Rapidly deployable floor power system

• US 10,283,952 B2
• Filed: 10/20/2017
• Issued: 05/07/2019
• Est. Priority Date: 06/22/2017
• Status: Active Grant

• Current Assignee: Bretford Manufacturing Incorporated
• Original Assignee: Bretford Manufacturing Incorporated
• Inventors: Dombrowski, Mike, Sadler, John, Maguire, Cary, Eiswerth, Patrick
• Primary Examiner(s): Lopez Cruz, Dimary S
• Application Number:
  US15/789,356
• Publication Number:
  US 20180375317A1
• Time in Patent Office: 564 Days
• Field of Search: None
• CPC Class Codes: H01R 13/6205 Two-part coupling devices held in engagement by a magnet
• CPC Class Codes: H01R 25/142 Their counterparts
• CPC Class Codes: H01R 25/145 Details, e.g. end pieces or joints H01R25/147 takes precedence
• CPC Class Codes: H01R 35/02 Flexible line connectors without frictional contact members
• CPC Class Codes: H02B 1/20 Bus-bar or other wiring layouts, e.g. in cubicles, in switchyards installations of bus-bars H02G5/00
• CPC Class Codes: H02B 1/26 Casings; Parts thereof or accessories therefor
• CPC Class Codes: H02G 3/00 Installations of electric cables or lines or protective tubing therefor in or on buildings, equivalent structures or vehicles installations of bus-bars H02G5/00; overhead installations H02G7/00; installations in or on the ground H02G9/00
• CPC Class Codes: H02G 3/0475 formed by a succession of articulated units
• CPC Class Codes: H02G 3/34 using separate protective tubing
• CPC Class Codes: H02G 9/025 Coverings therefor, e.g. tile
• CPC Class Codes: H02J 1/001 Hot plugging or unplugging of load or power modules to or from power distribution networks
• CPC Class Codes: H02J 1/06 Two-wire systems

Abstract

A rapidly deployable floor power system includes a base unit for supplying low voltage DC power to one or more foldable power tracks. Each foldable power track has a set of rigid track sections with exposed track power contacts on a top surface. The rigid track sections are electrically and mechanically interconnected by flexible track connectors that enable the power track to be folded when the power track is to be moved or stored, and unfolded for rapid deployment in an area to be supplied with power. The rigid track sections lie approximately flush with the floor to minimize tripping potential. Magnetic connectors engage the track to obtain power from the track, and are used to electrically interconnect adjacent tracks. A power distribution unit supplies power via low voltage ports such as USB ports and/or via one or more power whips equipped with barrel jack tips.

Claims

1. A rapidly deployable floor power system, comprising:

a base unit for receiving mains power and outputting a DC voltage on a DC power output;

a foldable power track in electrical communication with the base unit to receive the DC voltage, the foldable power track having a plurality of rigid track sections interconnected by flexible track connectors; and

a power distribution system, the power distribution system having a first magnetic electrical connector on a first end of a power distribution cable to magnetically connect to the foldable power track to receive the DC voltage, the power distribution system further having a power distribution unit on a second end of the power distribution cable, the power distribution unit receiving the DC voltage via the power distribution cable and converting the DC voltage to a second DC voltage.

2. The rapidly deployable floor power system of claim 1, wherein the base unit has a protection circuit to prevent an overcurrent and/or overvoltage condition on the DC power output.

3. The rapidly deployable floor power system of claim 2, wherein each rigid track section of the foldable power track has a first profile including a flat top surface and beveled edges;

wherein the DC power output has a DC power output profile that matches the first profile; and

wherein the magnetic electrical connector has a second profile to mate with the first profile of both the foldable power track and the DC power output.

4. The rapidly deployable floor power system of claim 1, wherein each rigid track section of the foldable power track has a first profile including a lower surface, a flat top surface, and beveled edges that taper from the flat top surface to the lower surface.

5. The rapidly deployable floor power system of claim 4, further comprising channels, formed within the flat top surface, to receive exposed track power contacts at the flat top surface.

6. The rapidly deployable floor power system of claim 4, further comprising magnetic attractors disposed below the flat top surface to engage magnets within the magnetic connector.

7. The rapidly deployable floor power system of claim 1, wherein the base unit has a power conditioning circuit to prevent the DC voltage from being output on the DC power output if the magnetic connector is not in electrical communication with the foldable power track.

8. The rapidly deployable floor power system of claim 1, wherein the base unit supplies DC voltage on the DC power output at approximately 36V DC.

9. The rapidly deployable floor power system of claim 1, wherein each of the rigid track sections has a plurality of exposed track power contacts on a top surface.

10. The rapidly deployable floor power system of claim 9, wherein each of the plurality of exposed track power contacts extends substantially a length of the top surface of the rigid track section.

11. The rapidly deployable floor power system of claim 9, wherein the exposed track power contacts of a first of the rigid track sections are electrically connected through the flexible track connectors to exposed track power contacts of a second of the rigid track sections.

12. The rapidly deployable floor power system of claim 11, wherein the first rigid track section is connected by the flexible track connector to the second rigid track section.

13. The rapidly deployable floor power system of claim 11, wherein the flexible track connector contains wires disposed within the flexible track connector to electrically connect the exposed track power contacts of the first and second rigid track sections.

14. The rapidly deployable floor power system of claim 9, wherein each of the rigid track sections has three exposed track power contacts.

15. The rapidly deployable floor power system of claim 14, wherein a first of the three exposed track power contacts is electrically connected to a positive output terminal of the DC power output;

and

wherein a second of the three exposed track power contacts is electrically connected to a ground output terminal of the DC power output.

16. The rapidly deployable floor power system of claim 15, wherein a third of the three exposed track power contacts is electrically connected to a ground output terminal of the DC power output.

17. The rapidly deployable floor power system of claim 15, wherein the base unit has a first communication unit, the power distribution unit has a second communication unit, and wherein at least one of the three exposed track power contacts is used to pass communication signals between the first communication unit and the second communication unit.

18. The rapidly deployable floor power system of claim 1, further comprising a track power cable, the track power cable being electrically connected on a first track power cable end to the foldable power track and being electrically connected on a second track power cable end to a second magnetic connector, the second magnetic connector having the same shape as the first magnetic connector.

19. The rapidly deployable floor power system of claim 18, wherein the track power cable is mechanically and electrically affixed on the first track power cable end to the foldable power track.

20. The rapidly deployable floor power system of claim 18, wherein the track power cable is connected to a third magnetic connector on the first track power cable end.

21. The rapidly deployable floor power system of claim 1, further comprising at least a second foldable power track, having a second track power in electrical communication with the first foldable power track.

22. The rapidly deployable floor power system of claim 1, wherein the magnetic electrical connector has three connectors that are not in a straight line.

23. The rapidly deployable floor power system of claim 1, wherein the magnetic electrical connector has at least three connectors formed in a straight line.

24. The rapidly deployable floor power system of claim 1, wherein the magnetic electrical connector has six connectors, a first set of three of the six connectors being in a first straight line and a second set of three of the six connectors being in a second straight line, the first straight line being parallel to the second straight line.

25. The rapidly deployable floor power system of claim 1, wherein the DC power output has exposed power contacts to mate with power contacts of the magnetic electrical connector.

26. The rapidly deployable floor power system of claim 25, wherein the DC power output has magnetic attractors spaced to engage magnets of the magnetic electrical connector.

27. The rapidly deployable floor power system of claim 1, wherein the magnetic electrical connector comprises:

a plurality of magnets;

a body having a lower exterior surface and a top shell defining an internal cavity;

a printed circuit board disposed within the internal cavity;

a plurality of contacts connected to the printed circuit board to extend through apertures in the lower surface; and

a plurality of springs disposed within the cavity to bias the contacts away from the top interior surface of the cavity.

28. The rapidly deployable floor power system of claim 27, wherein when the magnetic electrical connector engages the foldable power track, the magnets of the magnetic electrical connector engage magnetic attractors of the foldable power track to pull the lower surface of the magnetic electrical connector into mating relationship with a profile of the foldable power track.

29. The rapidly deployable floor power system of claim 27, wherein when the magnetic electrical connector engages the foldable power track the plurality of contacts are pushed up into the body of the magnetic electrical connector against a biasing force of the springs.

30. The rapidly deployable floor power system of claim 1, wherein the power distribution unit comprises:

a plurality of female low voltage DC output ports;

a DC-DC transformer configured to convert DC power received at a DC power input to a first voltage level for presentation at the plurality of female low voltage DC output ports;

a plurality of whips connected to the DC output ports;

an external body formed as a top clamshell, a bottom clamshell, and a shield configured to retain the plurality of whips from being removed from the power distribution unit.

31. The rapidly deployable floor power system of claim 30, wherein each whip has a male plug that engages one of the DC output ports on a first end, and the shield holds the male plug in the respective port so that the plug cannot be removed from the port.

32. The rapidly deployable floor power system of claim 31, wherein each whip has a male DC connector on a second end to connect to a female port of an electronic device.

33. The rapidly deployable floor power system of claim 31, wherein shield has apertures sized to engage and retain electrical plug inserts to retain the male plugs in the respective ports.

34. A foldable floor power track, comprising:

a first rigid track section having a first top surface with a first plurality of exposed DC power contacts extending substantially a length of the first track rigid section;

a second rigid track section having a second top surface with a second plurality of exposed DC power contacts extending substantially a length of the second rigid track section; and

at least one flexible connector electrically and mechanically interconnecting a first rigid track section to the second rigid track section;

wherein corresponding members of the first plurality of exposed DC power contacts of the first rigid track section are electrically connected through the flexible connector to corresponding members of the second plurality of exposed DC power contacts of the second rigid track section.

35. The foldable power track of claim 34, wherein the flexible connector has a first rigid tail piece connected to the first rigid track section, a second rigid tail piece connected to the second rigid track section, and a flexible ribbon extending between the rigid tail pieces.

36. The foldable power track of claim 35, wherein the first rigid tail piece is mechanically connected to the first rigid track section by first wedges formed on first tongues that engage corresponding first openings of the first rigid track section;

and

wherein the second rigid tail piece is mechanically connected to the second rigid track section by second wedges formed on second tongues that engage corresponding second openings of the second rigid track section.

37. The foldable power track of claim 35, wherein the flexible ribbon has three jacketed electrical wires extending between the rigid tail pieces through the flexible ribbon, each electrical connector having a brass tip at each end of the respective jacketed wire to interconnect with the DC power contacts of the rigid track sections.

38. The foldable power track of claim 35, wherein the flexible ribbon is formed as a pliable sheet substantially the width of the top surface of each rigid track section.

39. The foldable power track of claim 38, wherein the flexible ribbon is molded Thermo-Plastic Urethane (TPU).