AU2016201851A1 - Portable Power Supply Unit And Modular System Utilising Same - Google Patents

Abstract

A portable power supply unit including a housing having at least one deep cycle battery, at least one power inverter, at least one electrical safety switch to automatically shut off electricity when current is detected leaking from faulty switches, wiring or appliances, at least one power input connection, and at least one output connection to allow an external power cable to be connected to the housing as required to draw power from the unit as required. 12a Figure 3

Description

PORTABLE POWER SUPPLY UNIT AND MODULAR SYSTEM UTILISING SAME TECHNICAL FIELD

[0001] The present invention relates to a portable power supply unit and particularly to a power supply unit that provides electricity when and as required in an off grid situation.

BACKGROUND ART

[0002] When off grid, such as when boating, travelling and camping, a user may want to operate appliances such as lights, fridges and even televisions. To operate these appliances, the user will require a power source such as a generator or batteries and in the case of batteries, a mechanism for charging the batteries.

[0003] Automotive batteries are designed to provide a large burst of power and recharge quickly from an alternator, a shallow cycle, but are not designed to provide the slow steady discharge from running 12V appliances and the constant deep discharge and recharge.

[0004] Deep cycle batteries are designed with the ability run appliances for extended periods. They can be drained and charged repeatedly without destroying the battery. All batteries have a life span in terms of the number of recharges but quality deep cycle batteries can provide up to 500 - 1000 recharges.

[0005] At the heart of many power systems is a quality deep cycle battery or battery bank. A quality battery charger can ensure that the batteries are kept charged, without the risk of overcharging.

[0006] Many small automotive chargers are inadequate when it comes to charging large deep cycle batteries, especially when replacing large amounts of power drawn from the battery by high draw appliances. A 10 amp charger is capable of charging a large deep cycle battery overnight, which is ideal when running high draw appliances such as fridges and electric motors or when a mains power source operating at 240 volts to charge a battery bank. A smart charger will boost the battery rapidly up to about 70% and then gradually reduce the charge to avoid damaging the battery. Once the smart charger has completed its charging cycle, it drops to a safe ‘float’ voltage to maintain the batteries full charge, without overcharging.

[0007] Smaller battery chargers are suited for topping up a battery, but a 10 amp smart charger is a worthwhile investment when running fridges, electric motors and other high draw appliances or multiple pieces of equipment from a battery or battery bank.

[0008] Inverters change 12 volt DC (battery) power to 240 volt AC (household) power. This allows a user to operate 240 volt appliances from a 12 volt battery for mobile applications, emergencies or simple convenience. To run these appliances, the inverter must produce enough power to support the appliance.

[0009] Power inverters are generally small rectangular devices that have a wire lead with cigarette lighter plug, or alternatively alligator clips for connecting directly to a battery. The device normally has one or two outlets for standard electrical plugs.

[0010] When using a power inverter it is important to remember that the inverter is drawing power from the battery and battery levels should be monitored. A second, or separate, battery is ideal, as well as a means of charging such as a generator or solar.

[0011] There are two main types of inverters. Modified sine wave inverters deliver power that is consistent and efficient enough to run most devices fine. Due to price this type of inverter is the most popular. Modified sine wave inverters can cause minor buzzing on radios and minor buzzing and lines on televisions, but this can be overcome by using a pure sine wave inverter.

[0012] Pure sine wave inverters are the most expensive, but they also deliver power that is referred to as ‘clean’ or ‘pure’ power as there is no spikes or surges. Some sensitive equipment, like certain medical equipment and variable speed or rechargeable tools require pure sine. Any device will run on a pure sine wave, whether it requires it or not.

[0013] It will be clearly understood that, if a prior art publication is referred to herein, this reference does not constitute an admission that the publication forms part of the common general knowledge in the art in Australia or in any other country.

SUMMARY OF INVENTION

[0014] The present invention is directed to a portable power supply unit, which may at least partially overcome at least one of the abovementioned disadvantages or provide the consumer with a useful or commercial choice.

[0015] With the foregoing in view, the present invention in one form, resides broadly in a portable power supply unit including a housing having at least one deep cycle battery, at least one power inverter, at least one electrical safety switch to automatically shut off electricity when current is detected leaking from faulty switches, wiring or appliances, at least one electricity input connection, and at least one electricity output connection to allow an external power cable to be connected to the housing as required to draw electricity from the unit as required.

[0016] The portable power supply unit of the present invention can be used for any purpose. It is particularly preferred that the power supply unit is used for “off grid” apply when a mains power supply is not available. This will typically occur when a user is away from the mains power supply for fun or enjoyment such as camping or boating or similar or in times of natural disasters for example where the mains power supply can be lost for extended periods.

[0017] The power supply unit of the present invention is portable. Typically, the power supply unit will be small enough to allow two people to pick up and carry the power supply unit. A large portion of the weight of the power supply unit will be in the one or more deep cycle batteries. Therefore, the weight of the power supply unit can be adjusted by providing more or fewer deep cycle batteries in the unit. The number of deep cycle batteries in the unit will also typically define the size of the housing and there is no limitation intended on the size of housing or the weight of the unit.

[0018] It is preferred that the power supply unit of the present invention is able to power a number of items at once or provide power for a structure for example by connection to a mains power supply to the structure in place of a mains power supply which would normally be connected, but which is at least temporarily non-functioning.

[0019] The power supply unit of the present invention will be provided with adequate safety devices such as one or more circuit breakers, one or more safety switches and one or more fuse structures or assemblies.

[0020] The portable power supply unit of the present invention includes a housing. The housing is typically provided to contain other components therein and/or allow electricity inlets or outlets to be externally accessible on the housing.

[0021] Typically the housing will be provided in a form including a bottom containing portion with a lid or similar closure which can be opened and closed to allow access to the components within the housing. Normally, the lid or closure will seal the housing in order to protect the components inside the housing from inclement weather, dust or other detritus for example.

[0022] One or more closure mechanism will typically be provided in order to close the lid or closure and preferably seal the housing.

[0023] The bottom containing portion will preferably include a substantially planar base wall and a number of upstanding sidewalls extending therefrom. Normally, the bottom containing portion will be substantially rectangular and will therefore normally include four upstanding sidewalls. The sidewalls normally extend upward from the base wall at a substantially perpendicular angle. Normally, the sidewalls are each planar with an arcuate transition between the edges of each of the sidewalls, at the comers.

[0024] Preferably, the base wall and upstanding sidewalls are integrally formed, normally by vacuum forming or rotational moulding for example.

[0025] The bottom containing portion can be made from any material or combination of materials. Typically, the bottom containing portion is formed from at least one foamed material with one or more surface layers applied thereto, preferably on both sides. Normally, an interior plastic shell and exterior plastic shell are provided with a foam material core between the interior and exterior shells. Preferably, the interior plastic shell and exterior plastic shells seal the foam material core.

[0026] Preferably, an enlarged lip is provided at an upper end of the upstanding sidewalls in order to abut an underside of the lid or closure. One or more seals may be provided in association with the enlarged lip and/or the underside of the lid or closure.

[0027] One or more gripping portions or constructions may also be provided on the bottom containing portion in order to allow the container to be lifted and carried.

[0028] Normally, one or more openings are provided in one or more of the sidewalls and/or lid to allow access to the components located in the interior of the housing and/or to allow the components to extend through the sidewall or lid. Generally, components will be mounted into and preferably through one of the sidewalls of the bottom containing portion. In a particularly preferred embodiment, at least the input and output connections and any gauges or other componentry to which a user requires access on an ongoing basis in order to use the device, will be provided through one or more of the sidewalls and/or lid. Typically, the components mounted relative to the sidewalls and/or lid will be fixed in position relative to the sidewall and/or lid.

[0029] According to a particularly preferred form, for each through-wall component, a mounting plug is provided including a radially extending flange to abut the sidewall (normally an outer surface) and/or lid and an elongate tubular neck which extends into an opening formed in the sidewall and/or lid, into the interior of the housing. The elongate tubular neck will typically be threaded and a threaded nut or similar attachment member will normally be attached to the neck on the inside of the housing in order to hold the mounting plug in the sidewall and/or lid. The particular through-wall component is then normally provided with or attached to the mounting plug in order to allow the particular component to be accessible from the outside of the housing but remain fixed in position. One or more seals will normally be provided between the radially extending flange and an outer surface of the bottom containing portion.

[0030] Alternatively, a flange or mounting plate can be provided and attached directly to the containing portion using one or more fasteners, such as screws or similar. Again, one or more seals will normally be provided between the flange or mounting plate and an outer surface of the bottom containing portion.

[0031] The housing is preferably weatherproof or substantially weatherproof. Any opening in the housing and/or any through-wall component will typically be provided with a seal or cover or other type of deflection or prevention apparatus which will prevent inclement weather or dust or detritus or similar from entry into the interior of the housing. The housing is preferably provided with one or more closure mechanisms in order to releasably close and preferably seal the lid to the bottom containing portion. Any type of closures can be used and any number of closures can be used. In particular, the closures may be or include one or more clips, clamps, catches, latches or the like.

[0032] According to a particularly preferred embodiment, a pair of closures is provided at a forward or front side of the housing and at least one but normally a pair of hinges is provided at the rear of the housing. It is preferred that each closure is at least partially resilient. In particular, each closure will typically include one or more resilient bands or similar, attached to either the lid or the bottom containing portion and a corresponding retainer is preferably provided on the other of the lid or bottom containing portion. Normally, the one or more resilient bands will be stretched or deformed in order to engage with the corresponding retainer and once released, the resilient nature of the bands will hold the lid and the bottom containing portion together against accidental, but not determined removal.

[0033] Preferably, a gripping portion is provided in association with each one or more resilient bands to assist with the extension of the one or more resilient bands against the resilience of the one or more resilient bands. As will be apparent from this description, the one or more resilient bands will normally require elongation in order to be engaged and disengaged from the corresponding retainer. According to the most preferred embodiment, the one or more resilient bands are mounted on or relative to the lid, preferably on or relative to a forward edge of the lid and the corresponding retainer is provided on a front or forward wall, normally on the enlarged lip of the forward wall, of the bottom containing portion.

[0034] The corresponding retainer can be of any type, and normally, the retainer will be configured as either an elongate finger or hook. The elongate finger or hook may have a groove in order to seat the one or more resilient bands therein during engagement. The elongate finger or hook may be downwardly angled or include a downwardly angled portion in the particularly preferred embodiment in order to prevent accidental dislodgement of the one or more resilient bands from the retainer.

[0035] The portable power supply unit of the present invention also includes at least one deep cycle battery. Any type of deep cycle battery and any number of deep cycle batteries can be provided. Preferably, a single deep cycle battery is provided and is typically located in a lower portion of the bottom containing portion as the weight of the deep cycle battery will preferably stabilise the unit. Normally, the deep cycle battery will be separated from the remainder of the components in the unit by an internal bulkhead or similar, which is typically removable from the bottom containing portion in order to access the battery.

[0036] The unit of the present invention also includes at least one power inverter.

Preferably, at least one power inverter is connected to the at least one deep cycle battery. At least one power inverter is preferably provided in the unit of the present invention to convert direct current (DC) to alternating current (AC) as most of items which a user will require to be powered by the unit, operate primarily on alternating current.

[0037] Any type of power inverter can be provided. Normally, the power inverter is chosen for the particular application. Therefore, normally the power inverter will be voltage appropriate and power rating appropriate for the particular use for which the unit is to be used.

[0038] Any type of power inverter can be used. Power inverters are normally classified according to at least the input voltage and the output waveform. Other appropriate classification parameters include output frequency, output voltage and output power. It is particularly preferred that the power inverter be a “pure” sine wave power inverter.

[0039] More than one power inverter may be provided and if more than one power inverter is provided, they may be connected or interconnected in any way or not connected or interconnected at all. According to the most preferred embodiment of the invention however, a single pure sine wave inverter is provided.

[0040] The power inverter may be used to convert stored direct current to alternating current or input direct current to alternating current such as may be received or produced from an associated photovoltaic cell or array. Normally, different inverters may need to be provided for the different operating parameters according to the input voltage but again, preferably a single inverter is provided.

[0041] The power inverter is preferably located within the housing, normally above the at least one deep cycle battery. The inverter is normally separated from the at least one deep cycle battery by a bulkhead or similar. The bulkhead may be formed from any material but will normally be plastic. Typically, the bulkhead is removable from the housing in order to allow access to the at least one deep cycle battery.

[0042] The power inverter typically has or accepts 12V input from the at least one deep cycle battery. Where DC current is provided from a photovoltaic cell or array, the photovoltaic cell or array is normally connected to the respective terminals of the at least one deep cycle battery with a regulator interposed between, in order to regulate the DC current provided to the deep cycle battery.

[0043] The power inverter will normally have at least one power outlet. The at least one power outlet is normally connected to a safety switch and/or a circuit breaker. An actuation switch to turn the power inverter on and off is normally provided on the power inverter as well. Normally, fans are integrated into the power inverter housing in order to cool the internal components of the power inverter.

[0044] The portable power supply unit of the present invention also includes at least one safety switch. The safety switch may be provided in addition to or instead of a circuit breaker. Safety switches are often confused with circuit breakers and surge diverters. It is important to understand the differences between these three devices. Safety switches monitor the flow of electricity through a circuit and detect a problem that may pose a risk to personal safety and turn the power off. Safety switches usually have a test button and are also sometimes labelled with the words "safety switch". Surge diverters protect a circuit from voltage surges such as those resulting from a lightning strike for example. The surge diverter captures the voltage spikes in the wiring that would otherwise be transferred into the equipment. Circuit breakers provide short-circuit and overcurrent protection such as when a power point is overloaded. Surge diverters and circuit breakers do not normally act as safety switches for personal protection against electric shock.

[0045] The at least one safety switch is normally located between the power source, namely the at least one deep cycle battery and one or more of the power outlets, normally a general power outlet (GPO) commonly known as a power point. Preferably, the at least one safety switch is located between the power inverter and the GPO. Any type of safety switch may be provided.

[0046] The portable power supply unit of the present invention also includes at least one electricity input connection. Again, any number and any type of electricity input connections can be provided. According to a particularly preferred embodiment, the unit has at least one electricity input connection to receive electricity from a battery charger to charge the at least one on-board deep cycle battery. Other types of electricity input connection may be provided instead of or as well as the battery charger input connection. For example, a electricity input connection may be provided to allow electrical current from a photovoltaic cell or array to be provided, normally to the at least one deep cell battery. Normally, the separate electricity input connections are provided for different purposes.

[0047] The electricity input connections may be in any location on the housing but preferably, the electricity input connections are provided on one of the sidewalls of the bottom containing portion, preferably a front or forward wall through which other components are also mounted.

[0048] According to the most preferred type, at least one electricity input connection is provided as what is known in the art as an “Anderson” connector. Connectors such as these are made by Anderson Powered Products. Preferably, at least one power input connection is a multipole electricity input connection. According to the most preferred embodiment, two electricity connections are provided, one for a photovoltaic cell or array connection and a second electricity input connection for the connection of a battery charger which is then connected to a mains power supply. In this way, electrical power can be provided to charge the on-board at least one deep cycle battery from either a renewable source such as a photovoltaic cell or from a battery charger connected to a mains power supply as required and as circumstances allow.

[0049] The portable power supply unit of the present invention also includes at least one output electricity connection to allow external power cables to be connected to the housing as required to draw power from the unit as required. Again, any number and any type of output electricity connection may be provided. Generally, multiple output electricity connections are provided and a variety of types of output electricity connector are provided. According to the most preferred embodiment, at least one general power outlet (GPO) is provided, at least one Anderson connector outlet is provided, at least one USB outlet is provided and at least one direct current outlet is provided. According to the preferred embodiment, the direct current outlet will normally be what is commonly known as a cigarette lighter receptacle.

[0050] Any one or more of the output electricity connections can be provided on the one or more separate circuits. Typically, the Anderson connector outlet and the GPO are provided on one circuit and a 12 V direct current outlet and USB outlet are provided on another circuit. Typically, there is a separate switch to control electricity flow through each circuit.

[0051] The portable power supply unit of the present invention will also normally include at least one indicator to indicate the amount of charge or current stored in the at least one deep cycle battery at any time. One or more indicators may be provided in order to indicate the status of the charging or operation of the power supply unit or any component of the power supply unit and/or errors or faults. A remote operation switch may be provided for the unit and/or any one of the electricity circuits within the unit to allow a user to activate and deactivate the unit or individual electricity circuits within the unit remotely, normally by access to a wireless communication system.

[0052] Instead of an all in one configuration, the present invention can be provided in a modular, “plug and play” configuration which allows a number of individual battery units to be connected to one another and have one or more control or inverter units associated therewith. In the context of a preferred embodiment, the two main components are termed a battery box and an inverter box. Generally, one or more battery boxes will generally be provided in a stacked configuration with one or more inverter box associated with each stack.

[0053] Therefore, in an another form, the present invention resides in a portable power supply system including at least one battery box having a housing having at least one deep cycle battery, and at least one inverter box including at least one power inverter, at least one electrical safety switch to automatically shut off electricity when current is detected leaking from faulty switches, wiring or appliances, at least one electricity input connection, and at least one electricity output connection to allow an external power cable to be connected to the at least one inverter box as required to draw electricity from the system as required and at least one electrical connection to connect each at least one battery box to one or more battery boxes and at least one battery box to at least one inverter box.

[0054] According to a preferred embodiment, each inverter box will normally be provided with a lid which is typically capable of sealing onto or in relation to the inverter box. The inverter box will typically be substantially rectangular and have a volume within that contains control equipment used to control output from the one or more battery boxes relative to which the inverter box is connected in use.

[0055] Each inverter box will typically have at least one, and preferably a pair of vents or openings, normally in one or both of the end walls. Further, a cabling opening will normally be provided, again, typically in one or both of the end walls of the inverter box.

[0056] Each inverter box will typically be provided with one or more handles, preferably a handle at either end. In order to minimise or prevent the handles extending laterally from the ends, the handles are preferably provided as a slotted openings rather than outwardly extending handles.

[0057] At least a portion of at least one wall of each inverter box will preferably be recessed in order to allow mounting of components relative to the recessed portion of the wall. The components mounted relative to the recessed portion of the wall will normally be one or more gauges, switches or other devices that need to be accessible from the exterior of the inverter box, but also need to be protected if possible. The mounting of the components relative to the recessed portion of the wall results in these components not extending laterally past the wall and therefore, provide an element of protection by mounting them within the recessed portion.

[0058] One or more earthing bars are preferably provided on each inverter box. Preferably, a single earthing bar is provided. The preferred single earthing bar is normally provided at an upper portion of one of the sidewalls. Preferably, the earthing bar extends substantially perpendicular to the sidewall from which the earthing bar extends.

[0059] The inverter box will preferably also have a number of feet extending from a lower portion of the box. Preferably, each of the feet is provided extending downwardly from each comer of the inverter box. Each of the feet is preferably rectangular and stands proud of the bottom of the inverter box.

[0060] According to a preferred embodiment, each battery box will normally be provided with a lid which is typically capable of sealing onto or in relation to the battery box. The battery box will typically be substantially rectangular and have a volume within that contains one or more batteries to store electrical energy, access to which is typically controlled by the inverter box to which one or more battery boxes are connected in use.

[0061] Each battery box will typically contain at least one, and potentially more than one storage batteries for storing a charge. The storage batteries can be of any type. If more than one battery is provided, then it is preferred that the batteries are linked to one another in order to have a single output. In normal circumstances, and inverter box is provided for accessing control to the batteries in any one or more of the battery boxes which will normally be operatively connected to the at least one inverter box.

[0062] Each battery box will typically be provided with one or more handles, preferably a handle at either end. In order to minimise or prevent the handles extending laterally from the ends, the handles are preferably provided as a slotted openings rather than outwardly extending handles.

[0063] Each battery box will also preferably have at least one cable port opening, typically a cable port opening will be provided on both end walls of each battery box.

[0064] It is preferred that the configuration of the end walls of the battery boxes differ from one another. In a particularly preferred embodiment, it is preferred that each battery box have a male end wall and a female end wall. The male end wall is preferably generally planar and a slot opening is preferably provided therein to form a handle. The preferred configuration of the female end wall is the provision of a shaped recess into the end wall with the handle being formed from a land portion provided at an upper end of the recess.

[0065] The battery box will preferably also have a number of feet extending from a lower portion of the box. Preferably, one foot is provided extending downwardly from each corner of the battery box. Each of the feet is preferably rectangular and stands proud of the bottom of the battery box. It is further preferred that the two feet provided at the female end of the battery box are provided with an additional rebate or slot on the inner lateral sides of the feet, typically adjacent the body of the box in order to engage with flange is provided on the female end of the lid which will be explained further below.

[0066] Each of the battery boxes will typically have a lid. The lid will typically have a male end and a female end. Importantly, the lid of the battery box will normally be placed on the battery box with the male end of the lid located at the female end of the battery box and the female end of the lid located at the male end of the battery box. This configuration will typically allow stacking of battery boxes in alternating directions.

[0067] In a preferred configuration, the male end of the lid of the battery box preferably has a pair of rectangular rebate portions or depressions, one provided on either comer into an upper surface of the male end of the lid. The purpose of the rebates or depressions is to receive the feet of the battery box or inverter box directly above. The rebate portions or depressions are preferably separated by a central portion of the lid, preferably a full thickness portion.

[0068] In a preferred configuration, the female end of the lid of the battery box also typically has a pair of rectangular rebates or depressions, one on either comer into an upper surface of the female end of the lid. Again, the purpose of the rebates or depressions is to receive the feet of the battery box or inverter box directly above. In contrast to the male end of the lid, the female end of the lid typically has the central portion between the rebates removed. Instead, a flange or similar substantially perpendicularly extending portion upstanding from an edge of each of the rebates or depressions and defining the edge of the rebates or depressions is typically provided on either lateral side of the female end of the lid. The preferred flanges engage the additional rebate slot provided on an inner lateral side of the feet on the female end of the battery box or inverter box.

[0069] In use, the lid of the battery box will typically be oriented in the reverse direction to the box itself (with the female end of the lid adjacent the male end of the box and the male end of the lid adjacent the female end of the box). A number of battery boxes can then be stacked in alternating directions, one on top of the other with the feet of one battery box received in the rebates or depressions provided in the lid of the battery box below. Generally speaking, in this configuration, the lid of the box below is oriented in the same direction as the box above (the female end of the lid of a lower box will be adjacent the female end of the box above and the male end of the lid of the lower box will be adjacent the male end of the box above). Once a number of battery boxes have been stacked one on top of the other, and inverter box is typically located uppermost in the stack and cables are provided to connect the battery boxes to one another, generally with more or less standard connections such as Anderson plugs with the uppermost battery box connected to the inverter box in order to allow the inverter box to control access to the electric charge stored in the battery boxes of the stack.

[0070] The inverter box and battery box of the preferred configuration are both preferably formed in one piece, preferably moulded with the components/features of the respective boxes integrally formed.

[0071] The battery boxes may be connected (through the inverter box or not) to a recharge supply to recharge the at least one storage battery within.

[0072] Any of the features described herein can be combined in any combination with any one or more of the other features described herein within the scope of the invention.

[0073] The reference to any prior art in this specification is not, and should not be taken as an acknowledgement or any form of suggestion that the prior art forms part of the common general knowledge.

BRIEF DESCRIPTION OF DRAWINGS

[0074] Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of the Invention in any way. The Detailed Description will make reference to a number of drawings as follows: [0075] Figure 1 is an end elevation view of a portable power supply unit according to a preferred embodiment of the present invention.

[0076] Figure 2 is a front elevation view of a portable power supply unit according to a preferred embodiment of the present invention.

[0077] Figure 3 is a front elevation view of the portable power supply unit illustrated in Figure 2 with the lid open.

[0078] Figure 4 is as exploded front view of a portable power supply unit according to a preferred embodiment of the present invention.

[0079] Figure 5 is an isometric view of a power inverter according to a preferred embodiment of the present invention from a first end.

[0080] Figure 6 is an isometric view of a power inverter according to a preferred embodiment of the present invention from a second end.

[0081] Figure 7 is a view from above of an internal layout of a portable power supply unit according to a preferred embodiment of the present invention.

[0082] Figure 8 is a schematic view of a user connecting a power cable with connector to the portable power supply unit according to a preferred embodiment of the present invention.

[0083] Figure 9 is a schematic view of the components of a portable power supply unit according to a preferred embodiment of the present invention.

[0084] Figure 10 is a side elevation view of a possible use of the portable power supply unit according to a preferred embodiment of the present invention.

[0085] Figure 11 is a side elevation view of a second possible use of the portable power supply unit according to a preferred embodiment of the present invention.

[0086] Figure 12A to 12G is a transparent isometric view, transparent side view, end view, side view, opposite end view, isometric end view and opposite end isometric view of a battery box with lid assembled according to a preferred embodiment of the present invention.

[0087] Figure 13A to 13G is a transparent isometric view, transparent side view, end view, side view, opposite end view, isometric end view and opposite end isometric view of an exploded battery box with lid according to a preferred embodiment of the present invention.

[0088] Figure 14A to 14F is an isometric view from below, end view, side view, opposite end view, transparent isometric view and isometric end view of an inverter box with lid assembled according to a preferred embodiment of the present invention.

[0089] Figure 15A to 15F is an isometric view from below, side view, end view, opposite side view, transparent isometric view and isometric side view of an inverter box with lid exploded according to a preferred embodiment of the present invention.

[0090] Figure 16A to 16F is a side view, end view, opposite side view, isometric end view, plan view and isometric opposite side view of a modular power supply stack with lid exploded (without inverter box) according to a preferred embodiment of the present invention.

[0091] Figure 17A to 17F is a side view, end view, opposite side view, isometric end view, plan view and isometric opposite side view of a modular power supply stack with lid exploded with inverter box according to a preferred embodiment of the present invention.

[0092] Figure 18 shows various views of a battery box and lid separately from one another according to a preferred embodiment of the present invention.

[0093] Figure 19 shows various exploded views of a battery box with lid according to a preferred embodiment of the present invention.

[0094] Figure 20 shows various assembled views of a battery box with lid according to a preferred embodiment of the present invention.

[0095] Figure 21 shows various views of an inverter box and lid separately from one another according to a preferred embodiment of the present invention.

[0096] Figure 22 shows various exploded views of an inverter box with lid according to a preferred embodiment of the present invention.

[0097] Figure 23 shows various assembled views of an inverter box with lid according to a preferred embodiment of the present invention.

DESCRIPTION OF EMBODIMENTS

[0098] According to a particularly preferred embodiment of the present invention, a portable power supply unit is provided.

[0099] The portable power supply unit illustrated in the Figures includes a housing 40 having at least one deep cycle battery 41, a power inverter 13, an electrical safety switch 15 to automatically shut off electricity when current is detected leaking from faulty switches, wiring or appliances, an electricity input connection (illustrated as alternatives of solar power input or a mains power charge provided through a battery charger in Figure 9), and a plurality of electricity output connections to allow an external power cable to be connected to the housing 41 as required to draw electricity from the unit as required.

[00100] The power supply unit of the present invention is portable. Typically, the power supply unit will be small enough to allow two people to pick up and carry the power supply unit. A large portion of the weight of the power supply unit will be in the one or more deep cycle batteries. Therefore, the weight of the power supply unit can be adjusted by providing more or fewer deep cycle batteries in the unit. The number of deep cycle batteries in the unit will also typically define the size of the housing and there is no limitation intended on the size of housing or the weight of the unit.

[00101] It is preferred that the power supply unit of the present invention is able to power a number of items at once or to provide power for a structure for example by connection to a mains power supply to the structure in place of a mains power supply which would normally be connected, but which is at least temporarily non-functioning as illustrated in Figure 11.

[00102] As illustrated, the housing 40 is typically provided to contain other components therein and/or allow electricity inlets or outlets to be externally accessible on the housing 40.

[00103] Typically, the housing 40 will be provided in a form including a bottom containing portion 42 with a lid 1 which can be opened and closed to allow access to the components within the housing. Normally, the lid 1 will seal the housing in order to protect the components inside the housing from inclement weather, dust or other detritus for example.

[00104] The bottom containing portion 42 as illustrated, includes a substantially planar base wall and a number of upstanding sidewalls extending therefrom. Normally, the bottom containing portion will be substantially rectangular and includes four upstanding sidewalls. The sidewalls normally extend upward from the base wall at a substantially perpendicular angle. Normally, the sidewalls are each planar with an arcuate transition between the edges of each of the sidewalls, at the comers.

[00105] Preferably, the base wall and upstanding sidewalls are integrally formed, normally by vacuum forming or rotational moulding for example.

[00106] Preferably, an enlarged lip 48 is provided at an upper end of the upstanding sidewalls in order to abut an underside of the lid or closure. A perimeter seal 11 is provided on the lid 1 in association with the enlarged lip 48.

[00107] Normally, one or more openings are provided in one or more of the sidewalls to allow access to the components located in the interior of the housing and/or to allow the components to extend through the sidewall. Generally, components will be mounted into and preferably through one of the sidewalls of the bottom containing portion. In a particularly preferred embodiment, at least the input and output electricity connections and any gauges or other componentry to which a user requires access on an ongoing basis in order to use the device, will be provided through one or more of the sidewalls. Typically, the components mounted relative to the sidewalls will be fixed in position relative to the sidewall.

[00108] The housing is preferably weatherproof or substantially weatherproof. Any opening in the housing and/or any through-wall component will typically be provided with a seal or cover such as that illustrated in Figure 3 in relation to the USB connector 12b or other type of deflection or prevention apparatus which will prevent inclement weather or dust or detritus or similar from entry into the interior of the housing.

[00109] The housing 40 is preferably provided with a pair of closure mechanisms 6 in order to releasably close and seal the lid 1 to the bottom containing portion 42.

[00110] According to a particularly preferred embodiment, a pair of closures 6 is provided at a forward or front side of the housing and a pair of hinges is provided at the rear of the housing. As illustrated, each closure 6 includes a resilient band 47, attached to the lid which engages with a corresponding retainer 46 provided on the other of the bottom containing portion 42. Normally, the resilient bands 47 will be stretched or deformed in order to engage with the corresponding retainer 46 and once released, the resilient nature of the bands 47 will hold the lid 1 and the bottom containing portion 42 together against accidental, but not determined removal.

[00111] Preferably, a gripping portion 45 is provided in association with each of the resilient bands 47 to assist with the extension of the resilient bands 47 against the resilience of the bands. As will be apparent from this description, the resilient bands 47 require elongation in order to be engaged and disengaged from the corresponding retainer 46. According to the most preferred embodiment, each resilient band 47 are mounted on or relative to a forward edge of the lid 1 and the corresponding retainer 46 is provided on the enlarged lip 48 of the forward wall, of the bottom containing portion 42.

[00112] The corresponding retainer 46 is normally configured as either an elongate finger or hook. The elongate finger or hook may have a groove in order to seat the one or more resilient bands therein during engagement. The elongate finger or hook may be downwardly angled or include a downwardly angled portion in the particularly preferred embodiment in order to prevent accidental dislodgement of the one or more resilient bands from the retainer.

[00113] The housing illustrated in the Figures includes an air ventilation portion 2 and a breather opening 3 in a power portion to allow any fumes for example to escape from the unit.

[00114] The portable power supply unit of the present invention also includes at least one deep cycle battery 41. Any type of deep cycle battery and any number of deep cycle batteries can be provided. Preferably, a single deep cycle battery 41 is provided and is typically located in a lower portion of the bottom containing portion 42 as the weight of the deep cycle battery will also stabilise the unit. Normally, the deep cycle battery 41 is separated from the remainder of the components in the unit by an internal bulkhead 14 or similar, which is typically removable from the bottom containing portion 42 in order to access the battery 41.

[00115] The unit of the present invention also includes at least one power inverter 13 connected to the deep cycle battery 41. The power inverter is preferably provided in the unit of the present invention to convert direct current (DC) to alternating current (AC) as most of items which a user will require to be powered by the unit, operate primarily on alternating current.

[00116] Any type of power inverter can be provided. Normally, the power inverter is chosen for the particular application. Therefore, normally the power inverter 13 is voltage appropriate and power rating appropriate for the particular use for which the unit is to be used. It is particularly preferred that the power inverter 13 be a “pure” sine wave power inverter.

[00117] The power inverter 13 is located within the housing, normally above the deep cycle battery 41. The inverter 13 is normally separated from the at least one deep cycle battery by a bulkhead 14. The bulkhead 14 may be formed from any material but will normally be plastic. Typically, the bulkhead 14 is removable from the housing in order to allow access to the one deep cycle battery 41.

[00118] The power inverter 13 typically has or accepts 12V input from the one deep cycle battery 41. Where DC current is provided from a photovoltaic cell or array 50 such as illustrated in Figure 9, the photovoltaic cell or array 50 is normally connected to the respective terminals of the deep cycle battery 41 with a regulator 49 interposed between, in order to regulate the DC current provided to the deep cycle battery 41.

[00119] As illustrated in Figure 6, the power inverter 13 has a power outlet 20. The power outlet 20 is normally connected to a safety switch 15. An actuation switch 19 to turn the power inverter 13 on and off is normally provided on the power inverter 13 as well. As illustrated, fans 16 are integrated into the power inverter housing in order to cool the internal components of the power inverter. The power inverter illustrated in Figure 5 has a pair of 12v input connectors 17 each associated with a power bale 18.

[00120] The safety switch 15 may be provided in addition to or instead of a circuit breaker. The safety switch 15 is normally located between the power inverter 13 and the GPO 10. Any type of safety switch may be provided.

[00121] Any number and any type of electricity input connections can be provided. According to the illustrated preferred embodiment, the unit has an Anderson connector electricity input 8b to receive electricity from a battery charger 51 via a corresponding connector 27 and cable 28 to charge the on-board deep cycle battery 41 and an Anderson connector electricity input 8a to allow electrical current from a photovoltaic cell or array to be provided to the deep cell battery 41.

[00122] The electricity input connections 8a, 8b may be in any location on the housing but in the preferred embodiment, the electricity input connections are provided on a front or forward wall through which other components are also mounted.

[0100] Anderson connectors are made by Anderson Powered Products. Preferably, at least one power input connection is a multi-pole electricity input connection.

[0101] The portable power supply unit of the present invention also includes a number of output electricity connections or various types to allow external power cables to be connected to the unit as required to draw power from the unit as required. According to the illustrated embodiment, a general power outlet (GPO) 10 is provided, an Anderson connector outlet 22 is provided, at least one USB outlet 12b is provided and at least one direct current outlet 12a is provided. According to the preferred embodiment, the direct current outlet 12a will normally be what is commonly known as a cigarette lighter receptacle.

[0102] Any one or more of the output electricity connections can be provided on one or more separate circuits. Typically, the GPO 10 is provided on one circuit directly from the inverter 13 (through the safety switch 15) and the Anderson connector outlet 22, the 12 V direct current outlet 12a and USB outlet 12b are provided on another circuit drawing electricity from the battery 41 as illustrated in Figure 9. Typically, there is a separate switch 4, 7 to control electricity flow through each circuit.

[0103] The portable power supply unit of the present invention will also normally include at least one indicator 5 to indicate the amount of charge or current stored in the at least one deep cycle battery at any time. One or more indicators may be provided in order to indicate the status of the charging or operation of the power supply unit or any component of the power supply unit and/or errors or faults.

[0104] A remote operation switch 9 may be provided for the unit and/or any one of the electricity circuits within the unit to allow a user to activate and deactivate the unit or individual electricity circuits within the unit remotely, normally by access to a wireless communication system.

[0105] The internal layout of the preferred embodiment of the unit of the present invention is illustrated in figure 7. The deep cycle battery 41 is located below the separator bulkhead 14 and therefore is out of view in Figure 7. The inverter 13 is located above the separated bulkhead 14. As can be seen from Figure 7, the power outlet 21 from the inverter leads directly to the safety switch 15 which in turn connected to the GPO 10. The positive terminal 25 from the inverter is connected electrically to the positive DC bus bar 26 which is electrically connected to a DC circuit breaker 29 and into the positive terminal of the deep cycle battery 41. The negative terminal 24 from the inverter is electrically connected to the negative DC bus bar 23 which is connected to the negative terminal of the deep cycle battery 41 will stop the negative DC bus bar 26 is also electrically connected to the USB outlet 12b , the 12 V DC outlet 12a, and the preferred 12 V, 50A Anderson outlet 22. A 12 V fuse block 30 is connected to each of these outlets. The preferred eLite gauge or indicator is also electrically connected to show the power in the battery 41.

[0106] The portable power supply unit of the present invention can be used for any purpose. It is particularly preferred that the power supply unit is used for “off grid” apply when a mains power supply is not available. This will typically occur when a user is away from the mains power supply for fun or enjoyment such as camping or boating or similar such as is illustrated in Figure 10 or in times of natural disasters for example where the mains power supply can be lost for extended periods such as is illustrated in Figure 11.

[0107] Instead of an all in one configuration, the present invention can be provided in a modular, “plug and play” configuration which allows a number of individual battery units to be connected to one another and have one or more control or inverter units associated therewith one form of which is illustrated in Figures 12 to 23. In the context of this preferred embodiment, the two components of the modular system are termed a battery box 51 and an inverter box 51. Generally, one or more battery boxes will generally be provided in a stacked configuration with one or more inverter box associated with each stack as illustrated in Figures 16 and 17.

[0108] According to a preferred embodiment of inverter box illustrated in Figures 14 and 15, each inverter box 52 is provided with a lid 53 capable of sealing onto or in relation to the inverter box 52. The inverter box 52 illustrated is substantially rectangular and have an internal volume within that contains control equipment used to control output from and access to the one or more battery boxes 51 relative to which the inverter box 52 is connected in use.

[0109] Each inverter box 52 has a pair of vents openings 54, normally one in either of the end walls. Further, a cabling opening will normally be provided, again, typically in one or both of the end walls of the inverter box.

[0110] Each inverter box 52 is provided with a handle 55 at either end. In order to minimise or prevent the handles 55 extending laterally from the ends, the handles are preferably provided as a slotted openings rather than outwardly extending handles.

[0111] A recessed portion 56 is provided in at least one sidewall of the inverter box 52 in order to allow mounting of components relative to the recessed portion 56 of the wall as illustrated in Figure 14C. The components mounted relative to the recessed portion 56 of the wall will normally include one or more gauges, switches or other devices that need to be accessible from the exterior of the inverter box 52, but also need to be protected if possible. The mounting of the components relative to the recessed portion 56 of the wall results in these components not extending laterally past the exterior plane of the wall and therefore, provides an element of protection by mounting these components externally but within the recessed portion 56.

[0112] An earthing bar 57 is provided on each inverter box 52. As illustrated, the earthing bar 57 is normally provided at an upper portion of one of the sidewalls extending substantially perpendicular to the sidewall.

[0113] The inverter box 52 also has a number of feet 58 extending from a lower portion of the inverter box 52. Each of the feet 58 is provided extending downwardly from each corner of the inverter box 52. Each of the feet 58 is preferably rectangular and stands proud of the bottom of the inverter box 52.

[0114] According to the preferred embodiment illustrated in Figures 12 and 13, each battery box 51 is provided with a lid 60 capable of sealing onto or in relation to the battery box 51. The battery box is substantially rectangular and has an internal volume within that contains one or more batteries to store electrical energy, access to which is typically controlled by the inverter box 52 to which one or more battery boxes 51 are connected in use.

[0115] Each battery box 51 contains at least one, and potentially more than one storage batteries. The storage batteries can be of any type. If more than one battery is provided, then it is preferred that the batteries are linked to one another in order to have a single output. In normal circumstances, an inverter box 52 is provided for accessing control to the batteries in any one or more of the battery boxes 51 which will normally be operatively connected to the at least one inverter box 52.

[0116] Each battery box 51 is provided with one or more handles, preferably a handle at either end. In order to minimise or prevent the handles extending laterally from the ends, the handles are preferably provided as a slotted opening handle 61 or a land 62 in a shaped recess rather than outwardly extending handles.

[0117] Each battery box 51 also has a cable port opening 64 provided on each end wall of each battery box 51.

[0118] The preferred configuration of the end walls of the battery boxes 51 differ from one another in the illustrated embodiment. In this particularly preferred embodiment, each battery box 51 has a male end wall 65 (as illustrated in Figure 12C and 12G in particular) and a female end wall 66 (as illustrated in Figure 12E and 12F in particular). The male end wall 65 is generally planar and a slot opening 61 is provided therein to form the handle. The preferred configuration of the female end wall 66 has a shaped recess 63 formed into the end wall with the handle being formed from a land 62 provided at an upper end of the recess 63.

[0119] The battery box 51 has a number of feet 67 extending from a lower portion of the box 51. Preferably, each of the feet 67 extends downwardly from each comer of the battery box 51. Each of the feet 67 is rectangular and stands proud of the bottom of the battery box 51. It is further preferred that the two feet provided at the female end of the battery box 5 lare provided with an additional rebate or slot 68 on the inner lateral sides of the feet 67, typically adjacent the body of the box 51, each to engage with a flange 69 provided on the female end of the lid 60.

[0120] Each of the battery boxes 51 has a lid 60. The lid 60 of the preferred embodiment has a male end 70 and a female end 71. Importantly, the lid 60 of the battery box 51 is placed on the battery box 51 with the male end 70 of the lid 60 located at the female end 66 of the battery box 51 and the female end 71 of the lid 60 located at the male end 65 of the battery box 51. This configuration will typically allow stacking of battery boxes in alternating directions as illustrated in Figures 16 and 17.

[0121] In a preferred configuration, the male end 70 of the lid 60 of the battery box 51 has a pair of rectangular rebate portions or depressions 72, one provided on either corner into an upper surface of the male end 70 of the lid 60. The purpose of the rebates or depressions 72 is to receive the feet 67 of the battery box 51 or the feet 58 of the inverter box 53 directly above. The rebate portions or depressions 72 are preferably separated by a central portion of the lid 60, preferably a full thickness portion.

[0122] In a preferred configuration, the female end 71 of the lid 60 of the battery box 51 also has a pair of rectangular rebates or depressions 73, one on either corner into an upper surface of the female end 71 of the lid 60. Again, the purpose of the rebates or depressions 72 is to receive the feet 67 of the battery box 51 or the feet 58 of the inverter box 53directly above. In contrast to the male end 70 of the lid 60, the female end 71 of the lid 60 typically has the central portion between the rebates 73 removed. Instead, a flange 69 extending substantially perpendicularly upstanding from an edge of each of the rebates or depressions 73 is provided defining the edge of the rebates or depressions 73 on either lateral side of the female end 71 of the lid 60. The preferred flanges 69 engage the additional rebate or slot 68 provided on an inner lateral side of the feet on the female end 66 of the battery box 5 lor inverter box 52.

[0123] As illustrated in Figures 16 and 17, in use, the lid 60 of the battery box 51 is oriented in the reverse direction to the box 51 itself (with the female end 71 of the lid 60 adjacent the male end 65 of the box 51 and the male end 70 of the lid 60 adjacent the female end 66 of the box 51). A number of battery boxes 51 can then be stacked in alternating directions, one on top of the other, with the feet 67 of one battery box 51 received in the rebates or depressions 72, 73 provided in the lid 60 of the battery box 51below. Generally speaking, in this configuration, the lid 60 of the box 51 below is oriented in the same direction as the box 51 above (the female end 71 of the lid 60 of a lower box 51 is adjacent the female end 66 of the box 51 above and the male end 70 of the lid 60 of the lower box 51 is adjacent the male end 65 of the box 51 above) as illustrated in Figure 16.

[0124] Once a number of battery boxes 51 have been stacked one on top of the other, an inverter box 52 is typically located uppermost in the stack and connection cables 74 are provided to connect the battery boxes 51 to one another, generally with more or less standard connections such as Anderson plugs 75 with the uppermost battery box 51 connected to the inverter box52 in order to allow the inverter box 52 to control access to the electric charge stored in the battery boxes 51 of the stack.

[0125] The inverter box 52 and battery box 51of the preferred configuration are both preferably formed in one piece, preferably moulded (or rotomoulded) with the components/features of the respective boxes integrally formed.

[0126] In the present specification and claims (if any), the word ‘comprising’ and its derivatives including ‘comprises’ and ‘comprise’ include each of the stated integers but does not exclude the inclusion of one or more further integers.

[0127] Reference throughout this specification to ‘one embodiment’ or ‘an embodiment’ means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearance of the phrases ‘in one embodiment’ or ‘in an embodiment’ in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more combinations.

[0128] In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims (if any) appropriately interpreted by those skilled in the art.

Claims (21)

1. A portable power supply unit including a housing having at least one deep cycle battery, at least one power inverter, at least one electrical safety switch to automatically shut off electricity when current is detected leaking from faulty switches, wiring or appliances, at least one electricity input connection, and at least one electricity output connection to allow an external power cable to be connected to the housing as required to draw electricity from the unit as required.

2. A portable power supply unit as claimed in claim 1 wherein the housing contains all components therein and/or allow electricity inlets or outlets to be externally accessible on the housing.

3. A portable power supply unit as claimed in claim 2 wherein the housing includes a bottom, containing portion with a lid which can be opened and closed to allow access to the components within the housing, the lid or closure seals the housing in order to protect the components inside the housing.

4. A portable power supply unit as claimed in any one of the preceding claims wherein at least the input and output connections and any gauges or other componentry to which a user requires access on an ongoing basis in order to use the unit, are provided through one or more of the sidewalls and/or lid.

5. A portable power supply unit as claimed in any one of the preceding claims wherein a single deep cycle battery is provided in a lower portion of the unit and separated from the remainder of the components in the unit by an internal bulkhead, removable in order to access the battery.

6. A portable power supply unit as claimed in any one of the preceding claims wherein the at least one power inverter is connected to the at least one deep cycle battery to convert direct current (DC) to alternating current (AC).

7. A portable power supply unit as claimed in any one of the preceding claims wherein the at least one power inverter is a pure sine wave power inverter.

8. A portable power supply unit as claimed in any one of the preceding claims wherein at least one power inverter is associated with at least one power outlet connected to a safety switch and/or a circuit breaker.

9. A portable power supply unit as claimed in any one of the preceding claims wherein the at least one safety switch is located between the at least one deep cycle battery and one or more of the power outlets.

10. A portable power supply unit as claimed in any one of the preceding claims wherein the at least one safety switch is located between the power inverter and the GPO.

11. A portable power supply system including at least one battery box having a housing having at least one deep cycle battery, and at least one inverter box including at least one power inverter, at least one electrical safety switch to automatically shut off electricity when current is detected leaking from faulty switches, wiring or appliances, at least one electricity input connection, and at least one electricity output connection to allow an external power cable to be connected to the at least one inverter box as required to draw electricity from the system as required and at least one electrical connection to connect each at least one battery box to one or more battery boxes and at least one battery box to at least one inverter box.

12. A portable power supply system as claimed in claim 11 wherein a cabling opening is provided in at least one wall of the inverter box.

13. A portable power supply system as claimed in claim 11 or claim 12 wherein at least a portion of at least one wall of each inverter box is recessed inwardly in order to allow mounting of components relative to the recessed portion of the wall.

14. A portable power supply system as claimed in any one of claims 11 to 13 wherein one or more earthing bars are provided on each inverter box.

15. A portable power supply system as claimed in any one of claims 10 to 14 wherein the inverter box has a number of feet extending from a lower portion of the box. Preferably, one foot is provided extending downwardly from each comer of the inverter box.

16. A portable power supply system as claimed in any one of claims 10 to 15 wherein each battery box contains one or more deep cycle batteries to store electrical energy, access to which is controlled by the inverter box to which one or more battery boxes are connected in use.

17. A portable power supply system as claimed in claim 16 wherein each battery box also has at least one cable port opening.

18. A portable power supply system as claimed in any one of claims 10 to 17 wherein the battery box has a number of feet extending from a lower portion of the box.

19. A portable power supply system as claimed in any one of claims 10 to 18 wherein each battery box has a male end wall and a female end wall, the male end wall being generally planar and the female end wall provided with a shaped recess thereinto.

20. A portable power supply system as claimed in claim 19 wherein each battery box has a lid with a male end and a female end, each end having a pair of rectangular rebate portions or depressions thereinto, the lid placed on the battery box with the male end of the lid located at the female end of the battery box and the female end of the lid located at the male end of the battery box.

21. A portable power supply system as claimed in any one of claims 10 to 20 wherein a remote operation switch is provided for the system and/or any one of the electricity circuits within the system to allow a user to activate and deactivate the system or individual electricity circuits within the system remotely.