Apparatus that automates the connecting process between a primary connector and a secondary connector for charging an electric vehicle

• US 10,538,172 B2
• Filed: 07/06/2018
• Issued: 01/21/2020
• Est. Priority Date: 07/06/2017
• Status: Active Grant

• Current Assignee: Alan Kauffmann
• Original Assignee: Alan Kauffmann
• Inventors: Kauffmann, Alan
• Primary Examiner(s): Diao, M Baye
• Application Number:
  US16/028,834
• Publication Number:
  US 20190009680A1
• Time in Patent Office: 564 Days
• Field of Search: 320108
• CPC Class Codes: B60L 53/126 Methods for pairing a vehicle and a charging station, e.g. establishing a one-to-one relation between a wireless power transmitter and a wireless power receiver
• CPC Class Codes: B60L 53/16 Connectors, e.g. plugs or sockets, specially adapted for charging electric vehicles
• CPC Class Codes: B60L 53/38 specially adapted for charging by inductive energy transfer
• CPC Class Codes: H01R 13/5202 Sealing means between parts of housing or between housing part and a wall, e.g. sealing rings
• CPC Class Codes: H01R 13/5213 Covers
• CPC Class Codes: H01R 13/6205 Two-part coupling devices held in engagement by a magnet
• CPC Class Codes: H01R 13/631 for engagement only
• CPC Class Codes: H01R 13/73 Means for mounting coupling parts to apparatus or structures, e.g. to a wall
• CPC Class Codes: H01R 2201/26 for vehicles
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 90/12 Electric charging stations
• CPC Class Codes: Y02T 90/14 Plug-in electric vehicles

Abstract

Provided is an automated electrical connection apparatus for an electric vehicle. The automated electrical connection apparatus employs a primary connector connection apparatus at a charge site and a secondary connector connection apparatus on a vehicle. In its non-use state, the primary connector at the charge site is flush with the surface of the ground. When the charging system is activated, the primary connector will extend up from the surface of the ground to engage the secondary connector on the vehicle. The automated electrical connection apparatus provides a means to align the corresponding electrical connection within primary and secondary apparatus to establish a connection between the primary connector at the charge site and the secondary connector on the vehicle. Once the charging cycle is terminated, the component parts of the charging system will retract back to the flush position.

Claims

1. An automated electrical connection apparatus for charging a battery on an electric vehicle comprising:

a primary connector at a charging site comprising;

a pop-up apparatus positioned under a ground surface that is capable of being adjusted between an in use or extended position out of the ground surface and a non-use, retracted or stowed position beneath the ground surface, wherein the pop-up apparatus comprises a container positioned under the ground surface, wherein the container includes a bottom end, an open top and at least one side wall comprising an inside wall and an outside wall,

wherein the pop-up apparatus further comprises a primary adjustment mechanism having a top end and a bottom end positioned within the container and a primary connector cover housing an electrical connection device connected to the top end of the primary adjustment mechanism, wherein the primary connector cover is flush with the ground surface when the primary adjustment mechanism is in the retracted or stowed position

wherein the open top of the container includes a crown which provides a surface for the primary connector cover to rest on and a seal bed to prevent water and contaminants from entering the container;

a secondary connector on an electric vehicle comprising;

a secondary connector cover housing an electrical connection device and optionally, a secondary adjustment mechanism connected to the secondary connector cover which is positioned within the vehicle and is capable of being adjusted between an in use or extended position out from the vehicle and a non-use, retracted or stowed position within the vehicle,

wherein an electrical connection is established between the primary connector cover and the secondary connector cover when the pop-up apparatus is adjusted to its extended position,

wherein the electrical connection apparatus comprises at least one of the following;

1.) wherein the electrical connection device on the primary connector cover comprises one or more primary induction coils connected to a power source and the electrical connection device on the secondary connector cover comprises one or more secondary induction coils, wherein the secondary induction coil is connected to a vehicle'"'"'s circuitry to charge the battery on the vehicle, wherein an electrical connection between the primary connector cover and the secondary connector cover is established without the primary connector cover being in physical contact with the secondary connector cover;

2.) wherein the electrical connection device on the primary connector cover comprises a primary plug in connector connected to a power source and the electrical connection device on the secondary cover comprises a secondary plug in connector, wherein the secondary plug in connector is connected to a vehicle'"'"'s circuitry to charge the battery on the vehicle, wherein the primary plug in connector engages a secondary plug in connector when the pop-up apparatus of the primary connector is in the extended position;

3.) wherein the electrical connection device on the primary connector cover comprises a primary side of an electrical transformer and the electrical connection device on the secondary connector cover comprise a secondary side of the electrical transformer, wherein the primary side of the electrical transformer is connected to a power source, wherein the secondary side of the electrical transformer is connected to a vehicle'"'"'s circuitry to charge the battery on the vehicle, wherein the primary side of the transformer and the secondary side of the transformer form a single transformer unit when the primary connector cover is in its extended position and connected to the secondary connector cover.

2. The automated electrical connection apparatus of claim 1, wherein the pop-up apparatus further comprises bellows positioned between the container crown and the primary connector cover, wherein the bellows comprises at least one side wall, a top open and a bottom open end, wherein the bellows houses the primary adjustment mechanism and wherein the bellows maintains a watertight fit over the pop-up apparatus when the primary connector is in the extended position.

3. The automated electrical connection apparatus of claim 2, wherein the bottom end of the bellows comprises a movable bellows flange that fits against the inside wall of the crown forming a moveable watertight seal and wherein the top end of the bellows comprises an internal ring for attaching the bellows to the primary connector cover.

4. The automated electrical connection apparatus of claim 3, wherein the primary connector cover rests within the crown of the container when the primary connector cover or pop-up apparatus is in the retracted or stowed position, wherein a cover boot is attached to the primary connector cover, wherein the cover boot comprises a first aperture allowing compressed air to enter within an interior space formed within the cover boot and a second aperture allowing compressed air to exit from the interior space formed within the cover boot, wherein upon activation of a charging event, a blast of compressed air enters between the primary connector cover and the cover boot causing the cover boot to elongate and expand to loosen any debris and ice formed on its surface, wherein as air exits from the cover boot, loosed debris and ice are blown off from the cover boot and an actuator causes the primary adjustment mechanism to push the primary connector cover out of the crown.

5. The automated electrical connection apparatus of claim 4, wherein the primary connector cover comprises electromagnets and the secondary connector cover comprises electromagnets, wherein upon activation of a charging cycle, the electromagnets on the primary connector cover and the secondary connector cover are activated to attract the primary connector cover and the secondary connector cover towards each other, wherein the primary connector cover is pulled perpendicular to its extension by the primary adjustment mechanism allowing for alignment between the primary connector cover and the secondary connector cover.

6. The automated electrical connection apparatus of claim 5, wherein the primary connector cover comprises a nonconductive housing, clocking permanent magnets and male pins or female receptacles and/or a primary transformer side, wherein the secondary plug in connector comprises a nonconductive housing, clocking permanent magnets and male pins or female receptacles and/or a secondary transformer side.

7. The automated electrical connection apparatus of claim 6, wherein the primary plug in connector comprises male pins and the secondary plug in connector comprises female receptacles for engagement with the male pins of the primary plug in connector, wherein at least one of the primary plug in connector nonconductive housing and the secondary plug in connector nonconductive housing comprises a nonconductive disk housing the clocking permanent magnets and the male pins or female receptacles, wherein the clocking permanent magnets are mounted in such a manner that as the primary connector cover and the secondary connector cover approach each other, the clocking permanent magnets natural attractive and repulsive forces cause the nonconductive disk on at least one opposing connector cover to rotate to align the male pins with the female receptacles.

8. The automated electrical connection apparatus of claim 6, wherein the primary connector cover includes a primary transformer side and the secondary connector cover includes a second transformer side, wherein at least one of the primary connector cover nonconductive housing and the secondary connector cover nonconductive housing comprises a nonconductive disk housing the clocking permanent magnets and the primary transformer side and the secondary transformer side, wherein the clocking permanent magnets are mounted in such a manner that as the primary connector cover and the secondary connector cover approach each other, the clocking permanent magnets natural attractive and repulsive forces cause the nonconductive disk on at least one opposing connector cover to rotate to align the primary transformer side with the secondary transformer side.

9. The automated electrical connection apparatus of claim 8, wherein the primary transformer side slides in the primary connector cover rendering it flush with the surface of the primary connector cover when the primary connector is in a non-use, retracted or stowed position and wherein the primary transformer side slides out of the primary connector cover and into the secondary transformer side to form a single air gap transformer when the primary connector is in an in-use or extended position.

10. The automated electrical connection apparatus of claim 1, wherein the primary adjustment mechanism of the primary connector comprises a scissor mechanism having a first end and a second end which allows the primary connector to be adjusted between the in-use or extended position out of the ground surface and the non-use retracted or stowed position within the ground surface, wherein a scissor support bracket is positioned near the open top of the container for supporting the scissor mechanism within the bellows and wherein the scissor mechanism comprises a first universal joint which connects the first end of the scissor mechanism to the bottom end of the container and a second universal which connects the second end of the scissor mechanism to the primary connector cover.

11. The automated electrical connection apparatus of claim 1, wherein the primary adjustment mechanism comprises a power assisted push up mechanism that allows the primary connecter to be adjusted between the in-use or extended position out of the ground surface and the non-use retracted or stowed position within the ground surface.

12. The automated electrical connection apparatus of claim 11, wherein the power assisted push up mechanism comprises a vertically oriented shaft having a top end and a bottom end, wherein the vertically oriented shaft is positioned within the container when in a non-use, retracted or stowed position within the ground surface and wherein the vertically oriented shaft extends the primary connector out of the container when in an in-use or extended position above the ground surface to reach the secondary connector cover installed on the vehicle.

13. The automated electrical connection apparatus of claim 12, wherein a fastener connects the bottom end of the shaft to an actuator or to a pneumatic or hydraulic cylinder which operates to push the vertical oriented shaft out of the container when the primary connector is in an in use or extended position.

14. The automated electrical connection apparatus of claim 13, wherein the linear actuator or pneumatic or hydraulic cylinder is attached to the bottom end of the container and wherein the actuator is a linear actuator.

15. The automated electrical connection apparatus of claim 1, wherein the secondary connector comprises a container positioned within the vehicle, wherein the container includes an open bottom end and an open top end and at least one side wall, wherein the secondary connector does not include a secondary adjustment mechanism, and wherein the secondary connector cover housing the electrical connection device is mounted on a floating mounting device which is suspended between the top end and the bottom end of the container by closed cell foam.

16. The automated electrical connection apparatus of claim 15, wherein the closed cell foam pushes and pulls the floating device from side to side inside the container in order to achieve alignment between the pins and receptacles of the primary and secondary connectors and wherein the closed cell foam forms a watertight seal for the container.

17. The automated electrical connection apparatus of claim 16, wherein the bottom end of the container of the secondary connector has a cone shape which is larger in diameter than the primary connector cover allowing the primary connector cover to fit within the secondary connecter container and align itself with the electrical device on the secondary connector cover.

18. The charging system of claim 1, wherein activation of the primary connector adjustment mechanism and optionally, the secondary connector adjustment mechanism is initiated wirelessly and automatically through an onboard computer on the vehicle, through a command entered on a software application on a mobile computer device or by the driver pushing a button on a control panel within the vehicle or through an independent charging sit management system.

19. A method of charging an electric vehicle utilizing the charging system of claim 6 comprising:

driving a vehicle up to a charging station to renew a charge of a vehicle'"'"'s battery;

initiating contact between the secondary connector on the vehicle and the primary connector at the charging site, wherein contact is initiated wirelessly and automatically through an onboard computer on the vehicle, by a command on a software application on a mobile computing device or by the driver pushing a button on a control panel within the vehicle to send a wireless communication to a computing device within the primary connector or charging site to initiate the charging process

wherein upon acceptance of the charging process, the primary connector begins the process of deployment, wherein the deployment process comprises;

blowing a blast of air into a cavity between the primary connector cover and the primary connector cover boot, loosening ice and debris and allowing the air to exit through an aperture in the center of the cover boot blowing the ice and debris away,

activating the adjustment mechanism of the primary connector to cause the primary connector cover to extend upward from the ground surface toward the secondary connector cover on the vehicle,

initiating an actuator within the primary connector to cause the adjustment mechanism within the primary connector to push the primary connector cover out of the crown of the primary connector container

activating the electromagnets on the primary connector cover and the secondary connector cover to cause the primary connector cover to move towards the secondary connector cover

allowing permanent clocking magnets positioned on a nonconductive disk within a nonconductive housing on the primary connector and permanent clocking magnets positioned on a nonconductive housing on the secondary connector to allow the primary nonconductive disk and the secondary nonconductive disk to rotate with respect to each other in order to align the connection between the primary connector cover and the secondary connector cover;

engaging the primary connector to the secondary connector to form an electrical connection, wherein electrical power is unavailable to the primary connector until the primary connector is engaged with the secondary connector;

allowing electricity to flow through the electrical connection to charge the vehicle'"'"'s battery;

terminating contact between the secondary connector and the primary connector, wherein contact is automatically terminated wirelessly through an onboard computer on the vehicle upon the battery achieving full charge, by a command entered on a software application on a mobile computing device or by the driver pushing a button on a control panel within the vehicle to send a wireless communication to a computing device within the primary connector or charging site terminate the charging process,

wherein upon acceptance of the termination process, the primary connector begins the process of retraction, wherein the retraction process comprises;

deactivating the electromagnets on the primary connector cover and the secondary connector cover to allow the primary connector cover and the secondary connector cover to disengage;

discontinuing power to the primary connector prior to disconnection of the primary and secondary connectors;

activating the adjustment mechanism on the primary connector to cause the primary connector cover to disengage from the secondary connector cover and retract downward towards the ground surface and away from the secondary connector cover on the vehicle until the primary connector is in a fully retracted position within the container and the primary connector cover is flush with the ground.