AU2022100108A4

AU2022100108A4 - Over discharge protection circuit for additive manufactured battery adapters

Info

Publication number: AU2022100108A4
Application number: AU2022100108A
Authority: AU
Inventors: Wei Hong
Original assignee: Summit Trade and Investment Pty Ltd
Current assignee: Summit Trade and Investment Pty Ltd
Priority date: 2021-07-05
Filing date: 2022-08-15
Publication date: 2022-09-08
Anticipated expiration: 2029-07-05
Also published as: AU2021103879A4

Abstract

A novel over discharge protection circuit designed for additive manufactured battery powered adapters to prevent battery side from over-discharge and facilitate user experience and product lifespan. End users are able to apply this circuit to multi voltage based Li-lon batteries by replacing Zener diode and resistors on circuit and set their own capacity safety threshold accordingly. 1/1 DRAWINGS Q3 I S D 8 2 6 5 3 S D 6 2MiMG D B20 P03 R4 lOOK 1% Dl MMSZ4697TlG 2 10K 1% GND Q2 SK2310AAJ -. K GND Figure 1 GND Battery Power On S10 P/N MOS Voltage Detection S12 D->S /S->D 7 S14 N zener Diode Detection: If Battery Voltage >14.sV Yes F16 Figure 2 Circuit Operates

Description

1/1

DRAWINGS

Q3 I S D 8 2 6 5 3 S D 6 2MiMG D B20 P03 R4 lOOK 1% Dl MMSZ4697TlG

2

10K 1% GND Q2 SK2310AAJ -.

K GND Figure 1

GND

Battery Power On

S10

P/N MOS Voltage Detection

S12 D->S /S->D

S14 7

N zener Diode Detection: If Battery Voltage >14.sV

Yes F16 Figure 2 Circuit Operates

OVER DISCHARGE PROTECTION CIRCUIT FOR ADDITIVE MANUFACTURED BATTERYADAPTERS TECHNICAL FIELD

[0001] The novel invention relates to particularly an over discharge detection and

protection circuit designed for additive manufactured multi-volt battery adapters in

industrial application field.

BACKGROUND ART

[0002] Since 2000, different handheld power tools for building and construction became

widely accepted as rechargeable battery packs are widely adopted as power supply as

well. With multi-volt (7.2v, 14.4v, 18v, 20v, 21.6v, 36v, 54v and so on) Li-ion battery

power packs, portable power tools such as screwdrivers, cutting tools, lighting

equipment significantly improved end-users working efficiency by providing them with

high flexibility and more options. However, such tools may hardly be able to accompany

with dramatically increasing and changing demands in some industrial fields.

[0003] Additive manufacturing, or 3D-Printing technology for custom product

manufacturing has been widely accepted and successfully applied in various industries.

End-users are now being able to be directly benefit from the customized designed

projects to best match their demands with cost effective plans. For instance, the

application in 3D-Printed industrial lighting equipment with Multi-voltage based portable

power sources that using Li-Ion backed battery cells such as 18650 cells. In general, as

long as power tools (electric power consuming side) maintain the same nominal output

voltage that is compatible with the rated voltage of the battery packs (electric power

supplying side), power tools can operate normally. 18v battery pack has the dominate

marketplace nowadays thus examples and embodiment will present in 18v for the

convenient of explaining. However, this should not be viewed as limitation of the

possible applications on this novel invention in other different voltage range battery power packs as mentioned in the previous context. These battery packs comprise, for instance, li-ion batteries, and a plurality of battery cells is housed in a case; thereby, the battery pack can be reused by detaching it from the tool main body and then charging it using a separately available charger. However, misuse or the faulty of battery pack component may result in a phenomenon named over-discharge, whereby battery cells inside discharged beyond the lower safe voltage limit determined by the electrode chemistry coupling, and leading to the battery cells to suffer severe, permanent damage as over discharge is a potential problem in large battery packs since cells are discharged at the same rate, despite having different capacities. In such instances, additive manufactured adapters that can be powered by multi-volt battery can be significantly improved with the novel design.

SUMMARY OF THE INVENTION

[0004] Applying over discharge protection circuit on additive manufacturing products

can benefit end-users by saving their time and effort as they need to closely monitor

remaining battery cells capacity compared to ordinary 3D printed battery adapters.

With the increased demand for high brightness lights, measured in luminous flex (LM),

3D printed industrial lights require a special designed circuit that prevents the over

discharge circumstance to happen during the usage and also to improve overall user

experience.

[0005] Prior to the development of over discharge cut protection circuit that suits 3D

printed products, the lifespan of the power sources would be terribly impacted as end

users can hardly access the remaining capacity of the power source, for example, the

battery pack without indicator or with raw bar indicator that weighted in LED bars, or Li

Ion cells with decay inside already. The present invention is set to work automatically on

behalf of end users to provide protection for cells if it detects the low remaining capacity

inside cells. As a result, 3D printed products will provide extended sustainable solutions

and attract more potential clients in infrastructure field with specific demands. Luminous efficacy is a key measurement in 3D printed LED lighting tools kit. For example, the average lumen reading for indoor bulb is at 800LM whereas end users may require 5-6 times brightness for custom made purposes like implementing tunneling projects, building overnight. The higher brightness from custom 3D printed LEDs, the higher luminous flux and power consuming lights will be. To provide better user experience, the present over discharge circuit that can be embedded in 3D-Printed custom made products is necessary in real application. The over-discharge cut protection circuit designed particularly for additive manufactured products is not limited to above examples but also has a broad application in multiple 3D-Printed custom made products with further modifications on specific demand.

[0006] Accordingly, over discharge protection circuit is necessary to prevent potential

damages to the power supply side for additive manufactured custom made industrial

and infrastructural high output lighting equipment that can powered by 18v/20v/21.6v Li

ion battery.

BRIEF DESCRIPTION OF DRAWING

[0007] As illustrated in Figure 1, Q3 is the installed P-Channel Metal-oxide

semiconductor field effect transistor (MOSFET) B20P03 (Library reference number).

Q2 is the installed N-Channel MOSFET SK231OAA (Library reference number).

R1,R2,R3,R4,R5 and R6 are all SMD resistors whereas R2,R3,R5 and R6 are RS

K102JT (± 5%) and R1,R4 are RS-05K1002FT(± 1%). D1 is the Zener diode

(MMSZ4697T1G for library reference). C1, C2 are 24v Multiplayer ceramic chip

capacitors (MLCC).

[0008] As illustrated in Figure 2, when the 3D printed adapter base is connected to the

battery power source: P-Channel MOS and N Channel MOS start first-time battery

voltage checking process (sl0). When the voltage is greater than 14.5v, N-Channel

MOS operates. N-Channel MOS shut down when operating voltage from battery side is detected under 14.5v (s12). When Vg<Vs, P-Channel MOS operates, circuit operates

(s14). Circuit is powered successfully if all prior requirements meet (s16).

Description of Embodiments

[0009] Embodiment 1: Prior to the novel design, 3D printed lights most likely

manufactured with or without physical manual power switch which limited end-users'

choice and possibly lead to safety concerns. End users may need to manually switch

the 3D printed lights off or remove the 3D printed lights from battery based on almost

purely past using empirical experience of their battery.

The equations used by this embodiment:

P(w)= (v(m) / (im/w) Equation 1

W = im / (m/W) Equation 2

Table 1 Calculated operating power and relevant Lumen readings accordingly

Output Operating Power (w) Lumen Reading (LM)

75w 1055LM

100w 1521 LM

150w 2452 LM

200w 3452 LM

[0010] Incandescent light bulb models have relatively low luminous efficacy. For

example, 30001m with 200W thus higher brightness would incur even higher power

consumption on isolated power source like certain 18v/20v/21.6v battery. For example,

a standard 18v/20v/21.6v 4.0 Ah Li-ion battery with 18650 cells inside as power supply

for 34521m 3D additive printed LEDs will be depleted in 0.36 hours and end-users may

not have enough time to take further action manually to switch the LED off or remove the LED off the battery. In such instances, a phenomenon named over-discharge may occur, whereby battery cells inside discharged beyond the lower safe voltage limit determined by the electrode chemistry coupling, and leading to the battery cells to suffer obvious permanent damage as over discharge is a potential problem in large battery packs since cells are discharged at the same rate, despite having different capacities.

[0011] The over discharge protection circuit may be formed with other electrical

elements or custom products use additive manufacturing technology that not listed here.

Certain measures are recited in mutually different dependent claims. It does not indicate

that a combination of these listed embodiments cannot be used to advantage. Any

reference signs in the claims should not be construed as limiting the scope.

[0012] The invention is of primary interest for providing solutions to protecting li-ion

battery cells lifecycle from over-discharge on general additive manufactured custom

products that can be powered by multi-volt portable rechargeable Li-lon battery. The

circuit has installed N-MOS and P-MOS, resistors, and Zener diode to help 3D printed

products to determine if the powering battery is with sufficient capacity.

Claims

1. An additive manufactured battery adapter for portable power tools comprising:

a body adapted to releasably connect a multi-cell battery pack to a portable power tool; and

an over discharge protection circuit within the additive manufactured body, wherein the over discharge protection circuit is configured to detect a supply voltage of the multi-cell battery pack and prevent operation of the power tool when the supply voltage is below a threshold voltage.

2. The additive manufactured battery adapter as claimed in claim 1 wherein the over discharge protection circuit is configured to monitor individual cell voltages of each cell in the multi-cell battery and switch off the power tool when one or more of the individual cell voltages drops below the threshold voltage.

3. The additive manufactured battery adapter as claimed in either claim 1 or claim 2 wherein the discharge protection circuit comprises a Zener diode and adjustable resistor circuit allowing a user to adjust and set the threshold voltage.

4. The additive manufactured battery adapter as claimed in claim 3 further comprising a display, housed within the additive manufactured body, wherein the display is configured to display the set threshold voltage.

5. An additive manufactured battery adapter for connecting a multi-cell battery pack that is incompatible with a power tool to said power tool, the battery adapter comprising:

an additive manufactured body adapted to releasably connect the multi-cell battery pack to the portable power tool; and an over discharge protection circuit embedded within the additive manufactured body, wherein the over discharge protection circuit is configured to monitor individual cell voltages of each cell in the multi-cell battery and switch off the power tool when one or more of the individual cell voltages drops below a threshold voltage.