Rechargeable battery assemblies and methods of constructing rechargeable battery assemblies

• US 8,460,816 B2
• Filed: 10/08/2009
• Issued: 06/11/2013
• Est. Priority Date: 10/08/2009
• Status: Active Grant

• Current Assignee: Etymotic Research Incorporated
• Original Assignee: Etymotic Research Incorporated
• Inventors: Julstrom, Stephen D., Monroe, Timothy S., Killion, Mead C., Oltman, John E.
• Primary Examiner(s): Del Sole, Joseph S
• Assistant Examiner(s): Sultana, Nahida
• Application Number:
  US12/576,106
• Publication Number:
  US 20110086256A1
• Time in Patent Office: 1,342 Days
• Field of Search: 429/7, 429 90- 93, 429121-122, 320/108
• US Class Current: 429/121
• CPC Class Codes: H01F 2003/005 Magnetic cores for receiving several windings with perpendicular axes, e.g. for antennae or inductive power transfer
• CPC Class Codes: H01F 38/14 Inductive couplings for wireless supply or distribution of electric power using inductive coupling H02J50/10
• CPC Class Codes: H01M 10/425 Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing printed circuits H05K1/00
• CPC Class Codes: H01M 10/46 Accumulators structurally combined with charging apparatus circuits for charging H02J7/00
• CPC Class Codes: H02J 50/10 using inductive coupling
• CPC Class Codes: H02J 50/12 of the resonant type
• CPC Class Codes: H02J 50/70 involving the reduction of electric, magnetic or electromagnetic leakage fields
• CPC Class Codes: H02J 7/0042 characterised by the mechanical construction
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y10T 29/49108 Electric battery cell making

Abstract

Rechargeable battery assemblies and methods of constructing rechargeable battery assemblies are provided. Rechargeable battery assemblies can include a storage cell and receive circuitry comprising a receive coil operatively connected to receive control circuitry, the receive coil configured to receive inductively coupled current, the receive control circuitry configured to rectify the current and communicate charging power to the storage cell, the coil wound around a shield/core comprising magnetically permeable material, and the shield/core disposed around the storage cell. Methods of constructing rechargeable battery assemblies can include disposing a shield/core comprising magnetically permeable material around a storage cell; winding a receive coil around the shield/core; and providing the receive coil in operative connection with receive control circuitry and the storage cell, the receive coil configured to receive inductively coupled current, and the receive control circuitry configured to rectify the current and communicate charging power to the storage cell.

Claims

1. A rechargeable battery assembly comprising:

a storage cell; and

receive circuitry comprising a receive coil operatively connected to receive control circuitry, wherein the receive coil is configured to receive inductively coupled current, wherein the receive control circuitry is configured to rectify the current and communicate charging power to the storage cell, wherein the coil is wound around a shield/core comprising magnetically permeable material, and wherein the shield/core is disposed around the storage cell,

wherein the receive circuitry includes a receive resonant circuit that exhibits resonance at about a resonant frequency that a transmit resonant circuit exhibits resonance, wherein the receive resonant circuit exhibits a Q value of at least about 10 at the resonant frequency, wherein the transmit resonant circuit is associated with transmit circuitry and a transmit coil configured to produce an alternating magnetic field at about the resonant frequency.

2. The rechargeable battery assembly of claim 1, further comprising an electrically insulating layer disposed between the shield/core and the storage cell.

3. The rechargeable battery assembly of claim 1, further comprising an electrically insulating layer disposed between the shield/core and the receive coil.

4. The rechargeable battery assembly of claim 1, wherein the shield/core comprises metal.

5. The rechargeable battery assembly of claim 4, wherein the shield/core comprises a cobalt-based alloy comprising a cobalt content greater than 50%.

6. The rechargeable battery assembly of claim 1, wherein the assembly comprises a first end and a second end, and wherein the shield/core extends at least about 90% of the distance between the first end and the second end.

7. The rechargeable battery assembly of claim 1, wherein the assembly comprises a first end and a second end, and wherein the shield/core extends to within less than about 2.5 mm of each end of the assembly.

8. The rechargeable battery assembly of claim 1, wherein the assembly comprises the outer dimensions of a standard AA cell.

9. The rechargeable battery assembly of claim 8, wherein the storage cell has a volume of at least about 60% that of a storage volume of the standard AA cell.

10. The rechargeable battery assembly of claim 1, wherein the storage cell comprises a nickel metal hydride cell.

11. The rechargeable battery assembly of claim 1, wherein the storage cell comprises a plurality of cells.

12. The rechargeable battery assembly of claim 1, wherein the receive coil comprises about 50-200 turns.

13. The rechargeable battery assembly of claim 1, wherein the receive coil comprises a thickness of about 0.4 mm.

14. The rechargeable battery assembly of claim 1, wherein the receive coil comprises flat wire.

15. A method of constructing a rechargeable battery assembly comprising:

disposing a shield/core comprising magnetically permeable material around a storage cell;

winding a receive coil, of receive circuitry, around the shield/core; and

providing the receive coil in operative connection with receive control circuitry, of the receive circuitry, and the storage cell, wherein the receive coil is configured to receive inductively coupled current, and wherein the receive control circuitry is configured to rectify the current and communicate charging power to the storage cell,

wherein the receive circuitry includes a receive resonant circuit that exhibits resonance at about a resonant frequency that a transmit resonant circuit exhibits resonance, wherein the receive resonant circuit exhibits a Q value of at least about 10 at the resonant frequency, and wherein the transmit resonant circuit is associated with transmit circuitry and a transmit coil configured to produce an alternating magnetic field at about the resonant frequency.

16. The method of claim 15, wherein the shield/core comprises a gap that runs between a first end and a second end of the assembly, and wherein the receive coil includes a return wire disposed in the gap such that a first coil end and a second coil end can terminate at the same end of the assembly.

17. The method of claim 15, wherein the shield/core extends at least about 90% of a distance between a first end and a second end of the assembly.

18. The method of claim 15, wherein the assembly comprises the outer dimensions of a standard cell, and wherein the storage cell has a volume of at least about 60% that of a storage volume of the standard cell.

19. A rechargeable battery assembly comprising:

a storage cell; and

receive circuitry comprising a receive coil operatively connected to receive control circuitry, wherein the receive coil is configured to receive inductively coupled current, wherein the receive control circuitry is configured to rectify the current and communicate charging power to the storage cell, wherein the coil is wound around a shield/core comprising magnetically permeable material, and wherein the shield/core is disposed around the storage cell,

wherein the assembly comprises a first end and a second end, wherein the shield/core comprises a gap that runs between the first end and the second end, and wherein the receive coil includes a return wire disposed in the gap such that a first coil end and a second coil end can terminate at the same end of the assembly.

20. The rechargeable battery assembly of claim 19, further comprising an electrically insulating layer disposed between the shield/core and the storage cell.

21. The rechargeable battery assembly of claim 19, further comprising an electrically insulating layer disposed between the shield/core and the receive coil.

22. The rechargeable battery assembly of claim 19, wherein the shield/core comprises metal.

23. The rechargeable battery assembly of claim 22, wherein the shield/core comprises a cobalt-based alloy comprising a cobalt content greater than 50%.

24. The rechargeable battery assembly of claim 19, wherein the assembly comprises a first end and a second end, and wherein the shield/core extends at least about 90% of the distance between the first end and the second end.

25. The rechargeable battery assembly of claim 19, wherein the assembly comprises a first end and a second end, and wherein the shield/core extends to within less than about 2.5 mm of each end of the assembly.

26. The rechargeable battery assembly of claim 19, wherein the assembly comprises the outer dimensions of a standard AA cell.

27. The rechargeable battery assembly of claim 19, wherein the assembly comprises the outer dimensions of a standard cell, and wherein the storage cell has a volume of at least about 60% that of a storage volume of the standard cell.

28. The rechargeable battery assembly of claim 19, wherein the storage cell comprises a nickel metal hydride cell.

29. The rechargeable battery assembly of claim 19, wherein the storage cell comprises a plurality of cells.

30. The rechargeable battery assembly of claim 19, wherein the receive coil comprises about 50-200 turns.

31. The rechargeable battery assembly of claim 19, wherein the receive coil comprises a thickness of about 0.4 mm.

32. The rechargeable battery assembly of claim 19, wherein the receive coil comprises flat wire.

33. The rechargeable battery assembly of claim 19, wherein the receive circuitry includes a receive resonant circuit that exhibits resonance at about a resonant frequency that a transmit resonant circuit exhibits resonance, wherein the transmit resonant circuit is associated with transmit circuitry and a transmit coil configured to produce an alternating magnetic field at about the resonant frequency.

34. The rechargeable battery assembly of claim 33, wherein the receive resonant circuit exhibits a Q value of at least about 10 at the resonant frequency.

35. The rechargeable battery assembly of claim 33, wherein the receive resonant circuit exhibits a Q value of at least about 15 at the resonant frequency.

36. A method of constructing a rechargeable battery assembly comprising:

disposing a shield/core comprising magnetically permeable material around a storage cell, the shield/core comprising a gap that runs between a first end and a second end of the assembly;

winding a receive coil around the shield/core, the receive coil including a return wire disposed in the gap such that a first coil end and a second coil end can terminate at the same end of the assembly; and

providing the receive coil in operative connection with receive control circuitry and the storage cell, wherein the receive coil is configured to receive inductively coupled current, and wherein the receive control circuitry is configured to rectify the current and communicate charging power to the storage cell.

37. The method of claim 36, wherein the shield/core extends at least about 90% of a distance between a first end and a second end of the assembly.

38. The method of claim 36, wherein the assembly comprises the outer dimensions of a standard cell, and wherein the storage cell has a volume of at least about 60% that of a storage volume of the standard cell.