GB2574735A

GB2574735A - Cable retraction apparatus

Info

Publication number: GB2574735A
Application number: GB1910821.6A
Authority: GB
Inventors: Cook Christopher
Original assignee: Individual
Current assignee: Individual
Priority date: 2019-07-30
Filing date: 2019-07-30
Publication date: 2019-12-18
Also published as: GB201910821D0

Abstract

A cable retraction apparatus has a housing (102 fig. 1) with a cable opening, a moveable carriage or floating block and pulley 208 mounted for movement relative to the housing and comprising a body 222 and a plurality of spaced-apart rolling elements 224, 226, 228 mounted for rotation relative to the body 222 and arranged to be in contact with a cable 55 in use. Rolling elements 224, 226, 228 may be arranged on a common arc and body 222 may be shaped as a semi-circle. Carriage 208 may be resiliently biased to a cable retracted position by a resiliently extendible element 204 such as a tension coil spring arranged around a spring guide body 214 to follow a non-linear path. A static carriage or fixed block and pulley 210 may also comprising a body 234 and a plurality of spaced-apart rolling elements 236, 238, 240 mounted for rotation relative to the body 234 and arranged to be in contact with the cable 55 in use. The retraction apparatus may form part of a wall mounted consumer electronic charging station 100 with a support 174 for an electronic device or it may form part of a vehicle charging station (300 fig. 10). The retraction apparatus may be used with copper data cables, fibre cables or flexible fluid conduits such as hoses.

Description

Cable retraction apparatus

The present invention is concerned with a cable retraction apparatus. More specifically, the present invention is concerned with an apparatus for automatically retracting a charging cable into a housing after use.

Electrical cables are used for a wide range of applications. Cables can be used for transferring power (to e.g. charge or power an electric device), data or both. The present invention is primarily concerned with (although not limited to) power cables.

Although wireless charging is becoming more common for portable electrical devices, physical charger connections are still common. Furthermore, many wireless charging systems (such as charging pads) require a wired connection themselves.

For high power applications (such as the charging of electric vehicles), physical charger connections remain the primary means of transferring power.

For all applications, it is generally desirable to neatly store the charging cable when not in use.

For portable electronic, unused charging cables are unsightly and may be damaged if left trailing from a socket.

For larger, high power applications, such as electric vehicles, leaving high power cables lying on the ground can present a health and safety risk. This is both from the point of view of a trip hazard, as well as an electrical risk.

It is therefore desirable to provide a means of automatically retracting and storing said cables when not in use.

Various means of retraction and storage have been proposed. It is an aim of the present invention to provide an improved cable retraction apparatus.

According to a first aspect of the invention there is provided a cable retraction apparatus comprising: a housing defining a cable opening;

a moveable carriage mounted for movement relative to the housing such that movement of the moveable carriage retracts a cable extending from the cable opening, the moveable carriage comprising:

a body; and, a plurality of spaced-apart rolling elements mounted for rotation relative to the body, the rolling elements arranged to be in contact with a cable in use.

Advantageously, the provision of a plurality of spaced-apart rolling elements reduces the friction experienced by the cable during extension and retraction. The invention takes advantage of the fact that charging cables (typically copper wires with several layers of insulation) have an inherent flexural stiffness which means that they do not need a continuous, uninterrupted pulley surface to run against. As long as the cable is guided by the rolling elements, each of which has a diameter significantly smaller than the arc which the cable follows, the cable will naturally form a smooth, arcuate curve.

Advantageously, the carriage can be made much smaller than a traditional single wheel pulley (where the diameter is equal to the bend diameter of the cable). For example, the carriage can be made semicircular, which provides more space for movement allowing the cable to be retracted into a smaller space.

Advantageously, because the carriage does not need to be mounted at the axial centre of the cable curvature (unlike a traditional single wheel pulley), this space can be used to store other components. Preferably the plurality of rolling elements are disposed with respective axes of rotation on a common arc. More preferably the plurality of rolling elements comprises at least three rolling elements, and in which the at least three rolling elements are disposed with respective axes of rotation on a common arc.

Preferably the at least three rolling elements comprises a first end element and a second end element disposed equal to or less than 180 degrees apart. The first end element and the second end element may be disposed equal to or less than 160 degrees apart.

Preferably the moveable carriage is shaped as a circle segment. More preferably the moveable carriage is a semi-circle.

Preferably the moveable carriage is resiliently biased to a cable-retracted position in which a cable is retracted.

Preferably the moveable carriage is resiliently biased by a resiliently extendible element.

Preferably there is provided a resiliently extendible element carriage configured to provide a nonlinear path of the resiliently extendible element.

Preferably the resiliently extendible element is configured to pull the moveable carriage towards an interior surface of the housing, and wherein the non-linear path of the resiliently extendible element extends away from the interior surface of the housing.

Preferably there is provided a cable retraction apparatus according to the first aspect further comprising:

a static carriage mounted to the housing, the static carriage comprising:

Preferably the moveable carriage moves towards and away from the static carriage in use.

Preferably the body of the moveable carriage defines a flat, wherein the flat faces the static carriage.

Preferably the static carriage is shaped as a circle segment and defines a flat, wherein the flat faces the moveable carriage.

Preferably the apparatus is configured to provide a serpentine cable path therein.

The invention also provides a consumer electronic device charging station comprising a cable retraction apparatus according to the first aspect.

Preferably the station is wall mounted.

Preferably the housing comprises a support for supporting at least one electronic device.

Preferably the apparatus comprises a charger having a cable extending from inside the housing to outside the housing, the cable being retractable by the cable retraction apparatus.

According to the invention there is provided a vehicle charging station comprising a cable retraction apparatus according to the first aspect.

Example cable retraction apparatuses will now be described with reference to the accompanying Figures in which:

Figure 1 is a front perspective view of a first retraction apparatus according to the present invention;

Figure 2 is a front view of the apparatus of Figure 1;

Figure 3 is a rear perspective view of the apparatus of Figure 1;

Figure 4 is a side view of the apparatus of Figure 1;

Figure 5 is a front perspective view of the apparatus of Figure 1;

Figure 6 is a rear bottom perspective view of the apparatus of Figure 1;

Figure 7 is a front perspective view of a sectioned part of the apparatus of Figure 1;

Figure 8 is a rear view of a subassembly of the apparatus of Figure 1;

Figure 9 is a detail sectioned rear view of a subassembly of the apparatus of Figure 1;

Figure 10 is a front perspective view of a second retraction apparatus according to the invention;

Figure 11 is a front view of the apparatus of Figure 10;

Figure 12 is a perspective view of a part of the apparatus of Figure 10; and,

Figure 13 is a section view of the part of Figure 12.

First embodiment

Referring to Figure 1, a charging apparatus 100 according to the present invention is shown. A mobile device in the form of a cellular phone or tablet may be supported by the apparatus as will be described below. The apparatus is mounted to a plug socket 50 which in turn is mounted to a wall 52. A pair of chargers 54, 56 are provided.

The apparatus 100 comprises a housing 102. The housing 102 comprises sidewalls 104, 106, top wall 108, bottom wall 110, mounting plate 112 and support 114.

The sidewalls 104,106 are mirror images of each other. As such only the sidewall 104 will be described in detail.

The sidewall 104 is generally flat and quadrilateral in shape. From the side (Figure 4), it is trapezoidal having a top edge 116, bottom edge 118, rear edge 120 and a front edge 122. The top and bottom edges 116, 118 are parallel, and the rear edge normal thereto. The front edge 122 is at an angle A to the rear edge 120.

The top wall 108 is generally flat, elongate and rectangular comprising a first side edge 138, second side edge 140, rear edge 142 and front edge 144.

The bottom wall 110 comprises a first side edge 146, second side edge 148, rear edge 150 and front edge 152.

The mounting plate 112 (Figure 3) is flat and generally in the shape of an inverted U having a crossmember 158, and first and second side members 160, 162. A mounting flange 164 extends in a U shape around the inner periphery of the mounting plate 112.

The support 114 is generally planar having a top edge 166, bottom edge 168 and side edges 170,172. A support lip 174 extends from the plane of the support 114 along the bottom edge 168.

The socket 50 is a standard 2-gang plug plate which is well known in the art. It comprises a wall plate 58, a pair of switches 60, 62 attached to the plate 58 and a pair of socket openings (not visible). The wall plate 58 attaches to a back box (not shown) embedded in the wall 52 such that (without the apparatus 100) the plate 58 abuts the wall. The plate 58 is secured by screws provided in fixing bores 68.

The chargers 54, 56 identical and are of a known type. Each comprises a power cable 55, 57 respectively which extends from a respective USB plug 64, 66 to a respective device plug 65, 67 at a free end.

It will be noted that the drawings show a 2-gang UK 3-pin plug arrangement, but the present invention is also adaptable to 1-gang UK 3-pin, European, US or other types of plug and socket arrangement as required. It is also envisaged that instead of a mains power plug, a USB (Universal Serial Bus) cable could provide power to the charging plates via a socket comprising USB power output.

Referring to Figure 8, the internal components of the apparatus 100 are shown. The apparatus 100 comprises a first cable retraction system 200 and a second cable retraction system 202. The cable retraction systems 200, 202 similar to each other, and as such on the system 200 will be described in detail, with the differences explained below.

The cable retraction system 200 comprises a spring 204, spring guide 206, a floating carriage in the form of a block and pulley 208, a static carriage in the form of a fixed block and pulley 210 and a cable guide 212.

The spring 204 is a tension coil spring and is shown as a dashed line for clarity.

The spring guide 206 is attached to the housing 102 and comprises a spring guide body 214, a first pulley wheel 216 and a second pulley wheel 218. The pulley wheels 216, 218 are mounted for rotation within the spring guide body 218. The spring 204 is attached at a first end to a spring lug 220 on the housing 102. The spring then extends in a vertically downward direction (in use) towards the spring guide 206, passing through 90 degrees in contact with the first pulley wheel 216 towards the second pulley wheel 218, through 90 degrees from the second pulley wheel 218 vertically upwards (i.e. through approximately 180 degrees in total) to attach at a second end to the floating block and pulley 208. Because the pulley wheels 216, 218 can freely rotate about their respective axes, the spring 204 is permitted to extend and contract with movement of the floating block and pulley 208 as will be described below.

The floating block and pulley 208 comprises a body 222 to which three individually rotatable pulley wheels 224, 226, 228 are mounted. The body 222 is generally semi-circular in shape having a flat side

223 facing vertically upwards in use. The wheels 224, 226, 228 are mounted on an arc 230, with the first and third wheels 224, 228 being angle B = 160 degrees apart, and the second wheel 226 central thereto. The floating block and pulley body 222 defines a spring attachment lug 232 directly opposite the flat side 223. It will be noted that the radius of the wheels 224, 226, 228 is significantly less than the radius of arc 230.

The fixed block and pulley 210 comprises a body 234 to which three individually rotatable pulley wheels 236, 238, 240 are mounted. The body 234 is generally semi-circular in shape having a flat side 235 facing vertically downwards in use. The wheels 236, 238, 240 are mounted on an arc 242, with the first and third wheels 236, 240 being angle C = 160 degrees apart, and the second wheel 238 central thereto. The body 234 is attached to the housing 102 vertically above the floating block and pulley 208.

It will be noted that the flat sides 223, 235 of the block and pulleys 208, 210 face each other in use.

The cable guide 212 comprises two rolling elements 244, 246.

The main difference between the otherwise mirror-image cable retraction systems 200, 202 is the fact the fixed block and pulley 210 of the system 200 is provided at an angle to overlap the fixed block and pulley 210 of the system 202. This is visible in Figure 8.

The cable 55 is attached to the housing 102 at an attachment recess 248. This recess 248 may e.g. provide an interference fit with the cable 55. The primary function is to prevent any tension on the cable 55 from pulling the USB plug 64 from the charger 56.

The cable is then passed downwardly towards the floating block and pulley 208 where is passes over the rolling elements or wheels 224, 226, 228 in sequence before passing vertically upwards towards the fixed block and pulley 210. It will be noted that in doing so the cable 55 passes through 180 degrees.

The cable then passes upwardly towards the fixed block and pulley 210 where is passes over the rolling elements or wheels 236, 238, 240 in sequence before passing vertically downwards towards the cable guide 212. It will be noted that in doing so the cable 55 passes through 180 degrees again.

The cable 55 therefore forms an S or serpentine shape from the where it is fixed to the housing 102 at recess 248 to the cable guide 212. The device plug 67 is left protruding from the cable guide 212.

To install the apparatus 100, the plug socket 50 is moved away from the wall by a small distance (say 4-5mm) by partially unscrewing the plate 58 and pulling it away from the wall. The assembled sidewalls 104,106, top wall 108 and mounting plate 112 (having an open or U-shaped profile) are then slid in a downward direction relative to the socket 50 such that the flange 164 enters the gap between the plate 58 and the wall 52. The socket 50 is then tightened against the wall by screwing the plate 58 inwards to clamp the flange 164, and hence the apparatus against the wall.

The bottom wall 110 is then installed by sliding projections 154, 156 into respective channels 126 in the side walls 104, 106. At this point, the charger plugs 54, 56 can be placed into the socket 50, and the support 114 assembled with the rest of the apparatus 100.

Once in position, when a device is positioned on the support 114, resting on the lip 174. It should also be noted that the support 114 is oriented at angle A, which at 6 degrees is sufficient to ensure that the device 10 does not fall from the support, but the screen can be easily viewed.

In the condition shown in Figures 8 and 9, the cable retraction system 200 is in a retracted state.

To charge the device, the device plug 65 is manually pulled from the cable guide 212. As this occurs, the cable runs over the rolling element 244, and over the wheels 236, 238, 240 of the fixed block and pulley 210. Because the cable 55 is attached to the housing 102 at the recess 248, tension causes the cable to pull the floating block and pulley 208 vertically upwards (direction D, Figure 9) whilst rotating the wheels 224, 226, 228. This extends the spring 204 providing a resilient downward force on the floating block and pulley 208. The spring 204 is sufficiently weak not to pull the device plug 65 from the device, but only to retract the cable 55 when the device plug 65 is unplugged (free).

Therefore, once the device is charged and unplugged, releasing the plug 65 will allow the spring 204 to resiliently pull the block and pulley 208 downwardly, away from the fixed block and pulley 210 to move back to the retracted condition.

It will be noted that when in a fully extended condition, the floating block and pulley 208 can get very close to the block and pulley 210 because of the block and pullies' semi-circular shapes. Contrasting this to a traditional pulley system where two pulley wheels would be provided coincident with arcs 230, 242, where much less room for movement would be available.

Second embodiment

Referring to Figures 9 onwards, there is provided a charging apparatus 300 according to the present invention. The apparatus comprises a housing 302 and a retraction system 304. The retraction system 304 comprises a spring 306, spring guide 308, a floating block and pulley 310, a fixed block and pulley 312 and a cable guide 314.

The spring 306 is a tension coil spring and is shown as a dashed line for clarity.

The spring guide 308 is attached to the housing 302 and comprises a body 315, a first pulley wheel 316 and a second pulley wheel 318. The pulley wheels 316, 318 are mounted for rotation within a spring guide body 315. The spring 306 is attached at a first end to a spring lug 320 on the housing 302. The spring then extends in a vertically downward direction (in use) towards the spring guide 308, passing through 90 degrees in contact with the first pulley wheel 316 towards the second pulley wheel 318, through 90 degrees from the second pulley wheel 318 vertically upwards (i.e. through approximately 180 degrees in total) to attach at a second end to the floating block and pulley 310. Because the pulley wheels 316, 318 can freely rotate about their respective axes, the spring 306 is permitted to extend and contract with movement of the floating block and pulley 310 as will be described below.

The floating block and pulley 310 comprises a body 322 to which a first set of four individually rotatable pulley wheels 324, 326, 328, 329 are mounted and a second set four individually rotatable pulley wheels 336, 338, 340, 341 are mounted.

The first set of wheels are coplanar, and the second set are coplanar, the first set being offset from the second. The wheels are arranged in coaxial pairs as shown in Figure 12 (pairs 324, 336; 326, 338; 328, 340; and 329, 341).

The body 322 is generally semi-annular in shape having a concave side 323 facing vertically upwards in use. Both sets of wheels are mounted on an arc 330 when viewed from the side (Figure 13), with the first and fourth wheels 324, 329 (336, 341 of the second set) being angle D = 160 degrees apart, and the second and third wheels 326, 328 (338, 340 of the second set) equally spaced therebetween. The floating block and pulley body 322 defines a spring attachment lug (not shown) directly opposite the concave side. It will be noted that the radius of the wheels is significantly less than the radius of arc 330.

The fixed block and pulley 310 is identical to the floating block and pulley, albeit inverted so the concavities two semi-annular block and pullies face each other (Figure 11).

The cable guide 314 is a polymer sleeve defining an opening for passage of a cable.

A power cable 400 is provided having a fixed / supply end 402 and a connector 404. The cable 400 enters the housing at an entry opening 315, passes over two of the first set of wheels of the fixed block and pulley 312, turning through 90 degrees in the process to pass downwardly towards the floating block and pulley 310. There, the cable passes over all four wheels of the first set to return to the second set of wheels of the fixed block and pulley. The cable contacts each of the wheels to turn through 180 degrees to return to the floating block and pulley whereupon again it passes through 180 degrees to return to the remaining two wheels of the first set on the fixed block and pulley before being fed to the cable guide 314.

Therefore the cable forms two obround / elliptical loops between the entry and exit from the housing.

In the condition shown in Figures 10 and 11, the cable retraction system 300 is in a retracted state.

To extend the cable, for example when charging a vehicle, the connector 404 can be grabbed and pulled from the housing. As this occurs, the cable 400 runs over the wheels of the fixed block and pullies, pulling the floating block and pulley 310 in an upward direction (towards the fixed block and pulley 312) against the bias of the spring 306. The spring 204 is sufficiently weak not to pull the connector 404 from e.g. an electric vehicle, but only to retract the cable 400 when the device connector 404 is unplugged (free).

Therefore, once the vehicle is charged and unplugged, releasing the connector 404 will allow the spring 306 to resiliently pull the block and pulley 310 downwardly, away from the fixed block and pulley 312 to move back to the retracted condition.

It will be noted that when in a fully extended condition, the block and pulley 208 can get very close to the block and pulley 210 because of the block and pullies' semi-circular (annular) shapes.

It will be further noted that when the floating block and pulley 310 has moved all the way to the fixed block and pulley 312 (i.e. in the fully extended condition), a recess is provided within the completed annulus. This provides a storage region for e.g. electronics.

Variations of the above embodiments fall within the scope of the present invention.

As well as charging cables, the invention may be used for the extension and retraction of other cables such as copper data cables, fibre cables or combinations thereof. The invention (particularly the second embodiment) is also useful forextension and retraction of flexible fluid conduits such as hoses.

Claims

1. A cable retraction apparatus comprising:

a housing defining a cable opening;

2. A cable retraction apparatus according to claim 1, wherein the plurality of rolling elements are disposed with respective axes of rotation on a common arc.

3. A cable retraction apparatus according to claim 2, wherein the plurality of rolling elements comprises at least three rolling elements, and in which the at least three rolling elements are disposed with respective axes of rotation on a common arc.

4. A cable retraction apparatus according to claim 3, wherein the at least three rolling elements comprises a first end element and a second end element disposed equal to or less than 180 degrees apart.

5. A cable retraction apparatus according to claim 4, wherein the first end element and the second end element disposed equal to or less than 160 degrees apart.

6. A cable retraction apparatus according to any preceding claim, wherein the moveable carriage is shaped as a circle segment.

7. A cable retraction apparatus according to claim 6, wherein the moveable carriage is a semicircle.

8. A cable retraction apparatus according to any preceding claim, wherein the moveable carriage is resiliently biased to a cable-retracted position in which a cable is retracted.

9. A cable retraction apparatus according to claim 8, wherein the moveable carriage is resiliently biased by a resiliently extendible element.

10. A cable retraction apparatus according to claim 9, comprising a resiliently extendible element carriage configured to provide a non-linear path of the resiliently extendible element.

11. A cable retraction apparatus according to claim 10, wherein the resiliently extendible element is configured to pull the moveable carriage towards an interior surface of the housing, and wherein the non-linear path of the resiliently extendible element extends away from the interior surface of the housing.

12. A cable retraction apparatus according to any preceding claim comprising:

a static carriage mounted to the housing, the static carriage comprising:

13. A cable retraction apparatus according to claim 12, wherein the moveable carriage moves towards and away from the static carriage in use.

14. A cable retraction apparatus according to claim 12 or 13, dependent on claim 6, wherein the body of the moveable carriage defines a flat, wherein the flat faces the static carriage.

15. A cable retraction apparatus according to claim 14, wherein the static carriage is shaped as a circle segment and defines a flat, wherein the flat faces the moveable carriage.

16. A cable retraction apparatus according to any preceding claim, configured to provide a serpentine cable path therein.

17. A consumer electronic device charging station comprising a cable retraction apparatus according to any preceding claim.

18. A consumer electronic device charging station according to claim 17, in which the station is wall mounted.

19. A consumer electronic device charging station according to claim 17 or 18, wherein the housing comprises a support for supporting at least one electronic device.

20. A consumer electronic device charging station according to any of claims 17 to 19, comprising a charger having a cable extending from inside the housing to outside the housing, the cable being retractable by the cable retraction apparatus.

21. A vehicle charging station comprising a cable retraction apparatus according to any of claims 1 to 16.