GB2599157A

GB2599157A - Battery charging apparatus

Info

Publication number: GB2599157A
Application number: GB2015340.9A
Authority: GB
Inventors: Daniel Marshall-Andrews Thomas
Original assignee: Powerchute Ltd
Current assignee: Powerchute Ltd
Priority date: 2020-09-28
Filing date: 2020-09-28
Publication date: 2022-03-30
Also published as: WO2022064228A1; GB202015340D0

Abstract

A battery charging apparatus is described comprising a charging means 26, and a casing 14 configured to substantially surround and enclose the charging means 26, the casing 14 comprising an inlet hopper 35 configured to receive and store batteries 12 for charging and from which batteries are supplied, in use, to the charging means 26, and an outlet hopper 36 configured to receive and store charged batteries 12 received, in use, from the charging means. The casing may further define a reject hopper to deliver batteries which are unsuitable for charging. Also disclosed is a battery charging apparatus comprising a charging means and electrical contacts for making electrical contact with parts of the battery received in the charging means, the contacts being L-shaped and pivotably or otherwise moveably mounted to the charging means, and charging means where the contacts are moveable between a rest position and in-use position by a drive means

Description

BATTERY CHARGING APPARATUS

This invention relates to a battery charging apparatus. More particularly, the invention relates to a battery charging apparatus that allows automatic recharging, in turn, of discharged batteries and maintains a store of recharged batteries.

Battery chargers for charging rechargeable batteries are well known. Battery chargers for a single type of universal cell or single size of battery are known (e.g. AA-size cells), or for charging different sizes of the common types of universal cell (e.g. a single charging block with spaces for AAA-sized cells, AA-sized cells, C-sized cells, D-sized cells, etc). To charge the battery, a user inserts the discharged battery into the correct space in the charging block and ensures that power is running to the block. Charging the battery usually takes several hours, and at the end of the process, the battery is fully charged and can be removed and used as normal.

The effective use of chargers of this type relies on having more batteries available than are required for use at any one time, so that when a discharged cell is being charged, a user already has a same-size fully charged cell available to them for use. Alternatively a user can forego use of a particular battery-power device for as long as is required to charge the batteries that they do have.

It is an object of the present invention to provide a battery charging apparatus which goes at least some way to overcoming the disadvantages associated with known arrangements and/or which at least provides the public or industry with a useful choice.

According to a first aspect the invention there is provided a battery charging apparatus, comprising a charging means, and a casing configured to substantially surround and enclose the charging means, the casing comprising an inlet hopper configured to receive and store batteries for charging and from which batteries are supplied, in use, to the charging means, and an outlet hopper configured to receive and store charged batteries received, in use, from the charging means.

The casing may define a tortuous path along which batteries move, in use, between an inlet and an outlet, parts of the tortuous path defining the inlet and outlet hoppers.

The battery charging device may further comprise a receiving tray configured to receive and retain batteries passing out of the casing via the outlet and forming part of the outlet hopper.

The charging means may take a range of forms. By way of example, the charging means may comprise a generally cylindrical charging body arranged to rotate within the casing about its own central axis of rotation, the charging body preferably being aligned substantially horizontally across the casing. The charging body may comprise at least one cell groove or recess extending inwards from its circumferential perimeter, configured to receive a battery cell from the inlet hopper, and charging contacts, located at each end of each of the cell grooves or recesses to contact the ends of a battery cell as it locates into the cell groove.

Alternatively, the charging means may comprise an elongate upright internal cell charger comprising an endless belt having a number of charging bays mounted thereon, the cell charger preferably being aligned so that the belt passes downwards close to the rear wall of the casing, and upwards close to the front wall of the casing, with the axis of rotation conveniently running horizontally sideways across the casing. The cell charger may comprise a series of bays, substantially vertically aligned in a strip, and configured so that as the cells drop down from the inlet hopper, they will roll into the bays, the cells being held within the bays to charge and then released to pass forwards out of the bay into the outlet hopper.

The battery charging device may further comprise a sensing means configured to carry out checks on batteries introduced into the apparatus. The sensing means may be configured to read information from a battery, and may comprise, for example, a barcode reader or an RFID reader. The sensing means may be operable to check that the battery is a rechargeable battery suitable for charging using the apparatus, and/or may be arranged to check the polarity or orientation in which a battery has been inserted.

The casing may further define a reject hopper, and the charging means may be arranged to delivery batteries to the reject hopper in the event that the sensing means detects that the batteries are unsuitable for charging.

The charging means may include a first polarity charging circuit and a second polarity charging circuit, and may be arranged to select which of the charging circuits to use depending upon the output of the sensing means.

The charging means includes electrical contacts for making electrical contact with parts of the batteries, in use. The electrical contacts are preferably of generally L-shaped form, and are preferably pivotally or otherwise moveably mounted to the charging means. In such an arrangement, the weight of a battery resting upon parts of the generally L-shaped contacts may urge other parts of the generally L-shaped contacts into contact with terminals of the battery.

The electrical contacts may be spring biased towards a position in which the said other parts do not engage the terminals of the battery, thereby aiding receipt and/or discharge of a battery to or from the charging means.

Alternatively, at least one of the electrical contacts may be movable between a rest position and an in use position by a drive means. The drive means may comprise a cam surface shaped such that cooperation thereof with part of the electrical contact drives the contact for such movement. Where the charging means comprises a rotatable charging body, rotation of the charging body may drive the electrical contact relative to the cam surface between an angular position of the rotatable charging body in which the contact can occupy its rest position and an angular position in which cooperation between the contact and the cam surface urges the contact towards its in use position. In such an arrangement, the cam surface may be part of or fixed to the casing. The contact may be pivotally mounted to the charging body, or could comprise a flexible, resilient component The casing may include an inlet aperture configured to receive a battery for charging, and an outlet aperture configured to release a fully-charged battery, and an insertion/extraction means configured to allow the substantially simultaneous insertion of a discharged battery into the casing, and the release of a charged battery from the casing. Such an arrangement may be used to ensure that a charged battery may only be removed upon the insertion or introduction of a discharged battery into the apparatus.

The insertion/extraction means may take a wide range of forms. By way of example, the insertion means may comprise a plunger, configured to move between a first position and second position, the plunger in the first position blocking the inlet and the outlet apertures, and in the second position allowing batteries to pass freely through the apertures. The apparatus may comprise a spring configured to bias the plunger to an upwards position.

The plunger may comprise a solid body having an upper and a lower aperture configured to allow cells to pass therethrough when the plunger is in the second position.

Alternatively, the insertion means may comprise a plunger configured to move between a first position and second position, the plunger in the first position blocking the outlet aperture, and in the second position allowing batteries to pass freely therethrough. In such an arrangement, the plunger may comprise a solid body having an aperture configured to allow cells to pass therethrough when the plunger is in the second position.

In a further alternative, the insertion means may comprise a pivoting member configured to pivot around a substantially horizontally aligned axis, the pivoting member having a generally upright main body with a flat horizontally aligned top platform at the upper end, the casing and pivoting member being configured so that a cell on the top platform can pass into the casing when the pivoting member is rotated inwards towards the casing. In such an arrangement the pivoting member may comprise a fork at its lower end configured to fit around a cell on the lower shelf and hold this in place, the pivoting member further configured so that a cell held in the fork will drop downwards out of the fork when the pivoting member is rotated inwards. The battery charging apparatus may further comprise a spring configured to bias the upper part of the pivoting member towards an outwards position.

According to a second aspect of the invention there is provided a battery charging apparatus comprising a charging means and electrical contacts for making electrical contact with parts of the batteries received, in use, within the charging means, the electrical contacts being of generally L-shaped form, and being pivotally or otherwise moveably mounted to the charging means. As noted hereinbefore, in such an arrangement, the weight of a battery resting upon parts of the generally L-shaped contacts may urge other parts of the generally L-shaped contacts into contact with terminals of the battery. The electrical contacts may be spring biased towards a position in which the said other parts do not engage the terminals of the battery, thereby aiding receipt and/or discharge of a battery to or from the charging means.

According to another aspect of the invention there is provided a battery charging apparatus comprising a charging means and electrical contacts for making electrical contact with parts of the batteries received, in use, within the charging means, at least one of the electrical contacts being movable between a rest position and an in use position by a drive means. The drive means may comprise a cam surface shaped such that cooperation thereof with part of the electrical contact drives the contact for such movement. The charging means may comprise a rotatable charging body, and rotation of the charging body may drive the electrical contact relative to the cam surface between an angular position of the rotatable charging body in which the contact can occupy its rest position and an angular position in which cooperation between the contact and the cam surface urges the contact towards its in use position. In such an arrangement, the cam surface may be part of or fixed to a casing in which the charging means is located. The contact may be pivotally mounted to the charging body, or could comprise a flexible, resilient component.

The invention will further be described by way of example, with reference to the accompanying drawings, in which: Figure 1 is a partially exploded view illustrating part of a battery charging apparatus in accordance with a first embodiment of the invention; Figures 2a to 2d are diagrammatic representations illustrating the operation of the battery charging apparatus of Figure 1; Figures 3a and 3b are diagrammatic representations illustrating part of the battery charging apparatus of Figure 1, in use; Figures 4 to 9 are diagrammatic representations of a series of alternative embodiments of the invention; Figures 10a to 10e illustrate a modification to the arrangements described hereinbefore; and Figure n is an exploded view illustrating a further embodiment of the invention.

Referring firstly to Figures 1 to 3, a battery charging aparatus 10 is illustrated for use in charging rechargeable batteries 12. In the arrangmeent shown, the batteries 12 are of generally cylindrical shape, with positive and negative terminals at opposite ends thereof. The batteries may thus be of the type referred to as AA-cell batteries, or AAA-, C-, or D-cells, or 18650 cells. It will be appreciated, however, that the invention is not restricted in this regard and may be modified for use with a range of batteries of other shapes and sizes.

The apparatus 10 comprises a housing or casing 14 defined by a pair of side walls 16 (only one of which is shown) between which is located a central casing part 18. In the arrangement illustrated, the casing part 18 is secured to the side walls 16 by screws, but it will be appreciated that it could be secured thereto using a suitable adhesive or other means, or may be formed integrally with one or other, or both, of the side walls 16. Conveniently, the side walls 16 and the casing part 18 are of moulded plastics material form, but other materials may be used.

The casing part 18 is shaped to define a passageway 20 that extends between an inlet opening 22 located towards the top of the apparatus 10 and an outlet opening 24 located towards the bottom of the apparatus 10, the passageway 20 being of tortuous, zig-zagged shape so that the path followed by a battery 12 in passing between the inlet opening 22 and the outlet opening 24 is relatively long.

Located within the casing 14, approximately midway along the passageway 20, is a charging means 26. The charging means 26 takes the form of a generally cylindrical body 28 supported at its ends by the side walls 16 in such a manner that the body 28 can be rotated about its axis. An electrically powered motor 28a is provided to drive the body 28 for rotation, the operation of the motor 28a being controlled by a control unit (not shown). The body 28 is formed with a groove, cavity or recess 30, the dimensions of which are selected such that a battery 12 can be received within the recess 30. Adjacent each end of the recess 30 are located electrical contacts 32. The contacts 32 are electrically connected to the control unit so that, in use, a battery 12 located within the recess with its terminals engaging the contacts can be charged.

As best shown in Figures 3a and 3b, the contacts 32 are each of generally L-shaped form and are pivotally mounted to the body 28 by pivot pins 34 such that each contact 32 is able to undertake limited pivotal movement relative to the body 28. The contacts 32 are pivotable between the position illustrated in Figure 3a in which the arms 32a thereof are spread apart from one another, and the position shown in Figure 3b in which the presence of a battery 12 within the recess 30 and resting upon the arms 32b of the contacts 32 urges the arms 32a towards one another and into engagement with the terminals of the battery 12. Conveniently, springs (not shown) or the like are provided to bias the contacts 32 to the position shown in Figure 3a.

The part of the passageway 20 above the charging means 26 forms an inlet hopper 35 in which discharged batteries 12 inserted into the apparatus through the inlet opening 22 and awaiting charging can be stored, and the part of the passageway 20 beneath the charging means 26 forms an outlet hopper 36 in which charged batteries ready for use are stored. It will be appreciated that the inlet opening 22 communicates with the inlet hopper 35 and that the outlet opening 24 communicates with the outlet hopper 36.

In addition to the inlet and outlet hoppers 34, 36, the casing part 18 defines a reject hopper 38 to which batteries 12 can be deposited by the charging means 26 in the event that it is determined that the batteries are incapable of being charged.

In use, discharged batteries 12 for charging are introduced into the apparatus 10 through the inlet opening 22, the batteries sliding or rolling along the part of the tortuous passageway 20 above the charging means 30 until the batteries come to rest against the charging means 26 or against a preceding one of the batteries 12. It will be appreciated that the batteries 12 are thus stored within the inlet hopper 35 whilst awaiting charging. If charging of a battery is not currently underway then the body 28 is held in a rotary position such that the empty recess 30 thereof is presented to the inlet hopper 35 so that upon introduction of a battery into the passageway 20, it will drop into the recess 30 as shown in Figure 2a. As described hereinbefore, the action of dropping into the recess 30 causes the contacts 32 to pivot to engage the terminals of the battery 12 as shown in Figure 3b.

The presence of a battery 12 within the recess 30 can be detected by the control unit, and the control unit then causes operation of the motor 28a to drive the body 28 to the position shown in Figure 2b. In this position, the engagement between the battery 12 and the adjacent part of the casing part 18 aids in ensuring that the battery 12 is tightly gripped between the contacts 32. Once in this position, the control unit can undertake tests to identify the polarity of the battery 12 and to ensure that the battery 12 is of the correct type to allow recharging.

Provided the battery 12 is of the correct type, the control unit can connect an appropriate charging circuit to the contacts 32 (depending upon the detected polarity) and undertake charging of the battery 12. Conveniently, two charging circuits are provided, one for use when a battery 12 is inserted one way around, and the other for use when the batteries are inserted in a reversed orientation. Once charging is completed, the body 28 may be rotated to its initial position and then to a discharge position as shown in Figure 3c, whereon the battery 12 may drop from the body 28 into the part of the passageway 20 defining the outlet hopper 36 for storage until required. As shown in Figure 1, charged batteries 12 are presented at the outlet opening 24 and may be removed when required.

After deposition of the charged battery 12 in the outlet hopper 36, the body 28 is returned to its initial position ready to receive another battery for charging.

If, whilst undertaking tests, it is determined that the battery is not capable of being recharged, for example if it is of an incorrect single use type, rotation of the body 28 to the position shown in Figure 3d allows the battery to drop from the body 28 into the reject hopper 38, after which the body 28 may be rotated to its initial position ready to receive another battery 12 for charging.

It will be appreciated that the arrangement described hereinbefore is advantageous in that it permits recharging of batteries in an automated fashion and in ensuring that batteries are stored charged ready for use.

Whilst Figures 1 to 3 illustrate one specific embodiment of the invention, it will be appreciated that a wide range of modifications and alterations may be made thereto without departing from the scope of the invention, and Figures 4 to 9 illustrate certain alternative embodiments. These are merely examples of alternative embodiments, and the application is not restricted to these specific arrangements.

The arrangement shown diagrammatically in Figure 4 is similar in many respects to the arrangement shown in Figures 1 to 3, and like reference numerals are used to denote like parts.

Unlike the arrangement of Figures 1 to 3, the front of the casing 14 comprises a vertical passageway 40 that extends from the top of the casing 14 to the bottom, the passage 40 formed between a front-inner wall of the casing, and a front-outer wall. A spring-loaded plunger 42 is located in this passageway 40, with the passageway 40 and plunger 42 mutually sized and shaped so that the plunger 42 will snugly fit within the passageway 40, and can freely move upwards and downwards within the passageway 40. The plunger 42 is slightly wider than the diameter of the cells or batteries 12 with which the charging apparatus is intended to be used.

A coil spring 44 is located at the closed bottom of the passageway 40, so that the spring 44 will be compressed if the plunger 42 is depressed downwards into the passageway 44, and once the depressing force is removed, will return the plunger 42 to a default upwards position. The plunger 42 is sized so that the top of the plunger 42 extends from the open top of the passage 40.

The front-outer face of the casing 14 defines an outlet opening 24, sized and shaped such that a battery cell can pass through sideways (e.g. roll through). The front-inner face of the casing comprises a lower inner aperture 24a, substantially the same size and shape as the lower outer aperture 24, and slightly above the lower outer aperture 24.

The plunger 42 comprises a similarly sized and shaped lower plunger aperture 46 that passes through the plunger 42 towards the lower end of the plunger 42. The lower plunger aperture 46 is arranged at an angle through the plunger 42, so that when the plunger 42 is vertically upright in position in the passageway in normal use, the plunger aperture 46 is angled downwards from the inner side of the plunger 42 to the outer side. That is, a battery passing into the plunger aperture 46 on the inner side will roll under gravity through the plunger aperture 46 from the inner side to the outer side of the plunger 42.

When the plunger 42 is fully upwards, lower inner aperture 24a and plunger aperture 46 align, and a battery can roll on it's side through lower-inner aperture 24a to be fully contained within the plunger 42 in the lower plunger aperture 46. When the plunger 42 is depressed against the spring 44, the lower plunger aperture 46 and lower outer aperture 24 are substantially aligned, so the battery in the lower plunger aperture 46 can roll fully through the lower plunger aperture 46, through the lower outer aperture 24 and out of the casing 14.

The top end of the plunger 42 comprises a flange 48 extending upwards from the inner side of the top end of the plunger 42. The top end of the plunger 42 comprises an angled flat surface, angled downwards and inwards, so that items placed on the top end will roll inwards towards the bottom of the flange 48 where it meets and extends from the top end. A reader or sensor is located here to ensure that the batteries are suitable for use -e.g. they are suitable for the device. This will be determined from information about the battery associated with its electrical profile or encoded visually or electronically on or within the battery. The sensor 50 could be for example a barcode reader or an RFID reader. A lock can also be positioned here to prevent depression of the plunger if the battery is not suitable.

A flange aperture extends through the flange 48 at the base of the flange 48, sized and shaped such that a battery cell can pass through sideways (e.g. roll through).

When the plunger 42 is fully depressed against the spring 44, the flange aperture aligns with the inlet aperture 22 so that a battery cell located on the top end can roll through the apertures into the casing 14.

In the arrangement of Figure 4, the tortuous path is defined by a series of angled ledges that extend inwards and downwards from the inner front wall and the rear wall of the casing 14. A battery cell rolling inwards through the inlet aperture 22 will initially roll along and down a top ledge towards the rear wall, and drop at the end of the top ledge onto a lower ledge, rolling downwards and back towards the inner front wall, and so on.

A charging station 26 is located approximately at the mid-point or mid-height of the casing 14.

The charging station 26 comprises a generally cylindrical charging body 28 arranged to rotate within the casing 14 about its own central axis of rotation, aligned horizontally across (side-toside) the casing. The charging body 28 of this embodiment has four cell grooves or recesses 30, allowing several batteries to be charged simultaneously. Each of the cell grooves or recesses 30 is sized and shaped to receive a single battery cell. Charging contacts 32 are arranged at each end of each of the cell grooves, so that these will come into contact with the ends of a battery cell as it locates into the cell groove 30.

As the cells roll down the tortuous path, they encounter the charging body 28. The charging body 28 is controlled so that if an empty cell groove 30 is available, this will 'present' in order to receive the battery as it rolls down the ledge above the charging body 28, the battery slotting into the empty cell groove 30 between the charging contacts 32, in order to charge the battery. If no empty cell grooves are available, then the battery will be 'queued' on the ledge above the charging body along the tortuous path above/before the charging body, along with any other cells in the queue, with the cells prevented from further movement by the charging body 28, which blocks their path. The part of the tortuous path above the charging body 28 thus defines an inlet hopper 35 in which discharged batteries awaiting charging are stored. The charging body 28 rotates around its central axis (anti-clockwise as shown in Figure 4), and, once the battery is charged, it will be ejected from the charging body 28 onto ledge below the charging body 28. The charged cell then continues down the tortuous path to the bottom of the casing 14, and is stored in the outlet hopper 36. Discharge of the charged batteries from the outlet hopper 36 is controlled by the plunger 42 as described hereinbefore.

A receiving tray is located at the front of the casing 14, formed as an extension of the outlet hopper 36. This comprises a lipped tray. As the cell rolls into this area, it will be contained by the lip and a user can retrieve it ready for use.

The battery charging device of this configuration operates in a 'one in, one out' manner, so that charged batteries are continuously available for use, but cannot be accessed unless a discharged cell with the same specification is added to the charger. In this manner, charged batteries are continuously available, and there will never be a situation where all of the batteries are flat at the same time.

In operation, an owner will deposit a discharged/uncharged/flat cell or cells into the battery charging device. The device will check to ensure that the cell is of the rechargeable type, and will reject those that are non-rechargeable. The device includes a means of checking that the battery being inserted is suitable (in terms of type, size, alignment, and manufacturer) and rejecting it or preventing its insertion if not. This will be a device capable of reading information encoded onto or inside the battery visually or electronically.

Those that are of a suitable chargeable type are stored ready for charging, and will drop or be pushed into the charging station 26 once a free space is available. Faulty cells that fail to charge will be rejected. Once charging in the charging station has been completed, the fully-charged cells will be released from the charging station and will be stored ready for use. On insertion of a new discharged cell, a fully-charged cell will be released.

A further embodiment of the battery charging apparatus is shown in Figure 5. The battery charging apparatus in this embodiment is generally the same as that of Figure 4, but has a shorter internal tortuous path, and the charging station 213 is an elongate upright internal cell charger 217 in place of the cylindrical body 26 of the embodiment of Figure 4. The elongate upright internal cell charger 217 comprises an endless belt 224 with a number of charging bays or cell grooves 214 mounted on the belt. The charger 217 is aligned so that the belt 224 passes downwards close to the rear wall of the casing, and upwards close to the front wall of the casing, with the axis of rotation running horizontally sideways across the casing. Cells to be charged drop from an upper ledge into one of the charging bays 214 towards the rear of the casing, and pass downwards with the belt, dropping out of the charging bay 217 at the lower end and onto a lower ledge, where they are stored until required.

Another embodiment of the battery charging apparatus of the present invention is shown in Figure 6. The battery charging apparatus in this embodiment is generally the same as that for the embodiment of Figure 4 externally, with an insertion/extraction mechanism that is substantially the same (the plunger and inlet and outlet apertures). However, in this embodiment, the internal structure is configured such that discharged or flat cells entering the casing will pass along a top ledge defining an inlet hopper 35, and drop down the rear of the casing alongside the inner surface of the rear wall. The charger 317 in this embodiment comprises a strip or series of bays 314, vertically aligned and sized and spaced so that as the cells drop down, they will roll into the bays 314, filling up the charger strip from the bottom.

Once the strip is filled, further cells will be 'stored' behind the strip in a vertical column between the strip and the inner surface of the rear wall, and on the upper shelf. Once a cell within any one bay 314 is fully charged, a gate at the front is configured to open and the cell rolls forwards out of the bay and downwards onto a lower shelf defining an outlet hopper 36 for storage prior to release in the same or a similar manner to that described above.

Another embodiment of the battery charging apparatus of the present invention is shown in Figure 7. In this embodiment, the battery charging apparatus 401 is internally substantially the same as described hereinbefore. However, in this embodiment, there is no front passage or plunger. The insertion/extraction mechanism in this embodiment comprises a pivoting member 405 pivoting around an axis 430 aligned horizontally and running from side-to-side across the front of the casing 402 just in front of the front wall. The pivoting member 405 has a generally upright main body 431 with a flat horizontally aligned top platform 432 at the upper end. The casing 402 has an upper platform 433. An aperture 415 in the top platform 432 aligns such that a cell on the top surface of the top platform 432 can fall through the aperture 415 and roll along the platform 433, through the top casing aperture 412 into an inlet hopper 35 defined by the casing, when the upper part of the pivoting member 405 is rotated inwards towards the casing 402. The upper part of the pivoting member 405 is biased towards an outwards position by a coil spring 406 within the casing.

The pivoting member 405 is forked or Y-shaped at its lower end, so that it can fit around and trap a cell on the lower shelf defining the outlet hopper 36 of this embodiment, and hold this in place. When the pivoting member 405 is biased outwards by the spring 406, the y-shaped lower end is biased inwards, and sits just inside the lower inner aperture 411. The pivoting member 405 and the Y-shaped lower end are configured so that a cell can roll down the lower shelf and into the fork, and then be pushed/rolled forwards as the pivoting member 405 is pushed/rotated. When the pivoting member 405 is fully rotated, the cell held in the fork will drop downwards out of the fork and into the receiving tray.

Another embodiment of the battery charging apparatus of the present invention is shown in Figure 8. The battery charging apparatus in this embodiment has an electromechanical feed/release linkage that operates horizontally at the upper end to allow insertion of the uncharged cells, and vertically at the lower end to allow release of the charged cells. The plunger 505 in this embodiment operates within a closed passage 504 at the lower end, the plunger 504 operating against a spring 506 in a similar fashion to the first embodiment, but having an electromagnetic piston 540 at the upper end to press the plunger 504 downwards when required.

At the upper end, the uncharged cells are dropped through a top casing aperture 512 on the upper surface of the casing 502, into a tray on the outer end of a horizontally-aligned member 550. This moves inwards and outwards via an electromechanical actuator. The base of the tray is formed by part of the casing 502, and remains stationary as the member 550 moves inwards and outwards, so that in the inwards position, the cell drops through the tray ands onto the uppermost of the shelves 516 defining the inlet hopper 35. Charged cells drop into an outlet hopper 36 in much the same manner as described hereinbefore ready for discharge from the apparatus 10 and for use.

A further embodiment of the battery charging apparatus of the present invention is shown in Figure 9. In this embodiment, the casing 601 is formed internally so that it contains a tortuous path 624 that is wave-like or sinuous as it descends through the casing. The tortuous path 624 forms the inlet hopper 35 for the batteries once they enter the casing. A charging station 613, suitable for a single cell, is located at the rear and towards the bottom of the casing 602. An electromechanical actuator 625 is configured to eject charged batteries from the charging station 613 once they are charged. A second actuator 626 controls movement of the plunger 605. The casing below the charging station 613 comprises a ledge 621 defining an outlet hopper 35 to hold the charged batteries.

Whilst in the arrangements described hereinbefore and illustrated in the accompanying drawings only the arrangement of Figures 1 and 2 includes a reject hopper to which batteries unsuitable for charging (for example batteries of a non-rechargeable form or batteries that are of a rechargeable form but which will no longer accept recharging to a predetermined useful level) are delivered, it will be appreciated that the other embodiments described herein may be modified in such a manner as to include such a reject hopper.

In the arrangements described hereinbefore, the casing may be transparent or see-through. The charger may further comprise an LED located at or towards one end of the charger. This will be un-illuminated if no cells are in the charger (it is empty), red when charging a cell, and green when the cell is charged. A user can look through the transparent wall of the casing and see the LED, and thereby determine the status of batteries located therein.

In the arrangements described hereinbefore, a battery 12 entering a recess 30 engages contacts 32 that move, pivotally, due to the weight of the battery 12, to engage the terminals of the battery 12. Figures 10a to We illustrate a modification in which the contacts 32 are positively driven into contact with the battery terminals. As illustrated, each recess 30 has a fixed contact 32 and a movable contact 32b associated therewith. The movable contacts 32b may be pivotally mounted as shown in Figure 3, or may simply comprise resilient, flexible contact components. The recess 30 is provided in, for example, a rotatable body 28, and the casing 14 in which the body 28 is located is shaped to define a drive member 14a in the form of a cam surface located adjacent the rotatable body 28. Whilst the cam surface may form part of the casing 14, it could equally comprise a separate component rigidly secured to the casing 14. Parts of the moveable contacts 32b bear against the cam surface, and the cam surface is shaped so that, when the rotatable body 28 occupies an angular position in which a battery 12 is able to enter the recess 30 (Figures 10a and 10b), the cam surface allows the moveable contact to occupy a rest position spaced from the fixed contact by a distance sufficient to allow unimpeded entry of the battery 12 into the recess 30. Upon subsequent rotation or angular movement of the rotatable body 28, the moveable contact 32b rides over the cam surface and the cooperation between the cam surface and the moveable contact 32b, arising from the shape or profile of the cam surface, urges the moveable contact 32b to an in use position closer to the fixed contact 32 and in which the battery 12 is engaged between and electrically engages the fixed contact 32 and the moveable contact 32b (Figures 10c, 10c1 and We). In this position, charging of the battery 12 can take place. Subsequent rotation of the rotatable body 28 to an position in which the battery 12 can be released from the recess 30 causes further riding of the moveable contact 32b over the cam surface to a position in which it is spaced from the fixed contact 32 by an increased distance, allowing the battery 12 to move under gravity from the recess.

In the arrangement of Figures 10a to 10e, it will be appreciated that the contacts 32, 32b are mounted upon, and rotatable with, the rotatable body. This is advantageous in that no sliding movement occurs between the batteries and the contacts 32, 32b as the rotatable body is rotated, leading to less wear and less risk of the contacts 32, 32b becoming bent, or the like.

The modification of Figures 10a to 10e may be applied to any of the arrangements described hereinbefore.

Figure 11 is an exploded view illustrating another embodiment of the invention in which like reference numerals to those used in the embodiments described hereinbefore are used to denote like or similar parts. Whilst the embodiment of Figure 11 does not include the modification of Figures 10a to 10e, such an arrangement could be employed if desired.

In the arrangement of Figure 11, the rotatable body 28 is located within a sleeve 14b that, in use, is located within a suitably shaped and sized recess formed in the housing 14 and which includes windows 14c through which batteries can pass to enter and leave the rotatable body 28. The sleeve 14b includes an internally toothed ring 14d with which a pinion gear 28b associated with the motor 28a cooperates, in use, the motor 28a being located within a recess or void 28c defined within the rotatable body 28. It will be appreciated that the sleeve 14b containing the rotatable body 28 defines a self-contained charging unit which could potentially be fitted into suitable shaped and sized recesses formed in housings 14 of a wide range of designs. Accordingly, whilst a specific design of housing 14 is shown, the charging unit defined by the rotatable body and sleeve could be used with housings 14 of other overall shapes.

it will be appreciated that the embodiments of the apparatus described hereinbefore are merely example embodiments, and that a wide range of modifications and alterations may be made thereto without departing from the scope of the invention as defined by the appended claims.

Claims

CLAIMS: 1. A battery charging apparatus comprising a charging means, and a casing configured to substantially surround and enclose the charging means, the casing comprising an inlet hopper configured to receive and store batteries for charging and from which batteries are supplied, in use, to the charging means, and an outlet hopper configured to receive and store charged batteries received, in use, from the charging means.
2. An apparatus according to Claim 1, wherein the charging means includes at least one of electrical contact that is movable between a rest position and an in use position by a drive means.
3. An apparatus according to Claim 2, wherein the charging means includes a rotatable charging body, and the electrical contact is rotatable with the rotatable body.
4. An apparatus according to Claim 3, wherein the drive means comprises a cam surface shaped such that cooperation thereof with part of the electrical contact drives the contact for such movement.
5. An apparatus according to Claim 4, wherein rotation of the charging body drives the electrical contact relative to the cam surface between an angular position of the rotatable charging body in which the contact can occupy its rest position and an angular position in which cooperation between the contact and the cam surface urges the contact towards its in use position.
6. An apparatus according to Claim 4 or Claim 5, wherein the cam surface is part of or fixed to the casing.
7. An apparatus according to any of Claims 2 to 6, wherein the contact is pivotally mounted to the charging body, or comprises a flexible, resilient component.
8. An apparatus according to any of the preceding claims and including a rotatable charging body, wherein the body is driven for rotation, in use, by a motor.
9. An apparatus according to Claim 8, wherein the motor is located within the rotatable charging body.
1 0 10. An apparatus according to Claim 9, wherein the motor drives a gear for rotation, the gear meshing with a toothed formation located within a sleeve, the rotatable charging body being located within the sleeve.
11. An apparatus according to any of the preceding claims, wherein the casing defines a tortuous path along which batteries move, in use, between an inlet and an outlet, parts of the tortuous path defining the inlet and outlet hoppers.
12. An apparatus according to any of the preceding claims, wherein the battery charging device further comprises a receiving tray configured to receive and retain batteries passing out of the casing via the outlet and forming part of the outlet hopper.
13. An apparatus according to any of the preceding claims, wherein the casing further defines a reject hopper, and the charging means is arranged to deliver batteries to the reject hopper in the event that the sensing means detects that the batteries are unsuitable for charging.
14. An apparatus according to any of the preceding claims, wherein the charging means comprises a generally cylindrical charging body arranged to rotate within the casing about its own central axis of rotation, the charging body aligned substantially horizontally across the casing, the charging body comprising at least one cell groove extending inwards from its circumferential perimeter, configured to receive a battery cell, and charging contacts, located at each end of each of the cell grooves to contact the ends of a battery cell as it locates into the cell groove.
15. An apparatus according to any of Claims 1 to 13, wherein the charging means comprises an elongate upright internal cell charger comprising an endless belt having a number of charging bays mounted thereon, the charger aligned so that the belt passes downwards close to the rear wall of the casing, and upwards close to the front wall of the casing, with the axis of rotation running horizontally sideways across the casing.
16. An apparatus according to any of Claims 1 to 13, wherein the charging means comprises a series of bays, substantially vertically aligned in a strip, and configured so that as the cells drop down, they will roll into the bays, cells held within the bays to charge and then released to pass forwards out of the bay into a storage portion of the casing.
17. An apparatus according to any of the preceding claims, further comprising a sensing means configured to carry out checks on batteries.
18. An apparatus according to any of the preceding claims, and further comprising an insertion/extraction means configured to allow the substantially simultaneous insertion of a discharged battery into the casing, and the release of a charged battery from the casing, and optionally wherein the insertion means comprises a plunger, configured to move between a first position and second position, the plunger in the first position blocking the inlet and the outlet apertures, and in the second position allowing batteries to pass freely through the apertures, or wherein the insertion means comprises a plunger, configured to move between a first position and second position, the plunger in the first position blocking the outlet aperture, and in the second position allowing batteries to pass freely therethrough, or wherein the insertion means comprises a pivoting member configured to pivot around a substantially horizontally aligned axis, the pivoting member having a generally upright main body with a flat horizontally aligned top platform at the upper end, the casing and pivoting member configured so that a cell on the top platform can pass into the casing when the pivoting member is rotated inwards towards the casing.
19. An apparatus according to Claim 18, wherein the pivoting member comprises a fork at its lower end configured to fit around a cell on the lower shelf and hold this in place, the pivoting member further configured so that a cell held in the fork will drop downwards out of the fork when the pivoting member is rotated inwards.
20. A battery charging apparatus comprising a charging means and electrical contacts for making electrical contact with parts of the batteries received, in use, within the charging means, the electrical contacts being of generally L-shaped form, and being pivotally or otherwise moveably mounted to the charging means.
21. A battery charging apparatus comprising a charging means and electrical contacts for making electrical contact with parts of the batteries received, in use, within the charging means, at least one of the electrical contacts being movable between a rest position and an in use position by a drive means.
22. An apparatus according to Claim 21, wherein the drive means comprises a cam surface shaped such that cooperation thereof with part of the electrical contact drives the contact for such movement.
23. A battery charging apparatus comprising a charging means and electrical contacts for making electrical contact with parts of the batteries received, in use, within the charging means, the charging means comprising a rotatable charging body, wherein the body is driven for rotation, in use, by a motor, the motor being located within the rotatable charging body, the rotatable charging body being located within the sleeve.
24. An apparatus according to Claim 23, wherein the motor drives a gear for rotation, the gear meshing with a toothed formation located within a sleeve.