Inductive charger coupling

• US 6,084,381 A
• Filed: 01/13/1999
• Issued: 07/04/2000
• Est. Priority Date: 01/16/1998
• Status: Expired due to Fees

• Current Assignee: Kabushiki Kaisha Toyoda Jidoshokki Seisakusho
• Original Assignee: Kabushiki Kaisha Toyoda Jidoshokki Seisakusho
• Inventors: Kajiura, Katsuyuki
• Primary Examiner(s): Tso, Edward H.
• Application Number:
  US09/229,282
• Time in Patent Office: 538 Days
• Field of Search: 320/108, 320/FOR 101, 336/DIG. 2
• US Class Current: 320/108
• CPC Class Codes: B60L 53/12 Inductive energy transfer
• CPC Class Codes: B60L 53/34 Plug-like or socket-like devices specially adapted for contactless inductive charging of electric vehicles positioning means for charging devices using inductive energy transfer B60L53/38
• CPC Class Codes: H02J 50/10 using inductive coupling
• CPC Class Codes: H02J 50/90 involving detection or optimisation of position, e.g. alignment
• 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

An inductive charger coupling for charging a battery includes a generally flat charging paddle and a charging receptacle. The charging paddle includes a primary core and a primary coil. The paddle is electrically connected to an external power supply. The charging receptacle includes a secondary core and a secondary coil. The receptacle is electrically connected to the battery. The secondary core engages the primary core when the charging paddle is plugged into the charging receptacle. The paddle lacks corners at its distal end, and the secondary core is shaped to conform to the distal end of the paddle, which narrows the overall width of the coupling.

Claims

1. An inductive coupling for connecting a battery to a power source comprising:

a generally planar charging paddle, wherein the paddle includes a primary core and a primary coil, the primary coil being wound around the primary core, wherein the primary coil is adapted to connect to an external power supply, and wherein the paddle has a proximal end, a distal end, a longitudinal axis, a top surface, a bottom surface, and first and second sides, wherein the first and second sides are farther from the longitudinal axis than are the top and bottom surfaces, and the paddle extends farther in the distal direction in a region near the longitudinal axis than along the sides, whereby an imaginary polygon is defined at the distal end of the paddle, such that a distal end of the polygon is perpendicular to the longitudinal axis of the paddle and contacts the distal end of the paddle, and a pair of sides of the polygon, which intersect the distal end of the polygon, are coextensive with the first and second sides of the paddle, respectively; and

a receptacle for receiving the paddle to electrically couple the external power source with the battery, wherein the receptacle includes a secondary core and a secondary coil, the secondary coil being wound around the secondary core, wherein the secondary core engages the primary core when the paddle is plugged into the receptacle, the receptacle having a pair of pillars extending in a direction generally perpendicular to the paddle when the paddle is plugged in, wherein more than half of the cross sectional area of the pillars, when cut by a plane that includes the longitudinal axis of the paddle when the paddle is plugged in, lies within an area defined by the sides and the distal end of the polygon and the periphery of the paddle adjacent to the distal end of the paddle.

2. The inductive coupling according to claim 1, wherein the pillars are entirely located between the sides and the distal end of the polygon and the periphery of the paddle adjacent to the distal end of the paddle.

3. The inductive coupling according to claim 1, wherein the width of the secondary core, as measured in the side-to-side direction of the paddle when the paddle is plugged in, is substantially the same as the side-to-side dimension of the paddle.

4. The inductive coupling according to claim 1, wherein the distal end of the paddle has an arcuate shape.

5. The inductive coupling according to claim 1, wherein the secondary coil includes a pair of coaxial, hollow cylindrical supports, and wherein the paddle fits between the cylindrical supports when plugged in.

6. The inductive coupling according to claim 1, wherein the receptacle is installed in an automobile and is used to charge a battery in the automobile.

7. An inductive coupling for connecting a battery to a power source, the inductive coupling comprising:

a charging paddle including a primary core and a primary coil wound around the primary core, the primary coil being adapted to connect to an external power supply, the paddle having a proximal end, a distal end, a longitudinal axis that extends from the proximal end to the distal end, a top surface, a bottom surface, and first and second sides, wherein the first and second sides are farther from the longitudinal axis than are the top and bottom surfaces, and the paddle extends farther in the distal direction in a region near the longitudinal axis than along the sides such that a pair of individual and separate vacancies are provided at the respective sides of the paddle adjacent to the periphery of the paddle proximate to the distal end of the paddle; and

a receptacle for receiving the paddle to electrically couple the external power source with the battery, wherein the receptacle includes a secondary core and a secondary coil, the secondary coil being wound around the secondary core, wherein the secondary core engages the primary core when the paddle is plugged into the receptacle, the secondary core including an upper part and a lower part, wherein the upper and lower parts are joined by a pair of individual and separate pillars whereby, when the paddle is plugged in, the pillars each extend in a direction generally perpendicular to the paddle and respectively occupy respective ones of said pair of vacancies and substantially conform to the shape of the distal end of the paddle to reduce the size of the coupling.

8. The inductive coupling according to claim 7, wherein the width of the secondary core, as measured in the side-to-side direction of the paddle when the paddle is plugged in, is substantially the same as the side-to-side dimension of the paddle.

9. The inductive coupling according to claim 7, wherein the distal end of the paddle has an arcuate shape.

10. The inductive coupling according to claim 7, wherein the secondary coil includes a pair of coaxial, hollow cylindrical supports, and wherein the paddle fits between the cylindrical supports when plugged in.

11. The inductive coupling according to claim 7, wherein the receptacle is installed in an automobile and is used to charge a battery in the automobile.

12. An inductive coupling for connecting a battery to a power source, the inductive coupling comprising:

a charging paddle providing a primary core and a primary coil each mounted on the paddle, the primary coil being wound around the primary core and adapted to connect to an external power supply, the paddle having a proximal end, a distal end, a longitudinal axis that extends from the proximal end to the distal end of the paddle, a top surface, a bottom surface, and first and second sides, wherein the first and second side are farther from the longitudinal axis than are the top and bottom surfaces, and the paddle has an arcuate end such that the center of the distal end of the paddle extends farther in the distal direction than the sides thereby providing a pair of vacancies at respective sides of the paddle adjacent to the periphery of the paddle proximate to the distal end of the paddle; and

a receptacle for receiving the paddle to electrically couple the external power source with the battery, the receptacle including a secondary core and a secondary coil wound around the secondary core, wherein the secondary core engages the primary core when the paddle is plugged in to the receptacle, the secondary core including an upper part and a lower part between which the paddle is positioned when plugged in, the secondary core further including a pair of individual and separate pillars which join the upper and lower parts whereby, when the paddle is plugged in, the pillars each extend in a direction generally perpendicular to the paddle and respectively occupy the respective vacancies, and wherein the pillars each have an arcuate surface which substantially conforms to the shape of the distal end of the paddle to reduce the size of the coupling.

13. The inductive coupling according to claim 12, wherein the width of the secondary core, as measured in the side-to-side direction of the paddle when the paddle is plugged in, is substantially the same as the side-to-side dimension of the paddle.

14. The inductive coupling according to claim 12, wherein the distal end of the paddle has an arcuate shape.

15. The inductive coupling according to claim 12, wherein the secondary coil includes a pair of coaxial, hollow cylindrical supports, and wherein the paddle fits between the cylindrical supports when plugged in.

16. The inductive coupling according to claim 12, wherein the receptacle is installed in an automobile and is used to charge a battery in the automobile.