Inductively coupled power transfer assembly

• US 8,405,346 B2
• Filed: 02/17/2010
• Issued: 03/26/2013
• Est. Priority Date: 02/17/2009
• Status: Active Grant

• Current Assignee: Antonio Trigiani
• Original Assignee: Diversified Power International LLC
• Inventors: Trigiani, Antonio
• Primary Examiner(s): WILLIAMS, ARUN C
• Application Number:
  US12/706,914
• Publication Number:
  US 20100207771A1
• Time in Patent Office: 1,133 Days
• Field of Search: 320/108
• US Class Current: 320/108
• CPC Class Codes: B60L 53/14 Conductive 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 50/005 Mechanical details of housing or structure aiming to accommodate the power transfer means, e.g. mechanical integration of coils, antennas or transducers into emitting or receiving devices
• CPC Class Codes: H02J 50/10 using inductive coupling
• CPC Class Codes: H02J 50/80 involving the exchange of data, concerning supply or distribution of electric power, between transmitting devices and receiving devices
• CPC Class Codes: H02J 7/00302 Overcharge protection
• 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 90/14 Plug-in electric vehicles

Abstract

Apparatus for transferring power to through an isolated, insulated connection. A power transfer assembly includes a portable cable assembly and a receiver. The portable cable assembly includes a power plug and a transmitter with a plug portion that mates with a receptacle on the receiver. A magnetic latch secures the plug portion in the ring receptacle. The transmitter includes a power supply, a power switch, a signal sensor, and a transmitting inductor. The receiver includes a receiving inductor, a signal coil, a magnet, a power converter, a temperature sensor, and an isolation switch. When the transmitter is coupled with the receiver, the power switch is operated by the magnet, the signal sensor is magnetically coupled to the signal coil, and the transmitting inductor is magnetically coupled to the receiving inductor. The normally open isolation switch is operated when the power converter is energized by the transmitter.

Claims

1. An apparatus for transferring power, said apparatus comprising:

a transmitter including

a power cable configured to electrically connect to an external power source,

a power supply electrically connected to said power cable,

a power switch operatively connected to said power supply,

a transmitting inductor electrically connected to said power supply, and

a plug portion having at least one first magnetic latch portion;

a receiver including

a receptacle configured to receive said plug portion of said transmitter with a specified alignment,

at least one second magnetic latch portion positioned to engage a corresponding one of said at least one first magnetic latch portion when said plug portion is received in said receptacle, said transmitter releasably secured to said receiver by a magnetic attraction between said at least one first and second magnetic latch portions,

a magnet positioned to actuate said power switch when said plug portion is received in said receptacle thereby energizing said power supply when said power plug is electrically connected to a power source,

a receiving inductor positioned to be magnetically coupled to said transmitting inductor when said plug portion is received in said receptacle,

a power converter electrically connected to said receiving inductor, said receiving inductor providing power to said power converter when said power supply excites said transmitting inductor, and

an isolation switch electrically connected between an output of said power converter and an output of said receiver, said isolation switch actuated by said power converter being energized by said receiving inductor thereby allowing said power converter to be electrically connected to said output of said receiver, and

an alignment mechanism that maintains said specified alignment between said plug portion and said receptacle when said plug portion is received by said receptacle.

2. The apparatus of claim 1 further including a first communications device in said receiver and a second communications device in said transmitter, said first communications device connected to said power converter, said first communications device communicating with said second communications device to control said power supply in order to provide a quantity of power to said transmitting inductor that matches a requirement of said receiver, and said second communications device communicates with said first communications device to provide a signal corresponding to a capacity of said power supply and said power converter operates within said capacity of said power supply.

3. The apparatus of claim 1 wherein said alignment mechanism includes a key protruding from one of said receptacle and said plug portion, and a corresponding notch in an other one of said receptacle and said plug portion.

4. The apparatus of claim 1 wherein said receptacle includes a collar configured and dimensioned to receive said plug portion.

5. The apparatus of claim 1 wherein said power converter is a charger, and further including a temperature sensor electrically connected to said charger, said temperature sensor responsive to a temperature proximate said battery, and said charger providing a charging voltage dependent upon said temperature detected by said temperature sensor.

6. The apparatus of claim 1 wherein said power converter is a charger, and further including an indicator selectively displaying one of a charging status and a charged status, said transmitter including a light pipe coupled to said indicator wherein said light pipe provides visual indication on said transmitter from said indicator.

7. An apparatus for transferring power from a power source to a receiver on a vehicle, said receiver including a receiving inductor for power transfer, said apparatus comprising:

a power cable configured to electrically connect to the power source;

a power supply electrically connected to said power cable;

a transmitting inductor electrically connected to said power supply;

a plug portion configured to mate with a receptacle on the receiver with a specific alignment, said plug portion having a cylindrical shape with an end that is substantially flat, said end of said plug portion having a plug magnetic latch configured to cooperate with a corresponding receptacle magnetic latch in said receptacle, said transmitting inductor proximate a surface of said end of said plug portion, said transmitting inductor configured to be magnetically coupled with the receiving inductor in the receiver, said transmitting inductor configured to transfer power from said power supply to the receiving inductor; and

a power switch operatively connected to said power supply, said power switch selectively allowing said power supply to be energized when said plug portion is mated with said receptacle.

8. The apparatus of claim 7 further including an alignment mechanism on said plug portion, said alignment mechanism including one of a key and a notch positioned to engage a corresponding structure on the receiver.

9. The apparatus of claim 7 further including a first communications device said plug portion, said first communications device configured to be responsive to a second communications device in the receiver, said first communications device electrically connected to said power supply, and said first communications device receiving a feedback signal communicated to said power supply and sending a capacity signal to said receiver whereby said capacity signal corresponds to a maximum capacity of said plug.

10. The apparatus of claim 7 further including a sending unit in said plug portion, said sending unit configured to provide a signal to a signal coil in the receiver, said sending unit electrically connected to said power supply, and said sending unit configured to provide data to the receiver whereby said data includes a capacity of said power supply and said receiver operates so as not to exceed said capacity.

11. The apparatus of claim 7 further including an indicator selectively displaying one of a charging status and a charged status, said indicator including a light pipe attached to said plug portion, said light pipe receiving a visual signal from said receiver wherein said light pipe provides visual indication at said plug portion.

12. An apparatus for transferring power from a portable cable assembly that includes a plug with a plug magnetic latch, a transmitting inductor, and a power switch, said apparatus comprising:

a receptacle configured to receive the plug of the portable cable assembly, said receptacle having an alignment mechanism that aligns the plug when received by said receptacle, said receptacle having a cylindrical shape with an end that is substantially flat;

a receptacle magnetic latch in said receptacle proximate said end of said receptacle, said receptacle magnetic latch positioned to engage the corresponding plug magnetic latch when said receptacle receives the plug, said receptacle releasably securing said plug by a magnetic attraction between said receptacle magnetic latch and plug magnetic latch;

a receiving inductor proximate said end of said receptacle, said receiving inductor positioned to be magnetically coupled to the transmitting inductor in the plug when the plug is mated with said receptacle; and

a power converter electrically connected to said receiving inductor, said receiving inductor providing power to said power converter when the plug is received in said receptacle and said transmitting inductor is transmitting power.

13. The apparatus of claim 12 wherein said alignment mechanism includes a key protruding from said receptacle, said key engaging a corresponding structure in said plug when said plug is received by said receptacle.

14. The apparatus of claim 12 further including an isolation switch electrically connected to said power converter, said isolation switch actuated when said power converter is energized by said receiving inductor thereby allowing said power converter to be electrically connected to an external circuit.

15. The apparatus of claim 12 further including a magnet positioned proximate said receptacle, said magnet configured to actuate the power switch in the plug when the plug is mated with said receptacle.

16. The apparatus of claim 12 further including a first communications device proximate said receptacle, said first communications device connected to said power converter, said first communications device configured to communicate a feedback signal to said plug when said plug portion is received in said receptacle, said first communications device configured to receive a capacity signal from said plug portion and said power converter operates according to said capacity signal, whereby said capacity signal corresponds to a maximum capacity of said plug.

17. The apparatus of claim 12 wherein said receptacle is attached to a vehicle, said magnetic attraction sufficiently weak to allow said receptacle to separate from the plug when the plug is mated with said receptacle and said vehicle moves away from the plug.

18. The apparatus of claim 12 wherein said power converter is a charger, and further including a temperature sensor electrically connected to said charger, said temperature sensor responsive to a temperature proximate said battery, and said charger providing a charging voltage dependent upon said temperature detected by said temperature sensor.

19. The apparatus of claim 12 wherein said power converter is a charger, and further including a communication connection configured to connect the receiver to a battery management system to transfer data from said receiver to the battery management system.

20. The apparatus of claim 12 wherein said power converter is a charger, and further including an indicator selectively displaying one of a charging status and a charged status, said indicator positioned to direct a visual signal toward said plug wherein said visual signal is visible on said plug.