Electric vehicle inductive coupling charge port

• US 5,264,776 A
• Filed: 06/30/1992
• Issued: 11/23/1993
• Est. Priority Date: 06/30/1992
• Status: Expired due to Term

• Current Assignee: GM Global Technology Operations Incorporated (Motors Liquidation Co. GUC Trust)
• Original Assignee: Hughes Aircraft Company (Rtx Corporation)
• Inventors: Hulsey, Stephen J.
• Primary Examiner(s): Peckman, Kristine L.
• Application Number:
  US07/906,599
• Time in Patent Office: 511 Days
• Field of Search: 320/2, 320/21
• US Class Current: 320/108
• CPC Class Codes: B60L 2210/30 AC to DC converters
• CPC Class Codes: B60L 3/0069 relating to the isolation, e.g. ground fault or leak current
• CPC Class Codes: B60L 53/12 Inductive energy 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: H02J 50/10 using inductive coupling
• CPC Class Codes: H02J 50/70 involving the reduction of electric, magnetic or electromagnetic leakage fields
• 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 10/72 Electric energy management in electromobility
• CPC Class Codes: Y02T 90/12 Electric charging stations
• CPC Class Codes: Y02T 90/14 Plug-in electric vehicles
• CPC Class Codes: Y10S 439/95 Electrical connector adapted to transmit electricity to mating connector without physical contact, e.g. by induction, magnetism, or electrostatic field

Abstract

An inductive charge port for an electric vehicle in which part of the inductive coupling transformer core is attached to the inside of an access door on the vehicle, and wherein only a primary coil assembly is inserted into the charging device when charging the vehicle. The charge port includes a primary coil assembly having a primary winding that is coupled by way of an electrical cable to a power source, and a secondary coil assembly disposed in the vehicle. A housing in the vehicle has the secondary coil assembly disposed therein. The secondary coil assembly includes a transformer core having a first portion disposed in the housing. A secondary winding is disposed in a cavity in the first portion of the transformer core which receives the primary winding therein. A hinged access door has a compressible, resilient member disposed on its inner wall and a second portion of the transformer core is secured to the compressible member. The second portion of the transformer core forms a lid or cap that mates with the first portion to form a complete transformer core. The mating first and second portions tightly secure the primary winding in the cavity when the door is closed. The secondary winding is coupled by way of an electrical cable to a charging circuit that is coupled to a battery of the vehicle. When the primary coil is inserted into the cavity and the external power source is energized, power flows from the power source through the inductive charge port to the battery. The present invention provides for an easy and safe inductive coupling that eliminates the possibility of shock hazard to a user when recharging the electric vehicle.

Claims

1. Inductive charging apparatus that couples electrical power from a power source to a battery of an electric vehicle, said apparatus comprising:

a primary coil assembly comprising a removable primary winding and an electrical cable coupled between the primary winding and the power source; and

a secondary coil assembly comprising a housing disposed in the vehicle, a transformer core having a first portion disposed in the housing that has a cavity disposed therein, a secondary winding disposed in the cavity that is coupled to the battery of the electric vehicle and wherein a gap is formed between the secondary winding and the transformer core that receives the primary winding therein, a second portion of the transformer core that is mounted to a door of the vehicle by means of compressible material and said second portion mates with the first portion and secures the primary winding in the gap of the transformer core when the door is closed;

and wherein the primary and second coil assemblies form a transformer when the respective primary and secondary windings are mated.

2. The inductive charging apparatus of claim 1 further comprising:

a charging circuit comprising a rectifier and a filter coupoled between the secondary winding and the battery.

3. The inductive charging apparatus of claim 1 further comprising:

a hinge and a spring coupled between the door and the housing that holds the door in an open position.

4. The inductive charging apparatus of claim 1 wherein the compressible material comprises a sponge rubber material.

5. The inductive charging apparatus of claim 1 wherein the housing comprises metal that provides for EMI shielding.