Inductive power transmission for electrical devices

• US 10,320,238 B2
• Filed: 09/12/2016
• Issued: 06/11/2019
• Est. Priority Date: 03/05/2013
• Status: Active Grant

• Current Assignee: Eaton Intelligent Power Limited (Eaton Corporation PLC.)
• Original Assignee: Eaton Intelligent Power Limited (Eaton Corporation PLC.)
• Inventors: Manahan, Joseph Michael, Bowen, Scott J.
• Primary Examiner(s): Tran, Thienvu V
• Assistant Examiner(s): Stables, David M
• Application Number:
  US15/262,662
• Publication Number:
  US 20170004922A1
• Time in Patent Office: 1,002 Days
• Field of Search: None
• CPC Class Codes: H01F 27/02 Casings
• CPC Class Codes: H01F 38/14 Inductive couplings for wireless supply or distribution of electric power using inductive coupling H02J50/10
• CPC Class Codes: H02J 50/005 Mechanical details of housing or structure aiming to accommodate the power transfer means, e.g. mechanical integration of coils, antennas or transducers into emitting or receiving devices
• CPC Class Codes: H02J 50/12 of the resonant type
• CPC Class Codes: H02J 50/40 using two or more transmitting or receiving devices H02J50/50 takes precedence

Abstract

An electrical system that includes an enclosure and a power source located outside the enclosure and generating a first current. The electrical system can also include a transmitting inductor located within the enclosure and electrically connected to the power source, where the first current generated by the power source flows through the transmitting inductor. The electrical system can further include a receiving inductor positioned proximate to the transmitting inductor within the enclosure, where the first current flowing through the transmitting inductor induces a second current to flow through the receiving inductor. The electrical system can also include a device located within the enclosure and electrically connected to the receiving inductor, wherein the second current induced in the receiving conductor powers the device.

Claims

1. An electrical connector, comprising:

a first connector end comprising;

a first sleeve that forms a first cavity with a first open end;

a first insulator disposed within the first cavity;

a plurality of first conductors positioned within the first insulator; and

a plurality of transmitting inductors coupled to a distal end of the plurality of first conductors, wherein the plurality of transmitting inductors are positioned proximate to the first open end of the first sleeve; and

a second connector end mechanically coupled to the first connector end and comprising;

a second sleeve that forms a second cavity with a second open end;

a second insulator disposed within the second cavity;

a plurality of second conductors positioned within the second insulator; and

a plurality of receiving inductors coupled to a distal end of the plurality of second conductors, wherein the plurality of receiving inductors are positioned proximate to the second open end of the second sleeve,

wherein the plurality of transmitting inductors and the plurality of receiving inductors are disposed proximate to each other when the first connector end is mechanically coupled to the second connector end,

wherein the plurality of second conductors are configured to be coupled to at least one electrical device at their proximal end, wherein the at least one electrical device operates on multi-phase power induced through the plurality of receiving inductors.

2. The electrical connector of claim 1, wherein the first open end and the second open end abut against each other when the first connector end is mechanically coupled to the second connector end.

3. The electrical connector of claim 1, wherein the first plurality of conductors are part of a first electrical cable, and wherein the second plurality of conductors are part of a second electrical cable.

4. The electrical connector of claim 1, wherein coupling and decoupling of the first connector end from the second connector end causes substantially no mechanical wear on the first connector end and the second connector end.

5. The electrical connector of claim 1, wherein the first insulator is recessed within the first sleeve, and wherein the second insulator extends beyond the second sleeve.

6. The electrical connector of claim 1, wherein the second insulator of the second connector end is inserted into the first sleeve of the first connector end by hand without use of tools.

7. The electrical connector of claim 1, wherein the first sleeve comprises a first coupling feature, and wherein the second sleeve comprises a second coupling feature, wherein the first coupling feature and the second coupling feature couple to each other to fasten the first connector end to the second connector end.

8. The electrical connector of claim 7, wherein the first coupling feature and the second coupling feature comprise mating threads.

9. A system comprising:

a power source that generates a first current;

an electrical connector electrically coupled to the power source, wherein the electrical connector comprises;

a first connector end comprising;

a first sleeve that forms a first cavity with a first open end;

a first insulator disposed within the first cavity;

at least one first conductor positioned within the first insulator, wherein the first current flows through the at least one first conductor; and

at least one transmitting inductor coupled to the at least one first conductor, wherein the first current further flows through the at least one transmitting inductor, wherein the at least one transmitting inductor is positioned proximate to the first open end of the first sleeve; and

a second connector end mechanically coupled to the first connector end and comprising;

a second sleeve that forms a second cavity with a second open end;

a second insulator disposed within the second cavity;

at least one receiving inductor disposed within the second insulator proximate to the second open end of the second sleeve, wherein the first current flowing through the at least one transmitting inductor induces a second current to flow through the at least one receiving inductor; and

at least one second conductor coupled to the at least one receiving inductor, wherein the second current flows from the at least one receiving inductor through the at least one second conductor; and

a device electrically coupled to the at least one second conductor, wherein the second current flows through the device to provide power to the device,

wherein the at least one transmitting inductor and the at least one receiving inductor are disposed proximate to each other when the first connector end is mechanically coupled to the second connector end,

wherein the first connector end and the second connector end are separable from each other,

wherein the device is maintainable without interrupting the power source by separating the first connector end from the second connector end.

10. The system of claim 9, wherein the electrical connector is located in a hazardous environment.

11. The system of claim 10, wherein the electrical connector is disposed within an explosion-proof enclosure that complies with applicable National Electrical Manufacturers Association standards.

12. The system of claim 11, wherein generation of the second current induced in the receiving inductor and used to power the device prevents a condition that causes an explosion in the hazardous environment.

13. The system of claim 12, wherein decoupling the first connector end from the second connector end can safely be done when the first current is flowing through the at least one transmitting inductor.

14. The system of claim 9, further comprising:

an additional transmitting inductor electrically connected to the device, wherein the second current received by the device from the at least one receiving inductor of the electrical connector flows through the additional transmitting inductor;

an additional receiving inductor positioned proximate to the additional transmitting inductor, wherein the second current flowing through the additional transmitting inductor induces a third current to flow through the additional receiving inductor; and

an additional device electrically connected to the additional receiving inductor, wherein the third current induced in the additional receiving conductor powers the additional device.

15. The system of claim 14, wherein the additional receiving inductor and the additional transmitting inductor are part of an additional electrical connector.

16. The system of claim 14, wherein the at least one receiving inductor and the at least one transmitting inductor are disposed within a first electrical enclosure, and wherein the additional receiving inductor and the additional transmitting inductor are disposed within a second electrical enclosure.

17. The system of claim 9, further comprising:

an additional transmitting inductor electrically connected to the at least one transmitting inductor of the electrical connector, wherein the first current that flows through the at least one transmitting inductor of the electrical connector subsequently flows through the additional transmitting inductor;

an additional receiving inductor positioned proximate to the additional transmitting inductor, wherein the first current flowing through the additional transmitting inductor induces a third current to flow through the additional receiving inductor; and

an additional device electrically connected to the additional receiving inductor, wherein the third current induced in the additional receiving conductor powers the additional device.

18. The system of claim 17, wherein the additional receiving inductor and the additional transmitting inductor are part of an additional electrical connector.

19. The system of claim 17, wherein the at least one receiving inductor and the at least one transmitting inductor are disposed within a first electrical enclosure, and wherein the additional receiving inductor and the additional transmitting inductor are disposed within a second electrical enclosure.

20. A system comprising:

a power source that generates a first current having a first phase and a second phase;

an electrical connector electrically coupled to the power source, wherein the electrical connector comprises;

a first connector end comprising;

a first sleeve that forms a first cavity with a first open end;

a first insulator disposed within the first cavity;

a first conductor positioned within the first insulator, wherein the first phase of the first current flows through the first conductor;

a second conductor positioned within the first insulator, wherein the second phase of the first current flows through the second conductor;

a first transmitting inductor coupled to the first conductor, wherein the first phase of the first current further flows through the first transmitting inductor, wherein the first transmitting inductor is positioned proximate to the first open end of the first sleeve;

a second transmitting inductor coupled to the second conductor, wherein the second phase of the first current further flows through the second transmitting inductor, wherein the second transmitting inductor is positioned proximate to the first open end of the first sleeve; and

a second connector end mechanically coupled to the first connector end and comprising;

a second sleeve that forms a second cavity with a second open end;

a second insulator disposed within the second cavity;

a first receiving inductor disposed within the second insulator proximate to the second open end of the second sleeve, wherein the first phase of the first current flowing through the first transmitting inductor induces a first phase of a second current to flow through the first receiving inductor;

a second receiving inductor disposed within the second insulator proximate to the second open end of the second sleeve, wherein the second phase of the first current flowing through the second transmitting inductor induces a second phase of the second current to flow through the second receiving inductor;

a third conductor coupled to the first receiving inductor, wherein the first phase of the second current flows through the third conductor; and

a fourth conductor coupled to the second receiving inductor, wherein the second phase of the second current flows through the fourth conductor; and

at least one device electrically coupled to the third conductor and the fourth conductor, wherein the first phase and the second phase of the second current flows through the at least one device to provide power to the at least one device,

wherein the first transmitting inductor and the first receiving inductor are disposed proximate to each other when the first connector end is mechanically coupled to the second connector end,

wherein the second transmitting inductor and the second receiving inductor are disposed proximate to each other when the first connector end is mechanically coupled to the second connector end,

wherein the first connector end and the second connector end are separable from each other.