Battery exchange, recharge and recycle apparatus, system and method

• US 9,276,418 B2
• Filed: 09/10/2012
• Issued: 03/01/2016
• Est. Priority Date: 09/09/2011
• Status: Expired due to Fees

• Current Assignee: Green Box Batteries LLC
• Original Assignee: Green Box Batteries LLC
• Inventors: Kawasaki, Charles N., Wilson, Mark P.
• Primary Examiner(s): Memula, Suresh
• Application Number:
  US13/609,147
• Publication Number:
  US 20130063073A1
• Time in Patent Office: 1,268 Days
• Field of Search: 320/113
• US Class Current: 1/1
• CPC Class Codes: H02J 7/0013 acting upon several batteries simultaneously or sequentially H02J7/1423 takes precedence
• CPC Class Codes: H02J 7/0045 concerning the insertion or the connection of the batteries
• CPC Class Codes: H02J 7/35 with light sensitive cells
• CPC Class Codes: H02J 9/06 with automatic change-over , e.g. UPS systems
• CPC Class Codes: Y02B 10/70 Hybrid systems, e.g. uninterruptible or back-up power supplies integrating renewable energies

Abstract

A battery cartridge and kiosk apparatus, system and method, which enables consumers to conveniently exchange depleted rechargeable batteries for fully-charged batteries, and to recycle used primary batteries. The system includes a self-contained, typically automated kiosk designed for high volume battery exchange at low cost, and also includes re-usable battery trays for convenient, safe, and standardized handling and transport of rechargeable consumer batteries. A kiosk of the invented system may also be configured to utilize renewable-energy mechanisms to provide power for operation and/or recharging. Rechargeable batteries are stored and managed in a high-density, simple yet reliable storage rack wherein they are recharged in parallel while preserving long battery life. Batteries may be “keyed” to prevent recharging via third-party charging devices, enabling operating efficiencies and cost reductions.

Claims

1. A battery cartridge and kiosk system, configured to receive and retain one or more standard sizes of rechargeable consumer batteries and to facilitate receipt, recharging, and dispensing of the batteries, the cartridge comprising:

plural adjoining sidewalls defining an enclosure having an internal cavity configured to receive and retain one or more rechargeable consumer batteries in a predetermined arrangement and predetermined orientation;

a cover portion that closes the cavity when disposed in a secured position, and that allows insertion and removal of batteries from the cavity when disposed in an unsecured position;

a battery viewing window formed through a sidewall of the plural sidewalls and configured to expose to external view a portion of a battery disposed therein; and

a keying structure asymmetrically presented at an exterior of the cartridge.

2. The system of claim 1, wherein the cartridge further comprises:

a terminal access port provided through either or both of a sidewall and a cover of the cartridge and in alignment with a terminal of a battery disposed therein, the terminal access port providing access for establishing physical contact with the terminal by a probe that is external to the cartridge.

3. The system of claim 1, wherein the cartridge further comprises:

one or more electrical contacts coupled with the enclosure and presenting a first electrically-conductive portion at an outer surface of the enclosure, the one or more electrical contacts further presenting a second electrically-conductive portion inwardly, the second electrically-conductive portion configured and arranged to establish electrically-conductive contact with a terminal of one or more batteries disposed within the cavity when the cover portion is in the secured position.

4. The system of claim 1, wherein the cartridge further comprises:

either of a recess or a projection provided at an exterior surface of a sidewall of the cartridge and configured, when the cartridge is coupled with a recharging receptacle of the kiosk device, to detachably engage a corresponding retention mechanism coupled adjacent to the receptacle.

5. The system of claim 1, wherein one or more of the plural sidewalls of the cartridge comprise an electrically non-conductive material.

6. The system of claim 1, further including a corresponding kiosk device comprising:

an exterior housing;

an intake port provided through the housing, a portion of the intake port being differentially configured to allow passage of the keying structure of the cartridge when the cartridge is uniquely oriented for insertion therethrough;

a vertical gantry mechanism disposed within the housing and configured with one or more first drive mechanisms configured to traverse a handling mechanism in perpendicular axes of movement collectively defining a vertically-oriented plane of movement;

a handling mechanism coupled with the gantry and including an electromagnet, the electromagnet being coupled in communication with control circuitry and configured to actuate in response to control signals received therefrom; and

at least a second drive mechanism coupled with either or both of the gantry and the handling mechanism, the second drive mechanism being configured to translate a portion of the handling mechanism in a third direction perpendicular to the vertically-oriented plane.

7. The system of claim 6, wherein either or both of the first and second drive mechanisms are coupled in electrical communication with control circuitry of the kiosk and are configured to actuate in response to control signals received from the control circuitry.

8. The system of claim 6, wherein the kiosk further comprises:

a cartridge storage and battery recharging rack arranged along and spaced apart from the vertically-oriented plane of movement of the gantry, the rack including an array of plural cartridge receptacles.

9. The system of claim 8, wherein the kiosk further comprises:

an electrically-conductive probe arranged at each receptacle of the array of receptacles, the probe being configured to contact a battery terminal and to establish electrically-conductive contact therewith when the cartridge is coupled at the receptacle.

10. The system of claim 1, wherein the cartridge further comprises:

a magnetically-attractive material disposed at a sidewall of the enclosure confronting the electromagnet when the handling mechanism engages the cartridge.

11. The system of claim 6, wherein the electromagnet, when confronting the magnetically-attractive material of the cartridge and actuated, is configured to magnetically couple with the magnetically-attractive material and to retain the cartridge coupled with the handling mechanism.

12. The system of claim 6, wherein the control circuitry is further configured, in response to a cartridge being coupled with a receptacle, to determine a charge condition of a battery disposed within the cartridge.

13. The system of claim 1, wherein the cover portion of the cartridge is pivotably coupled with a sidewall of the cartridge and includes a latching structure configured to detachably retain the cover portion in the secured position.

14. The system of claim 1, wherein the battery viewing window is offset from a center of the sidewall, and wherein a predetermined portion of a battery is visible through the battery viewing window when the battery is disposed in the predetermined orientation but is not visible when the battery is disposed in other than the predetermined orientation.

15. The system of claim 8, wherein the plural cartridge receptacles are configured to receive and retain cartridges having a uniform exterior size and configuration.

16. The system of claim 8, further comprising:

a sensor associated with one of the plural receptacles and configured to be affected by either or both of a presence or an absence of a cartridge coupled with the receptacle, and further to responsively convey an electrical signal to the control circuitry.

17. The system of claim 16, further comprising:

a machine-readable memory medium coupled with the control circuitry and configured with a stored record of unique addresses for each of the plural receptacles.

18. The system of claim 17, further comprising:

a control unit configured to receive a signal from the sensor and to update the stored record with information indicating that a cartridge is coupled with the receptacle.

19. The system of claim 12, wherein:

upon determining that a battery possesses a discharged condition, the control circuitry causes a charging current to be applied to a terminal of the battery via an electrically-conductive probe associated with the receptacle and disposed in electrically-conductive contact with the terminal, and

upon determining that the battery has reached a charged condition, the control circuitry causes the charging current to cease being applied to the terminal of the battery.

20. The system of claim 19, wherein the control circuitry is configured to dynamically update a machine-readable memory medium coupled therewith and configured with a record of unique addresses for each of the plural receptacles with information indicating a real-time charge condition of each battery retained at each receptacle/address throughout the charging rack.

21. The system of claim 6, further comprising:

sensors suitably disposed and configured to dynamically sense a position of the handling mechanism relative to the recharging rack.

22. The system of claim 21, wherein the control circuitry is configured to:

cross-reference the position of the handling mechanism with an address of a closest available receptacle having coupled thereat one or more batteries determined to be in a charged condition; and

cause the handling mechanism to retrieve a cartridge at that receptacle for dispensing to a user.

23. The system of claim 21, wherein the control circuitry is configured to:

cross-reference the position of the handling mechanism with an address of a closest available receptacle having no cartridge coupled thereat; and

cause the handling mechanism to deliver to that receptacle as cartridge containing a battery suspected to be in a discharged condition.

24. The system of claim 8, wherein the recharging rack comprises plural recharging boards each coupled in electrical communication with the control circuitry.

25. The system of claim 6, wherein the intake port includes a reading means coupled therewith to read identity information associated with either or both of a cartridge or a battery disposed therein, wherein the reading means comprises one or more of a bar code reading device, a radio frequency identification (RFID) reading device, and a text reading device.

26. The system of claim 6, wherein the vertical gantry mechanism comprises:

plural parallel horizontal gantry beams extending horizontally from proximate a first side of the kiosk device to proximate an opposing second side of the kiosk device; and

at least a first vertical gantry beam extending between and moveably coupled in perpendicular relation with each of the plural horizontal gantry beams to traverse bi-directionally therealong when driven by one or more of the first drive mechanisms.

27. The system of claim 6, wherein the kiosk device is operably coupled with a solar array.

28. The system of claim 27, wherein control circuitry of the kiosk device is configured to cause an electrical current received from the solar array to be stored at a storage battery of the kiosk.

29. The system of claim 28, wherein control circuitry of the kiosk device is configured to utilize an electrical current received from either or both of the solar array and the storage battery when an electrical current from a primary continuous power source is interrupted.

30. The system of claim 27, wherein control circuitry of the kiosk device is configured to operate using an electrical current received from one or more batteries coupled at one or more receptacles when an electrical current from a primary continuous power source is interrupted.