GB2538941A

GB2538941A - Thermal imaging camera

Info

Publication number: GB2538941A
Application number: GB1506104.7A
Authority: GB
Inventors: Brooks James
Original assignee: K2 Tech Ltd
Current assignee: K2 Tech Ltd
Priority date: 2015-04-10
Filing date: 2015-04-10
Publication date: 2016-12-07
Also published as: GB201506104D0

Abstract

A thermal imaging camera for use in e.g. search and rescue operations, possibly via a helmet mounting, has a battery 202 which is permanently enclosed within the camera housing 201. The battery, for example a lithium ion battery, may be mounted by virtue of a shaped recess 207 within the inner wall 206 of the housing. Electronic components of the camera may be mounted on circuit boards 203, 204 possibly mounted on the battery 202 via elements 205a, 205b of a material, e.g. HDPE foam, to damp an effect on the circuit boards of physical shocks to the camera. A gap may be present between circuit boards and inner wall 206. Optionally, the housing 201 includes a battery recharging port. Because the battery is permanently enclosed, a larger (longer life) battery and/or space for protective elements to improve robustness may be included without making the camera larger.

Description

Thermal Imaging Camera

Technical Field

The present invention relates to thermal imaging cameras. More specifically but not exclusively, the present invention relates to particular techniques for mounting a battery or batteries within a thermal imaging camera.

Background

Thermal imaging cameras are often used in search and rescue situations. A helmet mounted thermal imaging camera can provide images to a rescue worker enabling them to see people in low visibility conditions such as dark or smoke filled spaces.

Such thermal imaging cameras are ideally as rugged as possible to withstand use in environments where they may be subject to impacts and other forces. This typically means "ruggedized" camera housings are used. Further, given that a rescue worker may be carrying a lot of other equipment and/or wearing heavy protective clothing, it is also desirable to minimise the weight and size of such thermal imaging equipment.

Conventional thermal imaging cameras use removable rechargeable batteries to provide power. Reducing the size of such batteries is desirable as it reduces the overall weight of the camera. However, the size of a battery determines the amount of energy that it can provide therefore providing a smaller battery will typically reduce the period of time the camera can operate for without replacing the battery. Using conventional techniques, it is difficult to reduce the size of a thermal imaging camera without reducing the amount of space available for a battery therefore compromising the battery life of the camera.

Further, it is also desirable to improve the robustness of thermal imaging cameras.

Conventionally, this can be achieved by using more "ruggedized" material in the camera housing. However, achieving this without increasing the overall size of the camera requires the amount of space within the camera housing to be reduced which reduces the amount of space available for the battery. It is therefore also difficult to improve the robustness of the camera without either making the camera larger or reducing the size of the battery.

It is an aim of the present invention to at least partly mitigate the above-mentioned problems by providing an improved thermal imaging camera.

Summary of the Invention

In accordance with a first aspect of the invention there is provided a thermal imaging camera comprising a camera unit coupled to electronic components and a battery. The camera unit, electronic components and battery are contained within a housing. The battery is permanently enclosed within said housing.

In accordance with this aspect of the invention a thermal imaging camera is provided which, in contrast to conventional thermal imaging cameras, includes a battery that is permanently enclosed within the camera housing. This means that there is no need for the additional structural components that are required in conventional thermal imaging cameras to accommodate a removable battery. These additional components include a battery hatch to allow insertion and extraction of the battery, insertion guides to ensure the battery is inserted in the correct fashion and into the correct position for electrical connection and releasable securing elements that secure the battery in place during normal use but that can be released when the battery is extracted. Further, as the battery used is permanently sealed within the camera, there is no need for the battery itself to include the protective outer casing normally found on replaceable batteries to allow the battery to be handled and protect it when it is inserted and extracted.

As a result of the fact that a battery is used that is permanently enclosed within the housing, a larger battery (with a longer battery life) can be used without increasing the size of the camera. Additionally, or alternatively, without reducing the size of the battery, more space is available for protective elements (such as thicker internal walls) to improve the overall robustness of the camera.

Accordingly, a thermal imaging camera can be provided with improved battery life (i.e. the amount of time the camera can be operated before the battery is depleted) without a need to increase the size of the camera housing to accommodate a larger battery, and/or a camera can be provided that is more robust, again without compromising on the size of the camera and battery life. In other words, for the same amount of energy delivered, a smaller space is required in the camera to accommodate the battery. This means that the overall size and weight of the camera can be reduced without compromising on the length of the time the camera can be operated before the battery is depleted.

Optionally, the battery is mounted to an inner wall of the housing.

In certain embodiments, the battery is mounted directly to the inner wall of the housing of the camera. Such mounting can be arranged to permanently fix the battery directly to the inner wall because there is no requirement for the battery to be removed. Such a direct mounting provides a simple and secure mounting of the battery with a reduced requirement for intermediate mounting elements.

Optionally, the battery is mounted to the inner wall of the housing by virtue of a shaped recess within the inner wall for receiving and securing the battery.

In certain embodiments, a shaped recess in the housing itself can be used to hold in place the battery. The use of a shaped recess, which can be shaped, at least in part, to complement the outer shape of the battery itself, reduces further the requirement of intermediate mounting elements and provides a particularly simple and secure mounting of the battery.

Optionally, the electronic components are supported by the battery.

In certain embodiments, the electronic components of the camera, in contrast with conventional arrangements, rather than being supported by a mounting which is connected directly to the inner wall of the housing, are instead supported by the battery. That is, the battery provides the intervening support element between the inner wall of the housing and the electronic components. This arrangement means the electronic components, which are typically more fragile and susceptible to damage than the battery, are isolated from impacts and forces applied to the camera by the battery itself. The electronic components are therefore less likely to be damaged as the extent to which energy from impacts and so on is transmitted to the electronic components is reduced.

Optionally, the electronic components are mounted on a first circuit board which is mounted on the battery.

In certain embodiments, the battery supports the electronic components by virtue of the electronic components being mounted on a circuit board which is mounted on the battery.

Optionally, the first circuit board is mounted on the battery by intermediate mounting elements.

Optionally, the intermediate mounting elements comprise a material to damp an effect on the first circuit board of physical shocks to the camera device.

In certain embodiments in which mounting elements are used to mount the circuit board to the battery, they comprise a material specifically chosen to damp the extent to which energy from impacts and so on is transmitted to the electronic components on the circuit board.

Optionally, the material of which the intermediate mounting elements comprise is foam.

Optionally, the first circuit board is mounted such that a gap is formed between the at least one circuit board and the internal wall of the housing.

In certain embodiments, the gap between the circuit board and the inner wall of the housing allows the circuit board to "float" within the camera. In the event of an impact of other force being applied to the camera which is such that energy is transmitted to the circuit board this energy can be dissipated as movement (e.g. vibration) of the circuit board with respect to the battery. However, the provision of the gap reduces the chance that the circuit board will strike the inner wall of the housing.

Optionally, the thermal imaging camera comprises one or more further circuit boards supported by the battery, said one or more further circuit boards mounted on the first circuit board by further intermediate mounting elements.

Optionally, the battery is a rechargeable battery and the housing includes a battery recharging port.

Optionally, the thermal imaging camera device is a thermal imaging camera for use in search and rescue.

In accordance with a second aspect of the invention there is provided a thermal imaging system comprising a thermal imaging camera according to any preceding claim, further comprising a display unit coupled to the thermal imaging camera device by a flexible arm.

Various aspects and features of the invention are defined in the claims.

Brief Description of Figures

Certain embodiments of the present invention will now be described hereinafter, by way of example only, with reference to the accompanying drawings in which: Figure 1 provides a schematic diagram of a thermal imaging camera system; Figure 2 provides a schematic diagram of a showing a cross sectional view of a thermal imaging camera in accordance with an embodiment of the invention; Figure 3 provides a schematic diagram showing a cross sectional view of a housing of a thermal imaging camera in accordance with an embodiment of the invention; Figure 4 provides a schematic diagram showing another cross sectional view of a housing of a thermal imaging camera in accordance with an embodiment of the invention, and Figure 5 provides a schematic diagram showing various components within a thermal imaging camera in accordance with embodiments of the invention

Detailed Description

In the drawings like reference numerals refer to like parts.

Figure 1 provides a schematic diagram of a thermal imaging camera system 101. The system includes a thermal imaging camera 102, a display unit 103 and a flexible connecting arm 104 which connects the thermal imaging camera 102 and the display unit 103.

The thermal imaging camera 102 includes a lens 105 optically connected to an imaging unit including a thermal sensor (the lens and the imaging unit including the sensor together forming a camera unit) within the thermal imaging camera 102 which generates image data. This image data is processed by image processing electronics also within the thermal imaging camera 102. This processed image data is then sent to the display unit 103 via an electronic coupling within the connecting arm 104. The system 101 includes control buttons 106, 107 allowing a user to control the operation of the system 101.

The system 101 in use might be attached to a rescue worker, for example on a helmet worn by the rescue worker. This attachment may be in such a manner that the lens 105 is generally directed in a direction in which the rescue worker's head is orientated and thus directed in the same direction that the rescue worker is looking. The display unit 103 may be positioned relative to one of the rescue worker's eyes using the flexible arm 104 such that images captured by the thermal imaging camera 102 can be seen by the rescue worker.

As the camera 102 is a thermal imaging camera, the lens 105, the imaging unit and the image processing electronics are arranged to be sensitive to infrared radiation. This means that the system 101 can display objects by virtue the emission of infrared radiation and without the requirement of visible illumination. This can allow rescue workers to find their way in low light environments and also help find people who may require rescue. Typically the thermal sensor of the imaging unit is provided by a microbolometer silicon chip.

Within the outer housing, the thermal imaging camera 102 includes the imaging unit optically coupled to the lens 105, a battery for powering the system (the display unit 103 can be powered by a power line passing through the flexible arm 104), and one or more circuit boards on which are mounted electronic components of the image processing electronics along with further electronic components for controlling the operation of the system.

Figure 2 provides a schematic diagram showing a cross sectional view of a thermal imaging camera suitable for use in a system as described with reference to Figure 1 and arranged in accordance with an example of the invention.

A housing 201 is provided within which is positioned a battery 202 and a first circuit board 203 and a second circuit board 204. The housing may be made from any suitable material, for example a resin such as 5285 PU resin or flame retardant ABS. The first circuit board 203 is mounted on the battery 202 by virtue of first mounting elements 205a. The second circuit board 204 is mounted on the first circuit board 203 by virtue of second mounting elements 205b. The battery is electrically coupled to all the components of the thermal imaging camera requiring power.

The circuit board (for example a printed circuit board PCB) has mounted thereon electronic components enabling the operation of the thermal imaging camera for example an FPGA processor, memory units, capacitors, resistors, Molex connectors and so on.

The battery 202 is mounted to an inner wall 206 of the housing 201 by virtue of a shaped recess 207 in the inner wall 206. The shaped recess 207 is shaped to match an outer profile of part of the battery 202 such that the battery 202 fits snugly and securely into the inner wall 206 of the housing 201.

Figure 3 provides a schematic diagram providing an illustration of the housing 201 without the battery or circuit boards shown, showing more clearly the shaped recess 207. As can be seen from Figure 3, the shaped recess is of a shape which matches (complements) the outer profile of the battery. The shaped recess includes portions 301a, 301b which extend over an upper edge of the battery, securing the battery in place vertically.

Figure 4 provides a schematic diagram providing a cross sectional view of part of the housing 201, without the battery or circuit boards shown, from above providing a further view of the shaped recess 207. During assembly of the thermal imaging camera, the battery can be slid into the recess in direction A before a front portion 401 of the housing 201 is fixed to a second portion 402 of the housing 201, for example by bonding.

As can be seen from Figure 4, the shaped recess 207 has a first end wall 404 and a second end wall 403 formed by the front portion 401 of the housing 206. This arrangement secures the battery in place horizontally.

In use, the battery 202 is permanently enclosed within the housing 201. That is, during normal operational use of the thermal imaging camera, the battery 202 is sealed within the housing and is not extracted. This is in contrast to conventional thermal imaging cameras which employ user-replaceable batteries which are extracted and reinserted in the camera housing. These conventional arrangements require internal structural components to allow the battery to be guided into position and then physically secured to hold the battery in place and also to ensure the requisite electrical connection is made with internal electrical connectors. These conventional arrangements also require an access hatch (provided by an opening) to be provided through the housing to allow batteries to be inserted and removed.

Typically, additional material is required around the access hatch to ensure that the structural integrity of the housing in this area is not compromised by the opening of forms the access hatch.

As the battery in accordance with examples of the present invention is permanently sealed within the housing there is no requirement for these additional structural components. This provides extra space allowing the use of a larger battery and/or a reduction in the overall size of the thermal imaging camera. Alternatively or additionally the extra space can be used to provide additional protective elements improving the robustness of the camera, for example thicker walls.

The housing 201 can be formed in any suitable way. In some examples two or more sections are bonded together at their peripheral edges during the assembly of the thermal imaging camera. In other examples, as shown in Figure 4, the second portion 402 of the housing is a single monolithic block into which is inserted the various components of the camera. The first portion 401, effectively forming a "lid" is then bonded to the second portion 402 forming the complete housing and permanently enclosing the various components of the camera, including the battery, within the housing.

As can be seen from Figure 2, the arrangement of the battery 202 and the mounting elements 205a, 205b is such that the circuit boards 203, 204 "float" within the housing 201. That is, a gap is provided between the circuit boards 203, 204 and the inner wall of the housing 201.

In the event of a kinetic shock (such as an impact of the type that might typically be expected to rise during use of the thermal imaging camera in a search and rescue situation), applied to the outside of the housing 201, the amount of kinetic energy that would otherwise be transmitted to the circuit boards is reduced as the circuit boards are isolated from the housing by virtue of the mounting elements 205a, 205b and the battery itself.

Further, the material with which the mounting elements 205a, 205b are made, can be selected to reduce further the effect of kinetic shocks applied to the outside of the housing 201 on the circuit boards 203, 204. For example, a foam material, such as a high density cell polyethylene (HDPE) foam can be used. In some examples, such foam is dual-side coated with acrylic adhesive. Such foam provides a "damping" effect which reduces further the extent to which energy from kinetic shocks applied to the outside of the housing 201 are transmitted to the circuit boards 203, 204.

As the battery is permanently enclosed within the housing of the thermal imaging camera, in some examples, thermal imaging cameras in accordance with examples of the invention will include a recharging port, for example a socket positioned through an aperture in the housing for receiving a connector connected to an electrical power source. The socket and connector electrically connect the battery with the electrical power source allowing the battery to charge.

The example shown in Figure 2 includes two circuit boards mounted on each other. It will be understood that in some examples further circuit boards could be mounted in this configuration, limited by the space available within the housing and the size of the circuit boards. In other examples, only one circuit board is used.

In the examples described above, the battery is mounted to the inner wall by virtue of a shaped recess. In other examples, the battery can be mounted using different techniques, for example bonding the battery to the inner wall of the housing using a suitable adhesive or by the use of supporting members projecting inwards from the inner wall of the housing.

As will be understood, any suitable battery can be used in examples of the invention. In certain examples a Lithium Ion 3.6V 2.0 MAh battery can be used.

In the examples described above, a single battery is discussed. However, it will be understood that in certain examples of the invention, multiple batteries can be used and the electronic components can be mounted on one or more of these batteries.

The principles of the invention can be used in any suitable thermal imaging camera arrangements but certain embodiments will be directed specifically to thermal imaging cameras for use in search and rescue. Such cameras are typically include a strengthened housing, include simple and easy to use controls and are of small and lightweight design such that they can easily be borne about the person of a rescue worker. Such cameras may typically include a suitable mounting for allowing mounting to the rescue worker, for example a helmet mounting.

In the examples described above, the camera housing has been described in terms of a casing formed from a monolithic portion and "lid" portion. However, it will be understood that in certain examples of the invention, the housing can be implemented in any suitable arrangement. For example, the housing may comprise multiple different elements for example, a number of layers formed from a number of different portions.

Figure 5 provides a schematic diagram showing the various components within a thermal imaging camera in accordance with examples of the present invention. As will be understood, further components may also be included. Interfaces to external components (for example a recharging port and a connection line with an external display) are not shown. Figure 5 shows a lens 501 and an imaging unit 502 (including a thermal sensor) together forming a camera unit. Figure 5 shows a circuit board 503 on which are mounted electronic components and a battery 504.

Features, integers, characteristics or groups described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith.

All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of the features and/or steps are mutually exclusive. The invention is not restricted to any details of any foregoing embodiments. The invention extends to any novel one, or novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

The reader's attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.

Claims

CLAIMS1. A thermal imaging camera comprising a camera unit coupled to electronic components and a battery, said camera unit, electronic components and battery contained within a housing, wherein said battery is permanently enclosed within said housing.
2. A thermal imaging camera according to claim 1, wherein the battery is mounted to an inner wall of the housing.
3. A thermal imaging camera according to claim 2, wherein the battery is mounted to the inner wall of the housing by virtue of a shaped recess within the inner wall for receiving and securing the battery.
4. A thermal imaging camera according to claim 2 or 3, wherein the electronic components are supported by the battery.
5. A thermal imaging camera according to claim 3 or 4, wherein the electronic components are mounted on a first circuit board which is mounted on the battery.
6. A thermal imaging camera according to claim 5, wherein the first circuit board is mounted on the battery by intermediate mounting elements.
7. A thermal imaging camera according to claim 6, wherein the intermediate mounting elements comprise a material to damp an effect on the first circuit board of physical shocks to the camera device.
8. A thermal imaging camera according to claim 7, wherein the material is foam.
9. A thermal imaging camera according to claim 7 or 8, wherein the first circuit board is mounted such that a gap is formed between the at least one circuit board and the internal wall of the housing.
10. A thermal imaging camera according to any of claims 5 to 9, comprising one or more further circuit boards supported by the battery, said one or more further circuit boards mounted on the first circuit board by further intermediate mounting elements.
11. A thermal imaging camera according to any preceding claim, wherein the battery is a rechargeable battery and the housing includes a battery recharging port.
12. A thermal imaging camera according to any preceding claim, wherein the camera device is a thermal imaging camera for use in search and rescue.
13. A thermal imaging system comprising a thermal imaging camera according to any preceding claim, further comprising a display unit coupled to the thermal imaging camera device by a flexible arm.
14. A thermal imaging camera or thermal imaging camera system as hereinbefore described with reference to the drawings.