Magnetic coupler and associated method for coupling conductors

• US 6,140,899 A
• Filed: 10/06/1998
• Issued: 10/31/2000
• Est. Priority Date: 10/10/1997
• Status: Expired due to Term

• Current Assignee: Northern Illinois University
• Original Assignee: Display Edge Technology, Ltd.
• Inventors: Kayser, Kenneth W., Frederick, W. Richard
• Primary Examiner(s): DONOVAN, LINCOLN D
• Application Number:
  US09/167,706
• Time in Patent Office: 756 Days
• Field of Search: 335/220-236, 335/250, 335/281, 335/282, 336/130-136
• US Class Current: 335/220
• CPC Class Codes: H01F 38/14 Inductive couplings for wireless supply or distribution of electric power using inductive coupling H02J50/10

Abstract

A magnetic coupler for magnetically or inductively coupling a pair of conductors. The coupler includes a first magnetic core member having prongs and at least one slot between the prongs for receiving the conductors, and a second magnetic core member. The coupler further includes a base for retaining the first core member and a shuttle for retaining the second core member. The shuttle is slidably mounted within the base such that the shuttle slides across and in contact with the prongs from an open position in which the slot is exposed to a closed position in which the slot is covered by the second core member, and the conductors are thereby contained within the slot. The sliding action of the cores cleans debris off the mating surfaces of the core elements to provide good mating contact between the core members for efficient coupling.

Claims

1. A coupler for magnetically or inductively coupling a first and a second electrical conductor, the coupler comprising:

a magnetic E core member having prongs, each prong having a mating end surface, said E core member further having slots between said prongs for receiving said conductors;

a second magnetic core member;

a base for retaining said E core member; and

a shuttle for retaining said second core member, said shuttle being slidably mounted to said base such that said second core member slides in a path across and in contact with said mating end surfaces from an open position in which said slots are uncovered to a closed position in which said slots are covered by said second core member and said conductors are thereby contained within said slots, wherein said sliding contact with said second core member cleans debris off said mating end surfaces to provide intimate contact between said core members.

2. The coupler of claim 1 wherein said second core member is an I-core member.

3. The coupler of claim 2 wherein said base further includes a plurality of extensions on either side of said path, each extension including an inwardly extending flange which receives said shuttle and retains said I core in contact with said mating end surfaces of said prongs.

4. The coupler of claim 3 wherein said shuttle has an upper surface and said shuttle further comprises a plurality of ramps extending from said upper surface such that when said shuttle nears said closed position said ramps are received by said flanges to form an interference fit therewith.

5. The coupler of claim 4 wherein said first conductor is mounted within said base, said first conductor including a pair of arms which fit within said slots and a pair of upwardly-extending flanges.

6. The coupler of claim 5 wherein said plurality of ramps comprises a first pair of opposed ramps located adjacent a front edge of said shuttle and a second pair of opposed ramps located adjacent a rear edge of said shuttle.

7. The coupler of claim 6 wherein said base further comprises a cover and a lattice, said cover including a generally rectangular plate and four generally rectangular panels, each panel extending from a respective edge of said plate and oriented generally perpendicular to said plate, said cover being shaped to receive and retain said lattice between said rectangular panels.

8. The coupler of claim 7 wherein said shuttle further includes a leg extending generally perpendicular to said path to limit the translation of said shuttle in a first direction.

9. The coupler of claim 8 wherein said cover includes a longitudinal cut-out in said plate to allow said flanges to pass therethrough.

10. The coupler of claim 9 wherein said I-core has a tapered surface on a forward end thereof, said tapered surface being shaped to prevent said shuttle from becoming jammed as said shuttle is slid to said closed position.

11. The coupler of claim 10 wherein said base further includes a pair of side tabs protruding therefrom, and wherein said first conductor further includes a pair of notches shaped and located so as to fit about said side tabs to thereby retain said first conductor and said E-core member in said base.

12. A method for coupling a first and a second electrical conductor comprising the steps of:

providing a coupler comprising a magnetic E core member having prongs, each prong having a mating end surface, said core member further having slots between said prongs for receiving said conductors, said coupler further comprising a second magnetic core member, a base for retaining said E core member, and a shuttle for retaining said second core member, said shuttle being slidably mounted to said base such that said second core member slides in a path across and in contact with said mating end surfaces from an open position in which said slots are uncovered to a closed position in which said slots are covered by said second core member;

placing said first and second conductors in said slots; and

sliding said shuttle to a closed position in which said slots are covered by said second core member and said conductors are thereby contained within said coupler, said sliding motion cleaning debris off said mating end surfaces to provide intimate contact between said core members.

13. The method of claim 12 wherein said second core member is an I-core member having one surface which slidingly contacts said mating end surfaces of said E core during said sliding step.

14. The method of claim 13 wherein said base further includes a plurality of extensions on either side of said path, each extension including an inwardly extending flange which receives and guides said shuttle during said sliding step.

15. The method of claim 14 wherein said shuttle has an upper surface and said shuttle further comprises a plurality of ramps extending from said upper surface such that when said shuttle nears said closed position said ramps are received by said flanges to form an interference fit therewith.

16. The method of claim 15 further comprising the step of mounting said first conductor within said base such that a pair of arms of said first conductor fit within said slots and a pair of upwardly-extending flanges extend through a longitudual cut-out of said base.

17. A method for coupling a pair of conductors utilizing at least two magnetic core members, said method comprising the steps of:

providing a first magnetic core member having at least one prong with a mating end surface;

providing a second magnetic core member;

placing said conductors adjacent said first magnetic core member; and

moving at least one of said magnetic core members to produce sliding contact between a portion of said second magnetic core member and said mating end surface of said first magnetic core member thereby cleaning debris off said mating end surface to provide intimate contact between said core members upon completion of said sliding contact.

18. A method for effecting efficient inductive coupling of conductors utilizing at least two magnetic core members, said method comprising the steps of:

providing a first magnetic core member having at least two prongs extending therefrom, each prong having a mating end surface, at least one slot formed between said prongs;

providing a second magnetic core member;

placing at least a portion of each of said conductors within said slot; and

moving at least one of said magnetic core members to produce sliding contact between a portion of said second magnetic core member and said mating end surfaces of said first magnetic core member thereby cleaning debris off said mating end surface to provide intimate contact between said magnetic core members upon completion of said sliding contact.

19. The method of claim 18 wherein upon completion of said moving step said conductors are enclosed within said slot by a portion of said second magnetic core member which extends over said slot.

20. The method of claim 18 wherein said first magnetic core member is an E core member including three prongs and in said moving step said second magnetic core member is moved.

21. A coupler for magnetically or inductively coupling at least a first and a second electrical conductor, the coupler comprising:

a first magnetic core member having at least two prongs extending therefrom, each prong having a mating end surface, said first core member further having at least one slot formed between said prongs for receiving said conductors;

a second magnetic core member;

a base for retaining said first core member; and

a shuttle for retaining said second core member,

wherein said base and said shuttle are movable relative to one another from an open position in which said slot is uncovered to a closed position in which said slot is covered by said second magnetic core member for retaining said conductors within said slot, wherein said relative movement produces sliding contact between said second magnetic core member and said mating end surfaces of said first magnetic core member for cleaning debris from said mating end surfaces.

22. The coupler of claim 21 wherein said first core member is an E core member having at least three prongs, and wherein said second core member is an I core member.

23. The coupler of claim 21 wherein said base further includes at least two extensions on either side of a path of said sliding contact, each extention including and inwardly facing flange which receives said shuttle and retains said second magnetic core member in contact with said mating end surfaces of said prongs.