U.S. patent application number 09/802112 was filed with the patent office on 2002-04-11 for apparatus for providing supplemental power to an electrical system and related methods.
Invention is credited to Purkey, Bruce.
Application Number | 20020041174 09/802112 |
Document ID | / |
Family ID | 26932065 |
Filed Date | 2002-04-11 |
United States Patent
Application |
20020041174 |
Kind Code |
A1 |
Purkey, Bruce |
April 11, 2002 |
Apparatus for providing supplemental power to an electrical system
and related methods
Abstract
An apparatus and method for providing supplementary power to an
electrical system of a vehicle or other machinery is provided. The
apparatus and methods specifically provide a rapid-delivery of high
amounts of power. The significant power levels are sufficient, for
example, to turn the starter of a heavy-duty commercial transport
vehicle stranded by a disabled battery. The power is supplied by a
power source having the combination of high-density capacitor and
battery. The power delivery is controlled to avoid such standard
problems as reverse or same polarity connections and overvoltage.
Control is effected by a combination voltage sensing circuit and
isolation circuit to prevent current between the power source and
the electrical system unless prescribed conditions are satisfied.
The energy level of the power source is sustained by the
capacitor-battery combination along with the capabilities to
receive return charging from the electrical system as well as from
alternating current and direct current sources.
Inventors: |
Purkey, Bruce; (Rogers,
AR) |
Correspondence
Address: |
Jeffery S. Whittle
Allen, Dyer, Doppelt, Milbrath & Gilchrist, P.A.
255 S. Orange Avenue, Suite 1401
P.O. BOX 3791
Orlando
FL
32802-3791
US
|
Family ID: |
26932065 |
Appl. No.: |
09/802112 |
Filed: |
March 8, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60238903 |
Oct 10, 2000 |
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Current U.S.
Class: |
320/103 |
Current CPC
Class: |
Y02E 60/10 20130101;
H02J 7/0042 20130101; H01M 10/4264 20130101; H02J 7/345 20130101;
H01M 50/296 20210101; H01M 50/247 20210101; H01M 10/46 20130101;
H02J 1/122 20200101; H01M 50/20 20210101; H01M 6/5033 20130101;
F02N 11/14 20130101 |
Class at
Publication: |
320/103 |
International
Class: |
H02J 007/00 |
Claims
That which is claimed is:
1. A rapid-delivery portable power booster for providing a
supplementary source of power to an electrical system, the
apparatus comprising: a housing; a power source positioned within
the housing; first and second electrical conductors electrically
connected to the power source and extending outwardly from the
housing to establish a power supply connection between the power
source and the electrical system to selectively exchange power
between the power source and the electrical system, the first
conductor being positioned to detachably connect to a positive
terminal of the electrical system and the second conductor being
positioned to detachably connect to a negative terminal of the
electrical system to selectively permit rapid delivery of a
concentrated amount of energy from the power source to the
electrical system; and a power delivery controller positioned
within the housing and connected to the power source to selectively
initiate an electrical current within the power supply connection
between the power source and the electrical system when the voltage
of the electrical system is within a first predetermined range, and
maintain the electrical current when the electrical system voltage
is within a second predetermined range; and a charger electrically
connected to the power source and positioned within the housing to
receive power from an external energy source to maintain a
predetermined energy level within the power source.
2. A rapid-delivery portable power booster as defined in claim 1
wherein the power delivery controller comprises: a voltage
detecting circuit connected to the first electrical conductor to
determine voltages within the electrical system; and a processor
responsive to the voltage detecting circuit to provide a numerical
indicator corresponding to the detected voltage of the electrical
system; and an isolation circuit responsive to the processor to
electrically isolate the power source from the electrical system
thereby blocking electrical current between them except under
predetermined voltage conditions in the electrical system, to
permit an electrical current to initiate between the power supply
and the electrical system when the processor-determined numerical
indicator of the electrical system voltage is within a first
predetermined range, and to permit the electrical current to
continue when the processor-determined numerical indicator of the
electrical system voltage is within a second predetermined
range.
3. A rapid-delivery portable power booster as defined in claim 2
wherein the processor comprises a voltage register to store an
initial numerical indicator corresponding to an initial detected
voltage of the electrical system and a voltage difference
determiner responsive to the voltage register to determine
numerical increases and decreases in electrical system voltage
relative to the initial detected voltage by computing a difference
between the initial numerical indicator and subsequent
processor-determined numerical indicators corresponding to
subsequent voltage levels of the electrical system so that the
processor-responsive isolation circuit permits initial
current-borne delivery of power from the power source to the
electrical system in response to a predetermined decrease in
electrical system voltage and continues delivery of power in
response to a subsequent predetermined increase in electrical
system voltage relative to the initial detected voltage.
4. A rapid-delivery portable power booster as defined in claim 3
wherein the processor further comprises a timer positioned to
measure elapsed time between discrete changes in the numerical
indicator of electrical system voltages and wherein the processor
signals the processor-responsive isolation circuit to interrupt and
block current between the power source and the electrical system
when said predetermined increase in voltage fails to occur within a
first preselected elapsed time interval.
5. A rapid-delivery portable power booster as defined in claim 4
wherein the timer is positioned to measure elapsed time during
which current is passed between the power source and wherein the
processor signals the isolation circuit to permit a current to be
maintained between the power source and the electrical system
within a second preselected elapsed time interval when the
preselected increase in voltage occurs within the first preselected
elapsed time interval so as to thereby permit a subsequent change
in current direction such that during the second preselected
elapsed time interval the electrical system will at least partially
recharge the power source.
6. A rapid-delivery portable power booster for providing a
supplementary source of power to an electrical system, the
apparatus comprising: a housing; and a power source positioned
within the housing and comprising a high-density capacitor to
rapidly deliver power to the electrical system and a battery
electrically connected to the capacitor to maintain the energy
level of the capacitor above a preselected minimum and to increase
the amount of power delivered to the electrical system; first and
second electrical conductors electrically connected to the power
source and extending outwardly from the housing to establish a
power supply connection between the power source and the electrical
system to selectively exchange power between the power source and
the electrical system, the first conductor being positioned to
detachably connect to a positive terminal of the electrical system
and the second conductor being positioned to detachably connect to
a negative terminal of the electrical system to selectively permit
rapid delivery of a concentrated amount of energy from the power
source to the electrical system; and a power delivery controller
positioned within the housing and connected to the power source
comprising: an isolation circuit electrically connected to the
power source to electrically isolate the power source from the
electrical system and prevent any current between the power source
and the electrical system when power is not being exchanged between
the power source and the electrical system, a voltage sensing
circuit electrically connected to the isolation circuit, the
voltage sensing circuit being responsive to the electrical system
to sense voltage levels within the electrical system, and an energy
delivery signaler electrically connected to the voltage measuring
circuit and the isolation circuit to electronically signal the
isolation circuit to permit current between the power source
capacitor and battery and the electrical system when the electrical
system voltage is within a predetermined range; and a charger
electrically connected to the power source and positioned within
the housing to receive power from an external energy source to
maintain at least a predetermined energy level within the power
source.
7. A rapid-delivery portable power booster as defined in claim 6
wherein the energy delivery signaler comprises an electrical relay
positioned within the housing which is responsive to an external
switch positioned outside the housing and in electrical
communication with the isolation circuit to provide remote control
over the exchange of power between the power source and the
electrical system.
8. A rapid-delivery portable power booster as defined in claim 7
wherein the high-density capacitor and battery jointly deliver a
minimum of approximately one hundred twenty kilojoules (120 kJ)
within ten seconds (10 s) to the electrical system with an
efficiency of approximately ninety percent (90%).
9. A rapid-delivery portable power booster as defined in claim 8
wherein the isolation circuit comprises at least a pair of magnetic
switches electrically connected to the first conductor.
10. A rapid-delivery portable power booster as defined in claim 1
wherein the charger includes first and second alternating current
conductors extending outwardly from the housing through which the
power source can obtain energy from an external source of
alternating current (AC) when the power booster is electrically
connected to an external source of alternating current as provided
by a standard AC electrical outlet, and wherein the charger further
includes first and second direct current (DC) conductors extending
outwardly from the housing through which the power source can
obtain energy from an external source of direct current when the
power booster is electrically connected to an external source of
direct current as provided by a standard transportation vehicle
battery.
11. A rapid delivery portable power booster apparatus for providing
a supplementary source of power to an electrical system, the
apparatus comprising: a housing; and rapid power delivery means
positioned within the housing for delivering a high-voltage burst
of power to the electrical system; voltage detecting means
positioned within the housing and responsive to the voltage of the
electrical system for detecting the voltage of the electrical
system; energy isolation means positioned within the housing and in
communication with the voltage detecting means for preventing an
exchange of power between the power booster and the electrical
system unless the voltage of the electrical system is within a
predetermined range; and connecting means in electrical
communication with the rapid energy delivery means and extending
outside the housing for connecting the apparatus to the electrical
system for rapid-burst energy delivery to the electrical
system.
12. A rapid delivery portable power booster as described in claim
11 further comprising electrical charging means positioned within
the housing and in communication with the rapid energy delivery
means to receive energy from an external energy source and transfer
the external energy to the rapid energy delivery means to maintain
the capacity of the rapid energy delivery means to deliver a
predetermined minimum level of energy to the electrical system.
13. A rapid delivery portable power booster as described in claim
11 wherein the rapid energy delivery means has a capacity to
deliver a minimum of approximately one hundred twenty kilojoules
(120 kJ) within ten seconds (10 s) to the electrical system with an
efficiency of approximately ninety percent (90%).
14. A rapid delivery portable power booster as described in claim
11 wherein the electrical charging means comprises alternative
direct current (DC) and alternating current (AC) receiving means to
selectively and alternatively receive power from an external source
of alternating current (AC) and an external source of direct
current (DC).
15. A rapid delivery portable power booster as described in claim
11 further comprising switching means positioned outside the
housing and in electrical communication with the energy isolation
means and the rapid energy delivery means for providing remote
control over the delivery of energy to the electrical system by
means of activating and deactivating the rapid energy delivery
means.
16. A rapid delivery portable power booster as described in claim
13 wherein the switching means is provided by a manually actuated
switch connected to the energy isolation means and the rapid energy
delivery means by an elongate electrical conductor.
17. A rapid-delivery portable power booster for providing a
supplementary source of power to an electrical system, the
apparatus comprising: a power source comprising a high-density
capacitor to rapidly deliver power to the electrical system and a
battery electrically connected to the capacitor to maintain the
energy level of the capacitor above a preselected minimum and to
increase the amount of power delivered to the electrical system;
first and second electrical conductors electrically connected to
the power source to establish a power supply connection between the
power source and the electrical system to selectively exchange
power between the power source and the electrical system, the first
conductor being positioned to detachably connect to a positive
terminal of the electrical system and the second conductor being
positioned to detachably connect to a negative terminal of the
electrical system to selectively permit rapid deliver of a
concentrated amount of energy from the power source to the
electrical system; and a power delivery controller connected to the
power source to selectively initiate an electrical current within
the power supply connection between the power source and the
electrical system when the voltage of the electrical system is
within a first predetermined range, and maintain the electrical
current when the electrical system voltage is within a second
predetermined range.
18. A rapid delivery portable power booster as described in claim
17 wherein the power source has a capacity to deliver a minimum of
approximately one hundred twenty kilojoules (120 kJ) within ten
seconds (10 s) to the electrical system with an efficiency of
approximately ninety percent (90%).
19. A rapid delivery portable power booster as described in claim
18 wherein the portable power booster further comprises a power
source recharger to recharge the power source by selectively and
alternatively receiving power from an external source of
alternating current (AC) and an external source of direct current
(DC).
20. A method for rapidly delivering power to an electrical system
so as to boost the voltage of the electrical system, the method
comprising the steps of: electrically connecting a high-voltage
capacitor to the electrical system to provide controlled
rapid-delivery of power to the electrical system; sensing the
voltage at the connection to determine when the power can optimally
and selectively be supplied to the electrical system; and
delivering power to the electrical system from the high-voltage
capacitor when the sensed voltage is within a predetermined
range.
21. A method as defined in claim 20 further comprising the step of
reversing power exchange to thereby deliver power from the
voltage-boosted electrical system to the high-voltage capacitor to
thereby maintain the energy level of the capacitor at or near a
preselected minimum level.
22. A method as described in claim 20 wherein the step of
delivering power to the electrical system from the high-voltage
capacitor comprises delivering a minimum of approximately one
hundred twenty kilojoules (120 kJ) within ten seconds (10 s) to the
electrical system with an efficiency of approximately ninety
percent (90%).
23. A method for recharging a starter battery of a vehicle powered
by an internal combustion engine and having an electrical system
with alternator associated with the starter battery and engine for
starting the vehicle engine, the method comprising the steps of:
positioning an independently transportable portable power source
having a high-density capacitor adjacent the vehicle; and
establishing a power supply connection between the electrical
system of the vehicle and the portable power source for rapid
delivery of power to the connected electrical system; and
delivering power to the electrical system of the vehicle in a
quantity sufficient to turn the alternator and thereby start the
internal combustion engine independently from the starter battery
and preventing any additional power delivery when the engine is
started.
23. A method as defined in claim 22, wherein the steps of
positioning a portable power source having a high-density capacitor
for rapid delivery of power to the connected electrical system
adjacent the vehicle and establishing a power supply connection
between the electrical system of the vehicle and the portable power
source comprises positioning a portable power source comprising an
electrochemical capacitor and establishing a power supply
connection between the electrical system of the vehicle and the
electrochemical capacitor of the portable power source.
24. A method for recharging a starter battery of a vehicle powered
by an internal combustion engine and having an electrical system
with alternator associated with the starter battery and engine for
starting the vehicle engine, the method comprising the steps of:
establishing a power supply connection between the electrical
system of the vehicle and a portable power source having a
high-density capacitor for rapid delivery of power to the connected
electrical system; sensing the voltage of the electrical system and
delivering power to the electrical system from the high-voltage
capacitor when the sensed voltage is within a predetermined range;
and delivering power to the electrical system of the vehicle in a
quantity sufficient to turn the alternator and thereby start the
internal combustion engine independently from the starter battery
and preventing any additional power delivery when the engine is
started.
25. A method as described in claim 24 further comprising the step
of maintaining the power supply connection after the engine is
started to thereby replenish the energy stored by the high-density
capacitor simultaneously as the now-running engine recharges the
vehicle battery.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of Provisional Patent
Application No. 60/238,903 filed Oct. 10, 2000, and titled
Apparatus For Providing Portable Power To Machinery And Related
Methods and is incorporated herein by reference in its
entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to the portable power source
industry and, more particularly, to the field of portable power
sources for providing supplemental power to electrical and
mechanical systems.
BACKGROUND OF THE INVENTION
[0003] The need for a portable power source arises frequently in a
variety of circumstances. Among the most common of circumstances is
the situation in which a commercial or family vehicle fails to
start because of a "dead" battery. A commercial or family vehicles
typically is powered by a conventional internal combustion engine
which requires a separate electric motor (i.e., "starter") that
rotates the engine crankshaft at a speed sufficient to start the
engine. Because the starter is electrically powered by an
automobile battery, if the battery goes dead or otherwise loses a
substantial amount of stored energy when the vehicle's lights or
radio are left on while the engine is off, then the engine will not
start. This phenomenon has existed since the introduction of the
electric starter and lead acid storage battery on a vehicle, and it
is especially prevalent during cold weather when vehicles are
generally more difficult to start and extra engineoff loads are
left on (e.g., electrical heaters) causing the vehicle's battery to
discharge even faster.
[0004] In such circumstances, it is necessary to have the benefit
of a supplemental source of power to "jump start" the vehicle's
engine. With a jump start, because the vehicle battery does not
have the needed energy or electrical "push" (i.e., voltage)
necessary, supplementary power is applied to the electrical system
or starter motors. Jump starts typically have been applied two
ways: (1) application of additional battery power in parallel with
the existing battery or batteries on the vehicle or machinery; and
(2) generation of direct current power produced by a generator or
alternator driven by a separate engine.
[0005] Thus, with respect to the first method of providing a jump
start, most conventional devices still continue to rely on a direct
current power source provided by a battery. Recent examples of such
devices are U.S. Pat. No. 6,130,519 to Whiting et al. titled
Portable Battery Charger Including Auto-Polarity Switch and U.S.
Pat. No. 5,793,185 to Prelec et al. titled Jump Starter, which
describe power booster devices using a battery. The jump start is
performed with the application of extra battery power in parallel
with the existing battery on a vehicle and requires that connecting
leads, or "jumper cables," be connected from an external power
source, conventionally a separate battery, to the battery on the
vehicle. With this method of jump starting, the separate, charged
battery provides extra energy to the disabled battery of the
vehicle and thus may enable the engine starting operation. In
essence, the extra battery is temporarily boosting the voltage, and
thus, the available power in the system, so that the starter motor
may have sufficient energy to start the engine; that is, this
momentary boost in electrical energy to the starter motor may be
sufficient to start the engine if the supplemental battery provides
sufficient power.
[0006] Unfortunately, the supplemental battery does not always
provide sufficient power. The amount of power required by the
supplemental battery is a function of many factors, including the
size of the engine to be started, its temperature, oil, and
viscosity, as well as the remaining energy of the disabled vehicle
battery. The supplemental battery must provide enough additional
energy to equal the normal level of power available from a fully
charged battery installed in the vehicle. If, for example, the
vehicle battery is completely discharged, the supplemental battery
may not have sufficient energy to make the starter motor function
properly. Some devices have sought to boost the energy supplied by
a supplementary battery used to recharge a disabled battery. U.S.
Pat. No. 5,637,978 to Kellett et al. titled Battery Booster, for
example, describes a "boost converter" comprising a switch, diode
and inductor to step up the primary power supplied by a battery.
Depending on the above-described conditions, however, the
additional 2 to 3 volts provided may not be sufficient, especially
in attempting to start the heavy engine of a large-sized heavy-duty
commercial vehicle. U.S. Pat. No. 4,510,431 to Winkler titled D.C.
Stepped-Up Voltage Transfomerless Battery Charger, steps up the
voltage of a direct current battery by applying a supplementary
source power via alternating current to a capacitor. While this may
be useful for recharging batteries in hand-held devices (e.g.,
walkie-talkies or radios), it may not be suitable for recharging
vehicle batteries stranded away from a source of alternating
current and requiring a much greater supplementary power.
[0007] Moreover, conventional devices, because of the limited
amount of supplementary power delivered in a single, short burst,
frequently require significant time durations to recharge the
vehicle battery. The level of discharge of the existing vehicle
battery, as noted, will determine at least partly the time
necessary to recharge a disabled battery, or even whether the
vehicle can be jump-started at all. If the supplementary battery
power has insufficient power itself, the discharged battery may
require significant time to receive the energy flow needed so that
it can work with the supplementary battery to start the engine. At
lower temperatures for example, the energy flow becomes slower.
When temperature is low the chemical properties of a conventional
battery do not allow the battery to function as well in any charge
condition, but especially when it is severely discharged. If
severely discharged, then the vehicle battery may take a
significant amount of time to recharge.
[0008] Conventional techniques pose other problems as well.
Initially, when batteries are connected in parallel, the discharged
battery begins to draw energy from the charged battery. If left in
a steady state, the discharged battery will eventually drain energy
from the charged battery to the point where the combination of the
parallel batteries will reach equilibrium with equal electrical
energy in each.
[0009] Conventional techniques also can create other potential
problems as well. Sparks can be generated when the supplementary
battery is electrically connected to the existing vehicle battery.
If the battery is connected improperly, the likelihood of sparks
increases. There is also potential damage to both the vehicle
battery and the vehicle electrical system. Gases produced by the
battery can be ignited causing explosion and bodily harm to the
installer along with damage to the vehicle.
[0010] Providing a power boost can alternatively be accomplished by
generation of direct current power produced by generators or
alternators that are driven by some type of engine. As with
providing a supplementary battery to boost power, in order for a
standby power generation unit to be effective, it needs the
capability to produce sufficient power to either activate the
starting motor independently or it must supplement the existing
vehicle battery as already described above. It is generally not
practical, due to size and cost, to have a generator set large
enough to turn the engine by itself. Therefore, a jump start using
this method is normally accomplished by boosting output voltage of
the generator set beyond normal operating levels in order to charge
the existing vehicle battery.
[0011] This increased voltage, however, leads to its own set of
potential problems. The voltage levels produced are conventionally
controlled either manually or by built in voltage regulators. When
set manually, an operator must monitor the output of the unit and
the charging process. The charging process takes time as described
above. This requires that the operator devote full attention to the
process. It is costly, though, for an operator to simply watch the
unit perform. If the unit performs out of control, however, damage
will be caused to the batteries and potentially to the starter
motor and electrical system of the vehicle. If the unit is left
completely unattended, the voltage can climb to an unsafe level and
explosion can occur causing damage to the battery, generator set,
vehicle electrical system, and potentially bodily harm to persons
within the vicinity of the vehicle. The least of the problems that
will result from overcharge is shortened life from the vehicle
battery.
[0012] If the unit is controlled by built-in voltage regulators,
they can and often do fail. Calibrations are seldom checked.
Regulators are seldom serviced. Therefore, even in an automatic
mode, potential runaway overcharge can and often does occur.
[0013] In either mode of supplying supplementary power, the engine
that drives the generator set must have fuel. If the unit is
operating unattended, the engine can run out of fuel at an
inopportune time. At this point, the generators attempt to reverse
action. They start drawing energy from the battery which was
formerly being charged as the generator attempts to function as a
starter motor to turn the engine which is normally its driver. The
result is that the battery is again discharged. In summary, the
operation of a standby generator set is costly with operator in
attendance, but very dangerous without operator in attendance.
SUMMARY OF THE INVENTION
[0014] In view of the foregoing background, the present invention
advantageously provides an apparatus and method for delivering
supplemental power to the electrical system of a vehicle or other
machinery. The advantages afforded by the claimed invention and
described herein provide particular benefits in boosting power in
the electrical system of a vehicle disabled by a discharged
battery. The claimed invention provides a power source with the
capability to convey concentrated, rapid-delivery power to an
electrical system, while automatically controlling the extent and
timing of power delivery so as to deliver an optimal amount of
power without risk of overloading the electrical system being
boosted.
[0015] Specifically, the claimed invention utilizes an
electronically controlled power booster combination of high-density
capacitor and battery. The capacitor, as described in detail below,
is capable of storing a tremendous amount of charge and is thereby
able to provide, via rapid transference of concentrated energy, a
substantial power boost to an electrical system. As further
described below, the claimed invention utilizes a capacitor-battery
combination that includes an electrochemical capacitor, which
depending on its particular construction can contribute to the
storage of tremendous amounts of charge. The energy level of the
capacitor is sustained at or above a preselected minimum level by
the electrically connected battery.
[0016] An apparent offset to the advantages associated with
rapid-burst, high-concentration power delivery, however, is that
too much power may be delivered too quickly to the electrical
system or before an improper connection between the power booster
and electrical system has been detected. The present invention
overcomes this problem by providing a power delivery controller
having electronic circuitry that optimally controls power delivery
as alluded to above. Specifically, the power delivery controller
includes voltage detecting capabilities to detect voltage
conditions in the electrical system to receive a power boost and an
isolation circuit responsive to the detected voltage conditions to
optimally control power delivery. More specifically, the voltage
conditions indicate when a proper connection between the power
source and the electrical system has been established, when power
is to be supplied from the power source, and when an optimal amount
of power has been delivered to the electrical system from the power
source. These capabilities, thus, work jointly to determine when
the proper conditions for power delivery exist, then respond by
permitting power delivery from a power booster source to the
electrical system, and finally block power delivery as soon as the
optimal amount of power has been delivered.
[0017] In the specific context of starting a vehicle disabled by a
discharged battery, the invention determines whether a power source
connection has been properly made between a power source and the
vehicle battery. If so, it allows the power source to rapidly
deliver concentrated power to the vehicle from the power source
comprising a combination capacitor (preferably an electrochemical
type) and battery. The concentrated power is delivered directly to
the vehicle's alternator and engine in sufficient amounts to start
the vehicle engine without having to rely on the vehicle's
discharged battery for power. When the vehicle engine starts, the
vehicle's engine begins to recharge the discharged vehicle battery,
and the electronically controlled isolation circuit blocks further
power delivery from the power source. Only power enough to turn the
alternator and start the vehicle's engine is delivered from the
power source and no more, thereby avoiding risk of providing too
much power too quickly.
[0018] Continuing in the context of providing a power boost to a
disabled vehicle, a further advantage of the present invention is
the ability to replenish the capacitor using the very vehicle which
has been started in the manner just described. As noted, the
electronically controlled isolation circuit blocks further power
delivery from the power source as soon as the engine of the
disabled vehicle has been started. The power connection between the
vehicle and the power source is maintained, though, according to
the present invention, so that as the now-started vehicle engine
begins to recharge the vehicle battery it also delivers energy to
the capacitor. The result is that power that was delivered from the
power source to start the vehicle is now returned to the power
source to be stored by the power source capacitor. In this sense,
the invention provides a sustainable source of power for boosting
an electrical system.
[0019] Again, in the context of boosting the disabled battery of a
heavy-duty vehicle, sufficient energy is provided by a power source
combining a high-density capacitor and battery as to turn a large
engine to thereby efficiently and rapidly start the vehicle. Thus,
the claimed invention's ability to provide a rapid-delivery,
concentrated power boost is uniquely suited to recharging disabled
batteries on large commercial transport vehicles quickly and
efficiently. The claimed invention's ability to provide substantial
power boosts, in contrast to the generators and similar devices
earlier described, is not at the expense of a large and cumbersome
construction; the claimed invention is highly portable. It can be
lifted by hand onto a vehicle or cart for long distance transport
and thus, the claimed invention's ability to provide a portable
power boost is uniquely suited to recharging disabled batteries on
large commercial transport vehicles stranded in remote areas. This
combination of rapid, high power delivery and portability provides
considerable advantages over conventional charging devices and
methods.
[0020] As described, although designed to deliver high levels of
power, the claimed invention also possesses unique features that
match voltages so as to avoid damage to the electrical system
during power transfers and control where dispensed energy is
delivered. Specifically, the claimed invention has a control
capacity to determine the voltage requirements of the electrical
system. It also isolates the source of power from the electrical
system until a proper power delivery connection is made so as to
avoid inadvertent discharge or overvoltages owing to improper
hook-up between the power source and the electrical system. There
is, thus, a built-in reverse polarity protection. Relatedly, there
is same polarity protection in the sense that an accidental
connection of power source conductors to the same terminal of the
electrical system battery causing a direct short will be "sensed"
before power delivery is initiated, thereby reducing risk of damage
to the invention and the electrical system.
[0021] The claimed invention achieves these advantages, as already
noted, by providing a combination voltage detecting or sensing
circuit working jointly with an isolation circuit that prevents
delivery of power from the invention's power source unless the
proper voltage determinations are made. In one specific embodiment
of the invention, a manually actuated switch prevents any current
exchange until the operator has connected the power booster and the
electrical system and is safely situated to remotely control power
delivery. Even after the switch is actuated, the sensing circuit
operates to detect whether the proper voltages exist at power
supply connection (i.e., a 0.7V voltage across the terminals of a
disabled battery). If not, the isolation circuit, which can be an
arrangement of magnetic switches, prevents any electrical current
to pass between the power source and the electrical system. If a
proper connection has been made, the capacitor-battery combination
power source delivers through the power supply connection a high
concentration of power.
[0022] In an alternative embodiment, the voltage detection circuit
and isolation circuit include a processor and timer. The voltage
within the electrical system is detected after the connection is
made between the power booster and the electrical system. The
process further includes a register to store a numerical indicator
of the initial voltage detected. If a subsequent drop in voltage is
detected (expected to be approximately a 2V drop in voltage), the
processor signals the isolation circuit to permit current-borne
delivery of power. In conjunction with the timer, then, the
processor compares subsequent voltage with the initial voltage and
determines whether an expected rise in voltage has occurred within
a prescribed time interval (expected to be approximately a 1.5V
rise in voltage within approximately 10 seconds). If so, then the
processor signals the isolation circuit to permit continued passage
of current for a second prescribed time interval, during which the
electrical system will be sufficiently recharged and current will
reverse so that the power source can be recharged by the
now-enabled electrical system. If the expected rise in voltage does
not occur within the first time interval, however, the isolation
circuit operates to block any further current passing because of an
incorrect connection or inherent problems in the electrical system
itself.
[0023] These alternative embodiments, with varying degrees in cost
of manufacture and of efficiency for the operator, each provide the
capabilities alluded to earlier regarding the avoidance of
overvoltage (with the corresponding risks of sparking), shorts, and
damaging polarity reversals. Specifically, the ability,
automatically and manually, to electrically isolate the power
source and the electrical system during the process of making a
power delivery connection avoids risks of sparking when connecting
and disconnecting the separate conductors. These alternative
embodiments also provide reverse polarity protection in that if an
improper hookup is made, the power booster avoids delivery of power
thereby reducing the risk that the electrical system or booster
will be damaged. Similarly, there is same-polarity protection in
that if a short condition is created by improperly connecting both
power booster conductors to the same terminal of the electrical
system, no power delivery will be initiated, thereby reducing the
risk that the electrical system or booster will be damaged.
[0024] It is further envisioned that the same voltage sensing
circuitry and associated isolation circuits would have other
applications in the context of electrical starting systems for
vehicle engines using capacitors in lieu of or in conjunction with
conventional starter batteries. The U.S. Army, for example has
experimented with starting systems comprising only two batteries
and a capacitor for use with the diesel engines for five- and
seven-ton vehicles. See, e.g., J. R. Miller, J. Burgel, H.
Catherino, F. Drestik, J. Monroe and J. R. Stafford, Truck Starting
Using Electrochemical Capacitors (1998). Such vehicles are
difficult to start (especially at low temperatures) and normally
require four batteries for starting, which necessitates frequent
and costly battery replacements. Use of such alternative systems
was pioneered more than a decade ago by the Russian military and is
expected to become increasingly more common in many vehicles in the
years ahead. One additional advantageous use, then, of the sensing
circuitry and associated isolation circuits of the present
invention, would be to provide monitoring within such a system to
detect a malfunctioning alternator or other impediment to starting
the engine that does not result from a discharged capacitor or
battery. Failure to start the engine owing to reasons having
nothing to do with a discharged battery or capacitor are important
to detect, and the earlier, the better. Doing so can avoid
unnecessary dissipation of the capacitor and/or battery as when
power is drained from the system by an internal system fault or by
vainly trying to start the engine disabled by a faulty electrical
system. Detection can also avoid potentially damaging attempts to
boost the capacitor or battery when in fact the failure to start is
due to some inherent problem in the electrical system.
[0025] Yet a further advantage of the present invention is the
ability to perform multiple power boosts, or "jump starts," between
recharging of the power source. Indeed, under normal operating
circumstances, it is expected that the claimed invention will
provide at least 10 times, and likely many more, the number of
power boosts than conventional devices and methods currently
provide. The high-density capacitor is maintained by the connected
batter. Moreover, as earlier described, after the invention
recharges an electrical system, the electrical system can return a
replenishing charge to the high-energy/battery combination. The
purposefully selected low internal resistance of the capacitor,
moreover, enhances the capacitor's capability to accept the
recharge current from even a small or nearly discharged battery.
This lower resistance further enables the capacitor to be rapidly
recharged, as for example by a jump started vehicle alternator.
Under normal circumstances, recharging can take less than a minute.
These features, therefore, allow the capacitor to maintain
sufficient voltage to provide enumerable power boosts over
virtually any span of time.
[0026] The advantages provided by this recharge capability are
further enhanced by the ability of the present invention to accept
energy via either alternative current or direct current. Thus, the
invention is adapted to include a conventional wall-plug to plug
into a 110 volt wall socket to be recharged by conventional
alternating current supplied to homes and businesses. At the same
time, the invention is adapted to connect to a conventional 12 volt
battery for recharging as well. Thus, for example, the invention
can be recharged by a vehicle battery as the invention is being
transported on the vehicle to a remote site where it is to be
employed to boost the discharged battery of a stranded vehicle,
thereby further supplementing the invention's advantage relative to
conventional devices and methods.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] Some of the features, advantages, and benefits of the
present invention having been stated, others will become apparent
as the description proceeds when taken in conjunction with the
accompanying drawings in which:
[0028] FIG. 1 is perspective view of a heavy-duty commercial-sized
vehicle stationarily placed and an apparatus for providing
supplemental power being positioned near the vehicle to provide
power to the vehicle's electrical system according to the present
invention;
[0029] FIG. 2 is a perspective view of the exposed conductors and
switch extending from a housing containing an apparatus for
providing supplemental power to an electrical system according to
the present invention;
[0030] FIG. 3 is a perspective view of an apparatus for providing
supplemental power to an electrical system connected to the
disabled battery of a commercial vehicle so as to provide power to
the battery according to the present invention;
[0031] FIG. 4 is schematic diagram of the circuit elements of a
power delivery controller, power source, and charger of a power
booster according to the present invention;
[0032] FIG. 5 is a schematic diagram of the circuit elements of a
processor used with a power booster to effect control of delivery
of power between a power source and electrical system according to
the present invention;
[0033] FIG. 6 is a schematic circuit diagram of the elements and
connections of detecting circuitry, voltage regulator, and
programmable microcontroller for control of delivery of power
between a power source and electrical system according to the
present invention;
[0034] FIG. 7 is a schematic diagram depicting the steps of a
method corresponding to the operation of a device for providing
supplemental power to an electrical system according to the present
invention;
[0035] FIG. 8 is a perspective view of an open housing revealing
the charger, isolation circuit switch elements, and the
capacitor-battery power source of an apparatus for providing
supplemental power to an electrical system according to the present
invention;
[0036] FIG. 9 is a fragmentary perspective view of an open housing
revealing the charger and switching circuit of an apparatus for
providing supplemental power to an electrical system according to
the present invention;
[0037] FIG. 10 is a fragmentary perspective view of an open housing
revealing an isolation circuit forming part of an apparatus for
providing supplemental power to an electrical system according to
the present invention;
[0038] FIG. 11 is a schematic diagram of the electrical elements of
one embodiment of an apparatus for providing supplemental power to
an electrical system according to the present invention;
[0039] FIG. 12 is a schematic diagram of a logic circuit for
detecting voltage levels of an electrical system and forming part
of a power delivery controller in an apparatus for providing
supplemental power to the electrical system according to the
present invention;
[0040] FIG. 13 is a schematic diagram of the method steps and
corresponding series of operational functions of an apparatus for
providing supplemental power to an electrical system;
[0041] FIG. 14 is a perspective view of an apparatus for providing
supplemental power to an electrical system being recharged with a
source of power supplied by an alternating current according to the
present invention;
[0042] FIG. 15 is a perspective view of an apparatus for providing
supplemental power to an electrical system being recharged with a
source of power supplied by a direct current provided by a
re-charged battery according to the present invention;
[0043] FIG. 16 is a graphical representation of the peak power
delivery (watts) to a battery powered electrical system as a
function of the state of charge of the electrical system battery
(percent), the power being supplied by a conventional battery
versus power being supplied by a capacitor according to the present
invention; and
[0044] FIG. 17 is a graphical representation of cranking current
(amperes) supplied by a battery singly, by a capacitor single, and
by a capacitor-battery combination combined capacitor and battery
as a function of time (seconds) according to the present
invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0045] The present invention will now be described more fully
hereinafter with reference to the accompanying drawings which
illustrate preferred embodiments of the invention. This invention
may, however, be embodied in many different forms and should not be
construed as limited to the embodiments set forth herein. Rather,
these embodiments are provided so that this disclosure will be
thorough and complete, and will fully convey the scope of the
invention to those skilled in the art. Like numbers refer to like
elements throughout, the prime notation, if used, indicates similar
elements in alternative embodiments.
[0046] FIG. 1 illustrates a rapid-delivery portable power booster
10 for providing a supplementary source of power to an electrical
system of a vehicle or other machinery as it is being positioned
next to a heavy-duty commercial vehicle 60 disabled by a discharged
vehicle battery 62. As illustrated in FIG. 2, the power booster 10
is contained within a power booster housing 12, extending outwardly
from which are first and second electrical conductors 14, 16. As
further illustrated in FIG. 3, the first and second electrical
conductors 14, 16 extending outwardly from the housing 12 are used
to establish a power supply connection between the power booster 10
and the respective positive and negative terminals 64, 66 of the
discharged battery 62 of the electrical system of the vehicle 60.
More generally, the first conductor 14 is positioned to detachably
connect to any positive terminal of an electrical system and the
second conductor 16 is positioned to detachably connect to any
negative terminal of an electrical system. The connection is
intended to selectively permit rapid delivery, of a concentrated
amount of energy from a power source 20 within the housing 12 of
the power booster 10 (see FIGS. 4, 8 and 11). A power supply
connection is thereby provided between the power source 20 and the
electrical system. Electrically connected, the power source 20
selectively exchanges power between the power source 20 and the
electrical system.
[0047] Selective exchange of power between the power source 20 and
the electrical system is preferably controlled by a power delivery
controller 30, 30' positioned within the housing 12 and connected
to the power source 20 (see FIGS. 4 and 11). In a first embodiment,
as illustrated in FIG. 4, the power delivery controller 30
preferably comprises a processor 34, a timer 39, and an isolation
circuit 40. The processor 34 preferably includes a detecting
circuit, defining a voltage sensor 32, connected to the first
electrical conductor 14 to thereby sense the voltage of the
electrical system and to provide numerical indicators X, Y, Z
corresponding to sequentially sensed voltage levels of the
electrical system. The processor 34 preferably also includes a
voltage register 36 to store the value X that corresponds to the
initial voltage sensed, and a voltage difference determiner 38
responsive to the voltage sensor 32 and the voltage register 36 to
determine numerical decreases X-Y and increases X+Z in electrical
system voltage relative to the initially detected voltage X.
[0048] As illstrated in FIG. 4, the isolation circuit 40, as noted,
is also preferably part of the power delivery controller 30 and
permits power exchange between the power source 20 and the
electrical system by selectively permitting and inhibiting current
flow through the power supply connection in response to specified
voltage conditions, r.sub.i, of the electrical system as determined
by the microprocessor 34. In addition, the power delivery
controller 30 preferably further includes a timer 39 positioned to
measure elapsed times t.sub.i between discrete changes in the
numerical indicator of electrical system voltages.
[0049] The power delivery controller 30 more specifically blocks
electrical current between the power source 20 and the electrical
system except under predetermined voltage conditions in the
electrical system; that is, the isolation circuit 40, being
responsive to the processor 34 remains open unless closed in
response to predetermined sensed voltage conditions indicated by
the processor 34. The power delivery controller 30 permits an
electrical current to initiate between the power source 20 and the
electrical system when the processor-determined numerical indicator
Y of the electrical system voltage is within a first predetermined
range r.sub.1. The power delivery controller 30 then permits the
electrical current to continue when the processor-determined
numerical indicator Z of the electrical system voltage is within a
second predetermined range r.sub.2.
[0050] In a first embodiment, then, the rapid-delivery portable
power booster 10 selectively initiates an electrical current within
the power supply connection between the power source 20 and the
electrical system when the voltage of the electrical system is
within a first predetermined range r.sub.1, and then maintains the
electrical current when the electrical system voltage is within a
second predetermined range r.sub.2 (see FIG. 7). In a second
embodiment, however, the electrical current is selectively
initiated when the voltage of the power source of portable power
booster is within a first predetermined range r.sub.1', and the
current in the power supply connection is maintained when the
voltage of the power source of the portable power system is within
a second predetermined range r.sub.2'. Under ordinary
circumstances, it is unimportant whether the sensed voltage is that
of the electrical system or the portable power booster because the
voltages will be identical; thus, too, r.sub.1=r.sub.1' and
r.sub.2=r.sub.2' under such conditions. Moreover, an additional
feature of the processor 34 is that it includes elements for
storing both data and processing instructions thereby allowing the
processor 34 to be programmed as will be readily understood by
those skilled in the art. This additional feature allows the
r.sub.i values and other parameters to be selected based on a
variety of factors such as specifications of the particular
electrical system (e.g., the make and model of a disabled vehicle
to be jump started) and external conditions (e.g., temperature)
that will affect the operation of the system.
[0051] More specifically, as illustrated in FIG. 4, the voltage
register 36 of the processor 34 stores an initial numerical
indicator X corresponding to an initial detected voltage of the
electrical system. The voltage difference determiner 38 of the
processor 34 is responsive to the voltage register 36 to determine
numerical decreases X-Y and increases X+Z in electrical system
voltage relative to the initial detected voltage. By computing a
difference between the initial numerical indicator X and subsequent
processor-determined numerical indicators Y,Z corresponding to
subsequent voltage levels of the electrical system, the proper
conditions for power exchange are determined so that the
processor-responsive isolation circuit 40 permits initial
current-borne delivery of power from the power source to the
electrical system in response to a predetermined decrease in
electrical system voltage and continues delivery of power in
response to a subsequent predetermined increase in electrical
system voltage relative to the initial detected voltage.
[0052] As already noted, the processor 34 preferably further
includes a timer 39 positioned to measure elapsed time t.sub.i
between discrete changes in the numerical indicator of electrical
system or power source voltages and to measure elapsed time t.sub.j
during which current is passed between the power source 20 and the
electrical system. The processor signals the processor-responsive
isolation circuit 40 to interrupt and block current between the
power source 20 and the electrical system when a predetermined
increase in voltage fails to occur within a first preselected
elapsed time interval t.sub.1. If, however, the preselected
increase in voltage in fact occurred within the first preselected
elapsed time interval t.sub.1, the processor 34 signals the
isolation circuit 40 to remain closed to thereby permit a current
to be maintained between the power source 20 and the electrical
system for a second preselected time interval t.sub.2. During the
second time interval t.sub.2, there occurs a change in current
direction, so that during the second preselected elapsed time
interval t.sub.2 the now-recharged electrical system will at least
partially recharge the power source 20.
[0053] FIG. 7 illustrates some of the method aspects of the present
invention while detailing the operation of the above-described
power booster 10 utilizing a power delivery controller 30 that
includes a voltage detecting circuit 32 and processor 34 having an
initial voltage register 36 and a voltage difference determiner 38.
Described in the context of providing power to the electrical
system battery 62 of a commercial vehicle 60, the first and second
electrical conductors 14, 16 of the power booster 10 are connected
to the respective positive and negative terminals 64, 66 of the
discharged battery 62 of the vehicle 60. The voltage detecting
circuit 32 detects the initial voltage in the electrical system
(Block 101). The initial voltage value is stored in the register of
the processor (Block 102). If the physical connection is correctly
established, there is an initial voltage drop in the electrical
system. The voltage detecting circuit 32 detects the electrical
system voltage (Block 103) and a determination is made by the
voltage difference determiner 38 of the processor 34 (Block 104)
regarding whether, in fact, the expected voltage drop has occurred.
For example, given the conventional physical parameters associated
with the electrical system battery in a large, heavy-duty
commercial transport vehicle, 2V voltage drop is to be expected
when an attempt to start the vehicle after the power supply
connection is made between the electrical system and the power
source 20. The voltage drop indicates that the power supply
connection has properly been made. In response, the processor 34
signals the isolation circuit 40 to permit an initial delivery of
current-borne power to the electrical system (Block 105); otherwise
current is blocked and the physical power supply connection must be
rechecked (Block 106).
[0054] While the isolation circuit permits current to pass, the
timer 39 will mark the elapsed time. The electrical system voltage
will continue to be detected (Block 107) by the voltage detecting
circuit 32 and the voltage difference determiner 38 of the
processor 34 will compare the new voltage numerical indicator Z
with the initial voltage numerical indicator X stored in the
register 36 of the processor 34 (Block 108). If after t.sub.1, the
voltage has risen, the processor signals the isolation circuit 40
to continue to permit current to pass between the power source 20
and the electrical system. Again, in the illustrative context of
recharging the large battery of a commercial vehicle, a subsequent
voltage increase of 1.5V can be expected within 10 seconds. Failure
to detect the rise in voltage with the prescribed time interval may
indicate an intrinsic problem in the electrical system itself
(e.g., the alternator of the vehicle 60 is malfunctioning), and the
processor 34 will signal the isolation circuit 40 to electrically
isolate the power source 20 from the electrical system (Block 109)
to avoid damage to the either the electrical system or the power
booster apparatus 10. If the rise in voltage is detected within the
prescribed time interval (Block 107), the processor 34 will respond
by signaling the isolation circuit to permit current to continue
between the power source 20 and the electrical system for a second
time interval t2 during which time the polarity will reverse so
that the electrical system's now re-charged battery can return
charge to the power source 20 of the power booster 10 (Block
110).
[0055] The isolation circuit 40 can be provided by a set of
magnetic switches or alternatively by at least one field effect
transistor (FET) as understood by those skilled in the art (see
FIGS. 8, 10, and 11). For example, four magnetic switches 41, 42,
43, 44 can be combined as specifically illustrated in FIG. 11.
Alternatively, the isolation circuit can comprise a high-current,
solid state on/off switch with very low on-resistance such as that
provided by the Solid State On/Off Switch, Part No. 13014,
manufactured by The IntraUSA Group, Inc. and incorporating Intra's
proprietary metallic oxide semi-conductor FET (MOSFET) switches as
will also be understood by those skilled in the art.
[0056] More generally, the isolation circuit 40 is responsive to
the signal of the processor 34, which registers an initial voltage
and determines whether a proper power supply connection between the
power source 20 and the electrical system has been made. As
described herein, when the proper conditions have been verified by
the processor 34, an electrical path is provided for controlled,
selective current exchange between the power source 20 and the
electrical system. When the isolation circuit 40 is closed in
response to the processor-based signal, it permits current to pass.
Power will then begin to be transferred from the power source 20 to
the electrical system. If the series of voltage changes described
above occur in sequence, power will continue to be delivered until
the current reverses to recharge the power source 20 as also
described above.
[0057] FIG. 5 provides a schematic overview of a processor 34 and
related circuitry which can be utilized for carrying out the
above-described functions of determining an initial voltage,
storing the voltage value, and comparing subsequent voltage levels.
The processor 34 specifically includes voltage detecting circuitry
32a, 32b for sensing the initial and subsequent voltages. The
sensed voltages are conveyed to a microcontroller 35, which can
include an analog to digital signal conversion capability that
interfaces with the voltage detecting circuitry. The
microcontroller 35 stores the initial voltage value in a register
36 and the microcontroller determiner 38 determines when the
appropriate conditions for power exchange exist. Accordingly, the
microcontroller determines whether the isolation circuit 40 is to
be open or closed. More specifically, the microcontroller 35
performs the processing functions of storing the value X that
corresponds to the initial voltage sensed and determining numerical
decreases X-Y and increases X+Z in electrical system voltage
relative to the initially detected voltage X to control power
delivery as described above.
[0058] The microcontroller 35 can be powered by the power source 20
of the portable power booster 10. A voltage regulator 35 is
included as part of the processor 34 to regulate the amount of
power delivered to thereby ensure that only as much as needed to
drive the microcontroller 35 is delivered.
[0059] To effect control over power exchange between the portable
power booster 10 and the electrical system, the microcontroller is
electrically connected to isolation drive circuitry 57 linking the
processor 34 to the isolation circuit 40. As further illustrated in
FIG. 5, the microcontroller 35 is also electrically connected to
status indicator circuitry 56. The status indicator circuitry 56
can provide numerical or other visual display indicators for
indicating the condition of the electrical system at a given moment
during the process of providing a power boost. For example, the
status indicator can be composed of a set of light emitting diodes
(LEDs) that indicate voltage conditions.
[0060] The microcontroller 35 is also connected to power override
circuitry 55. The power override function allows manual
intervention in the event that the electrical system has
insufficient residual power to provide even a minimum sensed
voltage that would automatically initiate a power boost. For
example, with respect to a disabled commercial vehicle, the
vehicle's battery may be completely discharged, in which case an
initial voltage drop would not be detected so as to signal a proper
electrical connection and initiate the power boost. In the event
that this occurs, a manual operator can check that, in fact, the
connection has been properly made and manually initiate power
delivery to the disabled vehicle's electrical system by overriding
the microcontroller 35. The override switch can be provided by a
standard push-button device 82 that extends outside of the housing
12 of the portable power booster 10 to thereby be operable from a
location remote from the electrical system and the portable power
booster 10. For example, an operator could manually control
delivery of power to a disabled vehicle while sitting in the cab of
a service vehicle sent to a remote location to assist the disabled
vehicle. The operator would monitor the status indicators and
control power delivery accordingly using the push-button switch
82.
[0061] FIG. 6 provides a schematic view of a processor 34 including
microcontroller 35 and related circuitry 55, 56, 57 that could be
used to provide the power delivery control functions described
above. The initial voltage detecting circuitry 32a connects via
wire lead W2 to the electrical conductor 14 that connects to the
electrical system to receive the power boost. The circuitry is
implemented using two transistors T1, T2 and corresponding
resistors R5, R7, one transistor T2 connecting to the power source
of the portable booster via wire lead W1. Two resistors R4, R5
serve as voltage dividers at the connection of the circuitry to the
microcontroller 35. The subsequent voltage detecting circuitry 32b
is effected using two resistors R11, R12 again serving as voltage
dividers, the circuitry connecting to the electrical conductor 14
at W8 and connected to the microcontroller 35. The voltage
regulator, as illustrated, comprises a linear regulator VR1, diode
D1, and two capacitors. The override circuitry 55 comprises
resistors R6, R7, R14 and connects to manual switch 82 via wire
leads W3, W4. Isolation drive circuitry 57 comprises a single field
effect transistor (FET) F1 and two resistors R10, R12. The
circuitry connects via wire lead W5 to the isolation circuit 40.
The status indicator circuitry 56, also connected to the
microcontroller 35, comprises two resistors R8, R9 and connects to
separate light emitting diodes (LEDs) via wire leads W7, W6.
[0062] As already noted, the isolation circuit 40 can comprise at
least one FET or a series of magnetic switches. FIG. 11
specifically illustrates an embodiment, of the power delivery
controller 30' that includes an isolation circuit 40' having a
plurality of magnetic switches 41, 42, 43, 44 electrically
connected to the power source 20 to electrically isolate the power
source 20 from the electrical system and prevent any electrical
current flow between the power source and the electrical system
power except under prescribed conditions for power exchange
determined as described below. Preferably, the magnetic switches
are arranged in first and second pairs of two series-connected
switches 41, 42 and 43, 44 with the first pair 41,42 connected in
parallel with the second 43, 44 between the electrical system
connected by the outwardly extending conductors 14, 16 and the
power source 20 (see FIGS. 6, 8 and 9). In this embodiment, voltage
detection is performed by an alternative voltage detecting circuit
32'. Preferably the voltage detecting circuit 32' comprises a
network of resistors R1, R2, R3, R4, R5, and transistor T1
connected to transistor and resistors T2,R5, and T3, R6, each
connected between the power source and a ground (GND), along with
the transistor T4, diode and resistor D1, R7, transistor and diode
T5, D2, Zenner diode Z1, and transistor and diode T6, D3 connecting
the switch and the electrical conductors as illustrated in FIG. 12
and understood by those skilled in the art. The voltage detecting
circuit 32' is electrically connected to the isolation circuit 40'
and is responsive to the electrical system to detect voltage levels
within the electrical system. This alternative embodiment of the
power delivery controller 30' includes an energy delivery signaler
33 electrically connected to the voltage detecting circuit 32' and
the isolation circuit 40' to electronically signal the isolation
circuit 40' to permit current between the power source 20 and the
electrical system when the electrical system voltage is within a
predetermined range. The energy delivery signaler preferably
includes a manually actuated switch 35 and internal relay circuit
37 responsive to the switch 35.
[0063] FIG. 13 illustrates the operation of this alternative
embodiment, as well as an alternative method aspect 200 of the
claimed invention. Again, illustrating the application of the
claimed invention in the context of providing a power boost to
start a disabled-battery-stranded vehicle 60, the portable power
booster 10 is positioned near the vehicle 60 (Block 201) and a
physical connection between the power source 20 and the vehicle's
electrical system is made by removably attaching first and second
conductors 14, 16 to the positive and negative terminals 64, 66 of
the vehicle's battery 62 (Block 202). An operator is positioned
with the switch 35 within the cab of the vehicle to which the
portable power booster is connected (Block 203). The operator
signals the relay 37 with the switch 35 (Block 204) to thereby
electrically engage the electrical system of the vehicle 60 if the
power supply connection has been properly made between the power
source 20 and the electrical system (Block 205). If the switch 35
has been manually actuated by the operator, voltage in the
electrical system is detected in the voltage detecting circuit 32'
indicating a proper power supply connection between the power
source 20 and the electrical system has been made (Block 206).
[0064] If the connection has been properly made so that a minimum
voltage level is detected in the electrical system, the magnetic
switches 41, 42, 43, 44 respond to the condition. For example,
continuing in the context of providing a power boost to a disabled
commercial vehicle, the switches respond if at least a 0.7 voltage
is detected in the electrical system. If the power supply
connection has been properly made so that at least this minimum
voltage is detected by the voltage detecting circuit 32' then an
electrical circuit is completed, the magnetic switches 41, 42, 43,
44 close and power is delivered to the disabled battery of the
electrical system of the vehicle 60 (Block 207). If sufficient
power is delivered, the engine of the vehicle will start (Block
208), and if the operator continues to engage the power source 20
using the manually actuated switch 35 so as to maintain an
electrical connection between the power source 20 and the
electrical system, current will reverse so that the power source 20
receives power from the now-charged battery (Block 209). If a
minimum voltage is not detected, however, the isolation circuit 40'
prevents any electrical current, and the operator must recheck the
connections (Block 110).
[0065] As perhaps best illustrated in FIGS. 6 and 9, the power
source 20 of the present invention is preferably provided by a
high-density capacitor 22 that rapidly delivers power to the
electrical system and a battery 24 electrically connected to the
high-density capacitor 22 to maintain the energy level of the
capacitor 22 above a preselected minimum and to increase the amount
of power delivered by the power source 20 to the electrical system.
The first and second electrical conductors 14, 16 extending
outwardly from the housing 12, as already described, are
electrically connected to the power source 20 and the electrical
system to establish a power supply connection between the power
source 20 and the electrical system to selectively exchange power
between the power source and the electrical system. The capacitor
stores a significant amount of charge so as to enable the power
source 20 to deliver tremendous energy at a sufficiently high rate,
thereby providing significant starting capabilities when the power
booster 10 is recharging the disabled battery of a vehicle's
electrical system. Specifically, The high-density capacitor 22 and
battery 24 of the present invention jointly deliver a minimum of
approximately one hundred twenty kilojoules (120 kJ) within ten
seconds (10 s) to the electrical system with an efficiency of
approximately ninety percent (90%).
[0066] Preferably, the high-density capacitor 22 is an
electrochemical capacitor. Through the physical-chemical
interactions between the ions in an electrolyte and a solid
electrode, such capacitors are able to store energy in the form of
a significant amount of charge at the interface between the
electrolyte and the solid electrode. Either an electric double
layer of excess charge density at the interface or the
electrosorption of ions at the interface, or both, contribute to
storage of a tremendous amount of charge or stored energy. Thus,
the high-density capacitor 22 of the present invention has the
capability to transfer a significant amount of power within a short
time span. FIG. 16 provides a graphical comparison of capacitor
peak power versus conventional battery peak power, both as a
function of the state of charge of a battery to be boosted. The
power source 20, therefore, provides high-level, rapid-delivery
power in an amount sufficient to turn the engine of a vehicle
stranded by a disabled battery at speeds sufficient to enable
ignition even under most extreme conditions with little or no time
delay. As already noted, the power source 20 power is further
enhanced by the capacitor-connected battery 24 so as to provide an
even greater power boost and to maintain the capacitor 22 at or
above a minimum prescribed level. FIG. 17 provides graphical data
of the "cranking" current (in amperes) provided by such a
combination as a function of time (in seconds). Thus, as
graphically illustrated, the capacitor 22 and battery combination
24 of the power source 20 provide a significant advantage over
other conventional power sources.
[0067] As illustrated in FIGS. 4 and 8-11, the power booster 10
preferably also includes a charger 70 electrically connected to the
power source 20 and positioned within the housing 12 to receive
power from an external energy source to maintain a predetermined
energy level within the power source. As further illustrated in
FIG. 14, the charger 70 preferably includes first and second
alternating current conductors 71, 72 extending outwardly within a
cord 75 from the housing 12 through which the power source can
obtain energy from an external source of alternating current, as
for example when the power booster is electrically connected to an
external source of alternating current as provided by a standard AC
electrical wall outlet. As illustrated in FIGS. 4 and 11, the
charger 70 further includes first and second direct current
conductors 73, 74 extending outwardly from the housing 12 through
which the power source can obtain energy from an external source of
direct current, as for example when the power booster is
electrically connected to an external source of direct current as
provided by a standard transportation vehicle battery.
[0068] Each of the present invention's different embodiments
described above are suitable, then, for providing a supplementary
power boost to start and recharge the battery (or batteries) of a
large, heavy-duty vehicle 60 such as a commercial transport truck
that has been disabled by a discharged battery 62. As described in
detail above, the rapid-delivery portable power booster 10 of the
present invention includes a power source 20 sufficient to turn the
alternator of the vehicle and start the engine. Preferably, as also
described, the power source is provided by a capacitor-battery
combination. The capacitor preferably is an electrochemical
capacitor 22, which is supplemented by a battery 24 so as to
maintain the high-density charge of the capacitor 22.
[0069] The power source 20 delivers in rapid time an intense power
boost to a vehicle's electrical system. As also noted above,
however, with respect to each embodiment, delivery of power to an
electrical system from the high-intensity, rapid-delivery power
source 20 is controlled by a power delivery controller 30, 30', as
described above, to thereby ensure that too much power is not
delivered too quickly. Instead, according to the present invention,
the power is delivered directly to the alternator and engine of the
disabled vehicle in sufficient quantity to turn the alternator and
thereby start the engine. The power delivery controller 30, 30'
sequentially detects voltages, makes the necessary comparisons of
changing voltage conditions in the vehicle's electrical system, and
directs power delivery from the power source 20 accordingly,
thereby delivering enough power but no more than necessary to power
boost the electrical system while avoiding overloading it with too
much rapid-delivery, high-intensity power.
[0070] Once the disabled vehicle is started, however, the power
delivery controller 30, 30' continues to monitor the voltage
conditions so that the engine now begins to transfer power back to
the power booster thereby renewing the charge of the capacitor 22
of the power source 20, the charge of which is also maintained with
the battery 24 of the power source. Hence, a significant advantage
of the present invention is the capability not only to provide a
portable source of high-intensity power sufficient to start large,
heavy-duty vehicles stranded in remote locations, but to do so
repeatedly using the same portable power source which maintains
power in virtual perpetuity.
[0071] Thus, in a specific illustrative situation, a commercial
transport truck disabled by a discharged battery and stranded in a
remote location can be started by an operator using the portable
power booster 10 described in alternative embodiments above. The
operator connects the portable power booster 10 so as to establish
a power supply connection. In one embodiment, as described above,
the voltage detecting circuit 32 of the power deliver controller
30, comprising at least one FET, senses the voltage of the
electrical system of the vehicle to be jump started and stores the
corresponding value X in a register 36. An attempt to start the
vehicle results in an expected 2.0 volt drop in voltage so that
X-2.0 volts is detected by the power delivery controller 30. This
voltage drop is an indication of a proper power supply connection
having been made so as to complete the circuit and allow the
electronic FET to close, upon which event power can be transferred
from the power source 20 via the electrical connectors 14, 16 to
the vehicle. The connection will be maintained only for time
t.sub.1 and then broken unless the voltage condition X+1.5 volts is
sensed before t.sub.1 elapses. Failure to detect the X+1.5
condition within time t.sub.1 is an indication the vehicle did not
start and/or the alternator is not working properly in which event
the power source would be depleted unless the power supply
connection is interrupted. If the X+1.5 condition is detected, this
indicates that the vehicle's alternator is working properly and the
vehicle did start. In this event, the power delivery controller 30
will maintain the connection for a sufficient time t.sub.2 to
thereby permit power to be supplied from the vehicle to the power
source 20 so that the power source is replenished by the alternator
of the very vehicle jump started by the portable power booster
10.
[0072] An almost identical scenario occurs using the alternative
embodiment of the present invention described above. Again,
assuming that an operator is using the the portable power booster
10 to start a disabled commercial transport truck stranded in a
remote location, the operator is positioned away from the vehicle
and portable power booster 10, which the operator controls remotely
using the remote switch 35. When the operator throws the switch,
current flows from the power source 20 to a coil of the relay 37
causing current to flow from the power source 20 through relay
contacts to coils of the magnetic switches and to the voltage
detecting circuit 32' of the power delivery controller 30'. At
least 0.7 volts should be detected if a proper power supply
connection between the power source 20 and the vehicle's electrical
system has been made. In this event, the power delivery controller
30' and circuit 32' will allow current to flow to ground at the
power source 20, and when the circuit is completed the magnetic
switches of the isolation circuit 40' close to allow power to be
delivered to the vehicle's electrical system via the electrical
connectors 14, 16 as described above. Again, the power supply
connection is maintained once the vehicle has been started so as to
permit the vehicle alternator to replenish the power source 20 of
the portable power booster 10. Otherwise, if the voltage conditions
indicate a failure to make a proper connection, then the isolation
circuit 40' will prevent any power exchange between the power
source 20 and the vehicle's electrical system.
[0073] These scenarios involving alternative embodiments
illustrate, again, the significant advantages of the present
invention described in detail above. The invention provides both a
portable power booster 10 having source of high-intensity power 20
able to delivery, in a short time, an amount of power sufficient to
start large, heavy-duty vehicles stranded in remote locations,
while controlling delivery using a power delivery controller 30 to
prevent power overload. Specifically, concentrated power is rapidly
delivered directly to a vehicle's alternator and engine in
sufficient amounts to start the vehicle engine without having to
rely on the vehicle's discharged battery for power. When the
vehicle engine starts, the vehicle's engine begins to recharge the
discharged vehicle battery, and the electronically controlled
isolation circuit blocks further power delivery from the power
source. Only power enough to turn the alternator and start the
vehicle's engine is delivered from the power source, and no more
thereby avoiding risk of providing too much power too quickly. Once
the disabled vehicle has been started, the current is reversed so
that the power source 20 is replenished by power delivered to the
power source 20 from the electrical system of the vehicle. Thus,
the portable power booster 10, according to the present invention,
has the capability to start a remotely stranded heavy-duty vehicle
by rapidly supplying sufficient power directly to the alternator so
as to start its engine and to do so repeatedly for numerous
stranded vehicles using the same portable power source, the power
of which is maintained in virtual perpetuity owing to its capacity
to be replenished by the very electrical systems to which it has
provided power boosts.
[0074] The method aspects of the present invention are also
illustrated in FIGS. 1-13. As illustrated, the method for rapidly
delivering energy to an electrical system so as to boost the
voltage of the electrical system include the steps of electrically
connecting a high-voltage capacitor to the electrical system to
provide controlled rapid-delivery of energy to the electrical
system, sensing the voltage at the connection to determine when the
energy can optimally and selectively be supplied to the electrical
system, and delivering power to the electrical system from the
high-voltage capacitor when the sensed voltage is within a
predetermined range.
[0075] These and other valuable uses of the present invention will
come to mind for those skilled in the relevant art. Indeed, many
modifications and other embodiments will come to the mind of one
skilled in the art and having the benefit of the teachings present
in the foregoing descriptions and the associated drawings.
Therefore, it is to be understood that the invention is not to be
limited to the specific embodiments disclosed herein, and that the
modifications and alternative embodiments are intended to be
included within the scope of the appended claims.
* * * * *