodiment of a handheld vehicle battery boost apparatus in accordance with an aspect of the invention;

[0021] FIG. 3 is a perspective view of a handheld jump starter booster device in accordance with one example embodiment of the invention; and

[0022] FIG. 4 is a plan view of a jumper cable usable with the handheld jump starter booster device in accordance with another aspect of the invention.

DETAILED DESCRIPTION

[0023] FIG. 1 is a functional block diagram of a handheld battery booster according to one aspect of the invention. At the heart of the handheld battery booster is a lithium polymer battery pack 32, which stores sufficient energy to jump start a vehicle engine served by a conventional 12 volt lead-acid or valve regulated lead-acid battery. In one example embodiment, a high-surge lithium polymer battery pack includes three 3.7V, 2666 mAh lithium polymer batteries in a 3S1P configuration. The resulting battery pack provides 11.1V, 2666 Ah (8000 Ah at 3.7V, 29.6 Wh). Continuous discharge current is 25C (or 200 amps), and burst discharge current is 50C (or 400 amps). The maximum charging current of the battery pack is 800 0mA (8 amps).

[0024] A programmable microcontroller unit (MCU) 1 receives various inputs and produces informational as well as control outputs. The programmable MCU 1 further provides flexibility to the system by allowing updates in functionality and system parameters, without requiring any change in hardware. According to one example embodiment, an 8 bit microcontroller with 2K15 bits of flash memory is used to control the system. One such microcontroller is the HT67F30, which is commercially available from Holtek Semiconductor Inc.

[0025] A car battery reverse sensor 10 monitors the polarity of the vehicle battery 72 when the handheld battery booster device is connected to the vehicle's electric system. As explained below, the booster device prevents the lithium battery pack from being connected to the vehicle battery 72 when the terminals of the battery 72 are connected to the wrong terminals of the booster device. A car battery isolation sensor 12 detects whether or not a vehicle battery 72 is connected to the booster device, and prevents the lithium battery pack from being connected to the output terminals of the booster device unless there is a good (e.g. chargeable) battery connected to the output terminals.

[0026] A smart switch FET circuit 15 electrically switches the handheld battery booster lithium battery to the vehicle's electric system only when the vehicle battery is determined by the MCU 1 to be present (in response to a detection signal provided by isolation sensor 12) and connected with the correct polarity (in response to a detection signal provided by reverse sensor 10). A lithium battery temperature sensor 20 monitors the temperature of the lithium battery pack 32 to detect overheating due to high ambient temperature conditions and overextended current draw during jump starting. A 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 dropping too low during a discharge operation.

[0027] Lithium battery back-charge protection diodes 28 prevent any charge current being delivered to the vehicle battery 72 from flowing back to the lithium battery pack 32 from the vehicle's electrical system. Flashlight LED circuit 36 is provided to furnish a flashlight function for enhancing light under a vehicle's hood in dark conditions, as well as providing SOS and strobe lighting functions for safety purposes when a vehicle may be disabled in a potentially dangerous location. Voltage regulator 42 provides regulation of internal operating voltage for the microcontroller and sensors. On/Off manual mode and flashlight switches 46 allow the user to control power-on for the handheld battery booster device, to control manual override operation if the vehicle has no battery, and to control the flashlight function. The manual button functions only when the booster device is powered on. This button allows the user to jump-start vehicles that have either a missing battery, or the battery voltage is so low that automatic detection by the MCU is not possible. When the user presses and holds the manual override button for a predetermined period time (such as three seconds) to prevent inadvertent actuation of the manual mode, the internal lithium ion battery power is switched to the vehicle battery connect port. The only exception to the manual override is if the car battery is connected in reverse. If the car battery is connected in reverse, the internal lithium battery power shall never be switched to the vehicle battery connect port.

[0028] USB charge circuit 52 converts power from any USB charger power source, to charge voltage and current for charging the lithium battery pack 32. USB output 56 provides a USB portable charger for charging smartphones, tablets, and other rechargeable electronic devices. Operation indicator LEDs 60 provide visual indication of lithium battery capacity status as well as an indication of smart switch activation status (indicating that power is being provided to the vehicle's electrical system).

[0029] Detailed operation of the handheld booster device will now be described with reference to the schematic diagrams of FIGS. 2A-DC. As shown in FIG. 2A, the microcontroller unit 1 is the center of all inputs and outputs. The reverse battery sensor 10 comprises an optically coupled isolator phototransistor (4N27) connected to the terminals of vehicle battery 72 at input pins 1 and 2 with a diode D8 in the lead conductor of pin 1 (associated with the negative terminal CB), such that if the battery 72 is connected to the terminals of the booster device with the correct polarity, the optocoupler LED 11 will not conduct current, and is therefore turned off, providing a 1 or high output signal to the MCU 1. The car battery isolation sensor 12 comprises an optically coupled isolator phototransistor (4N27) connected to the terminals of vehicle battery 72 at input pins 1 and 2 with a diode D7 in the lead conductor of pin 1 (associated with the positive terminal CB+), such that if the battery 72 is connected to the terminals of the booster device with the correct polarity, the optocoupler LED 11A will conduct current, and is therefore turned on, providing a 0 or low output signal to the MCU, indicating the presence of a battery across the jumper output terminals of the handheld booster device.

[0030] If the car battery 72 is connected to the handheld booster device with reverse polarity, the optocoupler LED 11 of the reverse sensor 10 will conduct current, providing a 0 or low signal to microcontroller unit 1. Further, if no battery is connected to the handheld booster device, the optocoupler LED 11A of the isolation sensor 12 will not conduct current, and is therefore turned off, providing a 1 or high output signal to the MCU, indicating the absence of any battery connected to the handheld booster device. Using these specific inputs, the microcontroller software of MCU 1 can determine when it is safe to turn on the smart switch FET 15, thereby connecting the lithium battery pack to the jumper terminals of the booster device. Consequently, if the car battery 72 either is not connected to the booster device at all, or is connected with reverse polarity, the MCU 1 can keep the smart switch FET 15 from being turned on, thus prevent sparking/short circuiting of the lithium battery pack.

[0031] As shown in FIG. 2B, the FET smart switch 15 is driven by an output of the microcontroller 1. The FET smart switch 15 includes three FETs (Q15, Q18, and Q19) in parallel, which spreads the distribution of power from the lithium battery pack over the FETs. When that microcontroller output is driven to a logic low, FETs 16 are all in a high resistance state, therefore not allowing current to flow from the internal lithium battery negative contact 17 to the car battery 72 negative contact. When the microcontroller output is driven to a logic high, the FETs 16 (Q15,Q18, and Q19) are in a low resistant state, allowing current to flow freely from the internal lithium battery pack negative contact 17 (LB) to the car battery 72 negative contact (CB). In this way, the microcontroller software controls the connection of the internal lithium battery pack 32 to the vehicle battery 72 for jumpstarting the car engine.

[0032] Referring back to FIG. 2A, the internal lithium battery pack voltage can be accurately measured using circuit 24 and one of the analog-to-digital inputs of the microcontroller 1. Circuit 24 is designed to sense when the main 3.3V regulator 42 voltage is on, and to turn on transistor 23 when the voltage of regulator 42 is on. When transistor 23 is conducting, it turns on FET 22, thereby providing positive contact (LB+) of the internal lithium battery a conductive path to voltage divider 21 allowing a lower voltage range to be brought to the microcontroller to be read. Using this input, the microcontroller software can determine if the lithium battery voltage is too low during discharge operation or too high during charge operation, and take appropriate action to prevent damage to electronic components.

[0033] Still referring to FIG. 2A, the temperature of the internal lithium battery pack 32 can be accurately measured by two negative temperature coefficient (NTC) devices 20. These are devices that reduce their resistance when their temperature rises. The circuit is a voltage divider that brings the result to two analog-to-digital (A/D) inputs on the microcontroller 1. The microcontroller software can then determine when the internal lithium battery is too hot to allow jumpstarting, adding safety to the design.

[0034] The main voltage regulator circuit 42 is designed to convert internal lithium battery voltage to a regulated 3.3 volts that is utilized by the microcontroller 1 as well as by other components of the booster device for internal operating power. Three lithium battery back charge protection diodes 28 (see FIG. 2B) are in place to allow current to flow only from the internal lithium battery pack 32 to the car battery 72, and not from the car battery to the internal lithium battery. In this way, if the car electrical system is charging from its alternator, it cannot back-charge (and thereby damage) the internal lithium battery, providing another level of safety.

[0035] The main power on switch 46 (FIG. 2A) is a combination that allows for double pole, double throw operation so that with one push, the product can be turned on if it is in the off state, or turned off if it is in the on state. This circuit also uses a microcontroller output 47 to keep alive the power when it is activated by the on switch. When the switch is pressed the microcontroller turns this output to a high logic level to keep power on when the switch is released. In this way, the microcontroller maintains control of when the power is turned off when the on/off switch is activated again or when the lithium battery voltage is getting too low. The microcontroller software also includes a timer that turns the power off after a predefined period of time, (such as, e.g. 8 hours) if not used.

[0036] The flashlight LED circuit 45 shown in FIG. 2B controls the operation of flashlight LEDs. Two outputs from the microcontroller 1 are dedicated to two separate LEDs. Thus, the LEDs can be independently software-controlled for strobe and SOS patterns, providing yet another safety feature to the booster device. LED indicators provide the feedback the operator needs to understand what is happening with the product. Four separate LEDs 61 (FIG. 2A) are controlled by corresponding individual outputs of microcontroller 1 to provide indication of the remaining capacity of the internal lithium battery. These LEDs are controlled in a fuel gauge type format with 25%, 50%, 75% ad 100% (red, red, yellow, green) capacity indications. An LED indicator 63 (FIG. 2B) provides a visual warning to the user when the vehicle battery 72 has been connected in reverse polarity. Boost and on/off LEDs 62 provide visual indications when the booster device is provide jump-start power, and when the booster device is turned on, respectively.

[0037] A USB output 56 circuit (FIG. DC) is included to provide a USB output for charging portable electronic devices such as smartphones from the internal lithium battery pack 32. Control circuit 57 from the microcontroller 1 allows the USB Out 56 to be turned on and off by software control to prevent the internal lithium battery getting too low in capacity. The USB output is brought to the outside of the device on a standard USB connector 58, which includes the standard voltage divider required for enabling charge to certain smartphones that require it.

[0038] The USB charge circuit 52 allows the internal lithium battery pack 32 to be charged using a standard USB charger. This charge input uses a standard micro-USB connector 48 allowing standard cables to be used. The 5V potential provided from standard USB chargers is up-converted to the 12.4 VDC voltage required for charging the internal lithium battery pack using a DC-DC converter 49. The DC-DC converter 49 can be turned on and off via circuit 53 by an output from the microcontroller 1.

[0039] In this way, the microcontroller software can turn the charge off if the battery voltage is measured to be too high by the A/D input 22. Additional safety is provided for helping to eliminate overcharge to the internal lithium battery using a lithium battery charge controller 50 that provides charge balance to the internal lithium battery cells 51. This controller also provides safety redundancy for eliminating over discharge of the internal lithium battery.

[0040] FIG. 3 is a perspective view of a handheld device 300 in accordance with an exemplary embodiment of the invention. 301 is a power on switch. 302 shows the LED fuel gauge indicators 61. 303 shows a 12 volt output port connectable to a cable device 400, described further below. 304 shows a flashlight control switch for activating flashlight LEDs 45. 305 is a USB input port for charging the internal lithium battery, and 306 is a USB output port for providing charge from the lithium battery to other portable devices such as smartphones, tablets, music players, etc. 307 is a boost on indicator showing that power is being provided to the 12V output port. 308 is a reverse indicator showing that the vehicle battery is improperly connected with respect to polarity. 309 is a power on indicator showing that the device is powered up for operation.

[0041] FIG. 4 shows a jumper cable device 400 specifically designed for use with the handheld device 300. Device 400 has a plug 401 configured to plug into 12 volt output port 303 of the handheld device 300. A pair of cables 402a and 402b are integrated with the plug 401, and are respectively connected to battery terminal clamps 403a and 403b via ring terminals 404a and 404b. The port 303 and plug 401 may be dimensioned so that the plug 401 will only fit into the port 303 in a specific orientation, thus ensuring that clamp 403a will correspond to positive polarity, and clamp 403b will correspond to negative polarity, as indicated thereon. Additionally, the ring terminals 404a and 404b may be disconnected from the clamps and connected directly to the terminals of a vehicle battery. This feature may be useful, for example, to permanently attach the cables 302a-302b to the battery of a vehicle. In the event that the battery voltage becomes depleted, the handheld booster device 300 could be properly connected to the battery very simply by plugging in the plug 401 to the port 303.

[0042] The invention having been thus described, 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 encompassed within the scope of the following claims.