WO2017072516A1 - A battery charging system and associated elements - Google Patents

A battery charging system and associated elements Download PDF

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Publication number
WO2017072516A1
WO2017072516A1 PCT/GB2016/053344 GB2016053344W WO2017072516A1 WO 2017072516 A1 WO2017072516 A1 WO 2017072516A1 GB 2016053344 W GB2016053344 W GB 2016053344W WO 2017072516 A1 WO2017072516 A1 WO 2017072516A1
Authority
WO
WIPO (PCT)
Prior art keywords
contacts
charging
contact
battery
signal
Prior art date
Application number
PCT/GB2016/053344
Other languages
French (fr)
Inventor
Leigh Nigel PURNELL
Original Assignee
Petalite Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Petalite Limited filed Critical Petalite Limited
Priority to GB1806870.0A priority Critical patent/GB2557853B/en
Publication of WO2017072516A1 publication Critical patent/WO2017072516A1/en

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Classifications

    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02JCIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J7/00Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02JCIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J7/00Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
    • H02J7/0029Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries with safety or protection devices or circuits
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/62Means for facilitating engagement or disengagement of coupling parts or for holding them in engagement
    • H01R13/6205Two-part coupling devices held in engagement by a magnet
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02JCIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J7/00Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
    • H02J7/00032Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries characterised by data exchange
    • H02J7/00036Charger exchanging data with battery
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02JCIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J7/00Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
    • H02J7/00047Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries with provisions for charging different types of batteries
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02JCIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J7/00Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
    • H02J7/0029Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries with safety or protection devices or circuits
    • H02J7/0036Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries with safety or protection devices or circuits using connection detecting circuits
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02JCIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J7/00Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
    • H02J7/0042Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries characterised by the mechanical construction
    • H02J7/0045Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries characterised by the mechanical construction concerning the insertion or the connection of the batteries
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60LPROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L53/00Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles
    • B60L53/10Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles characterised by the energy transfer between the charging station and the vehicle
    • B60L53/14Conductive energy transfer
    • B60L53/16Connectors, e.g. plugs or sockets, specially adapted for charging electric vehicles
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02TCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T90/00Enabling technologies or technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02T90/10Technologies relating to charging of electric vehicles
    • Y02T90/16Information or communication technologies improving the operation of electric vehicles

Definitions

  • Embodiments of the present invention relate to a battery charging system, a mounting configuration and mounting assembly combination, a mounting configuration/member, battery, a charging station, a device, and a vehicle.
  • the batteries for such devices can often only meet the power demands of the devices for a very limited period before they are depleted - in some instances less than a day of normal use (in the case of a vehicle, the batteries are often depleted after a relatively short distance of travel).
  • the length of time to charge a battery is also an issue for smaller capacity batteries as may be found in other devices such as mobile computing devices and telephones.
  • a mains electrical charging system is not available - e.g. because the user and device are moving (e.g. travelling) or just not near a useable connection to the mains electrical system.
  • auxiliary or secondary batteries have been developed.
  • An auxiliary or secondary battery can be used to charge the battery of a device and/or to power the device.
  • auxiliary or secondary batteries also need to be charged. This is inconvenient and users often forget to charge the auxiliary or secondary batteries. This issue is exasperated by the length of time which auxiliary or secondary batteries require to charge - particularly, as they may be larger capacity than the battery of the device.
  • Charging times of batteries are dependent on the speed at which energy can be delivered to the battery. As the voltage which can be applied to the battery for charging is normally limited, the charging time is normally dependent on the electric current which can be delivered to the battery. Very high current, however, increases the risk of injury.
  • Insecure fitting of a high current charger to a battery can cause arcing between contacts of the charger and/or battery - which can cause damage to the battery and/or charger. There is also a relatively high risk of injury to users if the battery and charger are not securely connected. Insecure connection could also mean a relatively high resistance between the charger and the battery which may cause overheating and/or may increase charge time.
  • Embodiments of the invention seek to alleviate one or more problems associated with the prior art.
  • an aspect of the invention provides a battery charging system including a battery and a charging station, wherein: the battery includes a mounting configuration having a first charging contact, a second charging contact, and a first signal contact, and the charging station includes a mounting assembly having a third charging contact, a fourth charging contact, and a second signal contact, the mounting configuration and mounting assembly are configured to connect to each other such that: the first and third charging contacts engage in electrical communication; the second and fourth charging contacts engage in electrical communication; the first and second signal contacts engage in electrical communication, and wherein: preferably the engagement of the first and second signal contacts is more fragile than the engagement of the charging contacts; and the charging station is configured to deliver a charging current to the battery using the charging contacts when the charging contacts and signal contacts are engaged and not to deliver the charging current to the battery when the signal contacts are disengaged and the charging contacts are engaged.
  • an aspect of the invention provides a battery charging system including a battery and a charging station, wherein: the battery includes a mounting configuration having a first charging contact, a second charging contact, and a first signal contact, and the charging station includes a mounting assembly having a third charging contact, a fourth charging contact, and a second signal contact, the mounting configuration and mounting assembly are configured to connect to each other such that: the first and third charging contacts engage in electrical communication; the second and fourth charging contacts engage in electrical communication; and the first and second signal contacts engage in electrical communication.
  • the engagement of the first and second signal contacts is more fragile than the engagement of the charging contacts.
  • the charging station is configured to deliver a charging current to the battery using the charging contacts when the charging contacts and signal contacts are engaged and not to deliver the charging current to the battery when the signal contacts are disengaged and the charging contacts are engaged.
  • the signal contacts By providing a fragile engagement of the signal contacts the signal contacts can become disengaged before the charging contacts become disengaged.
  • the disengagement of the signal contacts can thus provide an advance indication of the charging contacts becoming disengaged.
  • power to the charging contacts can be interrupted, in advance of the charging contacts become disengaged and exposed. This can help prevent the occurrence of arcing at the charging contacts, which can cause damage and degradation of the contacts, and can also help protect a user from exposure to electrical power which could cause injury to the user.
  • the charging contacts are the first to engage each other and the last to disengage each other, and the signal contacts are the last to engage each other and the first to disengage each other.
  • the power contacts engage before the signal contacts; and during disconnection of the mounting configuration and mounting assembly the signal contacts disengage before the power contacts.
  • the first and second power contacts may be moveable to a greater extent with respect to a surface of the mounting configuration than the first signal contact is moveable with respect to the surface of the mounting configuration.
  • the third and fourth power contacts may be moveable to a greater extent with respect to a surface of the mounting assembly than the second signal contact is moveable with respect to the surface of the mounting assembly. This can enable the charging contacts to be the first to engage each other and the last to disengage each other, and the signal contacts to be the last to engage each other and the first to disengage each other.
  • the mounting configuration may include a third signal contact; the mounting assembly may include a fourth signal contact; and the mounting configuration and mounting assembly may be configured to connect to each other such that the third and fourth signal contacts may engage in electrical communication.
  • One or more of the charging contacts may include at least a portion which is magnetic such that the first and third charging contacts may be attracted to each other and/or the second and fourth charging contacts may be attached to each other and/or the second and fourth charging contacts may be attracted to each other. Because the contacts are attracted to each other, good engagement of the contacts with each other can be promoted. Over time engagement surfaces of the contacts may be formed due to the magnetic attraction to fit closely against each other to provide good engagement over the whole contact area. Problems that may occur with fatigue of resilient biasing mechanisms to encourage engagement of contacts can be avoided. Resilient biasing mechanisms may be used in addition to the attraction by magnetic means.
  • a magnetic portion is preferably integrated in a charging contact.
  • One or more of the signal contacts may include at least a portion which is magnetic such that at least the first and second signal contacts may be attracted to each other.
  • One or more of the charging and signal contacts may include a portion made from a ferrous metal. As used herein a ferrous metal preferably connotes a ferromagnetic material.
  • One or more of the charging and signal contacts may include a permanent magnet.
  • One or more of the charging and signal contacts may include an electromagnet. The electromagnet may be powered in proportion to a power flowing through the charging contacts. This can enable an adaptive attractive force, with greater attraction occurring when greater power is transmitted and hence greater risk of damage if the contacts become exposed.
  • One or more of the charging and signal contacts may include a permanent magnet and an electromagnet.
  • a permanent magnet can provide an initial attraction for the contacts to assist in the contacts becoming engaged, and an electromagnet can provide a locking mechanism or at least a strong attraction to assist in the contacts maintaining engagement even if the battery charging system is jostled. This can protect a user against inadvertently disconnecting the contacts and can ensure that the power to the contacts is interrupted before the contacts can become disengaged.
  • each charging contact includes a magnet or a magnetic portion.
  • charging contacts only include a magnet or a magnetic portion. This can enable the charging contacts to be less fragile than the signal contacts.
  • One or more of the charging and signal contacts may include a contact tab or a cap of an electrically conductive material.
  • the contact tab or cap may comprise copper.
  • the contact tab or cap may comprise a coating for low electrical resistivity. Low electrical resistivity can reduce the generation of heat in the contacts.
  • the coating may be a nickel-gold coating.
  • the contact tab or cap is preferably not a ferromagnetic material.
  • the contact tab or cap may comprise a cavity for housing a magnetic part (or magnetic portion, optionally as aforementioned). The cavity is preferably arranged such that the magnetic part is housed beneath an engagement surface of the contact tab or cap intended to engage with another contact.
  • the cavity is preferably arranged such that the magnetic part is housed opposite where another contact is intended to engage with the contact tab or cap.
  • One or more of the charging contacts may include a floating ground contact.
  • the first and second charging contacts may be carried by a base member of the mounting configuration and at least one of the first and second charging contacts may be configured to move between an extended and a retracted position with respect to the base member of the mounting configuration. Movement can enable a transition between a configuration where all contacts are engaged and a configuration where signal contacts are disengaged and charging contacts are engaged. Movement can enable that only once the charging contacts have moved from a retracted to an extended configuration and the signal contacts have become disengaged do the charging contacts become disengaged. This can help ensure that power to the charging contacts is interrupted in advance of the charging contacts become exposed.
  • the contacts may be configured to move between 0.1 mm and 5 mm between an extended and a retracted position.
  • the contacts may be configured to move between 0.5 mm and 2 mm between an extended and a retracted position.
  • the contacts may be configured to move approximately 1 mm between an extended and a retracted position. This range of movement can provide sufficient time, for example approximately 0.5 seconds, during disconnection to interrupt power to the charging contacts in advance of exposure of the charging contacts becoming a danger.
  • the contacts may be configured to move axially.
  • the mounting configuration may further include a resilient biasing arrangement which is configured to bias the at least one charging contact towards the extended position.
  • the third and fourth charging contacts may be carried by a base member of the mounting assembly and at least one of the first and second charging contacts may be configured to move between an extended and a retracted position with respect to the base member of the mounting assembly.
  • the mounting assembly may further include a resilient biasing arrangement which is configured to bias the at least one charging contact towards the extended position.
  • the first signal contact may be carried by a base member of the mounting configuration and may be configured to move between an extended and a retracted position with respect to the base member of the mounting configuration.
  • the mounting configuration may further include a resilient biasing arrangement which is configured to bias the first signal contact towards the extended position.
  • the second signal contact may be carried by a base member of the mounting assembly and may be configured to move between an extended and a retracted position with respect to the base member of the mounting assembly.
  • the mounting assembly may further include a resilient biasing arrangement which is configured to bias the second signal contact towards the extended position.
  • the first signal contact may be configured to extend from a surface of the mounting configuration by a shorter distance than the first and second charging contacts may extend from the surface of the mounting configuration.
  • the second signal contact may be configured to extend from a surface of the mounting assembly by a shorter distance than the third and fourth charging contacts extend from the surface of the mounting assembly. This can enable the charging contacts to be the first to engage each other and the last to disengage each other, and the signal contacts to be the last to engage each other and the first to disengage each other.
  • the first and second power contacts may be moveable to a greater extent with respect to a surface of the mounting configuration than the first signal contact is moveable with respect to the surface of the mounting configuration.
  • the third and fourth power contacts may be moveable to a greater extent with respect to a surface of the mounting assembly than the second signal contact is moveable with respect to the surface of the mounting assembly. This can enable the charging contacts to be the first to engage each other and the last to disengage each other, and the signal contacts to be the last to engage each other and the first to disengage each other.
  • One or more of the signal and charging contacts may include a cap of an electrically conductive material.
  • One or more of the signal and charging contacts may include an insulation sleeve which surrounds at least a portion of the or each contact.
  • the mounting configuration and/or mounting assembly may include an electromagnet configured to attract at least a portion of the other of the mounting configuration and mounting assembly.
  • the electromagnet may be associated with one or more of the charging contacts.
  • One or more of the charging and signal contacts may be tiltable. At least one of the mounting configuration and mounting assembly may include a magnet located adjacent one or more of the contacts thereof.
  • the battery may further include a charge confirmation sub-system and the charging station may further include a charge actuation sub-system, and the charge confirmation sub-system and charge actuation sub-system may be configured to communicate using the or each signal contact to confirm that the mounting configuration and mounting assembly are connected such that the respective signal contacts engage each other in electrical communication.
  • a battery charging system including a battery, optionally as aforementioned, and a charging station, optionally as aforementioned, wherein the battery includes a charge confirmation sub-system and the charging station includes a charge actuation sub-system, and the charge confirmation sub-system and charge actuation sub-system are configured to communicate using signal contacts arranged to engage each other in electrical communication to confirm that the battery and the charging station are connected.
  • the communication comprises transmission of data from the battery to the charging station and/or from the charging station to the battery.
  • the data comprises one or more of:
  • an identifier for the battery an identifier for the charging station, a charging parameter for the battery, and identification of a suitable charging profile for use with the battery, an indication of a number of charge cycles the battery has undertaken, an update of a number of charge cycles the battery has undertaken, information regarding one or more historic charging cycles, a historic voltage level reached, a historic length of a time on charge, a maximum charging current of the charging station, a temperature of the battery, a temperature of the charging station, a measurement of the internal impedance of the battery cells, and a measurement of the internal resistance of the battery cells.
  • the data can be used, for example, to indicate the health of the battery cells.
  • the mounting configuration including: a first power contact, a second power contact, and a first signal contact
  • the mounting assembly including: a third power contact, a fourth power contact, and a second signal contact
  • the mounting configuration and mounting assembly are configured to connect to each other such that: the first and third power contacts engage in electrical communication; the second and fourth power contacts engage in electrical communication; the first and second signal contacts engage in electrical communication, and wherein: preferably the engagement of the first and second signal contacts is more fragile than the engagement of the power contacts; and during connection of the mounting configuration and mounting assembly, the power contacts engage before the signal contacts, and during disconnection of the mounting configuration and mounting assembly the signal contacts disengage before the power contacts.
  • the signal and power contacts also referred to as charging contacts
  • the mounting configuration and/or the mounting assembly is as aforementioned.
  • the first and second power contacts and the first signal contact may be carried by a base member of the mounting configuration.
  • the third and fourth power contacts and the second signal contact may be carried by a base member of the mounting assembly.
  • One or more of the contacts may be moveable with respect to the base member which carries the or each contact.
  • One or more of the contacts may be axially moveable with respect to the base member which carries the or each contact.
  • the or each contact may be tiltable.
  • At least one of the power contacts may be moveable, at least one of the signal contacts may be moveable, and the at least one power contact may be moveable to a greater extent than the at least one signal contact.
  • the first and second power contacts may extend a greater distance from a surface of the mounting configuration than the first signal contact.
  • the third and fourth power contacts may extend a greater distance from a surface of the mounting assembly than the second signal contact.
  • One or more of the contacts may be magnetic.
  • a mounting configuration/member including: a base member, a plurality of power contacts carried by the base member, a first signal contact carried by the base member, wherein the first signal contact and power contacts are configured such that: the power contacts extend a greater distance from a surface of the mounting configuration/member than the signal contact; and/or the power contacts are moveable to a greater extent with respect to the base member than the signal contact is moveable with respect to the base member.
  • Power contacts are also referred to herein as charging contacts.
  • One or more of the contacts may be magnetic.
  • One or more of the contacts may include a permanent magnet.
  • One or more of the contacts may include an electromagnet. The electromagnet may be adapted to be powered in proportion to a power flowing through the power contacts.
  • the mounting configuration/member may further include a resilient biasing arrangement configured to bias one or more of the power contacts into an extended position.
  • One or more of the contacts may include a contact tab.
  • One or more of the contacts may include a cap of an electrically conductive material.
  • the power contacts may extend between 0.1 mm and 5 mm more from a surface of the mounting configuration/member than the signal contact.
  • the power contacts may extend between 0.5 mm and 2 mm more from a surface of the mounting configuration/member than the signal contact.
  • the power contacts may extend approximately 1 mm more from a surface of the mounting configuration/member than the signal contact.
  • the power contacts may be moveable between 0.1 mm and 5 mm more than the signal contact with respect to the base member.
  • the power contacts may be moveable between 0.5 mm and 2 mm more than the signal contact with respect to the base member.
  • the power contacts may be moveable approximately 1 mm more than the signal contact with respect to the base member. This range of movement can provide sufficient time, for example approximately 0.5 seconds, during disconnection to interrupt power to the charging contacts in advance of exposure of the charging contacts becoming a danger.
  • one or more of the signal and power (or charging) contacts are as aforementioned.
  • the mounting configuration and/or the mounting assembly is as aforementioned.
  • a mounting configuration/member including: a base member, a plurality of power contacts (also referred to herein as charging contacts) carried by the base member, optionally a first signal contact carried by the base member, wherein one or more of the contacts is magnetic.
  • the mounting configuration/member may optionally be as aforementioned.
  • a battery including a mounting configuration/member.
  • the mounting configuration/member is a mounting configuration and/or a mounting assembly and/or a mounting configuration/member as aforementioned.
  • a charging station including a mounting configuration/member.
  • the mounting configuration/member is a mounting configuration and/or a mounting assembly and/or a mounting configuration/member as aforementioned.
  • Another aspect provides a device including a mounting configuration/member.
  • the mounting configuration/member is a mounting configuration and/or a mounting assembly and/or a mounting configuration/member as aforementioned.
  • a vehicle or item of furniture including a mounting configuration/member.
  • the mounting configuration/member is a mounting configuration and/or a mounting assembly and/or a mounting configuration/member as aforementioned.
  • a battery charging system including a battery and a charging station, wherein: the battery includes a mounting configuration having a first charging contact, a second charging contact, and a first signal contact, and the charging station includes a mounting assembly having a third charging contact, a fourth charging contact, and a second signal contact, the mounting configuration and mounting assembly are configured to connect to each other such that: the first and third charging contacts engage in electrical communication; the second and fourth charging contacts engage in electrical communication; the first and second signal contacts engage in electrical communication, and wherein the charging contacts are the first to engage each other and the last to disengage each other, and the signal contacts are the last to engage each other and the first to disengage each other, and the charging station is configured to deliver a charging current to the battery using the charging contacts when the charging contacts and signal contacts are engaged and not to deliver the charging current to the battery when the signal contacts are disengaged and the charging contacts are engaged.
  • a battery charging system including a battery and a charging station, wherein: the battery includes a mounting configuration having a first charging contact and a second charging contact, and the charging station includes a mounting assembly having a third charging contact and a fourth charging contact, the mounting configuration and mounting assembly are configured to connect to each other such that: the first and third charging contacts engage in electrical communication; the second and fourth charging contacts engage in electrical communication, and wherein one or more of the charging contacts includes at least a portion which is magnetic such that the first and third charging contacts are attracted to each other and/or the second and fourth charging contacts are attracted to each other, and the charging station is configured to deliver a charging current to the battery using the charging contacts.
  • the invention extends to a battery charging system substantially as herein described and/or as illustrated with reference to the figures.
  • the invention also extends to a method of charging a battery substantially as herein described and/or as illustrated with reference to the figures.
  • the invention also provides a computer program and a computer program product for carrying out any of the methods described herein and/or for embodying any of the apparatus features described herein, and a computer readable medium having stored thereon a program for carrying out any of the methods described herein and/or for embodying any of the apparatus features described herein.
  • the invention also provides a signal embodying a computer program for carrying out any of the methods described herein and/or for embodying any of the apparatus features described herein, a method of transmitting such a signal, and a computer product having an operating system which supports a computer program for carrying out any of the methods described herein and/or for embodying any of the apparatus features described herein.
  • Any apparatus feature as described herein may also be provided as a method feature, and vice versa.
  • means plus function features may be expressed alternatively in terms of their corresponding structure, such as a suitably programmed processor and associated memory.
  • any feature in one aspect of the invention may be applied to other aspects of the invention, in any appropriate combination.
  • method aspects may be applied to apparatus aspects, and vice versa.
  • any, some and/or all features in one aspect can be applied to any, some and/or all features in any other aspect, in any appropriate combination.
  • Figure 1 shows a perspective view of an embodiment
  • Figure 2 shows a cross-sectional view, in perspective, of the embodiment of figure 2;
  • Figure 3 shows a cross-sectional view of the embodiment of figures 1 and 2;
  • Figure 4 shows an exploded view of the embodiment of figure 1 ;
  • Figure 5 shows a side view of an embodiment
  • Figure 6 shows a perspective view of an embodiment
  • Figure 7 shows a cross-sectional view of an embodiment
  • Figure 8 shows a side view of the embodiment of figure 7
  • Figure 9 shows an exploded view of the embodiment of figure 7;
  • Figure 10 shows a side view of an embodiment
  • Figure 11 shows a top perspective view of the embodiment of figure 10
  • Figure 12 shows a perspective view of part of the embodiment of figure 10
  • Figure 13 shows a perspective view of part of an embodiment
  • Figure 14 shows a cross-sectional view of an embodiment
  • Figure 15 shows a contact of some embodiments
  • Figure 16 shows a contact of some embodiments
  • Figure 17 shows a cross-sectional view of an embodiment
  • Figure 18 shows two contacts close to each other according to an embodiment
  • Figure 19 shows the two contacts of figure 18 engaging each other
  • Figure 20 shows the two contacts of figure 18 close to each other with one contact tilted with respect to the other;
  • Figure 21 shows the two contacts of figure 20 engaged
  • Figure 22 shows an example schematic view of some embodiments
  • Figures 23 to 26 show different views of an embodiment with the contacts engaged and disengaged variously
  • Figure 27 shows an embodiment with contacts engaged
  • Figures 28 to 30 show the process of engaging embodiments
  • Figures 31 and 32 show two views of an embodiment including data contacts, with the contacts in different states of engagement
  • Figure 33 shows an example schematic view of some embodiments.
  • Figure 34 shows a system of embodiments.
  • Embodiments of the present invention may include a battery charging system 1 (see figure 34).
  • the battery charging system 1 includes a battery 11 and a charging station 12.
  • the battery 11 is configured to be mounted to the charging station 12 to deliver electrical power from the charging station 12 to the battery 11.
  • the charging station 12 may comprise an electrical power input 121 which is, in some embodiments, configured to be coupled to a mains electrical supply - see figure 34, for example.
  • the electrical power input 121 could be in the form of a socket configured to mate with a corresponding plug which may, in turn, be connected to the mains electrical supply.
  • the electrical power input 121 includes a cable and a plug configured to be connected to a mains electrical supply outlet (e.g.
  • the mains electrical supply may include one or more phases of a multi-phase supply and, in the case of a three phase supply, could include all three phases - with the electrical power input 121 configured to receive the one or more phases of the supply.
  • the mains electrical supply is, in fact, a DC electrical supply rather than an AC electrical supply (and, similarly, the electrical power input 121 may be configured to receive AC or DC electrical power, as the case may be).
  • the references herein to a mains power supply are not limitations to a power supply forming part of a national power grid, for example. Instead, the mains power supply could be a reference to power supplied from another source (including another battery or other form of power storage system).
  • the electrical power input 121 may be coupled in electrical connection with a power regulation sub-system 122.
  • the power regulation sub-system 122 may be configured to convert the electrical power received through the electrical power input 121 into a desired form for delivery to the battery 11.
  • the electrical power input 121 may include one or more of a transformer, a rectifier, a voltage regulator, a current regulator, DC-DC power converter, and the like.
  • the power regulation sub-system 122 may be configured to receive an AC electrical power input from a mains power supply (e.g. a 230V or 120V supply) and to convert that input power into a DC electrical power output for use in charging the battery 11.
  • a mains power supply e.g. a 230V or 120V supply
  • the electrical power input 121 may be configured to receive a supply which has a higher voltage than indicated above (but may be less than or equal to around 33kV).
  • the power regulation sub-system 122 may be coupled in electrical communication with a charging controller 123 which may be configured to control the electrical power delivered to the battery 11 in accordance with one or more predetermined charging profiles (e.g. varying the electric current and/or voltage over time).
  • the charging profile may be selected for the battery 11 to achieve a fast charge time, and/or to ensure the battery 11 is charged more than a predetermined amount, and/or to maximise the number of charge/discharge cycles the battery 11 can undertake.
  • the charging controller 123 includes a charge actuation sub-system 1231.
  • the charging controller 123 is coupled in electrical communication with at least two charging contacts 13 of the charging station 12.
  • Each charging contact 13 of the charging station 12 is configured to connect in electrical communication with a respective charging contact 111 of the battery 11.
  • the charge actuation sub-system 1231 is configured for use in controlling whether or not electrical power is delivered to the at least two electrical contacts 13 of the charging station 12.
  • the charging controller 123 includes a control unit 1232 which is configured to control the operation of the charge actuation sub-system 1231. Accordingly, the charging station 12 is configured to receive electrical power and to deliver that electrical power (or a portion thereof) to the battery 11, whilst regulating and controlling the power so that it is in an appropriate form for charging the battery 11.
  • the charging station 12 may include a charging station housing 124 which may house one or more of the electrical power input 121, the power regulation sub-system 122, and the charging controller 121 (including the charge actuation sub-system 1231 and control unit 1232).
  • the electrical power input 121 includes a cable (see above) which may extend from the charging station housing 124.
  • the charging station 12 is part of a larger item such as an item of furniture (e.g. a cupboard or desk) or a vehicle.
  • the battery 11 is part of a larger item such as an item of furniture or a vehicle.
  • the charging station 12 is a charging station for equipment such as a vehicle (e.g. a car, a truck, a lorry, a van, a boat, a ship, or an aircraft).
  • a vehicle e.g. a car, a truck, a lorry, a van, a boat, a ship, or an aircraft.
  • the charging station 12 includes a mounting assembly 14 and the charging contacts 13 of the charging station 12 may be a part of that mounting assembly 14.
  • the mounting assembly 14 is configured to engage (i.e. connect to), selectively, a mounting configuration 112 of the battery 11 such that the respective charging contacts 13,111 of the charging station 12 and the battery 11 are in electrical communication when the mounting assembly 14 and mounting configuration 112 are engaged.
  • the charging contacts 111 of the battery 11 may be part of the mounting configuration 112.
  • the mounting assembly 14 of the charging station 12 is secured to a wand which is moveable with respect to the charging station housing 124.
  • the wand may include its own housing and may be coupled to the charging station housing 124 via a cable (through which electrical power may be transmitted).
  • Such arrangements may be particularly useful in embodiments in which the battery 11 cannot easily be manoeuvred such that the mounting assembly 14 and mounting configuration 112 engage - e.g. because the battery 11 is large or is part of a larger object (such as a vehicle - see above).
  • the wand may be configured for manual movement (e.g. may be configured to be grasped by a user and moved).
  • the battery 11 e.g. as part of a vehicle
  • the mounting assembly 14 and mounting configuration 112 engaged by automated movement of either or both of the mounting configuration 112 and mounting assembly 14 - in other words, the vehicle may be moved to a charging pad or location to allow for automated engagement as described above.
  • the battery 11 includes the mounting configuration 112 along with one or more rechargeable battery cells 113. In embodiments in which there is a plurality of such rechargeable battery cells 113, they may be connected in a variety of different configurations: such as in parallel, in series, or a combination of series and parallel configurations. In some embodiments, the mounting configuration 112 is part of another device or piece of equipment (e.g. a vehicle) but is coupled to the battery 11).
  • the mounting configuration 112 is part of another device or piece of equipment (e.g. a vehicle) but is coupled to the battery 11).
  • the or each battery cell 113 is configured to store electrical power for delivery to a device 100 - such as a mobile (e.g. cellular) telephone, a tablet, a smart watch, a laptop, or some other form of device (including other forms of mobile device and mobile computing device).
  • a device 100 such as a mobile (e.g. cellular) telephone, a tablet, a smart watch, a laptop, or some other form of device (including other forms of mobile device and mobile computing device).
  • the device 100 is part of another item - such as an item of furniture or a vehicle.
  • the device 100 may be equipment such as a vehicle, a portable power supply, uninterruptable power supply system, or industrial equipment.
  • the or each battery cell 113 is further configured to be recharged with electrical power delivered to the battery 11 by the charging station 12 (when the battery 11 is mounted to the charging station 12 with the mounting configuration 112 and mounting assembly 14 engaged (i.e. connected)).
  • the electrical power to recharge the battery 11 is provided via the charging contacts 13 of the charging station 12 and the charging contacts 111 of the battery 11.
  • the battery 11 may include, in some embodiments, a charging controller 115 which may be provided in addition to or instead of the charging controller 123 of the charging station 12.
  • the charging controller 115 of the battery 11 may be configured to control an aspect of the charging of the battery 11 (i.e. of the or each battery cell 113). Accordingly, the charging controller 115 may be configured to receive electrical power from the charging station 12 (e.g. via the charging contacts 13 of the charging station and the charging contacts 111 of the battery 11) and to control the delivery of all or part of that electrical power to the or each battery cell 113 of the battery 11.
  • the battery 11 may, in some embodiments, further include a charge confirmation sub-system 114.
  • the charge confirmation sub-system 114 is configured to communicate with the charging station 12 to confirm whether or not charging of the battery 11 should take place (e.g. whether electrical power should be delivered from the charging station 12 to the battery 11).
  • the charge confirmation sub-system 114 is configured to communicate with the charge actuation sub-system 1231 of the charging station 12 for this purpose.
  • the charge actuation subsystem 1231 may be configured to communicate with the battery 11 (and, in some embodiments, the charge confirmation sub-system 114).
  • the battery 11 may include a battery housing 116 which houses the or each component of the battery 11 which may include one or more of the or each battery cell 113, the mounting configuration 112 (which may include the charging contacts 111 of the battery 11), the charge confirmation sub-system 114, and the charging controller 115.
  • the battery 11 and the charging station 12 engage each other (i.e. connect) using the mounting configuration 112 and mounting assembly 14, which may take a number of different forms.
  • the mounting configuration 112 and mounting assembly 14 may include the charging contacts 111,13 as discussed above.
  • the mounting configuration 112 and mounting assembly 14 each further include at least one respective signal contact 131,1111, such that when the mounting configuration 112 and the mounting system 14 are engaged, the or each signal contact 131 of the mounting assembly 14 is in electrical communication with a respective one of the or each signal contact 1111 of the mounting configuration 112.
  • the mounting configuration 112 and mounting system 14 each further include at least one respective data contact 132,1112, such that when the mounting configuration 112 and the mounting system 14 are engaged, the or each data contact 132 of the mounting system 14 is in electrical communication with a respective one of the or each data contact 1112 of the mounting configuration 112.
  • the signal and/or data contacts 131,132,1111,1112 may be used for communication between the battery 11 and the charging station 12, as described herein. Accordingly, therefore, in some embodiments the signal and/or data contacts 1111,1112 of the battery 11 may be in electrical communication with the charge confirmation sub-system 114 and/or the charging controller 115 of the battery 11. In some embodiments the signal and/or data contacts 131,132 of the charging station 12 may be in electrical communication with the charge actuation sub-system 1231 and/or the charging controller 123 of the charging station 12.
  • one or more of the charging contacts 111,13, the signal contacts 1111,131, and the data contacts 1112,132 is magnetic and is configured to attract the corresponding contact 111,13,1111,131,1112,132 of the battery 11 or charging station 12 as the case may be.
  • the charging contacts 111 of the battery 11 include a first charging contact 111a and a second charging contact 111b.
  • the first charging contact 111a may be connected for electrical communication with a first terminal of one or more of the or each battery cell 113.
  • the second charging contact 111b may be connected for electrical communication with a second terminal of one or more of the or each battery cell 113.
  • the first and second charging contacts 11 la,l 1 lb of the battery 11 may be configured to engage respective first and second charging contacts 13a,13b of the charging station 12 when the mounting assembly 14 and mounting configuration 112 are engaged.
  • the first charging contact 111a of the battery 11 may be a first magnetic polarisation (e.g.
  • the first charging contact 13a of the charging station 12 may be a second magnetic polarisation (e.g. North or South) which is opposite to the first magnetic polarisation - such that the two first charging contacts 11 la, 13a are attracted to each other.
  • a second magnetic polarisation e.g. North or South
  • the second charging contact 111b of the battery 11 may be the second magnetic polarisation (e.g. North or South) and the second charging contact 13b of the charging station 12 may be the first magnetic polarisation (e.g. North or South) - such that the two second charging contacts 11 lb, 13b are attracted to each other.
  • the second charging contact 11 lb of the battery 11 will be repelled by the first charging contact 13a of the charging station 12 (and the same will be true of the first charging contacts 111a of the battery 11 and the second charging contact 13b of the charging station 12).
  • This repulsion may be a sufficient force to resist or substantially prevent mounting of the battery 11 to the charging station 12 (and, in particular, the mounting configuration 112 to the mounting assembly 14) when the charging contacts 111,13 are incorrectly oriented with respect to each other.
  • mounting of the battery 11 to the charging station 12 is not prevented by the repulsive force but the charging contacts 111,13 of the battery 11 and charging station 12 are sufficiently repulsed to prevent substantial contact of the charging contacts 111,13.
  • the use of different magnetic polarisations of the charging contacts 111 of the battery 11 helps to provide a mechanism to ensure that the battery 11 is mounted to the charging station 12 in the correct orientation.
  • the signal contacts 131,1111 of the charging station 12 and battery 11 may similarly magnetic such that a first signal contact 131a of the charging station 12 may be an opposite magnetic polarisation to a first signal contact 1111a of the battery 11 (with the same potential effects discussed above regarding repulsion in relation to the charging contacts 13,111). This may be in addition to or instead of the magnetic arrangement of the charging contacts 13,111 discussed above.
  • Second signal contacts 131b,l 11 lb of the battery 11 and charging station 12 may also be magnetic in the same manner; however, the second signal contact 131b of the charging station 12 may be of an opposite polarisation to the first signal contact 131a of the charging station 12 (making a second signal contact 111 lb of the battery 11 an opposite polarisation to the first signal contact 111 la of the battery 11).
  • the data contacts 132,1112 of the charging station 12 and battery 11 may be similarly magnetic such that a first data contact 132a of the charging station 12 may an opposite magnetic polarisation to a first data contact 1112a of the battery 11.
  • Second data contacts 132b,1112b may also be magnetic in a similar manner; however, the second data contact 132b of the charging station 12 may be of an opposite polarisation to the first data contact 132b of the charging station 12 (making a second data contact 1112b of the battery 11 and opposite polarisation to the first data contact 1112a of the battery 11).
  • the same effects regarding potential repulsion of contacts may be achieved as discussed above in relation to the charging contacts 13,111.
  • the battery 11 may include a plurality of contacts at least some of which are magnetic.
  • the charging station 12 may include a corresponding plurality of contacts which are configured to engage respective contacts of the battery 11 in electrical communication therewith.
  • the plurality of contacts of the battery 11 and charging station 12 may have magnetic polarisations which cause attraction of the contacts which are configured to engage each other but contacts which are not configured to engage each other may repel each other.
  • One or more of the or each of the contact 13,131,132 of the charging station 12 may be mounted such that it is (or they are) moveable between an extended and a retracted position (e.g.
  • one or more of the or each of the contact 13,131,132 of the charging station 12 may be mounted such that it is (or they are) axially moveable between the extended and retracted positions.
  • One or more of the or each contact 13,131,132 of the charging station 12 may be mounted such that it is (or they are) rotatable about at least one axis which is perpendicular to the longitudinal axis of the contact 13,131,132.
  • one or more of the or each contacts 13,131,132 may be tiltable with respect to the charging station 12 (and, in particular, part of the mounting system 14 in some embodiments). This may be in addition to or instead of movement between the extended and retracted positions.
  • One or more of the or each contact 111,1111,1112 of the battery 11 may be similarly mounted such that it is (or they are) moveable between an extended and a retracted position (e.g.
  • one or more of the or each contact 111,1111,1112 of the battery 11 may be axially moveable between the extended and retracted positions.
  • One or more of the or each contact 111,1111,1112 of the battery 11 may be mounted such that it is (or they are) rotatable about at least one axis which is perpendicular to the longitudinal axis of the contact 111,1111,11112.
  • the of each contact 13,131,132 may be tiltable with respect to the battery 11 (and, in particular, part of the mounting configuration 112 in some embodiments) between a first tilt position and at least one second tilt position. Again, this may be in addition to or instead of movement between the extended and retracted positions.
  • the or each contact 13,131,132,111,1111,1112 may be biased towards the extended or retracted position by respective resilient biasing arrangements 133,1113 of the battery 11 and charging station 12 (the resilient biasing arrangements 133,1113 may be part of the mounting configuration 112 and the mounting assembly 14).
  • Resilient biasing may not be provided in relation to all such contacts 13,131,132,111,1111,1112 and may only be provided in relation to the charge contacts 13,111, for example.
  • the or each contact 13,131,132,111,1111,1112 may be biased towards the first tilt position by respective resilient biasing arrangements 133,1113 of the battery 11 and charging station 12 (the resilient biasing arrangements 133,1113 may be part of the mounting configuration 112 and the mounting assembly 14).
  • the resilient biasing arrangements 133,1113 which bias the or each contact 13,131,132,111,1111,1112 towards the first tilt position may be the same resilient biasing arrangements 133,1113 which bias the or each contact 13,131,132,111,1111,1112 towards the extended or retracted position, in some embodiments.
  • the amount of possible extension and retraction and/or tilt of the or each such contact 13,131,132,111,1111,1112 of the charging station 12 and/or the battery 11 may be limited and these limits may be different for different ones of the contacts 13,131,132,111,1111,1112.
  • the or each contact 13,131,132,111,1111,1112 may have an end which is located within a fluid - which may be viscous liquid.
  • This fluid may be housed within the mounting configuration 112 and/or the mounting assembly 14 as the case may be.
  • the fluid may, in some embodiments, act to slow a tilting or extension/retraction movement of the associated contact 13,131,132,111,1111,1112 with respect to the mounting configuration 112 and/or the mounting assembly 14 as the case may be.
  • Such a fluid may also be provided in embodiments in which there is no tilting and/or extension of one or more of the contacts 13,131,132,111,1111,1112.
  • the fluid may alternatively or additionally provide a mechanism to carry heat away from the or each contact 13,131,132,111,1111,1112. This may be especially important in relation to the charging contacts 111,13 - due to the potentially high electrical currents passing therethrough.
  • the charging station 12 and/or battery 11 may, therefore, be provided with a heat transfer system which is configured to provide a heat pipe (i.e. a thermal conduction path) from one or more of the or each contacts 13,131,132,111,1111,1112 to a different location (at which the heat may be exhausted).
  • This heat pipe may include a channel including a static thermally conductive material (which may include the fluid, which may be a viscous liquid (see above)), or may include a channel through which a thermally conductive material may travel (e.g. through which the fluid may travel).
  • This path may be in a circuit and may include a heat exchanger which is configured to exhaust the heat from the thermally conductive material to the atmosphere, for example.
  • the fluid may be a dielectric fluid.
  • the fluid may be or form part of the resilient biasing arrangements 133,1113.
  • the ability of one or more of the contacts 13,131,132,111,1111,1112 of the charging station 12 and/or the battery 11 to extend or retract and/or tilt ensures a better connection between the contacts 13,131,132,111,1111,1112 and may help to guide the contacts 13,131,132,111,1111,1112 into engagement.
  • the differing limits of movement between contacts 13,131,132,111,1111,1112 means that the engagement of some contacts with their corresponding contacts 13,131,132,111,1111,1112 is more fragile than the engagement of other contacts 13,131,132,111,1111,1112 with their corresponding contacts 13,131,132,1111,1112.
  • the length of at least one of the contacts 13,131,132 of the charging station 12 may be different to the length of another of the contacts 13,131,132 of the charging station 12.
  • the charging contacts 13 of the charging station 12 are longer than the signal and/or data contacts 131,132 of the charging station 12.
  • at least one of the contacts 13,131,132 of the charging station 12 extends to a greater height with respect to a part (e.g. a surface of a base member 141) of the mounting assembly 14 compared to another of the contacts 13,131,132 of the charging station 12 with respect to the part of the mounting assembly 14 - the charging contacts 13 of the charging station 12 may be the contacts which extend higher than the signal and/or data contacts 131,132. These arrangements may also or additionally provide a more fragile engagement of some contacts 13,111,131,1111,132,1112 than others.
  • the length of at least one of the contacts 111,1111,1112 of the battery 11 may be different to the length of another of the contacts 111,1111,1112 of the battery 11.
  • the charging contacts 111 of the battery 11 are longer than the signal and/or data contacts 1111,1112 of the battery 11.
  • at least one of the contacts 111,1111,1112 of the battery 11 extends to a greater height with respect to a part (e.g.
  • the mounting assembly 14 may include the base member 141 and the base member 141 may carry a plurality of charge contacts 13 (a first charge contact 13a and a second charge contact 13b) of the charging station 12 and at least one signal contact 131.
  • the base member 141 is generally rectangular in shape in this depicted embodiment but could be a different shape (e.g. circular, square, etc.). In this and some other embodiments, the base member 141 carries two signal contacts 131a,131b.
  • the charge contacts 13 and signal contacts 131 carried by the base member 141 extend in a first direction from the base member 141. In some embodiments, longitudinal axes of the charge and signal contacts 13,131 carried by the base member 141 are substantially parallel to each other.
  • the charge and signal contacts 13,131 carried by the base member 141 may form an array of contacts 13,131 (such as a linear array but in some other embodiments, the contacts 13,131 carried by the base member 141 may form a different pattern).
  • the charge and signal contacts 13,131 carried by the base member 141 may have a substantially circular cross-section. In some other embodiments, however, the charge and signal contacts 13,131 may be other cross-sectional shapes such as square, rectangular, triangular, hexagonal, pentagonal, or the like. In some embodiments, one or more of the contacts 13,111,131,1111,132,1112 are spherical in shape. In some embodiments, the charge and signal contacts 13,131 need not be the same cross-sectional shape - e.g.
  • the charge contacts 13 may be a different cross-sectional shape to the signal contacts 131 and/or one charge contact 13 may be a different cross-sectional shape to another charge contact 13 and/or one signal contact 131 may be a different cross-sectional shape 131 to another signal contact 131.
  • the or each charge 13 and signal contact 131 has a respective engagement surface which is configured to engage a corresponding engagement surface of a corresponding contact 111,1111 of the battery 11 (and, specifically, of the mounting configuration 112).
  • the size of the surface area of the engagement surface of each charging contacts 13 of the charging station 12 is greater than the surface area of the engagement surfaces of each of the signal contact 131 of the charging station 12.
  • the signal contacts 131 may be located between the charge contacts 13.
  • the charge contacts 13 may be located generally towards opposing parts of the mounting assembly 14 and, in particular, the base member 141 - this may reduce the risk of short circuits and/or arcing between the charge contacts 13.
  • the pattern of contacts 13,131,132 of the charge station 12 is referred to as a charge station contact pattern. This pattern includes the position of the contacts 13,131,132 with respect to the rest of the mounting assembly 14 and may also include the size and/or shape of the engagement surfaces of these contacts 13,131,132.
  • each contact 13,131 of the charge station 12 may be associated with a conductor 15 (e.g. a wire or cable) such that each contact is 13,131 is in electrical communication with at least one such conductor 15.
  • each contact 13,131 of the charging station 12 is associated with a respective distinct conductor 15 but in other embodiments, a plurality of contacts 13,131 may be associated with a single conductor 15.
  • one or more of the contacts 13,131 may have a first portion 13c, 131c which is located within the base member 141 of the mounting assembly 14.
  • a second portion 13d, 13 Id of each of these one or more contacts 13,131 may extend through a respective aperture defined by the base member 141, such that an end surface of the second portion 13d, 13 Id forms the engagement surface of that contact 13,131.
  • the first portion 13c, 131c of the or each such contact 13,131 may be retained within a chamber which is defined by the base member 141 into which the aperture (through which the second portion 13d,131d of the same contact 13,131 extends) leads.
  • the or each chamber may have a larger cross-section than an adjacent part of the cross-section of the aperture leading to that chamber.
  • the first portion 13c, 131c may have a width (e.g. a diameter) which is greater than a width of the cross-section of the aperture but smaller than a width of the adjacent part of the cross-section of the chamber.
  • the or each contact 13,131 may, therefore, be in the general shape of a top hat.
  • the or each contact 13,131 could equally be referred to as respective pins, for example.
  • the or each contact 13,131 may be substantially prevented from being removed from the base member 141 by abutment of the first portion 113c, 131c of the contact 13,131 with a part of the base member 14 (e.g. a surface between the chamber and the aperture).
  • the or each chamber defined by the base member 141 has a depth which is greater than a depth of the first portion 13c, 131c of the contact 13,131 which is retained in that chamber. Accordingly, axial movement of the contact 13,131 (as described above) may be permitted between the extended and retracted positions with respect to the base member 141 of the mounting assembly 14.
  • the or each aperture defined by the base member 141 through which the second portion 13d,131d of one of the contacts 13,131 extends has a width (e.g. a diameter) which is greater than the corresponding part of the width (e.g. diameter) of the second portion 13d,131d contact 13,131.
  • a width e.g. a diameter
  • the second portion 13d,131d contact 13,131 With a chamber which is deeper than the first portion 13c, 131c of that contact 13,131, this allows the contact 13,131 to tilt (as described above) with respect to the base member 141 and mounting assembly 14.
  • the dimensions of the aperture and chamber defined by the base member 141 i.e. by the mounting assembly 14 and configured to receive a respective contact 13,131, along with the relative dimensions of that contact 13,131, define limits of tilt and/or axial movement of the contact 13,131 with respect to the base member 141 (i.e. with respect to the amounting assembly 14).
  • the charging contacts 13 may extend to a greater height above a surface of the base member 141 of the mounting assembly 14 than the or each signal contact 131. In some embodiments, this may be because the charge contacts 13 are of a greater height than the signal contacts 131 but this need not be the case - e.g. the second portions 13d of the charging contacts 13 may be shorter than the second portions 13 Id of the signal contacts 131.
  • Figure 4 shows an exploded view of the embodiment of figures 1-3 and is representative of how this and some other embodiments may be formed.
  • Each conductor 15 may, in some embodiments, include a first portion 151 which is configured to extend into the base member 141 or other part of the mounting assembly 14 such that each conductor 15 is in electrical communication with at least one of the contacts 13,131 (in the depicted embodiment, each conductor 15 is configured to be connected in electric communication with a single contact 13,131).
  • a second portion 152 of each conductor 15 is configured to be connected in electric communication with one or more other parts of the charging station 12.
  • the base member 141 in this depicted embodiments, and in some other embodiments, comprises a first base sub-member 1411 and a second base sub-member 1412.
  • the first and second base sub- member 1411,1412 are configured to be connected together to form the base member 141.
  • the first base sub-member 1411 defines at least part of the or each chamber (which each receives the first portion 13c, 131c of a contact 13,131).
  • the first base sub-member 1411 may also define at least part of one or more channels 142 which are each configured to receive at least part of a respective conductor 15 (e.g. the first portion 151 of a respective conductor 15).
  • the or each chamber may be configured to hold the fluid discussed above.
  • the or each chamber is further or alternatively configured to hold a heat transfer plate which may be thermally coupled to the channel containing thermally conductive material - as described above.
  • the first base sub-member 1411 may define one or more dowel receiving openings 143 which are each configured to receive a respective dowel 144 of the second base sub-member 1412.
  • one or more dowels may extend from the first base sub-member 1411 and may be configured to be received by one or more dowel receiving openings defined by the second base sub-member 1412.
  • the first base sub-member 1411 may define one or more dowel receiving openings 143 and one or more dowels, with the second based sub-member 1412 defining an opposing configuration of dowel(s) 144 and dowel receiving openings.
  • the or each dowel 144 and the or each dowel receiving opening 143 are configured such that they mate when the two sub-members 1411,1412 of the base member 141 are connected to each other. This may help to hold the two base sub- members 1411,1412 together and may assist in ensuring the correct orientation of the two base sub-members 1411,1412.
  • the second base sub-member 1412 may define at least part of the or each chamber and defines the or each aperture - through which the contacts 13,131 extend as described herein.
  • the second base sub-member 1412 may define at least part of the or each channel 142 for the or each conductor 15 - as described herein.
  • the first and second base sub-members 1411,1412 may be, therefore, configured to trap and retain part of the or each contact 13,131 when connected to each other.
  • the resilient biasing arrangements 133 may be located within the chambers.
  • the or each resilient biasing arrangement 133 of this embodiment, and some other embodiments, may be configured to be received within the base member 14 and, specifically, may be within one of the chambers.
  • the or each resilient biasing arrangement 133 may be configured to act between the first base sub-member 1411 and the first portion 13c, 131c of the or each contact 13,131 - e.g. with one resilient biasing arrangement 133 provided for each contact 13,131.
  • resilient biasing arrangements 133 are provided for the charging contacts 13 and may not be provided for the signal contacts 131.
  • the resilient biasing arrangements 133 may each take a number of different forms - for example, a helical spring, a spring washer, a Belleville washer, a wave washer, and the like.
  • the or each resilient biasing arrangement 133 may be configured to bias a respective contact 13,131 (or contacts 13,131) towards the extended position and, in particular, into a position in which the first portion 13c, 131c of the contact 13,131 abuts a surface between the chamber and the aperture in which the contact 13,131 is located, as defined by the base member 141.
  • the first portion 13c, 131c of one or more the contacts 13 may each define a groove 13e,131e which is configured to receive at least part of a respective one of the or each conductor 15 (e.g. the first portion 151 of one of the conductors 15). This part (e.g. the first portion 151) may be attached to the contact 13,131 in the groove 13e,131e and may be soldered in position.
  • part of the conductor 15 may be located between a part of the base member 141 (e.g. at the base of the chamber) and the resilient biasing arrangement 133, and the resilient biasing arrangement 133 may be conductive such that electrical communication between the conductor 15 and the contact 13,131 is via the resilient biasing arrangement 133.
  • part of the conductor 15 e.g. the first portion 151 may be located between the resilient biasing arrangement 133 and the contact 13,131 (e.g. the first portion 13c, 131c of the contact 13,131) such that the part of the conductor 15 moves with the contact 13,131.
  • the conductor 15 may be flexible to permit such movement.
  • each of the two base sub-members 1411,1412 may be formed from a moulded plastics material - e.g. with the or each dowel 144 integrally formed therewith, if provided.
  • the or each contact 13,131 may be formed from a ferrous metal.
  • the of each contact 13,131 may be a permanent magnet which can also conduct electricity.
  • the or each data contact 132 of some embodiments may have a substantially identical form to the or each signal contact 131 (including all aspects of the signal contacts 131 described above such as how they are carried by the base member 141 and how they are connected to a conductor 15). The description in relation to the signal contacts 131, therefore, applies equally to the data contacts 132.
  • FIG. 5 An embodiment including two data contacts 132 (as well as two charging contacts 13 and two signal contacts 131), is shown in figure 5 for example.
  • the or each data contact 132 is provided between the charging contacts 13.
  • the or each data contact 132 may be provided between the signal contacts 131.
  • Figure 5 also provides an example arrangement of magnetic polarities for the charging 13 and signal 131 contacts - with the two charging contacts 13 of the charging station 12 being of opposing magnetic polarity and the two signal contacts 131 of the charging station 12 also being of opposing magnetic polarity.
  • the data contacts 132 may or may not be magnetic. In embodiments in which the data contacts 132 of the charging station 12 are magnetic, they may be of opposing magnetic polarity.
  • the mounting configuration 112 of the battery 11 may be of a substantially identical construction to the mounting assembly 14 of the charging station.
  • the description above applies equally to the corresponding parts of the mounting configuration - which may, accordingly, include the base member 1211, charging contacts 111 (with their first and second portions 111c, 11 Id and grooves l l le), one or more signal contacts 1111 (with their first and second portions 1111c, l l l ld and grooves), and/or one or more data contacts 1112.
  • the base member 1121 of the mounting configuration 112 may include a first base sub-member 1121a corresponding with the first base sub-member 1411 of the mounting assembly 14, and a second base sub-member 1121b corresponding with the second base sub-member 1412 of the mounting assembly 14.
  • the base member 1211 of the mounting configuration 112 may define one or more apertures and chambers for the contacts 111,1111,1112 of the mounting configuration 112.
  • the first and second sub-members 1121a,1121b of the mounting configuration 112 may include one or more dowels 1122 and one or more dowel receiving openings 1123 and one or more channels 1124, corresponding with the one or more dowels 144, the dowel receiving openings 143, and the channels 142 of the mounting assembly 14.
  • the conductors 15 of the charging station 12 may have counterparts in the battery 11 in the form of conductors 16 (again with first 161 and second 162 portions).
  • the description of the mounting assembly 14 may apply equally to the mounting configuration 112, in a particular example, the mounting assembly 14 and mounting configuration 112 need not be of identical form to each other for connection to occur. Indeed, as will be appreciated the charge station contact pattern at least will be associated with a corresponding battery contact pattern which is a mirror image of the charge station contact pattern.
  • Figure 6 shows an example of some embodiments in which a concentric arrangement of contacts 13,131,132,111,1111,1112 is provided.
  • These contacts 13,131,132,111,1111,1112 may include charging contacts 13,111, one or more signal contacts 1111,131, and one or more data contacts 1112,132 of the battery 11 or charging station 12, as the case may be.
  • each contact 13,131,132,111,1111,1112 may be a portion of the perimeter of a circle - e.g. half or a quarter of the perimeter of a circle - or a substantially complete circle.
  • the contacts 13,131,132,111,1111,1112 may be portions of the perimeter of a plurality of different circles - with each contact 13,131,132,111,1111,1112 being a portion of the perimeter of one such circle and the circles being of different diameters.
  • more than one separate portion of the perimeter of a circle may form a single contact 13,131,132,111,1111,1112.
  • the first charging contact 13a,l l la (which may be a negative charging contact) is provided by an outer contact in the form of the perimeter of a first circle.
  • the first charging contact 13a, 11 la may be two contacts each forming approximately half of the perimeter of the first circle.
  • the second charging contact 13b,l 1 lb (which may be a positive charging contact) is provided by an inner contact which may be a contact in the form of the perimeter of a second circle.
  • the second charging contact 13b,l 1 lb may be two contacts each forming approximately half of the perimeter of the second circle.
  • the first circle may be of a larger diameter than the second circle - as can be seen in figure 6 as an example.
  • signal and/or data contacts 131,132,1111,1112 may be provided by one or more intermediate contacts in the form of the perimeter of one or more further circles.
  • the signal and/or data contacts 131,132,1111,1112 may each be two contacts, each forming approximately half of the perimeter of a respective one of the further circles.
  • the two halves of the perimeter of a particular further circle may form separate ones of the signal and/or data contacts 131,132,1111,1112.
  • the or each further circle has a diameter which is less than the diameter of the first circle and more than the diameter of the second circle.
  • each contact 131,132,1111,1112 of such embodiments may be mounted for axial movement and/or may be tiltable and/or may be resiliently biased, all as discussed herein in relation to other embodiments. As will also be appreciated, it need not be necessary to provide all of the depicted signal 131,1111 and data 132,1112 contacts in some such embodiments.
  • FIGS 7 to 9 show an example of some embodiments including contact tabs 17.
  • the construction of the mounting configuration 112 and/or assembly 14 is generally as described above.
  • the base member 141,1121 includes to base sub-parts 1411,1121a,1412,l 121b of a similar construction to the embodiments discussed above - including the provision of one or more dowels 1122,144 and one or more dowel receiving openings 1123,143.
  • the base member 141,1121 may carry one or more contacts 13,131,132,111,1111,1112 in the same manner as any other embodiment of the invention (e.g. in the same manner described in relation to figures 1 to 5) - which may include the use of one or more resilient biasing arrangements, in some embodiments, even though these are not shown in figure 9.
  • the base member 141,1121 further carries one or more contact tabs 17.
  • the or each contact tab 17 is associated with a contact 13,131,132,111,1111,1112.
  • the or each contact tab 17 is configured to be the electric current carrying member for the contact 13,131,132,111,1111,1112 with which it is associated. Accordingly, in some embodiments, another part of the contact 13,131,132,111,1111,1112 (e.g. the magnetic part) does not itself conduct electricity (or at least not electricity which is used in the operation of the present invention).
  • the or each contact tab 17 may include a mounting part 171 and an engagement part 172 - also see figure 15.
  • the mounting part 171 is configured for using in mounting the contact tab 17 to base member 141,1121. Accordingly, at least part of the mounting part 171 may extend through at least part of the base member 141,1121 and may extend through a depth of the base member 141,1121 - i.e. through the entire depth of both the base sub-members 1411,1412,1121a,l 121b.
  • the engagement part 172 is configured to engage a contact 13,131,132,111,1111,1112 of the other of the mounting assembly 14 or mounting configuration 112. Accordingly, in some embodiments in which both the mounting configuration 112 and mounting assembly 14 use contact tabs 17, the engagement parts 172 of the mounting assembly and mounting configuration 112 may engage. In some embodiments, one or more of the charging contacts 13,111 are associated with respective contact tabs 17.
  • the mounting parts 171 of respective contact tabs 17 may be located towards an outside of the mounting assembly 14 or configuration 112 such that the engagement parts 172 extend inwardly.
  • the engagement 172 and mounting parts 171 of a contact tab 17 may be substantially perpendicular to each other.
  • the mounting parts 171 of the or each contact tab 17 may be connected in electrical communication with one or more other parts of the battery 11 or charging station 12, as the case may be.
  • Such embodiments using contact tabs 17 may mean that conductors 15,16 for the associated contacts 13,131,132,111,1111,1112 as described above (e.g. located in grooves) are not needed.
  • the charging contacts 13,111 are not resiliently biased and/or are held against axial and/or tilt movement.
  • contact tabs 17 are associated with the charging contacts 13,111 but are not associated with the signal or data contacts 131,132,1111,1112.
  • the or each contact tab 17 may be formed from a different material to the rest of the contacts 13,131,132,111,1111,1112 (e.g. to the magnetic parts thereof).
  • the material may be selected for its electrical conductivity and its hardness and/or its decorative appeal.
  • the material may be nickel, for example.
  • Figures 10 to 12 show an example of an embodiment which uses one or more magnets 18 which are separate from the or each contact 13,131,132,111,1111,1112.
  • a pair of magnets 18 is provided, with one magnet 18 at either end of a linear array of contacts 13,131,132,111,1111,1112.
  • the magnets 18 may have a different configuration and there may be one or more magnets 18 interspersed between the contacts 13,131,132,111,1111,1112.
  • each magnet 18 comprises a cylindrical magnet 18 which is retained in a respective cavity which is defined by the base member 141,1121 - e.g. by the two base sub-members 1411,1412,1121a,l 121b (see figure 12 in particular which shows two such magnets 18 partially retained in the first base sub-member 1411,1121a).
  • the or each magnet 19 may be a permanent magnet and may be substantially covered by the second base sub-member 1412,1121b such that no part of the or each magnet 19 is visible externally of the mounting configuration 112 or mounting assembly 14 - see figure 11 in particular as an example.
  • each contact 13,131,132,111,1111,1112 may otherwise, in such embodiments, be as described above and retained in the same manner as in other embodiments (and may be in electrical communication with conductors 15,16 in a similar manner).
  • some embodiments include one or more electromagnets 19.
  • the or each electromagnet 19 may be used in place of the or each magnet 18 of the embodiments described above with reference to figures 10 to 12.
  • the or each electromagnet 19 may be associated with a respective contact 13,131,132,111,1111,1112.
  • the electromagnet may include a coil 191 through which an electric current is passed in order to generate a magnetic field.
  • the coil 191 may be located around the contact 13,131,132,111,1111,1112 or a part thereof.
  • the contact 13,131,132,111,1111,1112 may be a solid ferrous metal contact, a hollow ferrous metal contact, or even a permanent magnet (whose magnetic field is "boosted” by the electromagnet 19). Electric current for the charging still passes through the charge contacts 13,111 in such embodiments.
  • embodiments of a mounting configuration or assembly 112,14 using one or more electromagnets need not necessarily be used with the other of the mounting configuration or assembly 112,14 also using electromagnets 19 - the or each corresponding contact 13,131,132,111,1111,1112 of the other of the mounting configuration or assembly 112,14 may be a permanent magnet or a ferrous metal, for example.
  • at least one of the contacts 13,131,132,111,1111,1112, and in particular the second part thereof, includes an insulation sheath 20 - see figures 16 and 17, for example.
  • the insulation sheath 20 may substantially surround an external surface of the contact 13,131,132,111,1111,1112 to which it is fitted.
  • the insulation sheath 20 is provided around an external surface of the contact 13,131,132,111,1111,1112 to which is it is fitted, wherein that external surface faces outwardly from the mounting assembly 14 or mounting configuration 112, as the case may be.
  • the insulation sheath 20 may, in some embodiments, be an annular sheath. In some embodiments, little or no portion of the contact 13,131,132,111,1111,1112 to which the insulation sheath 20 is fitted extends above the top of the insulation sheath 20. In some embodiments, the insulation sheath 20 covers substantially all of the exposed outer surface or surfaces of the contact 13,131,132,111,1111,1112 to which it is fitted when the contact is in the extended position. The insulation sheath 20 may be mounted on the contact 13,131,132,111,1111,1112 to which it is fitted such that it moves with the contact 13,131,132,111,1111,1112.
  • the contact 13,131,132,111,1111,1112 to which the insulation sheath 20 is fitted can move within the insulation sheath 13 , 131 , 132, 111 , 1111 , 1112 axially and may also be tiltable.
  • the or each contact 13,131,132,111,1111,1112 may be fitted with an insulation sheath 20.
  • each charging contact 13,111 is fitted with an insulation sheath 20.
  • the or each signal and/or data contact 131,132,1111,1112 is not fitted with an insulation sheath 20.
  • the aperture defined by the base member 141,1121 for receiving the second part of the contact 13,131,132,111,1111,1112 may also need to be sized to receive the insulation sheath 20 if fitted to that contact 13,131,132,111,1111,1112.
  • a cap 21 for one or more of the contacts 13,131,132,111,1111,1112 (and, in particular, for one or more of the charge contacts 13,111).
  • the or each cap 21 may be configured to fit over an end of the contact 13,131,132,111,1111,1112 (e.g. the end of the second part defining the engagement surface) such that the cap 21 forms the engagement surface for the contact 13,131,132,111,1111,1112.
  • the or each cap 21 may also be configured to extend along at least part of a length of the associated contact 13,131,132,111,1111,1112.
  • the cap 21 includes one or more protrusions 211 which extend inwardly into a volume at least partially defined by the cap 21 (the volume in which the contact 13,131,132,111,1111,1112 is received).
  • the first and second part of one or more of the contacts 13,131,132,111,1111,1112 may be separate parts which are coupled together. That coupling may be achieved using the cap 21.
  • the cap 21 may fit around the second part of the contact 13,131,132,111,1111,1112 and the open end of the cap 21 may be received by a recess in the first part of the contact 13,131,132,111,1111,1112.
  • the wall or walls of the cap 21 may be biased outwardly (e.g.
  • the or each cap 21 may provide a more electrically conductive and/or harder wearing and/or more decorative contact 13,131,132,111,1111,1112 (compared to the material used for the rest of the contact 13,131,132,111,1111,1112).
  • the use of one or more insulation sheathes 20 inhibits interference with the contacts 13,131,132,111,1111,1112 and makes it more difficult for the contacts 13,131,132,111,1111,1112 to be short circuited or to contact other conductors which a user may attempt to introduce between the mounting configuration 112 and mounting assembly 14.
  • the use of one or more insulation sheathes 20 may, therefore, improve the safety of the operation of the battery charging system 1.
  • the or each insulation sheath 20 may be formed from an electrical insulator.
  • the or each insulation sheath 20 is a thermal conductor (e.g. more thermally conductive than a material of the base member 1121,141).
  • the insulation sheath 20 may be a dielectric material which may be a thermally conductive dielectric material.
  • the or each insulation sheath 20 is in thermal communication with the above described fluid to provide a thermal conduction pathway to the contact 13,131,132,111,1111,1112.
  • the contacts 13,131,132,111,1111,1112 are attracted to each other due to magnetic attraction.
  • Figure 18 shows two contacts 13,131,132,111,1111,1112 close to each other but substantially aligned and without a substantial degree of relative tilt (i.e. tilt relative to each other).
  • the contacts 13,131,132,111,1111,1112 reach a point at which they engage each other such that they are in electrical communication with each other as shown in figure 19.
  • the contacts 13,131,132,111,1111,1112 will not be perfectly aligned and/or will have an undesirable degree of relative tilt with respect to each other. This may be because the battery 11 is tilted or misaligned with the charging station 12 (i.e. the mounting configuration 112 and mounting assembly 14 are misaligned or tilted with respect to each other) or may be due to manufacturing tolerances. Accordingly, the situation as shown in figure 20 is common in practical situations.
  • one or more of the contacts 13,131,132,111,1111,1112 is tiltable such that, as the corresponding contacts 13,131,132,111,1111,1112 approach each other one or both of the corresponding contacts 13,131,132,111,1111,1112 will tilt with respect to its mounting configuration 112 or mounting assembly 14, as the case may be, to match the angle of the engagement surface of the other contact 13,131,132,111,1111,1112.
  • the corresponding contacts 13,131,132,111,1111,1112 will still mate securely (as shown in either figure 19 or figure 20) over a substantial portion of the respective engagement surfaces of the contacts 13,131,132,111,1111,1112 (and, in some embodiments, over substantially all of these engagement surfaces 13,131,132,111,1111,1112).
  • the or each contact 13,131,132,111,1111,1112 is cylindrical. In other embodiments, the or each contact has a non-cylindrical form permitting engagement, for example right prisms, or the or each contact may have a form that cooperates with another contact.
  • Figure 22 shows an example mounting configuration 112 and mounting assembly 14 of an embodiment of the invention with a simplified schematic representation of the associated circuitry. It will be appreciated that the explanation and discussion of the example in figure 22 will apply to other example embodiments of the mounting configuration 112 and mounting assembly 14 as described herein.
  • the outer contacts 13a,13b,l l la,l l lb are the charging contacts of the charging station 12 and battery 11.
  • the inner pair of contacts 131a,131b,l l l la,l l l lb are signal contacts of the charging station 12 and the battery 11.
  • the first charging contact 111a of the battery 11 is connected in electrical communication with the charge confirmation sub-system 114 and may be connected to a first switch 1141 of the charge confirmation sub-system 114.
  • the charge confirmation subsystem 114 e.g. the first switch 1141 is also connected in electrical communication with the or each battery cell 113 (of which two are schematically depicted in figure 22).
  • the charge confirmation sub-system 114 (e.g. the first switch 1141) is also connected in electrical communication with the first signal contact 111 la of the battery 11.
  • the first signal contact 1111a is connected to the charge confirmation sub-system 114 such that an electrical signal received via the first signal contact 1111a controls actuation of the charge confirmation sub-system 114 and, in particular, actuation of the first switch 1141.
  • Actuation of the charge confirmation sub-system 114 (e.g. actuation of the first switch 1141) to a closed configuration connects a first terminal of the or each battery cell 113 (e.g. the positive terminal) in electrical communication with the first charge contact 111a of the battery 11.
  • Actuation of the charge confirmation sub-system 114 (e.g. actuation of the first switch 1141) to an open configuration disconnects the first terminal of the or each battery cell 113 (e.g. the positive terminal) from electrical communication with the first charge contact 111a of the battery 11.
  • the charge confirmation sub-system 114 and, in some embodiments, the first switch 1141 is configured to control whether or not the first charge contact 11 la of the battery 11 is in electrical communication with the or each battery cell 113.
  • the second charge contact 111b of the battery 11 is, in the depicted embodiment and other embodiments, connected in electrical communication with a second terminal of the one or more battery cells 113 (e.g. to the negative terminal).
  • the second signal contact 111 lb of the battery 11 may be connected in electrical communication with the first terminal of the one or more battery cells 113 (e.g. via a resistor 1142).
  • the second charge contact 13b of the charge station 12 is connected in electrical communication with one or more of the electrical power input 121, the power regulation sub-system 122, the charging controller 123 (and the charge actuation sub-system 1231 and/or the control unit 1232).
  • the second signal contact 131b of the charge station 12 is connected in electrical communication with the charging controller 123 (and, in particular, may be connected in electrical communication with the control unit 1232).
  • the first signal contact 131a of the charge station 12 is connected in electrical communication with the charging controller 123 (and, in particular, may be connected to the charge actuation subsystem 1231 and/or the control unit 1232).
  • the first charging contact 13a of the charging station 12 is also connected in electrical communication with the charging controller 123 (and, in particular, may be connected to the charge actuation sub-system 1231).
  • the first charging contact 13a of the charging station 12 may be connected in electrical communication with a second switch 1232 of the charge actuation sub-system 1231.
  • the charge actuation sub-system 1231 e.g. the second switch 1232 may be further connected in electrical communication with one or more of the electrical power input 121 and the power regulation sub-system 122.
  • Operation of the charge actuation sub-system 1231 may be controlled by the control unit 1232, in accordance with an output of the control unit 1232 which may also be sent to the first signal contact 131a of the charging station 12.
  • the charge actuation sub-system 1231 (e.g. the second switch 1232) may be configured to be actuated between an open configuration (in which the first charging contact 13a is not in electrical communication with one or more of the electrical power input 121, and the power regulation subsystem 122) and a closed configuration (in which the first charging contact 13a is in electrical communication with one or more of the electrical power input 121 and the power regulation subsystem 122). Accordingly, with reference to figure 22, when the battery 11 is connected to the charging station 12 such that the mounting assembly 14 and mounting configuration 112 connect each other, then the corresponding contacts 13,131,132,111,1111,1112 engage each other as depicted.
  • a voltage across the or each battery cell 113 is detected by the charging controller 123 of the charging station 12, and, in particular, by the control unit 1232 - which detects a voltage across the second signal contact 131b and the second charging contact 13b.
  • a relatively low current flows through the resistor 1142 (which might have a relatively high electrical resistance as a result) to the charging controller 123 (e.g. to the control unit 1232).
  • This detected or sensed voltage using one or more of the signal contacts 131 of the charging station 12 (and one or more of the signal contacts 1111 of the battery 11) indicates that a battery 11 has been mounted to the charging station 12 and that the signal contacts 131,1111 and the charging contacts 13,111 are engaged.
  • the charging controller 123 and, in particular, the control unit 1233 is configured to sense this voltage and to output a signal to control the operation of the charge actuation sub-system 1231 - to actuate the charge actuation sub-system 1231 (e.g. the second switch 1232) to the closed configuration (e.g. from the open configuration).
  • the output signal from the charging controller 123 (and, in particular, the control unit 1233) is configured to be sent to the charge confirmation sub-system 114 of the battery 11 via the first signal contacts 131 a, 1111 a.
  • This output signal therefore, also further causes the actuation of the charge confirmation sub-system 114 (and, in particular, the first switch 1141).
  • the actuation of the charge actuation sub-system 1231 to the closed configuration and the actuation of the charge confirmation sub-system 114 to the closed configuration causes the or each battery cell 113 to be connected in electrical communication (e.g. at both terminals thereof) to one or more of the electrical power input 121, and the power regulation sub-system 122, such that the or each battery cell 113 receives electrical power from the charging station 12 to charge the or each battery cell 113.
  • This electrical power may be delivered at a relatively high electrical current.
  • the or each signal contact 131 of the charging station 12 may disengage the of each corresponding signal contact 1111 of the battery 11 before the charging contacts 13,111 disengage - i.e. the engagement of the signal contacts 131,1111 may be relatively fragile compared to that of the charging contacts 13,111. This fragility may be provided by the features of the contacts discussed above including the relative distance of extension of the signal contacts 131,1111, the relative height of the signal contacts 131,1111, restrictions on the axial or tilt movement of the signal contacts 131,1111, and the like. The relatively small engagement surfaces of the signal contacts 131,1111 compared to the charge contacts 13,111 may also assist in providing the required relative fragility of the engagement.
  • the charge confirmation sub-system 114 and/or the charge actuation sub-system 1231 are configured to actuate to their respective open configurations.
  • the charging controller 123 and, in particular, the control unit 1233 may detect the disappearance of the voltage across the second signal contact 131b of the charging station 12 and the second charging contact 13b of the charging station 12. Accordingly, the charging controller 123 (e.g. the control unit 1233) may output a signal to actuate the second switch 1232 to the open configuration - or, in some embodiments, may cease to output the signal which actuated the second switch to the closed configuration.
  • the output signal from the charging controller 123 and, in particular, the control unit 1233 will also be received by the charge confirmation sub-system 114 (e.g. by the first switch 1141) which will also actuate to the open configuration.
  • the output signal causing the charge confirmation sub-system 114 (e.g. the first switch 1141) to remain in the closed configuration will be lost and so the charge confirmation sub-system 114 (e.g. the first switch 1141) will actuate to the open configuration.
  • the charge confirmation subsystem 114 (e.g. the first switch 1141) will actuate to the open configuration (due to loss of the output from the charging controller 123 (i.e. from the control unit 1233) to keep it in the closed configuration).
  • the charging controller 123 e.g. the control unit 1233 may be configured to identify a change in the detected voltage across the second signal contact 131b and the second charging contact 13b indicative of the charge confirmation sub-system 114 (e.g. the first switch 1141) actuating to the open configuration.
  • This detection may be, for example, a reduction in the voltage and may be a rate of reduction in the voltage.
  • the charge controller 123 e.g. the control unit 1233 may output the signal to actuate the charge actuation sub-system 1231 (e.g. the second switch 1232) to the open configuration - or cease to output the signal which kept it in the closed configuration as the case may be.
  • figures 24 and 25 show the mounting assembly 14 and mounting configuration 112 (of the embodiment used in figure 22) with the signal contacts 131,1111 engaged.
  • Figures 23 and 26 show the same mounting assembly 14 and mounting configuration 112 with the signal contacts 131,1111 disengaged but the charging contacts 13,111 still engaged - as would happen during engagement/connection and disengagement/disconnection of the mounting assembly 14 and mounting configuration 112 to and from each other.
  • Figure 27 shows the same embodiment in which the engagement of the contacts 13,111,1111,1112,131,132 has occurred but the mounting assembly 14 and mounting configuration 112 are tilted with respect to each other. Engagement has, nevertheless, occurred but, it will be appreciated, that movement of the mounting assembly 14 relative to the mounting configuration 112 may cause the or both signal contacts 1111,131 to disengage.
  • Embodiments which include one or more data contacts 132,1112 operate in a similar manner - see figures 31-33.
  • the description above in relation to the operation of embodiments not including data contacts 131,1112 applies equally to embodiments which do include data contacts 131,1112 and, as such, common reference numerals have been used in figures 31-33.
  • the data contacts 132,1112 enable the transmission of data from the battery 11 to the charging station 12 and/or from the charging station 12 to the battery 11.
  • This data may include one or more of an identifier for the battery 11, an identifier for the charging station 12, a charging parameter for the battery 11 (e.g.
  • the identification of a suitable charging profile for use with the battery 11 (which may be sent by the battery 11 to the charging station 12)), an indication of the number of charge cycles the battery 11 has undertaken (which may be updated by the battery 11 on receipt of a signal from the charging station 12), information regarding one or more historic charging cycles (e.g. the voltage level reached, the length of the time on charge, and the like), one or more parameters of the charging station 12 (such as a maximum charging current), a temperature of the battery 11 or charging station 12, and the like.
  • one or more historic charging cycles e.g. the voltage level reached, the length of the time on charge, and the like
  • one or more parameters of the charging station 12 such as a maximum charging current
  • the identifier for the battery 11 and/or the identifier for the charging station 12 may be substantially unique to that battery 11 and/or charging station 12, may be common to that make of battery 11 and/or charging station 12, may be common to that model of battery 11 and/or charging station 12, or the like.
  • the battery 11 and the charging station 12 may include respective data processing and storage systems 22 for the handling and storage of data transmitted and/or received via the data contacts 132,1112.
  • the data processing and storage system 22 of the charging station 12 is configured to communicate with the charging controller 123 to control the operation thereof in accordance with data received from the battery 11 - e.g. the selection of a charging profile.
  • the identifier of the battery 11, as received from the battery 11 by the charging station 12 may be used by the data processing and storage system 22 of the charging station 12 to determine whether the battery 11 can or should be charged - e.g. is the battery 11 a legitimate battery 11.
  • the identifier of the charging station 12, as received from the charging station 12 by the battery 11, may be used by the data processing and storage system 22 of the battery 11 to determine whether the charging station 12 can or should charge the battery - e.g. is the charging station 12 a legitimate charging station 12.
  • the data processing and storage system 22 of the charging station 12 may be configured to control the operation of the charge actuation sub-system 1231 (e.g. the second switch 1232).
  • the data processing and storage system 22 of the battery 11 may be configured to control the operation of the charge confirmation sub-system 114 (e.g. the first switch 1141).
  • the data contacts 1112,132 may be configured to use any number of different communication protocols - e.g. CANBus, USB, PCIE, V2G, or another automotive communication protocol, or the like.
  • the data contacts 1112,132 may use an analogue communication signal.
  • the engagement of the data contacts 132,1112 may be more fragile than the engagement of the charge contacts 13,111.
  • the engagement of the data contacts 132,1112 may be more fragile or less fragile than the engagement of the signal contacts 131,1111.
  • Various of the figures have indications of possible arrangements of magnetic polarisations of various contacts 13,131,132,111,1111,1112. It will be appreciated that these are examples only.
  • the charging station 12 may confirm one or more parameters associated with the battery 11 prior to commencing (or continuing) charging. Equally, the battery 11 may check one or more parameters associated with the charging station 12 prior to commencing (or continuing) charging. These one or more parameters may include data transmitted via the data contacts 132,1112 and/or may include an indication that the battery 11 is correctly mounted to the charging station 12 (using the signal contacts 131,1111).
  • Some embodiments of the present invention also provide a mechanism for confirming engagement of the battery 11 and charging station 12 which is at least partially mechanical - e.g. the use of signal and/or data contacts 131,132,1111,1112 with more fragile engagement with each other than the charging contacts 13,111.
  • This provides improved safety in the operation of the system 1 of some embodiments.
  • both the battery 11 and the charging station 12 can determine whether to commence or continue charging - through the use of the charge confirmation sub-system 114 and the charge actuation sub-system 1231, for example. Again, this improves the safety of the operation of the invention.
  • in electrical communication has been used herein to indicate the connection of two elements in such a manner that there is an electrically conductive path between the elements and, in particular, a path between the parts of the elements to allow for operation of those elements as described herein - e.g. between input/output pins of the elements.
  • the elements may or may not be physically connected to each other when in electrical communication and two physically connected elements need not be in electrical communication, as will be appreciated.
  • contacts 13,111,131,1111,132,1112 of the mounting assembly 14 and mounting configuration 112 have been numbered “first” and “second” in respect of the contacts of each of the mounting assembly and the configuration 14,112 separately. These contacts 13,111,131,1111,132,1112 could equally have been numbered in relation to the battery charging system 1 as a whole.
  • the first charging contact 111a may be the first charging contact 111a of the battery charging system 1
  • the second charging contact 111b may be the second charging contact of the battery charging system 1
  • the first charging contact 13a may be the third charging contact 13b of the battery charging system 1
  • the second charging contact 13b may be the fourth charging contact 13b of the battery charging system 1.
  • the first signal contact 1111a of the mounting configuration 112 may be the first signal contact 1111a of the battery charging system 1
  • the first signal contact 131a of the mounting assembly 14 may be the second signal contact 131a of the battery charging system 1.
  • the second signal contact 1111b of the mounting configuration 112 may be the third signal contact 1111b of the battery charging system 1
  • the second signal contact 131b of the mounting assembly 14 may be the fourth signal contact 131b of the battery charging system 1.
  • the same may apply, of course, to the data contacts 132,1112.
  • some embodiments provide relatively fragile engagement of some of the contacts (particularly the signal 131,1111 and/or the data 132,1112 contacts).
  • This fragility is relative to the engagement of the charging contacts 13,111 and is such that if the battery 11 and the charging station 12 are moved into connection with each other (by engagement of the mounting configuration 112 and mounting assembly 14) then the charging contacts 13,111 will engage before the signal 131,1111 and/or data 132,1112 contacts engage each other.
  • the battery 11 and the charging station 12 are moved out of connection with each other (by disengagement of the mounting configuration 112 and mounting assembly 14) then the signal 131,1111 and/or data 132,1112 contacts disengage each other before the charging contacts 13,111 disengage each other.
  • the charging contacts 13,111 are the first to engage and the last to disengage typically.
  • the signal and/or data contacts 131,132,1111,1112 are the last to engage each other and the first to disengage each other. This helps to ensure that a charging current is not delivered to the battery 11 , and/or the battery 11 does not draw a charging current, from the charging station 12 (over the charging contacts 12) unless the battery 11 and charging station 12 are properly engaged. This also ensures that any charging does not occur until the battery 11 and charging station 12 are properly engaged, and ceases to occur before the battery 11 and charging station 12 are full disengaged. Some embodiments of the present invention are particularly useful in relation to applications which use relatively high electric currents and with which there are, therefore, safety concerns.
  • the mounting configuration 112 and mounting assembly 14 could be used in other applications - which may or may not include the charging of a battery 11. Therefore, in some embodiments, it charging contacts 111,13 could be power contacts 111,13, and the above described elements are to be construed accordingly - with the charge confirmation sub-system 114 and charge actuation sub-system 1231 being a power confirmation sub-system 114 and power actuation sub-system 1231 respectively. Of course, in such embodiments, the operation of these sub-systems 1231,114 may be altered so that correct operation is achieved (i.e.
  • the charge or power current which may be delivered through the charge/power contacts 13,111 may be greater than or equal to 10A, greater than or equal to 30A, or greater than or equal to 300A.
  • the voltage across the charge/power contacts 13,111 may be between 5V and 400V. In some embodiments, the current and/or voltage may be greater than these ranges - particular in relation to the charging of larger capacity batteries 11 as might be used in a vehicle, for example.
  • the roles of the data and signal contacts 1111,1112,131,132 are interchanged and/or mixed.
  • the data and/or signal contacts 1111,1112,131,132 may use any of the communication protocol disclosed herein (or others) to provide communication between the battery 11 and charging station 12. This communication may include information such as encryption keys, encrypted data, and/or the parameters discussed above.
  • the date and/or signal contacts 1111,1112,131,132 (and the associated parts of the battery charger 11 and charging station 12) may be configured to use an analog or a digital communication protocol in some embodiments.
  • the battery 11 and charging station 12 are locked together - in particular, the mounting configuration 112 and mounting assembly 14 are locked together - during charging of the battery 11.
  • This locking may be achieved by use of the electromagnet(s) 19 in embodiments including this feature.
  • a mechanical locking mechanism may be provided - such as in the form of a latch of the battery 11 or charging station 12 which is configured to engage a part of the other of the battery 11 or charging station 12.
  • Operation of the electromagnet(s) 19 or other locking mechanism may be controlled by one or both of the charging controller 115 of the battery 11 and/or the charging controller 123 of the charging station 12 - and may be based on one or more signals or other data transmitted through the data and/or signal contacts 1111,1112,131,132. So for example, at the end of a charging process, the battery 11 may be released by disengagement or deactivation of the locking mechanism and at the start (and during) a charging process the locking mechanism may be engaged or activated.
  • data may be sent via the data and/or signal contacts 1111,1112,131,132 to prevent or limit operation of a device or of equipment to which the battery 11 is attached or of which it forms a part during charging. This may occur even if there is no physical or electromagnetic locking of the battery 11 and charging station 12 together.
  • the power regulation sub-system 122 may be configured to impose a current limit on the current drawn from the charging station 12 by the battery 11. This may, for example, act to filter or reduce current spikes which may occur during operation.
  • the charging station 12 includes a discharge system which is configured to take electrical power from the battery 11 and do one or both of convert that electrical power to heat which is then exhausted (e.g. to the atmosphere) or to return that electrical power to the power supply (or use the power to charge another battery 11).
  • the charging station 12 may, therefore, operate in a first mode of operation (the charging mode) and a second mode of operation (the discharging mode). Actuation between the two modes may be controlled by a user interface of the charging station 12 and/or via data received at the charging station from another source (e.g. over the data and/or signal contactsl 111,1112,131,132.
  • the battery 11 may form part of another device or of other equipment and the description is to be construed accordingly.
  • the battery 11 is an auxiliary or secondary battery but this need not be the case.

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  • Engineering & Computer Science (AREA)
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  • Charge And Discharge Circuits For Batteries Or The Like (AREA)

Abstract

A battery charging system including a battery and a charging station, wherein: the battery includes a mounting configuration having a first charging contact, a second charging contact, and a first signal contact, and the charging station includes a mounting assembly having a third charging contact, a fourth charging contact, and a second signal contact, the mounting configuration and mounting assembly are configured to connect to each other such that: the first and third charging contacts engage in electrical communication; the second and fourth charging contacts engage in electrical communication; the first and second signal contacts engage in electrical communication, and wherein the engagement of the first and second signal contacts is more fragile than the engagement of the charging contacts, and the charging station is configured to deliver a charging current to the battery using the charging contacts when the charging contacts and signal contacts are engaged and not to deliver the charging current to the battery when the signal contacts are disengaged and the charging contacts are engaged.

Description

Title: A battery charging system and associated elements Description of Invention Embodiments of the present invention relate to a battery charging system, a mounting configuration and mounting assembly combination, a mounting configuration/member, battery, a charging station, a device, and a vehicle.
Many modern electronic devices include a battery to supply electricity to the device. The pace of development of such devices has been rapid and these devices often now provide a vast array of features and functions. With the increase in functionality, there has been a corresponding increase in the power requirements for modern electronic devices.
In other examples, there has been a recent drive to replace or supplement equipment previously powered by internal combustion engines with electrically powered equipment. So, for example, vehicles such as a cars, vans, trucks, lorries, boats, ships, and aircraft may now be provided with one or more batteries to power their movement (or to meet a more significant portion of their other power needs than would conventionally have been the case). The batteries in such devices and equipment are typically rechargeable and, in many instances, the batteries are integral to the device or equipment - so that recharging of the battery is required and replacement of a depleted battery with a fresh battery is not readily possible.
The batteries for such devices can often only meet the power demands of the devices for a very limited period before they are depleted - in some instances less than a day of normal use (in the case of a vehicle, the batteries are often depleted after a relatively short distance of travel).
Users need to recharge the batteries for their devices and equipment, and this is conventionally achieved using a mains electrical charging system. However, this is not necessarily convenient.
In the case of large capacity batteries (such as in the case of vehicles) this may be, in part, due to the length of time that recharging can take - often a number of hours (which does not compare well with the time required to refuel a vehicle powered by a conventional internal combustion engine, for example).
The length of time to charge a battery is also an issue for smaller capacity batteries as may be found in other devices such as mobile computing devices and telephones.
In other instances, a mains electrical charging system is not available - e.g. because the user and device are moving (e.g. travelling) or just not near a useable connection to the mains electrical system. As a result, auxiliary or secondary batteries have been developed. An auxiliary or secondary battery can be used to charge the battery of a device and/or to power the device. However, such auxiliary or secondary batteries also need to be charged. This is inconvenient and users often forget to charge the auxiliary or secondary batteries. This issue is exasperated by the length of time which auxiliary or secondary batteries require to charge - particularly, as they may be larger capacity than the battery of the device.
Charging times of batteries (be they auxiliary or secondary batteries or otherwise) are dependent on the speed at which energy can be delivered to the battery. As the voltage which can be applied to the battery for charging is normally limited, the charging time is normally dependent on the electric current which can be delivered to the battery. Very high current, however, increases the risk of injury.
Insecure fitting of a high current charger to a battery can cause arcing between contacts of the charger and/or battery - which can cause damage to the battery and/or charger. There is also a relatively high risk of injury to users if the battery and charger are not securely connected. Insecure connection could also mean a relatively high resistance between the charger and the battery which may cause overheating and/or may increase charge time.
Embodiments of the invention seek to alleviate one or more problems associated with the prior art.
Accordingly, an aspect of the invention provides a battery charging system including a battery and a charging station, wherein: the battery includes a mounting configuration having a first charging contact, a second charging contact, and a first signal contact, and the charging station includes a mounting assembly having a third charging contact, a fourth charging contact, and a second signal contact, the mounting configuration and mounting assembly are configured to connect to each other such that: the first and third charging contacts engage in electrical communication; the second and fourth charging contacts engage in electrical communication; the first and second signal contacts engage in electrical communication, and wherein: preferably the engagement of the first and second signal contacts is more fragile than the engagement of the charging contacts; and the charging station is configured to deliver a charging current to the battery using the charging contacts when the charging contacts and signal contacts are engaged and not to deliver the charging current to the battery when the signal contacts are disengaged and the charging contacts are engaged.
Accordingly, an aspect of the invention provides a battery charging system including a battery and a charging station, wherein: the battery includes a mounting configuration having a first charging contact, a second charging contact, and a first signal contact, and the charging station includes a mounting assembly having a third charging contact, a fourth charging contact, and a second signal contact, the mounting configuration and mounting assembly are configured to connect to each other such that: the first and third charging contacts engage in electrical communication; the second and fourth charging contacts engage in electrical communication; and the first and second signal contacts engage in electrical communication.
Preferably the engagement of the first and second signal contacts is more fragile than the engagement of the charging contacts.
Preferably the charging station is configured to deliver a charging current to the battery using the charging contacts when the charging contacts and signal contacts are engaged and not to deliver the charging current to the battery when the signal contacts are disengaged and the charging contacts are engaged.
By providing a fragile engagement of the signal contacts the signal contacts can become disengaged before the charging contacts become disengaged. The disengagement of the signal contacts can thus provide an advance indication of the charging contacts becoming disengaged. Hence once the signal contacts are disengaged (and while the charging contacts are engaged) power to the charging contacts can be interrupted, in advance of the charging contacts become disengaged and exposed. This can help prevent the occurrence of arcing at the charging contacts, which can cause damage and degradation of the contacts, and can also help protect a user from exposure to electrical power which could cause injury to the user.
Preferably the charging contacts are the first to engage each other and the last to disengage each other, and the signal contacts are the last to engage each other and the first to disengage each other. This can enable a fragile engagement of the signal contacts. Preferably during connection of the mounting configuration and mounting assembly, the power contacts engage before the signal contacts; and during disconnection of the mounting configuration and mounting assembly the signal contacts disengage before the power contacts. This can enable a fragile engagement of the signal contacts. The first and second power contacts may be moveable to a greater extent with respect to a surface of the mounting configuration than the first signal contact is moveable with respect to the surface of the mounting configuration. The third and fourth power contacts may be moveable to a greater extent with respect to a surface of the mounting assembly than the second signal contact is moveable with respect to the surface of the mounting assembly. This can enable the charging contacts to be the first to engage each other and the last to disengage each other, and the signal contacts to be the last to engage each other and the first to disengage each other.
The mounting configuration may include a third signal contact; the mounting assembly may include a fourth signal contact; and the mounting configuration and mounting assembly may be configured to connect to each other such that the third and fourth signal contacts may engage in electrical communication. One or more of the charging contacts may include at least a portion which is magnetic such that the first and third charging contacts may be attracted to each other and/or the second and fourth charging contacts may be attached to each other and/or the second and fourth charging contacts may be attracted to each other. Because the contacts are attracted to each other, good engagement of the contacts with each other can be promoted. Over time engagement surfaces of the contacts may be formed due to the magnetic attraction to fit closely against each other to provide good engagement over the whole contact area. Problems that may occur with fatigue of resilient biasing mechanisms to encourage engagement of contacts can be avoided. Resilient biasing mechanisms may be used in addition to the attraction by magnetic means. A magnetic portion is preferably integrated in a charging contact.
One or more of the signal contacts may include at least a portion which is magnetic such that at least the first and second signal contacts may be attracted to each other. One or more of the charging and signal contacts may include a portion made from a ferrous metal. As used herein a ferrous metal preferably connotes a ferromagnetic material. One or more of the charging and signal contacts may include a permanent magnet. One or more of the charging and signal contacts may include an electromagnet. The electromagnet may be powered in proportion to a power flowing through the charging contacts. This can enable an adaptive attractive force, with greater attraction occurring when greater power is transmitted and hence greater risk of damage if the contacts become exposed. One or more of the charging and signal contacts may include a permanent magnet and an electromagnet. A permanent magnet can provide an initial attraction for the contacts to assist in the contacts becoming engaged, and an electromagnet can provide a locking mechanism or at least a strong attraction to assist in the contacts maintaining engagement even if the battery charging system is jostled. This can protect a user against inadvertently disconnecting the contacts and can ensure that the power to the contacts is interrupted before the contacts can become disengaged. Preferably each charging contact includes a magnet or a magnetic portion. Preferably charging contacts only include a magnet or a magnetic portion. This can enable the charging contacts to be less fragile than the signal contacts.
One or more of the charging and signal contacts may include a contact tab or a cap of an electrically conductive material. For durability and low electrical resistivity the contact tab or cap may comprise copper. The contact tab or cap may comprise a coating for low electrical resistivity. Low electrical resistivity can reduce the generation of heat in the contacts. For low corrosion and low electrical resistivity the coating may be a nickel-gold coating. The contact tab or cap is preferably not a ferromagnetic material. The contact tab or cap may comprise a cavity for housing a magnetic part (or magnetic portion, optionally as aforementioned). The cavity is preferably arranged such that the magnetic part is housed beneath an engagement surface of the contact tab or cap intended to engage with another contact. The cavity is preferably arranged such that the magnetic part is housed opposite where another contact is intended to engage with the contact tab or cap. One or more of the charging contacts may include a floating ground contact. The first and second charging contacts may be carried by a base member of the mounting configuration and at least one of the first and second charging contacts may be configured to move between an extended and a retracted position with respect to the base member of the mounting configuration. Movement can enable a transition between a configuration where all contacts are engaged and a configuration where signal contacts are disengaged and charging contacts are engaged. Movement can enable that only once the charging contacts have moved from a retracted to an extended configuration and the signal contacts have become disengaged do the charging contacts become disengaged. This can help ensure that power to the charging contacts is interrupted in advance of the charging contacts become exposed. The contacts may be configured to move between 0.1 mm and 5 mm between an extended and a retracted position. The contacts may be configured to move between 0.5 mm and 2 mm between an extended and a retracted position. The contacts may be configured to move approximately 1 mm between an extended and a retracted position. This range of movement can provide sufficient time, for example approximately 0.5 seconds, during disconnection to interrupt power to the charging contacts in advance of exposure of the charging contacts becoming a danger. The contacts may be configured to move axially.
The mounting configuration may further include a resilient biasing arrangement which is configured to bias the at least one charging contact towards the extended position.
The third and fourth charging contacts may be carried by a base member of the mounting assembly and at least one of the first and second charging contacts may be configured to move between an extended and a retracted position with respect to the base member of the mounting assembly.
The mounting assembly may further include a resilient biasing arrangement which is configured to bias the at least one charging contact towards the extended position.
The first signal contact may be carried by a base member of the mounting configuration and may be configured to move between an extended and a retracted position with respect to the base member of the mounting configuration.
The mounting configuration may further include a resilient biasing arrangement which is configured to bias the first signal contact towards the extended position.
The second signal contact may be carried by a base member of the mounting assembly and may be configured to move between an extended and a retracted position with respect to the base member of the mounting assembly. The mounting assembly may further include a resilient biasing arrangement which is configured to bias the second signal contact towards the extended position. The first signal contact may be configured to extend from a surface of the mounting configuration by a shorter distance than the first and second charging contacts may extend from the surface of the mounting configuration. The second signal contact may be configured to extend from a surface of the mounting assembly by a shorter distance than the third and fourth charging contacts extend from the surface of the mounting assembly. This can enable the charging contacts to be the first to engage each other and the last to disengage each other, and the signal contacts to be the last to engage each other and the first to disengage each other.
The first and second power contacts may be moveable to a greater extent with respect to a surface of the mounting configuration than the first signal contact is moveable with respect to the surface of the mounting configuration. The third and fourth power contacts may be moveable to a greater extent with respect to a surface of the mounting assembly than the second signal contact is moveable with respect to the surface of the mounting assembly. This can enable the charging contacts to be the first to engage each other and the last to disengage each other, and the signal contacts to be the last to engage each other and the first to disengage each other.
One or more of the signal and charging contacts may include a cap of an electrically conductive material. One or more of the signal and charging contacts may include an insulation sleeve which surrounds at least a portion of the or each contact.
The mounting configuration and/or mounting assembly may include an electromagnet configured to attract at least a portion of the other of the mounting configuration and mounting assembly.
The electromagnet may be associated with one or more of the charging contacts.
One or more of the charging and signal contacts may be tiltable. At least one of the mounting configuration and mounting assembly may include a magnet located adjacent one or more of the contacts thereof.
The battery may further include a charge confirmation sub-system and the charging station may further include a charge actuation sub-system, and the charge confirmation sub-system and charge actuation sub-system may be configured to communicate using the or each signal contact to confirm that the mounting configuration and mounting assembly are connected such that the respective signal contacts engage each other in electrical communication.
According to another aspect there is provided a battery charging system including a battery, optionally as aforementioned, and a charging station, optionally as aforementioned, wherein the battery includes a charge confirmation sub-system and the charging station includes a charge actuation sub-system, and the charge confirmation sub-system and charge actuation sub-system are configured to communicate using signal contacts arranged to engage each other in electrical communication to confirm that the battery and the charging station are connected.
Preferably the communication comprises transmission of data from the battery to the charging station and/or from the charging station to the battery.
Preferably the data comprises one or more of:
an identifier for the battery, an identifier for the charging station, a charging parameter for the battery, and identification of a suitable charging profile for use with the battery, an indication of a number of charge cycles the battery has undertaken, an update of a number of charge cycles the battery has undertaken, information regarding one or more historic charging cycles, a historic voltage level reached, a historic length of a time on charge, a maximum charging current of the charging station, a temperature of the battery, a temperature of the charging station, a measurement of the internal impedance of the battery cells, and a measurement of the internal resistance of the battery cells. The data can be used, for example, to indicate the health of the battery cells.
Another aspect provides a mounting configuration and mounting assembly combination, the mounting configuration including: a first power contact, a second power contact, and a first signal contact, the mounting assembly including: a third power contact, a fourth power contact, and a second signal contact, wherein the mounting configuration and mounting assembly are configured to connect to each other such that: the first and third power contacts engage in electrical communication; the second and fourth power contacts engage in electrical communication; the first and second signal contacts engage in electrical communication, and wherein: preferably the engagement of the first and second signal contacts is more fragile than the engagement of the power contacts; and during connection of the mounting configuration and mounting assembly, the power contacts engage before the signal contacts, and during disconnection of the mounting configuration and mounting assembly the signal contacts disengage before the power contacts. Optionally one or more of the signal and power contacts (also referred to as charging contacts) is as aforementioned. Optionally the mounting configuration and/or the mounting assembly is as aforementioned.
The first and second power contacts and the first signal contact may be carried by a base member of the mounting configuration.
The third and fourth power contacts and the second signal contact may be carried by a base member of the mounting assembly. One or more of the contacts may be moveable with respect to the base member which carries the or each contact. One or more of the contacts may be axially moveable with respect to the base member which carries the or each contact. The or each contact may be tiltable. At least one of the power contacts may be moveable, at least one of the signal contacts may be moveable, and the at least one power contact may be moveable to a greater extent than the at least one signal contact.
The first and second power contacts may extend a greater distance from a surface of the mounting configuration than the first signal contact.
The third and fourth power contacts may extend a greater distance from a surface of the mounting assembly than the second signal contact.
One or more of the contacts may be magnetic.
Another aspect provides a mounting configuration/member including: a base member, a plurality of power contacts carried by the base member, a first signal contact carried by the base member, wherein the first signal contact and power contacts are configured such that: the power contacts extend a greater distance from a surface of the mounting configuration/member than the signal contact; and/or the power contacts are moveable to a greater extent with respect to the base member than the signal contact is moveable with respect to the base member. Power contacts are also referred to herein as charging contacts.
One or more of the contacts may be magnetic. One or more of the contacts may include a permanent magnet. One or more of the contacts may include an electromagnet. The electromagnet may be adapted to be powered in proportion to a power flowing through the power contacts.
The mounting configuration/member may further include a resilient biasing arrangement configured to bias one or more of the power contacts into an extended position.
One or more of the contacts may include a contact tab.
One or more of the contacts may include a cap of an electrically conductive material.
The power contacts may extend between 0.1 mm and 5 mm more from a surface of the mounting configuration/member than the signal contact. The power contacts may extend between 0.5 mm and 2 mm more from a surface of the mounting configuration/member than the signal contact. The power contacts may extend approximately 1 mm more from a surface of the mounting configuration/member than the signal contact.
The power contacts may be moveable between 0.1 mm and 5 mm more than the signal contact with respect to the base member. The power contacts may be moveable between 0.5 mm and 2 mm more than the signal contact with respect to the base member. The power contacts may be moveable approximately 1 mm more than the signal contact with respect to the base member. This range of movement can provide sufficient time, for example approximately 0.5 seconds, during disconnection to interrupt power to the charging contacts in advance of exposure of the charging contacts becoming a danger. Optionally one or more of the signal and power (or charging) contacts are as aforementioned. Optionally the mounting configuration and/or the mounting assembly is as aforementioned.
Another aspect provides a mounting configuration/member including: a base member, a plurality of power contacts (also referred to herein as charging contacts) carried by the base member, optionally a first signal contact carried by the base member, wherein one or more of the contacts is magnetic. The mounting configuration/member may optionally be as aforementioned.
Another aspect provides a battery including a mounting configuration/member. Optionally the mounting configuration/member is a mounting configuration and/or a mounting assembly and/or a mounting configuration/member as aforementioned.
Another aspect provides a charging station including a mounting configuration/member. Optionally the mounting configuration/member is a mounting configuration and/or a mounting assembly and/or a mounting configuration/member as aforementioned.
Another aspect provides a device including a mounting configuration/member. Optionally the mounting configuration/member is a mounting configuration and/or a mounting assembly and/or a mounting configuration/member as aforementioned. Another aspect provides a vehicle or item of furniture including a mounting configuration/member. Optionally the mounting configuration/member is a mounting configuration and/or a mounting assembly and/or a mounting configuration/member as aforementioned. According to another aspect there is provided a battery charging system including a battery and a charging station, wherein: the battery includes a mounting configuration having a first charging contact, a second charging contact, and a first signal contact, and the charging station includes a mounting assembly having a third charging contact, a fourth charging contact, and a second signal contact, the mounting configuration and mounting assembly are configured to connect to each other such that: the first and third charging contacts engage in electrical communication; the second and fourth charging contacts engage in electrical communication; the first and second signal contacts engage in electrical communication, and wherein the charging contacts are the first to engage each other and the last to disengage each other, and the signal contacts are the last to engage each other and the first to disengage each other, and the charging station is configured to deliver a charging current to the battery using the charging contacts when the charging contacts and signal contacts are engaged and not to deliver the charging current to the battery when the signal contacts are disengaged and the charging contacts are engaged. According to another aspect there is provided a battery charging system including a battery and a charging station, wherein: the battery includes a mounting configuration having a first charging contact and a second charging contact, and the charging station includes a mounting assembly having a third charging contact and a fourth charging contact, the mounting configuration and mounting assembly are configured to connect to each other such that: the first and third charging contacts engage in electrical communication; the second and fourth charging contacts engage in electrical communication, and wherein one or more of the charging contacts includes at least a portion which is magnetic such that the first and third charging contacts are attracted to each other and/or the second and fourth charging contacts are attracted to each other, and the charging station is configured to deliver a charging current to the battery using the charging contacts.
The invention extends to a battery charging system substantially as herein described and/or as illustrated with reference to the figures. The invention also extends to a method of charging a battery substantially as herein described and/or as illustrated with reference to the figures.
The invention also provides a computer program and a computer program product for carrying out any of the methods described herein and/or for embodying any of the apparatus features described herein, and a computer readable medium having stored thereon a program for carrying out any of the methods described herein and/or for embodying any of the apparatus features described herein.
The invention also provides a signal embodying a computer program for carrying out any of the methods described herein and/or for embodying any of the apparatus features described herein, a method of transmitting such a signal, and a computer product having an operating system which supports a computer program for carrying out any of the methods described herein and/or for embodying any of the apparatus features described herein.
Any apparatus feature as described herein may also be provided as a method feature, and vice versa. As used herein, means plus function features may be expressed alternatively in terms of their corresponding structure, such as a suitably programmed processor and associated memory.
Any feature in one aspect of the invention may be applied to other aspects of the invention, in any appropriate combination. In particular, method aspects may be applied to apparatus aspects, and vice versa. Furthermore, any, some and/or all features in one aspect can be applied to any, some and/or all features in any other aspect, in any appropriate combination.
It should also be appreciated that particular combinations of the various features described and defined in any aspects of the invention can be implemented and/or supplied and/or used independently. Furthermore, features implemented in hardware may generally be implemented in software, and vice versa. Any reference to software and hardware features herein should be construed accordingly.
Embodiments of the present invention are described with reference to the accompanying drawing, in which:
Figure 1 shows a perspective view of an embodiment;
Figure 2 shows a cross-sectional view, in perspective, of the embodiment of figure 2;
Figure 3 shows a cross-sectional view of the embodiment of figures 1 and 2;
Figure 4 shows an exploded view of the embodiment of figure 1 ;
Figure 5 shows a side view of an embodiment;
Figure 6 shows a perspective view of an embodiment;
Figure 7 shows a cross-sectional view of an embodiment;
Figure 8 shows a side view of the embodiment of figure 7;
Figure 9 shows an exploded view of the embodiment of figure 7;
Figure 10 shows a side view of an embodiment;
Figure 11 shows a top perspective view of the embodiment of figure 10;
Figure 12 shows a perspective view of part of the embodiment of figure 10;
Figure 13 shows a perspective view of part of an embodiment;
Figure 14 shows a cross-sectional view of an embodiment;
Figure 15 shows a contact of some embodiments;
Figure 16 shows a contact of some embodiments;
Figure 17 shows a cross-sectional view of an embodiment;
Figure 18 shows two contacts close to each other according to an embodiment;
Figure 19 shows the two contacts of figure 18 engaging each other;
Figure 20 shows the two contacts of figure 18 close to each other with one contact tilted with respect to the other;
Figure 21 shows the two contacts of figure 20 engaged;
Figure 22 shows an example schematic view of some embodiments;
Figures 23 to 26 show different views of an embodiment with the contacts engaged and disengaged variously;
Figure 27 shows an embodiment with contacts engaged;
Figures 28 to 30 show the process of engaging embodiments;
Figures 31 and 32 show two views of an embodiment including data contacts, with the contacts in different states of engagement;
Figure 33 shows an example schematic view of some embodiments; and
Figure 34 shows a system of embodiments.
Embodiments of the present invention may include a battery charging system 1 (see figure 34). The battery charging system 1 includes a battery 11 and a charging station 12. The battery 11 is configured to be mounted to the charging station 12 to deliver electrical power from the charging station 12 to the battery 11. The charging station 12 may comprise an electrical power input 121 which is, in some embodiments, configured to be coupled to a mains electrical supply - see figure 34, for example. The electrical power input 121 could be in the form of a socket configured to mate with a corresponding plug which may, in turn, be connected to the mains electrical supply. In some embodiments, the electrical power input 121 includes a cable and a plug configured to be connected to a mains electrical supply outlet (e.g. a conventional mains electrical supply outlet of a two- or three-pin design). The mains electrical supply may include one or more phases of a multi-phase supply and, in the case of a three phase supply, could include all three phases - with the electrical power input 121 configured to receive the one or more phases of the supply. In some embodiments, the mains electrical supply is, in fact, a DC electrical supply rather than an AC electrical supply (and, similarly, the electrical power input 121 may be configured to receive AC or DC electrical power, as the case may be). It will also be appreciated that the references herein to a mains power supply are not limitations to a power supply forming part of a national power grid, for example. Instead, the mains power supply could be a reference to power supplied from another source (including another battery or other form of power storage system).
The electrical power input 121 may be coupled in electrical connection with a power regulation sub-system 122. The power regulation sub-system 122 may be configured to convert the electrical power received through the electrical power input 121 into a desired form for delivery to the battery 11. Accordingly, the electrical power input 121 may include one or more of a transformer, a rectifier, a voltage regulator, a current regulator, DC-DC power converter, and the like.
In some embodiments, the power regulation sub-system 122 may be configured to receive an AC electrical power input from a mains power supply (e.g. a 230V or 120V supply) and to convert that input power into a DC electrical power output for use in charging the battery 11. As will be understood, in some embodiments, the electrical power input 121 may be configured to receive a supply which has a higher voltage than indicated above (but may be less than or equal to around 33kV).
The power regulation sub-system 122 may be coupled in electrical communication with a charging controller 123 which may be configured to control the electrical power delivered to the battery 11 in accordance with one or more predetermined charging profiles (e.g. varying the electric current and/or voltage over time). The charging profile may be selected for the battery 11 to achieve a fast charge time, and/or to ensure the battery 11 is charged more than a predetermined amount, and/or to maximise the number of charge/discharge cycles the battery 11 can undertake.
In some embodiments, the charging controller 123 includes a charge actuation sub-system 1231. The charging controller 123 is coupled in electrical communication with at least two charging contacts 13 of the charging station 12. Each charging contact 13 of the charging station 12 is configured to connect in electrical communication with a respective charging contact 111 of the battery 11. The charge actuation sub-system 1231 is configured for use in controlling whether or not electrical power is delivered to the at least two electrical contacts 13 of the charging station 12. In some embodiments, the charging controller 123 includes a control unit 1232 which is configured to control the operation of the charge actuation sub-system 1231. Accordingly, the charging station 12 is configured to receive electrical power and to deliver that electrical power (or a portion thereof) to the battery 11, whilst regulating and controlling the power so that it is in an appropriate form for charging the battery 11.
The charging station 12 may include a charging station housing 124 which may house one or more of the electrical power input 121, the power regulation sub-system 122, and the charging controller 121 (including the charge actuation sub-system 1231 and control unit 1232). In some embodiments, the electrical power input 121 includes a cable (see above) which may extend from the charging station housing 124. In some embodiments, the charging station 12 is part of a larger item such as an item of furniture (e.g. a cupboard or desk) or a vehicle. In some embodiments, the battery 11 is part of a larger item such as an item of furniture or a vehicle.
In some embodiments, the charging station 12 is a charging station for equipment such as a vehicle (e.g. a car, a truck, a lorry, a van, a boat, a ship, or an aircraft).
The charging station 12 includes a mounting assembly 14 and the charging contacts 13 of the charging station 12 may be a part of that mounting assembly 14. The mounting assembly 14 is configured to engage (i.e. connect to), selectively, a mounting configuration 112 of the battery 11 such that the respective charging contacts 13,111 of the charging station 12 and the battery 11 are in electrical communication when the mounting assembly 14 and mounting configuration 112 are engaged. For the avoidance of doubt, the charging contacts 111 of the battery 11 may be part of the mounting configuration 112. In some embodiments, the mounting assembly 14 of the charging station 12 is secured to a wand which is moveable with respect to the charging station housing 124. The wand may include its own housing and may be coupled to the charging station housing 124 via a cable (through which electrical power may be transmitted). Such arrangements may be particularly useful in embodiments in which the battery 11 cannot easily be manoeuvred such that the mounting assembly 14 and mounting configuration 112 engage - e.g. because the battery 11 is large or is part of a larger object (such as a vehicle - see above). The wand may be configured for manual movement (e.g. may be configured to be grasped by a user and moved). In other embodiments, the battery 11 (e.g. as part of a vehicle) may be manoeuvred with respect to the charging station 12 and then the mounting assembly 14 and mounting configuration 112 engaged by automated movement of either or both of the mounting configuration 112 and mounting assembly 14 - in other words, the vehicle may be moved to a charging pad or location to allow for automated engagement as described above. The battery 11 includes the mounting configuration 112 along with one or more rechargeable battery cells 113. In embodiments in which there is a plurality of such rechargeable battery cells 113, they may be connected in a variety of different configurations: such as in parallel, in series, or a combination of series and parallel configurations. In some embodiments, the mounting configuration 112 is part of another device or piece of equipment (e.g. a vehicle) but is coupled to the battery 11).
The or each battery cell 113 is configured to store electrical power for delivery to a device 100 - such as a mobile (e.g. cellular) telephone, a tablet, a smart watch, a laptop, or some other form of device (including other forms of mobile device and mobile computing device). In some embodiments, the device 100 is part of another item - such as an item of furniture or a vehicle. In some embodiments the device 100 may be equipment such as a vehicle, a portable power supply, uninterruptable power supply system, or industrial equipment.
The or each battery cell 113 is further configured to be recharged with electrical power delivered to the battery 11 by the charging station 12 (when the battery 11 is mounted to the charging station 12 with the mounting configuration 112 and mounting assembly 14 engaged (i.e. connected)). As will be appreciated, the electrical power to recharge the battery 11 is provided via the charging contacts 13 of the charging station 12 and the charging contacts 111 of the battery 11.
The battery 11 may include, in some embodiments, a charging controller 115 which may be provided in addition to or instead of the charging controller 123 of the charging station 12. The charging controller 115 of the battery 11 may be configured to control an aspect of the charging of the battery 11 (i.e. of the or each battery cell 113). Accordingly, the charging controller 115 may be configured to receive electrical power from the charging station 12 (e.g. via the charging contacts 13 of the charging station and the charging contacts 111 of the battery 11) and to control the delivery of all or part of that electrical power to the or each battery cell 113 of the battery 11.
The battery 11 may, in some embodiments, further include a charge confirmation sub-system 114. The charge confirmation sub-system 114 is configured to communicate with the charging station 12 to confirm whether or not charging of the battery 11 should take place (e.g. whether electrical power should be delivered from the charging station 12 to the battery 11). In some embodiments, the charge confirmation sub-system 114 is configured to communicate with the charge actuation sub-system 1231 of the charging station 12 for this purpose. Likewise, the charge actuation subsystem 1231 may be configured to communicate with the battery 11 (and, in some embodiments, the charge confirmation sub-system 114). The battery 11 may include a battery housing 116 which houses the or each component of the battery 11 which may include one or more of the or each battery cell 113, the mounting configuration 112 (which may include the charging contacts 111 of the battery 11), the charge confirmation sub-system 114, and the charging controller 115.
As discussed above, the battery 11 and the charging station 12 engage each other (i.e. connect) using the mounting configuration 112 and mounting assembly 14, which may take a number of different forms.
The mounting configuration 112 and mounting assembly 14 may include the charging contacts 111,13 as discussed above. In some embodiments, the mounting configuration 112 and mounting assembly 14 each further include at least one respective signal contact 131,1111, such that when the mounting configuration 112 and the mounting system 14 are engaged, the or each signal contact 131 of the mounting assembly 14 is in electrical communication with a respective one of the or each signal contact 1111 of the mounting configuration 112. In some embodiments, the mounting configuration 112 and mounting system 14 each further include at least one respective data contact 132,1112, such that when the mounting configuration 112 and the mounting system 14 are engaged, the or each data contact 132 of the mounting system 14 is in electrical communication with a respective one of the or each data contact 1112 of the mounting configuration 112.
The signal and/or data contacts 131,132,1111,1112 may be used for communication between the battery 11 and the charging station 12, as described herein. Accordingly, therefore, in some embodiments the signal and/or data contacts 1111,1112 of the battery 11 may be in electrical communication with the charge confirmation sub-system 114 and/or the charging controller 115 of the battery 11. In some embodiments the signal and/or data contacts 131,132 of the charging station 12 may be in electrical communication with the charge actuation sub-system 1231 and/or the charging controller 123 of the charging station 12.
In some embodiments, one or more of the charging contacts 111,13, the signal contacts 1111,131, and the data contacts 1112,132 is magnetic and is configured to attract the corresponding contact 111,13,1111,131,1112,132 of the battery 11 or charging station 12 as the case may be.
In some embodiments, the charging contacts 111 of the battery 11 include a first charging contact 111a and a second charging contact 111b. The first charging contact 111a may be connected for electrical communication with a first terminal of one or more of the or each battery cell 113. The second charging contact 111b may be connected for electrical communication with a second terminal of one or more of the or each battery cell 113. The first and second charging contacts 11 la,l 1 lb of the battery 11 may be configured to engage respective first and second charging contacts 13a,13b of the charging station 12 when the mounting assembly 14 and mounting configuration 112 are engaged. Accordingly, in some embodiments, the first charging contact 111a of the battery 11 may be a first magnetic polarisation (e.g. North or South) and the first charging contact 13a of the charging station 12 may be a second magnetic polarisation (e.g. North or South) which is opposite to the first magnetic polarisation - such that the two first charging contacts 11 la, 13a are attracted to each other.
Similarly, in some embodiments, the second charging contact 111b of the battery 11 may be the second magnetic polarisation (e.g. North or South) and the second charging contact 13b of the charging station 12 may be the first magnetic polarisation (e.g. North or South) - such that the two second charging contacts 11 lb, 13b are attracted to each other.
As will be appreciated, if the first and second charging contacts 111 of the battery 11 are opposing magnetic polarisations, then the second charging contact 11 lb of the battery 11 will be repelled by the first charging contact 13a of the charging station 12 (and the same will be true of the first charging contacts 111a of the battery 11 and the second charging contact 13b of the charging station 12). This repulsion may be a sufficient force to resist or substantially prevent mounting of the battery 11 to the charging station 12 (and, in particular, the mounting configuration 112 to the mounting assembly 14) when the charging contacts 111,13 are incorrectly oriented with respect to each other. In some embodiments, mounting of the battery 11 to the charging station 12 is not prevented by the repulsive force but the charging contacts 111,13 of the battery 11 and charging station 12 are sufficiently repulsed to prevent substantial contact of the charging contacts 111,13. The use of different magnetic polarisations of the charging contacts 111 of the battery 11 (and the corresponding use of different magnetic polarisations of the charging contacts 13 of the charging station 12) helps to provide a mechanism to ensure that the battery 11 is mounted to the charging station 12 in the correct orientation.
The signal contacts 131,1111 of the charging station 12 and battery 11 may similarly magnetic such that a first signal contact 131a of the charging station 12 may be an opposite magnetic polarisation to a first signal contact 1111a of the battery 11 (with the same potential effects discussed above regarding repulsion in relation to the charging contacts 13,111). This may be in addition to or instead of the magnetic arrangement of the charging contacts 13,111 discussed above. Second signal contacts 131b,l 11 lb of the battery 11 and charging station 12 may also be magnetic in the same manner; however, the second signal contact 131b of the charging station 12 may be of an opposite polarisation to the first signal contact 131a of the charging station 12 (making a second signal contact 111 lb of the battery 11 an opposite polarisation to the first signal contact 111 la of the battery 11).
Similarly, the data contacts 132,1112 of the charging station 12 and battery 11 may be similarly magnetic such that a first data contact 132a of the charging station 12 may an opposite magnetic polarisation to a first data contact 1112a of the battery 11. This may be in addition to or instead of the magnetic arrangement of the charging contacts 13,111 and/or the signal contacts 131,1111 discussed above. Second data contacts 132b,1112b may also be magnetic in a similar manner; however, the second data contact 132b of the charging station 12 may be of an opposite polarisation to the first data contact 132b of the charging station 12 (making a second data contact 1112b of the battery 11 and opposite polarisation to the first data contact 1112a of the battery 11). The same effects regarding potential repulsion of contacts may be achieved as discussed above in relation to the charging contacts 13,111.
Accordingly, as will be appreciated, the battery 11 may include a plurality of contacts at least some of which are magnetic. The charging station 12 may include a corresponding plurality of contacts which are configured to engage respective contacts of the battery 11 in electrical communication therewith. Accordingly, the plurality of contacts of the battery 11 and charging station 12 may have magnetic polarisations which cause attraction of the contacts which are configured to engage each other but contacts which are not configured to engage each other may repel each other. One or more of the or each of the contact 13,131,132 of the charging station 12 may be mounted such that it is (or they are) moveable between an extended and a retracted position (e.g. by movement of the along a longitudinal axis of the contact 13,131,132) with respect to the charging station 12 (and, in particular, part of the mounting assembly 14, such as a surface thereof, in some embodiments). In other words, one or more of the or each of the contact 13,131,132 of the charging station 12 may be mounted such that it is (or they are) axially moveable between the extended and retracted positions.
One or more of the or each contact 13,131,132 of the charging station 12 may be mounted such that it is (or they are) rotatable about at least one axis which is perpendicular to the longitudinal axis of the contact 13,131,132. In other words, one or more of the or each contacts 13,131,132 may be tiltable with respect to the charging station 12 (and, in particular, part of the mounting system 14 in some embodiments). This may be in addition to or instead of movement between the extended and retracted positions. One or more of the or each contact 111,1111,1112 of the battery 11 may be similarly mounted such that it is (or they are) moveable between an extended and a retracted position (e.g. by movement of the along a longitudinal axis of the contact 111,1111,1112) with respect to the battery 11 (and, in particular, part of the mounting configuration 112, such as a surface thereof, in some embodiments). In other words, one or more of the or each contact 111,1111,1112 of the battery 11 may be axially moveable between the extended and retracted positions.
One or more of the or each contact 111,1111,1112 of the battery 11 may be mounted such that it is (or they are) rotatable about at least one axis which is perpendicular to the longitudinal axis of the contact 111,1111,11112. In other words, the of each contact 13,131,132 may be tiltable with respect to the battery 11 (and, in particular, part of the mounting configuration 112 in some embodiments) between a first tilt position and at least one second tilt position. Again, this may be in addition to or instead of movement between the extended and retracted positions. In embodiments in which one or more contacts 13,131,132,111,1111,1112 of the battery 11 or charging station 12 are axially moveable, the or each contact 13,131,132,111,1111,1112 may be biased towards the extended or retracted position by respective resilient biasing arrangements 133,1113 of the battery 11 and charging station 12 (the resilient biasing arrangements 133,1113 may be part of the mounting configuration 112 and the mounting assembly 14). Resilient biasing may not be provided in relation to all such contacts 13,131,132,111,1111,1112 and may only be provided in relation to the charge contacts 13,111, for example. In embodiments in which one or more contacts 13,131,132,111,1111,1112 of the battery 11 or charging station 12 are tiltable, the or each contact 13,131,132,111,1111,1112 may be biased towards the first tilt position by respective resilient biasing arrangements 133,1113 of the battery 11 and charging station 12 (the resilient biasing arrangements 133,1113 may be part of the mounting configuration 112 and the mounting assembly 14). The resilient biasing arrangements 133,1113 which bias the or each contact 13,131,132,111,1111,1112 towards the first tilt position may be the same resilient biasing arrangements 133,1113 which bias the or each contact 13,131,132,111,1111,1112 towards the extended or retracted position, in some embodiments.
The amount of possible extension and retraction and/or tilt of the or each such contact 13,131,132,111,1111,1112 of the charging station 12 and/or the battery 11 may be limited and these limits may be different for different ones of the contacts 13,131,132,111,1111,1112.
In embodiments in which one or more contacts 13,131,132,111,1111,1112 of the battery 11 or charging station 12 are tiltable and/or extendable, the or each contact 13,131,132,111,1111,1112 may have an end which is located within a fluid - which may be viscous liquid. This fluid may be housed within the mounting configuration 112 and/or the mounting assembly 14 as the case may be. The fluid may, in some embodiments, act to slow a tilting or extension/retraction movement of the associated contact 13,131,132,111,1111,1112 with respect to the mounting configuration 112 and/or the mounting assembly 14 as the case may be.
Such a fluid may also be provided in embodiments in which there is no tilting and/or extension of one or more of the contacts 13,131,132,111,1111,1112.
In some embodiments, therefore, the fluid may alternatively or additionally provide a mechanism to carry heat away from the or each contact 13,131,132,111,1111,1112. This may be especially important in relation to the charging contacts 111,13 - due to the potentially high electrical currents passing therethrough. The charging station 12 and/or battery 11 may, therefore, be provided with a heat transfer system which is configured to provide a heat pipe (i.e. a thermal conduction path) from one or more of the or each contacts 13,131,132,111,1111,1112 to a different location (at which the heat may be exhausted). This heat pipe may include a channel including a static thermally conductive material (which may include the fluid, which may be a viscous liquid (see above)), or may include a channel through which a thermally conductive material may travel (e.g. through which the fluid may travel). This path may be in a circuit and may include a heat exchanger which is configured to exhaust the heat from the thermally conductive material to the atmosphere, for example. The fluid may be a dielectric fluid.
In some embodiments, the fluid may be or form part of the resilient biasing arrangements 133,1113. In some embodiments, the ability of one or more of the contacts 13,131,132,111,1111,1112 of the charging station 12 and/or the battery 11 to extend or retract and/or tilt ensures a better connection between the contacts 13,131,132,111,1111,1112 and may help to guide the contacts 13,131,132,111,1111,1112 into engagement. In some embodiments, the differing limits of movement between contacts 13,131,132,111,1111,1112 means that the engagement of some contacts with their corresponding contacts 13,131,132,111,1111,1112 is more fragile than the engagement of other contacts 13,131,132,111,1111,1112 with their corresponding contacts 13,131,132,111,1111,1112. This can be used, as will become apparent, to provide safety mechanisms such that a disconnection (i.e. disengagement) of some of the contacts 131,132,1111,1112 is determined before the charging contacts 13,111 are disconnected (i.e. disengaged) from each other (allowing pre -disengagement safety steps to be taken).
In some embodiments, the length of at least one of the contacts 13,131,132 of the charging station 12 may be different to the length of another of the contacts 13,131,132 of the charging station 12. In some embodiments, the charging contacts 13 of the charging station 12 are longer than the signal and/or data contacts 131,132 of the charging station 12. In some embodiments, at least one of the contacts 13,131,132 of the charging station 12 extends to a greater height with respect to a part (e.g. a surface of a base member 141) of the mounting assembly 14 compared to another of the contacts 13,131,132 of the charging station 12 with respect to the part of the mounting assembly 14 - the charging contacts 13 of the charging station 12 may be the contacts which extend higher than the signal and/or data contacts 131,132. These arrangements may also or additionally provide a more fragile engagement of some contacts 13,111,131,1111,132,1112 than others.
In some embodiments, the length of at least one of the contacts 111,1111,1112 of the battery 11 may be different to the length of another of the contacts 111,1111,1112 of the battery 11. In some embodiments, the charging contacts 111 of the battery 11 are longer than the signal and/or data contacts 1111,1112 of the battery 11. In some embodiments, at least one of the contacts 111,1111,1112 of the battery 11 extends to a greater height with respect to a part (e.g. a surface of a base member 1121) of the mounting configuration 112 compared to another of the contacts 111,1111,1112 of the battery 11 with respect to the part of the mounting configuration 112 - the charging contacts 111 of the battery 11 may be the contacts which extend higher than the signal and/or data contacts 1111,1112. These arrangements may also or additionally provide a more fragile engagement of some contacts 13,111,131,1111,132,1112 than others. With reference to figures 1-33, the mounting assembly 14 may include the base member 141 and the base member 141 may carry a plurality of charge contacts 13 (a first charge contact 13a and a second charge contact 13b) of the charging station 12 and at least one signal contact 131. The base member 141 is generally rectangular in shape in this depicted embodiment but could be a different shape (e.g. circular, square, etc.). In this and some other embodiments, the base member 141 carries two signal contacts 131a,131b.
The charge contacts 13 and signal contacts 131 carried by the base member 141 extend in a first direction from the base member 141. In some embodiments, longitudinal axes of the charge and signal contacts 13,131 carried by the base member 141 are substantially parallel to each other. The charge and signal contacts 13,131 carried by the base member 141 may form an array of contacts 13,131 (such as a linear array but in some other embodiments, the contacts 13,131 carried by the base member 141 may form a different pattern).
In this and some other embodiments, the charge and signal contacts 13,131 carried by the base member 141 may have a substantially circular cross-section. In some other embodiments, however, the charge and signal contacts 13,131 may be other cross-sectional shapes such as square, rectangular, triangular, hexagonal, pentagonal, or the like. In some embodiments, one or more of the contacts 13,111,131,1111,132,1112 are spherical in shape. In some embodiments, the charge and signal contacts 13,131 need not be the same cross-sectional shape - e.g. the charge contacts 13 may be a different cross-sectional shape to the signal contacts 131 and/or one charge contact 13 may be a different cross-sectional shape to another charge contact 13 and/or one signal contact 131 may be a different cross-sectional shape 131 to another signal contact 131.
As will be appreciated, the or each charge 13 and signal contact 131 has a respective engagement surface which is configured to engage a corresponding engagement surface of a corresponding contact 111,1111 of the battery 11 (and, specifically, of the mounting configuration 112).
In this and some other embodiments, the size of the surface area of the engagement surface of each charging contacts 13 of the charging station 12 is greater than the surface area of the engagement surfaces of each of the signal contact 131 of the charging station 12.
In this and some embodiments, the signal contacts 131 may be located between the charge contacts 13. In other words, the charge contacts 13 may be located generally towards opposing parts of the mounting assembly 14 and, in particular, the base member 141 - this may reduce the risk of short circuits and/or arcing between the charge contacts 13. In general, the pattern of contacts 13,131,132 of the charge station 12 is referred to as a charge station contact pattern. This pattern includes the position of the contacts 13,131,132 with respect to the rest of the mounting assembly 14 and may also include the size and/or shape of the engagement surfaces of these contacts 13,131,132.
As can be seen, for example in figure 1, each contact 13,131 of the charge station 12 may be associated with a conductor 15 (e.g. a wire or cable) such that each contact is 13,131 is in electrical communication with at least one such conductor 15. In some embodiments, each contact 13,131 of the charging station 12 is associated with a respective distinct conductor 15 but in other embodiments, a plurality of contacts 13,131 may be associated with a single conductor 15.
As can be seen from figure 2, in this and some other embodiments, one or more of the contacts 13,131 may have a first portion 13c, 131c which is located within the base member 141 of the mounting assembly 14. A second portion 13d, 13 Id of each of these one or more contacts 13,131 may extend through a respective aperture defined by the base member 141, such that an end surface of the second portion 13d, 13 Id forms the engagement surface of that contact 13,131.
The first portion 13c, 131c of the or each such contact 13,131 may be retained within a chamber which is defined by the base member 141 into which the aperture (through which the second portion 13d,131d of the same contact 13,131 extends) leads. The or each chamber may have a larger cross-section than an adjacent part of the cross-section of the aperture leading to that chamber. Similarly, the first portion 13c, 131c may have a width (e.g. a diameter) which is greater than a width of the cross-section of the aperture but smaller than a width of the adjacent part of the cross-section of the chamber.
The or each contact 13,131 may, therefore, be in the general shape of a top hat. The or each contact 13,131 could equally be referred to as respective pins, for example. As will be appreciated, therefore, the or each contact 13,131 may be substantially prevented from being removed from the base member 141 by abutment of the first portion 113c, 131c of the contact 13,131 with a part of the base member 14 (e.g. a surface between the chamber and the aperture). In some embodiments, the or each chamber defined by the base member 141 has a depth which is greater than a depth of the first portion 13c, 131c of the contact 13,131 which is retained in that chamber. Accordingly, axial movement of the contact 13,131 (as described above) may be permitted between the extended and retracted positions with respect to the base member 141 of the mounting assembly 14.
In some embodiments, the or each aperture defined by the base member 141 through which the second portion 13d,131d of one of the contacts 13,131 extends has a width (e.g. a diameter) which is greater than the corresponding part of the width (e.g. diameter) of the second portion 13d,131d contact 13,131. With a chamber which is deeper than the first portion 13c, 131c of that contact 13,131, this allows the contact 13,131 to tilt (as described above) with respect to the base member 141 and mounting assembly 14.
As will be appreciated, the dimensions of the aperture and chamber defined by the base member 141 (i.e. by the mounting assembly 14) and configured to receive a respective contact 13,131, along with the relative dimensions of that contact 13,131, define limits of tilt and/or axial movement of the contact 13,131 with respect to the base member 141 (i.e. with respect to the amounting assembly 14).
As can be seen in figure 3, in this and some other embodiments, the charging contacts 13 may extend to a greater height above a surface of the base member 141 of the mounting assembly 14 than the or each signal contact 131. In some embodiments, this may be because the charge contacts 13 are of a greater height than the signal contacts 131 but this need not be the case - e.g. the second portions 13d of the charging contacts 13 may be shorter than the second portions 13 Id of the signal contacts 131.
Figure 4 shows an exploded view of the embodiment of figures 1-3 and is representative of how this and some other embodiments may be formed.
Each conductor 15 may, in some embodiments, include a first portion 151 which is configured to extend into the base member 141 or other part of the mounting assembly 14 such that each conductor 15 is in electrical communication with at least one of the contacts 13,131 (in the depicted embodiment, each conductor 15 is configured to be connected in electric communication with a single contact 13,131). A second portion 152 of each conductor 15 is configured to be connected in electric communication with one or more other parts of the charging station 12.
The base member 141 in this depicted embodiments, and in some other embodiments, comprises a first base sub-member 1411 and a second base sub-member 1412. The first and second base sub- member 1411,1412 are configured to be connected together to form the base member 141.
In the depicted embodiment and in some other embodiments, the first base sub-member 1411 defines at least part of the or each chamber (which each receives the first portion 13c, 131c of a contact 13,131). The first base sub-member 1411 may also define at least part of one or more channels 142 which are each configured to receive at least part of a respective conductor 15 (e.g. the first portion 151 of a respective conductor 15). The or each chamber may be configured to hold the fluid discussed above. In some embodiments, the or each chamber is further or alternatively configured to hold a heat transfer plate which may be thermally coupled to the channel containing thermally conductive material - as described above. In the depicted embodiment and in some other embodiments, the first base sub-member 1411 may define one or more dowel receiving openings 143 which are each configured to receive a respective dowel 144 of the second base sub-member 1412. In some embodiments, one or more dowels may extend from the first base sub-member 1411 and may be configured to be received by one or more dowel receiving openings defined by the second base sub-member 1412. Likewise, the first base sub-member 1411 may define one or more dowel receiving openings 143 and one or more dowels, with the second based sub-member 1412 defining an opposing configuration of dowel(s) 144 and dowel receiving openings. The or each dowel 144 and the or each dowel receiving opening 143 are configured such that they mate when the two sub-members 1411,1412 of the base member 141 are connected to each other. This may help to hold the two base sub- members 1411,1412 together and may assist in ensuring the correct orientation of the two base sub-members 1411,1412.
The second base sub-member 1412 may define at least part of the or each chamber and defines the or each aperture - through which the contacts 13,131 extend as described herein.
The second base sub-member 1412 may define at least part of the or each channel 142 for the or each conductor 15 - as described herein. The first and second base sub-members 1411,1412 may be, therefore, configured to trap and retain part of the or each contact 13,131 when connected to each other.
Also as shown in figure 4, the resilient biasing arrangements 133 may be located within the chambers. As such, the or each resilient biasing arrangement 133 of this embodiment, and some other embodiments, may be configured to be received within the base member 14 and, specifically, may be within one of the chambers. The or each resilient biasing arrangement 133 may be configured to act between the first base sub-member 1411 and the first portion 13c, 131c of the or each contact 13,131 - e.g. with one resilient biasing arrangement 133 provided for each contact 13,131.
In the depicted embodiment, and some other embodiments, resilient biasing arrangements 133 are provided for the charging contacts 13 and may not be provided for the signal contacts 131.
The resilient biasing arrangements 133 may each take a number of different forms - for example, a helical spring, a spring washer, a Belleville washer, a wave washer, and the like.
The or each resilient biasing arrangement 133 may be configured to bias a respective contact 13,131 (or contacts 13,131) towards the extended position and, in particular, into a position in which the first portion 13c, 131c of the contact 13,131 abuts a surface between the chamber and the aperture in which the contact 13,131 is located, as defined by the base member 141. In some embodiments, see figures 2 and 3 for example, the first portion 13c, 131c of one or more the contacts 13 may each define a groove 13e,131e which is configured to receive at least part of a respective one of the or each conductor 15 (e.g. the first portion 151 of one of the conductors 15). This part (e.g. the first portion 151) may be attached to the contact 13,131 in the groove 13e,131e and may be soldered in position.
In some embodiments, in which a resilient biasing arrangement 133 is provided for a particular contact 13,131, part of the conductor 15 (e.g. the first portion 151) may be located between a part of the base member 141 (e.g. at the base of the chamber) and the resilient biasing arrangement 133, and the resilient biasing arrangement 133 may be conductive such that electrical communication between the conductor 15 and the contact 13,131 is via the resilient biasing arrangement 133. In some embodiments, in which there is a resilient biasing arrangement 133 for a particular contact 13,131, part of the conductor 15 (e.g. the first portion 151) may be located between the resilient biasing arrangement 133 and the contact 13,131 (e.g. the first portion 13c, 131c of the contact 13,131) such that the part of the conductor 15 moves with the contact 13,131. In some embodiments, therefore, the conductor 15 may be flexible to permit such movement.
In embodiments including a base member 141 with two base sub-members 1411,1412, each of the two base sub-members 1411,1412 may be formed from a moulded plastics material - e.g. with the or each dowel 144 integrally formed therewith, if provided.
The or each contact 13,131 may be formed from a ferrous metal. The of each contact 13,131 may be a permanent magnet which can also conduct electricity.
Many of the above described embodiments (with reference to figures 1-4) have not necessarily included data contacts 132. The or each data contact 132 of some embodiments may have a substantially identical form to the or each signal contact 131 (including all aspects of the signal contacts 131 described above such as how they are carried by the base member 141 and how they are connected to a conductor 15). The description in relation to the signal contacts 131, therefore, applies equally to the data contacts 132.
An embodiment including two data contacts 132 (as well as two charging contacts 13 and two signal contacts 131), is shown in figure 5 for example.
In some embodiments, such as in figure 5, the or each data contact 132 is provided between the charging contacts 13. In addition, the or each data contact 132 may be provided between the signal contacts 131. Figure 5 also provides an example arrangement of magnetic polarities for the charging 13 and signal 131 contacts - with the two charging contacts 13 of the charging station 12 being of opposing magnetic polarity and the two signal contacts 131 of the charging station 12 also being of opposing magnetic polarity. The data contacts 132 may or may not be magnetic. In embodiments in which the data contacts 132 of the charging station 12 are magnetic, they may be of opposing magnetic polarity. The mounting configuration 112 of the battery 11 may be of a substantially identical construction to the mounting assembly 14 of the charging station. Therefore, the description above applies equally to the corresponding parts of the mounting configuration - which may, accordingly, include the base member 1211, charging contacts 111 (with their first and second portions 111c, 11 Id and grooves l l le), one or more signal contacts 1111 (with their first and second portions 1111c, l l l ld and grooves), and/or one or more data contacts 1112. Likewise, the base member 1121 of the mounting configuration 112 may include a first base sub-member 1121a corresponding with the first base sub-member 1411 of the mounting assembly 14, and a second base sub-member 1121b corresponding with the second base sub-member 1412 of the mounting assembly 14. The base member 1211 of the mounting configuration 112 may define one or more apertures and chambers for the contacts 111,1111,1112 of the mounting configuration 112. The first and second sub-members 1121a,1121b of the mounting configuration 112 may include one or more dowels 1122 and one or more dowel receiving openings 1123 and one or more channels 1124, corresponding with the one or more dowels 144, the dowel receiving openings 143, and the channels 142 of the mounting assembly 14. Similarly, the conductors 15 of the charging station 12 may have counterparts in the battery 11 in the form of conductors 16 (again with first 161 and second 162 portions).
Although the description of the mounting assembly 14 may apply equally to the mounting configuration 112, in a particular example, the mounting assembly 14 and mounting configuration 112 need not be of identical form to each other for connection to occur. Indeed, as will be appreciated the charge station contact pattern at least will be associated with a corresponding battery contact pattern which is a mirror image of the charge station contact pattern.
Figure 6 shows an example of some embodiments in which a concentric arrangement of contacts 13,131,132,111,1111,1112 is provided. These contacts 13,131,132,111,1111,1112 may include charging contacts 13,111, one or more signal contacts 1111,131, and one or more data contacts 1112,132 of the battery 11 or charging station 12, as the case may be.
In the depicted embodiment, and some other embodiments, each contact 13,131,132,111,1111,1112 may be a portion of the perimeter of a circle - e.g. half or a quarter of the perimeter of a circle - or a substantially complete circle. To provide a concentric arrangement of contacts 13,131,132,111,1111,1112, the contacts 13,131,132,111,1111,1112 may be portions of the perimeter of a plurality of different circles - with each contact 13,131,132,111,1111,1112 being a portion of the perimeter of one such circle and the circles being of different diameters.
In some embodiments, more than one separate portion of the perimeter of a circle may form a single contact 13,131,132,111,1111,1112. For example, in the embodiment of figure 6 (and some other embodiments), the first charging contact 13a,l l la (which may be a negative charging contact) is provided by an outer contact in the form of the perimeter of a first circle. In the depicted embodiment, the first charging contact 13a, 11 la may be two contacts each forming approximately half of the perimeter of the first circle.
In the depicted embodiment, and some other embodiments, the second charging contact 13b,l 1 lb (which may be a positive charging contact) is provided by an inner contact which may be a contact in the form of the perimeter of a second circle. In the depicted embodiment, the second charging contact 13b,l 1 lb may be two contacts each forming approximately half of the perimeter of the second circle.
The first circle may be of a larger diameter than the second circle - as can be seen in figure 6 as an example.
In some embodiments, including the depicted embodiment, signal and/or data contacts 131,132,1111,1112 may be provided by one or more intermediate contacts in the form of the perimeter of one or more further circles. In the depicted embodiment, the signal and/or data contacts 131,132,1111,1112 may each be two contacts, each forming approximately half of the perimeter of a respective one of the further circles. In some embodiments, the two halves of the perimeter of a particular further circle may form separate ones of the signal and/or data contacts 131,132,1111,1112.
The or each further circle has a diameter which is less than the diameter of the first circle and more than the diameter of the second circle.
The or each contact 131,132,1111,1112 of such embodiments may be mounted for axial movement and/or may be tiltable and/or may be resiliently biased, all as discussed herein in relation to other embodiments. As will also be appreciated, it need not be necessary to provide all of the depicted signal 131,1111 and data 132,1112 contacts in some such embodiments.
Figures 7 to 9 show an example of some embodiments including contact tabs 17. As can be seen from the figures, the construction of the mounting configuration 112 and/or assembly 14 is generally as described above.
In some such embodiments, the base member 141,1121 includes to base sub-parts 1411,1121a,1412,l 121b of a similar construction to the embodiments discussed above - including the provision of one or more dowels 1122,144 and one or more dowel receiving openings 1123,143. In particular, the base member 141,1121 may carry one or more contacts 13,131,132,111,1111,1112 in the same manner as any other embodiment of the invention (e.g. in the same manner described in relation to figures 1 to 5) - which may include the use of one or more resilient biasing arrangements, in some embodiments, even though these are not shown in figure 9.
In addition, the base member 141,1121 further carries one or more contact tabs 17. The or each contact tab 17 is associated with a contact 13,131,132,111,1111,1112. The or each contact tab 17 is configured to be the electric current carrying member for the contact 13,131,132,111,1111,1112 with which it is associated. Accordingly, in some embodiments, another part of the contact 13,131,132,111,1111,1112 (e.g. the magnetic part) does not itself conduct electricity (or at least not electricity which is used in the operation of the present invention).
The or each contact tab 17 may include a mounting part 171 and an engagement part 172 - also see figure 15. The mounting part 171 is configured for using in mounting the contact tab 17 to base member 141,1121. Accordingly, at least part of the mounting part 171 may extend through at least part of the base member 141,1121 and may extend through a depth of the base member 141,1121 - i.e. through the entire depth of both the base sub-members 1411,1412,1121a,l 121b.
The engagement part 172 is configured to engage a contact 13,131,132,111,1111,1112 of the other of the mounting assembly 14 or mounting configuration 112. Accordingly, in some embodiments in which both the mounting configuration 112 and mounting assembly 14 use contact tabs 17, the engagement parts 172 of the mounting assembly and mounting configuration 112 may engage. In some embodiments, one or more of the charging contacts 13,111 are associated with respective contact tabs 17.
In some embodiments, the mounting parts 171 of respective contact tabs 17 may be located towards an outside of the mounting assembly 14 or configuration 112 such that the engagement parts 172 extend inwardly. The engagement 172 and mounting parts 171 of a contact tab 17 may be substantially perpendicular to each other.
In some embodiments, the mounting parts 171 of the or each contact tab 17 may be connected in electrical communication with one or more other parts of the battery 11 or charging station 12, as the case may be.
Such embodiments using contact tabs 17 may mean that conductors 15,16 for the associated contacts 13,131,132,111,1111,1112 as described above (e.g. located in grooves) are not needed.
In some such embodiments, the charging contacts 13,111 are not resiliently biased and/or are held against axial and/or tilt movement.
Other parts of the or each contact 13,131,132,111,1111,1112 associated with a contact tab 17 may, however, be magnetic - as in other embodiments. In some embodiments, contact tabs 17 are associated with the charging contacts 13,111 but are not associated with the signal or data contacts 131,132,1111,1112.
The or each contact tab 17 may be formed from a different material to the rest of the contacts 13,131,132,111,1111,1112 (e.g. to the magnetic parts thereof). The material may be selected for its electrical conductivity and its hardness and/or its decorative appeal. The material may be nickel, for example.
Figures 10 to 12 show an example of an embodiment which uses one or more magnets 18 which are separate from the or each contact 13,131,132,111,1111,1112. In the depicted example, and some other such embodiments, a pair of magnets 18 is provided, with one magnet 18 at either end of a linear array of contacts 13,131,132,111,1111,1112. In some embodiments, the magnets 18 may have a different configuration and there may be one or more magnets 18 interspersed between the contacts 13,131,132,111,1111,1112.
In the depicted embodiments, and some other embodiments, each magnet 18 comprises a cylindrical magnet 18 which is retained in a respective cavity which is defined by the base member 141,1121 - e.g. by the two base sub-members 1411,1412,1121a,l 121b (see figure 12 in particular which shows two such magnets 18 partially retained in the first base sub-member 1411,1121a).
The or each magnet 19 may be a permanent magnet and may be substantially covered by the second base sub-member 1412,1121b such that no part of the or each magnet 19 is visible externally of the mounting configuration 112 or mounting assembly 14 - see figure 11 in particular as an example.
The or each contact 13,131,132,111,1111,1112 may otherwise, in such embodiments, be as described above and retained in the same manner as in other embodiments (and may be in electrical communication with conductors 15,16 in a similar manner).
With reference to figures 13 and 14 as an example, some embodiments include one or more electromagnets 19. In some embodiments, the or each electromagnet 19 may be used in place of the or each magnet 18 of the embodiments described above with reference to figures 10 to 12. In other embodiments, as depicted in figures 13 and 14 for example, the or each electromagnet 19 may be associated with a respective contact 13,131,132,111,1111,1112. In particular, there may be one electromagnet 19 associated with each charge contact 13,111 in some embodiments. The electromagnet may include a coil 191 through which an electric current is passed in order to generate a magnetic field. As will be appreciated, the coil 191 may be located around the contact 13,131,132,111,1111,1112 or a part thereof. The contact 13,131,132,111,1111,1112 may be a solid ferrous metal contact, a hollow ferrous metal contact, or even a permanent magnet (whose magnetic field is "boosted" by the electromagnet 19). Electric current for the charging still passes through the charge contacts 13,111 in such embodiments.
As will be appreciated, embodiments of a mounting configuration or assembly 112,14 using one or more electromagnets need not necessarily be used with the other of the mounting configuration or assembly 112,14 also using electromagnets 19 - the or each corresponding contact 13,131,132,111,1111,1112 of the other of the mounting configuration or assembly 112,14 may be a permanent magnet or a ferrous metal, for example. In some embodiments, at least one of the contacts 13,131,132,111,1111,1112, and in particular the second part thereof, includes an insulation sheath 20 - see figures 16 and 17, for example. The insulation sheath 20 may substantially surround an external surface of the contact 13,131,132,111,1111,1112 to which it is fitted. In some embodiments, the insulation sheath 20 is provided around an external surface of the contact 13,131,132,111,1111,1112 to which is it is fitted, wherein that external surface faces outwardly from the mounting assembly 14 or mounting configuration 112, as the case may be.
The insulation sheath 20 may, in some embodiments, be an annular sheath. In some embodiments, little or no portion of the contact 13,131,132,111,1111,1112 to which the insulation sheath 20 is fitted extends above the top of the insulation sheath 20. In some embodiments, the insulation sheath 20 covers substantially all of the exposed outer surface or surfaces of the contact 13,131,132,111,1111,1112 to which it is fitted when the contact is in the extended position. The insulation sheath 20 may be mounted on the contact 13,131,132,111,1111,1112 to which it is fitted such that it moves with the contact 13,131,132,111,1111,1112. In some embodiments, the contact 13,131,132,111,1111,1112 to which the insulation sheath 20 is fitted can move within the insulation sheath 13 , 131 , 132, 111 , 1111 , 1112 axially and may also be tiltable. The or each contact 13,131,132,111,1111,1112 may be fitted with an insulation sheath 20. In some embodiments, each charging contact 13,111 is fitted with an insulation sheath 20. In some embodiments, the or each signal and/or data contact 131,132,1111,1112 is not fitted with an insulation sheath 20. As will be appreciated, the aperture defined by the base member 141,1121 for receiving the second part of the contact 13,131,132,111,1111,1112 may also need to be sized to receive the insulation sheath 20 if fitted to that contact 13,131,132,111,1111,1112.
In some embodiments, as in figures 16 and 17, irrespective of whether or not an insulation sheath 20 is provided for a particular contact 13,131,132,111,1111,1112, there may be provided a cap 21 for one or more of the contacts 13,131,132,111,1111,1112 (and, in particular, for one or more of the charge contacts 13,111). The or each cap 21 may be configured to fit over an end of the contact 13,131,132,111,1111,1112 (e.g. the end of the second part defining the engagement surface) such that the cap 21 forms the engagement surface for the contact 13,131,132,111,1111,1112. The or each cap 21 may also be configured to extend along at least part of a length of the associated contact 13,131,132,111,1111,1112. In some embodiments, the cap 21 includes one or more protrusions 211 which extend inwardly into a volume at least partially defined by the cap 21 (the volume in which the contact 13,131,132,111,1111,1112 is received).
In some such embodiments, the first and second part of one or more of the contacts 13,131,132,111,1111,1112 may be separate parts which are coupled together. That coupling may be achieved using the cap 21. For example, the cap 21 may fit around the second part of the contact 13,131,132,111,1111,1112 and the open end of the cap 21 may be received by a recess in the first part of the contact 13,131,132,111,1111,1112. The wall or walls of the cap 21 may be biased outwardly (e.g. by the action of the one or more protrusions 211 on the second part of the contact 13,131,132,111,1111,1112) and may, act outwardly on the first part of the contact 13,131,132,111,1111,1112 to hold the cap 21 in place with respect to the first part (the or each protrusion 211 holding the second part in place with respect to the cap 21).
Other aspects of these embodiments using one or more insulating sheathes 20 and/or caps 21 may be substantially as herein described elsewhere.
As will be appreciated, the or each cap 21 may provide a more electrically conductive and/or harder wearing and/or more decorative contact 13,131,132,111,1111,1112 (compared to the material used for the rest of the contact 13,131,132,111,1111,1112).
The use of one or more insulation sheathes 20 inhibits interference with the contacts 13,131,132,111,1111,1112 and makes it more difficult for the contacts 13,131,132,111,1111,1112 to be short circuited or to contact other conductors which a user may attempt to introduce between the mounting configuration 112 and mounting assembly 14. The use of one or more insulation sheathes 20 may, therefore, improve the safety of the operation of the battery charging system 1.
The or each insulation sheath 20 may be formed from an electrical insulator. In some embodiments, the or each insulation sheath 20 is a thermal conductor (e.g. more thermally conductive than a material of the base member 1121,141). In some embodiments, the insulation sheath 20 may be a dielectric material which may be a thermally conductive dielectric material.
In some embodiments, the or each insulation sheath 20 is in thermal communication with the above described fluid to provide a thermal conduction pathway to the contact 13,131,132,111,1111,1112. With reference to figures 18 to 20, as two corresponding contacts 13,131,132,111,1111,1112 of the mounting configuration 112 and mounting assembly 14 approach each other, the contacts 13,131,132,111,1111,1112 are attracted to each other due to magnetic attraction. Figure 18 shows two contacts 13,131,132,111,1111,1112 close to each other but substantially aligned and without a substantial degree of relative tilt (i.e. tilt relative to each other).
Ideally, the contacts 13,131,132,111,1111,1112 reach a point at which they engage each other such that they are in electrical communication with each other as shown in figure 19.
In many practical situations, however, the contacts 13,131,132,111,1111,1112 will not be perfectly aligned and/or will have an undesirable degree of relative tilt with respect to each other. This may be because the battery 11 is tilted or misaligned with the charging station 12 (i.e. the mounting configuration 112 and mounting assembly 14 are misaligned or tilted with respect to each other) or may be due to manufacturing tolerances. Accordingly, the situation as shown in figure 20 is common in practical situations.
In accordance with some embodiments, one or more of the contacts 13,131,132,111,1111,1112 is tiltable such that, as the corresponding contacts 13,131,132,111,1111,1112 approach each other one or both of the corresponding contacts 13,131,132,111,1111,1112 will tilt with respect to its mounting configuration 112 or mounting assembly 14, as the case may be, to match the angle of the engagement surface of the other contact 13,131,132,111,1111,1112. As such, the corresponding contacts 13,131,132,111,1111,1112 will still mate securely (as shown in either figure 19 or figure 20) over a substantial portion of the respective engagement surfaces of the contacts 13,131,132,111,1111,1112 (and, in some embodiments, over substantially all of these engagement surfaces 13,131,132,111,1111,1112).
This is especially important in high current charging applications in which poorly aligned and engaging contacts 13,131,132,111,1111,1112 (particularly, the charging contacts 13,111) can increase electrical resistance and cause rapid heating, or in which arcing between contacts 13,131,132,111,1111,1112 is more likely to occur.
In some embodiments, the or each contact 13,131,132,111,1111,1112 is cylindrical. In other embodiments, the or each contact has a non-cylindrical form permitting engagement, for example right prisms, or the or each contact may have a form that cooperates with another contact.
The operation of embodiments is discussed below with reference to the simplified schematic diagram of figure 22 and variations thereof. Figure 22 shows an example mounting configuration 112 and mounting assembly 14 of an embodiment of the invention with a simplified schematic representation of the associated circuitry. It will be appreciated that the explanation and discussion of the example in figure 22 will apply to other example embodiments of the mounting configuration 112 and mounting assembly 14 as described herein.
In accordance with the example in figure 22, the outer contacts 13a,13b,l l la,l l lb are the charging contacts of the charging station 12 and battery 11. The inner pair of contacts 131a,131b,l l l la,l l l lb are signal contacts of the charging station 12 and the battery 11.
With regard to the battery 11, the first charging contact 111a of the battery 11 is connected in electrical communication with the charge confirmation sub-system 114 and may be connected to a first switch 1141 of the charge confirmation sub-system 114. The charge confirmation subsystem 114 (e.g. the first switch 1141) is also connected in electrical communication with the or each battery cell 113 (of which two are schematically depicted in figure 22).
The charge confirmation sub-system 114 (e.g. the first switch 1141) is also connected in electrical communication with the first signal contact 111 la of the battery 11. In the depicted embodiment, and some other embodiments, the first signal contact 1111a is connected to the charge confirmation sub-system 114 such that an electrical signal received via the first signal contact 1111a controls actuation of the charge confirmation sub-system 114 and, in particular, actuation of the first switch 1141.
Actuation of the charge confirmation sub-system 114 (e.g. actuation of the first switch 1141) to a closed configuration connects a first terminal of the or each battery cell 113 (e.g. the positive terminal) in electrical communication with the first charge contact 111a of the battery 11. Actuation of the charge confirmation sub-system 114 (e.g. actuation of the first switch 1141) to an open configuration disconnects the first terminal of the or each battery cell 113 (e.g. the positive terminal) from electrical communication with the first charge contact 111a of the battery 11. Accordingly, at will be appreciated, the charge confirmation sub-system 114 and, in some embodiments, the first switch 1141, is configured to control whether or not the first charge contact 11 la of the battery 11 is in electrical communication with the or each battery cell 113.
The second charge contact 111b of the battery 11 is, in the depicted embodiment and other embodiments, connected in electrical communication with a second terminal of the one or more battery cells 113 (e.g. to the negative terminal). The second signal contact 111 lb of the battery 11 may be connected in electrical communication with the first terminal of the one or more battery cells 113 (e.g. via a resistor 1142).
The second charge contact 13b of the charge station 12 is connected in electrical communication with one or more of the electrical power input 121, the power regulation sub-system 122, the charging controller 123 (and the charge actuation sub-system 1231 and/or the control unit 1232). The second signal contact 131b of the charge station 12 is connected in electrical communication with the charging controller 123 (and, in particular, may be connected in electrical communication with the control unit 1232). The first signal contact 131a of the charge station 12 is connected in electrical communication with the charging controller 123 (and, in particular, may be connected to the charge actuation subsystem 1231 and/or the control unit 1232).
The first charging contact 13a of the charging station 12 is also connected in electrical communication with the charging controller 123 (and, in particular, may be connected to the charge actuation sub-system 1231). In particular, the first charging contact 13a of the charging station 12 may be connected in electrical communication with a second switch 1232 of the charge actuation sub-system 1231. The charge actuation sub-system 1231 (e.g. the second switch 1232) may be further connected in electrical communication with one or more of the electrical power input 121 and the power regulation sub-system 122.
Operation of the charge actuation sub-system 1231 (e.g. the second switch 1232) may be controlled by the control unit 1232, in accordance with an output of the control unit 1232 which may also be sent to the first signal contact 131a of the charging station 12.
The charge actuation sub-system 1231 (e.g. the second switch 1232) may be configured to be actuated between an open configuration (in which the first charging contact 13a is not in electrical communication with one or more of the electrical power input 121, and the power regulation subsystem 122) and a closed configuration (in which the first charging contact 13a is in electrical communication with one or more of the electrical power input 121 and the power regulation subsystem 122). Accordingly, with reference to figure 22, when the battery 11 is connected to the charging station 12 such that the mounting assembly 14 and mounting configuration 112 connect each other, then the corresponding contacts 13,131,132,111,1111,1112 engage each other as depicted.
A voltage across the or each battery cell 113 is detected by the charging controller 123 of the charging station 12, and, in particular, by the control unit 1232 - which detects a voltage across the second signal contact 131b and the second charging contact 13b. A relatively low current flows through the resistor 1142 (which might have a relatively high electrical resistance as a result) to the charging controller 123 (e.g. to the control unit 1232). This detected or sensed voltage using one or more of the signal contacts 131 of the charging station 12 (and one or more of the signal contacts 1111 of the battery 11), indicates that a battery 11 has been mounted to the charging station 12 and that the signal contacts 131,1111 and the charging contacts 13,111 are engaged.
The charging controller 123 and, in particular, the control unit 1233 is configured to sense this voltage and to output a signal to control the operation of the charge actuation sub-system 1231 - to actuate the charge actuation sub-system 1231 (e.g. the second switch 1232) to the closed configuration (e.g. from the open configuration).
The output signal from the charging controller 123 (and, in particular, the control unit 1233) is configured to be sent to the charge confirmation sub-system 114 of the battery 11 via the first signal contacts 131 a, 1111 a. This output signal, therefore, also further causes the actuation of the charge confirmation sub-system 114 (and, in particular, the first switch 1141).
The actuation of the charge actuation sub-system 1231 to the closed configuration and the actuation of the charge confirmation sub-system 114 to the closed configuration causes the or each battery cell 113 to be connected in electrical communication (e.g. at both terminals thereof) to one or more of the electrical power input 121, and the power regulation sub-system 122, such that the or each battery cell 113 receives electrical power from the charging station 12 to charge the or each battery cell 113. This electrical power may be delivered at a relatively high electrical current.
In some embodiments, on disconnection of the battery 11 from the charging station 12 (i.e. on disengagement of the mounting assembly 14 and mounting configuration 112) the or each signal contact 131 of the charging station 12 may disengage the of each corresponding signal contact 1111 of the battery 11 before the charging contacts 13,111 disengage - i.e. the engagement of the signal contacts 131,1111 may be relatively fragile compared to that of the charging contacts 13,111. This fragility may be provided by the features of the contacts discussed above including the relative distance of extension of the signal contacts 131,1111, the relative height of the signal contacts 131,1111, restrictions on the axial or tilt movement of the signal contacts 131,1111, and the like. The relatively small engagement surfaces of the signal contacts 131,1111 compared to the charge contacts 13,111 may also assist in providing the required relative fragility of the engagement.
When the or each signal contacts 131,1111 disengage then the charge confirmation sub-system 114 and/or the charge actuation sub-system 1231 (e.g. the first and second switches 1141,1232) are configured to actuate to their respective open configurations.
In particular, the charging controller 123 and, in particular, the control unit 1233 may detect the disappearance of the voltage across the second signal contact 131b of the charging station 12 and the second charging contact 13b of the charging station 12. Accordingly, the charging controller 123 (e.g. the control unit 1233) may output a signal to actuate the second switch 1232 to the open configuration - or, in some embodiments, may cease to output the signal which actuated the second switch to the closed configuration.
If the first signal contacts 131 a, 1111a are still engaged, then the output signal from the charging controller 123 and, in particular, the control unit 1233 will also be received by the charge confirmation sub-system 114 (e.g. by the first switch 1141) which will also actuate to the open configuration.
If the first signal contacts 131 a, 1111a have already been disengaged, then the output signal causing the charge confirmation sub-system 114 (e.g. the first switch 1141) to remain in the closed configuration will be lost and so the charge confirmation sub-system 114 (e.g. the first switch 1141) will actuate to the open configuration.
If, on the other hand, the disengagement of the first signal contacts 131 a, 1111a occurs before the disengagement of the second signal contacts 131b,l 11 lb, then the charge confirmation subsystem 114 (e.g. the first switch 1141) will actuate to the open configuration (due to loss of the output from the charging controller 123 (i.e. from the control unit 1233) to keep it in the closed configuration). In some embodiments, the charging controller 123 (e.g. the control unit 1233) may be configured to identify a change in the detected voltage across the second signal contact 131b and the second charging contact 13b indicative of the charge confirmation sub-system 114 (e.g. the first switch 1141) actuating to the open configuration. This may be useful, for example, if the second signal contacts 131b,l 11 lb are still engaged following disengagement of the first signal contacts 131a,l l l la. This detection may be, for example, a reduction in the voltage and may be a rate of reduction in the voltage. In such embodiments, on detecting this opening of the charge confirmation sub-system 114 (e.g. the first switch 1141), the charge controller 123 (e.g. the control unit 1233) may output the signal to actuate the charge actuation sub-system 1231 (e.g. the second switch 1232) to the open configuration - or cease to output the signal which kept it in the closed configuration as the case may be.
For reference, figures 24 and 25 show the mounting assembly 14 and mounting configuration 112 (of the embodiment used in figure 22) with the signal contacts 131,1111 engaged. Figures 23 and 26 show the same mounting assembly 14 and mounting configuration 112 with the signal contacts 131,1111 disengaged but the charging contacts 13,111 still engaged - as would happen during engagement/connection and disengagement/disconnection of the mounting assembly 14 and mounting configuration 112 to and from each other. Figure 27 shows the same embodiment in which the engagement of the contacts 13,111,1111,1112,131,132 has occurred but the mounting assembly 14 and mounting configuration 112 are tilted with respect to each other. Engagement has, nevertheless, occurred but, it will be appreciated, that movement of the mounting assembly 14 relative to the mounting configuration 112 may cause the or both signal contacts 1111,131 to disengage. The same process occurs during engagement of the mounting assembly 14 and the mounting configuration 112 - as can be seen in figures 29 to 30. In particular, as the contacts 13,111,1111,131 are moved from a spaced apart position (as in figure 28) towards each other, the charging contacts 13,111 will engage first in accordance with some embodiments. Nevertheless, charging will not yet commence because the signal contacts 1111,131 are not engaged (so there is no voltage detected by the charge controller 123 as described above). As the signal contacts 1111,131 are brought closer together, the charging contacts 13,111 may move towards their retracted positions and/or the signal contacts 1111,131 otherwise move towards each other. The signal contacts 1111,131 then engage (see figure 30) when the mounting assembly 14 and mounting configuration 112 are engaged fully. This enables charging to commence (as the voltage from the battery 11 will now be detected by the charge controller 123, as described above). Embodiments which include one or more data contacts 132,1112 operate in a similar manner - see figures 31-33. The description above in relation to the operation of embodiments not including data contacts 131,1112 applies equally to embodiments which do include data contacts 131,1112 and, as such, common reference numerals have been used in figures 31-33. In addition, the data contacts 132,1112 enable the transmission of data from the battery 11 to the charging station 12 and/or from the charging station 12 to the battery 11. This data may include one or more of an identifier for the battery 11, an identifier for the charging station 12, a charging parameter for the battery 11 (e.g. the identification of a suitable charging profile for use with the battery 11 (which may be sent by the battery 11 to the charging station 12)), an indication of the number of charge cycles the battery 11 has undertaken (which may be updated by the battery 11 on receipt of a signal from the charging station 12), information regarding one or more historic charging cycles (e.g. the voltage level reached, the length of the time on charge, and the like), one or more parameters of the charging station 12 (such as a maximum charging current), a temperature of the battery 11 or charging station 12, and the like.
The identifier for the battery 11 and/or the identifier for the charging station 12 may be substantially unique to that battery 11 and/or charging station 12, may be common to that make of battery 11 and/or charging station 12, may be common to that model of battery 11 and/or charging station 12, or the like.
As will be appreciated the battery 11 and the charging station 12 may include respective data processing and storage systems 22 for the handling and storage of data transmitted and/or received via the data contacts 132,1112. In some embodiments, the data processing and storage system 22 of the charging station 12 is configured to communicate with the charging controller 123 to control the operation thereof in accordance with data received from the battery 11 - e.g. the selection of a charging profile. In some embodiments, the identifier of the battery 11, as received from the battery 11 by the charging station 12, may be used by the data processing and storage system 22 of the charging station 12 to determine whether the battery 11 can or should be charged - e.g. is the battery 11 a legitimate battery 11. Similarly, in some embodiments, the identifier of the charging station 12, as received from the charging station 12 by the battery 11, may be used by the data processing and storage system 22 of the battery 11 to determine whether the charging station 12 can or should charge the battery - e.g. is the charging station 12 a legitimate charging station 12.
Accordingly, the data processing and storage system 22 of the charging station 12 may be configured to control the operation of the charge actuation sub-system 1231 (e.g. the second switch 1232). Likewise, the data processing and storage system 22 of the battery 11 may be configured to control the operation of the charge confirmation sub-system 114 (e.g. the first switch 1141). The data contacts 1112,132 may be configured to use any number of different communication protocols - e.g. CANBus, USB, PCIE, V2G, or another automotive communication protocol, or the like. In some embodiments, the data contacts 1112,132 may use an analogue communication signal. As discussed above, the engagement of the data contacts 132,1112 may be more fragile than the engagement of the charge contacts 13,111. In some embodiments, the engagement of the data contacts 132,1112 may be more fragile or less fragile than the engagement of the signal contacts 131,1111. Various of the figures have indications of possible arrangements of magnetic polarisations of various contacts 13,131,132,111,1111,1112. It will be appreciated that these are examples only.
As will be appreciated, in accordance with some embodiments of the invention, the charging station 12 may confirm one or more parameters associated with the battery 11 prior to commencing (or continuing) charging. Equally, the battery 11 may check one or more parameters associated with the charging station 12 prior to commencing (or continuing) charging. These one or more parameters may include data transmitted via the data contacts 132,1112 and/or may include an indication that the battery 11 is correctly mounted to the charging station 12 (using the signal contacts 131,1111).
Some embodiments of the present invention also provide a mechanism for confirming engagement of the battery 11 and charging station 12 which is at least partially mechanical - e.g. the use of signal and/or data contacts 131,132,1111,1112 with more fragile engagement with each other than the charging contacts 13,111. This provides improved safety in the operation of the system 1 of some embodiments. In accordance with some embodiments, both the battery 11 and the charging station 12 can determine whether to commence or continue charging - through the use of the charge confirmation sub-system 114 and the charge actuation sub-system 1231, for example. Again, this improves the safety of the operation of the invention.
The term "in electrical communication" has been used herein to indicate the connection of two elements in such a manner that there is an electrically conductive path between the elements and, in particular, a path between the parts of the elements to allow for operation of those elements as described herein - e.g. between input/output pins of the elements. The elements may or may not be physically connected to each other when in electrical communication and two physically connected elements need not be in electrical communication, as will be appreciated.
As will be appreciated the contacts 13,111,131,1111,132,1112 of the mounting assembly 14 and mounting configuration 112 have been numbered "first" and "second" in respect of the contacts of each of the mounting assembly and the configuration 14,112 separately. These contacts 13,111,131,1111,132,1112 could equally have been numbered in relation to the battery charging system 1 as a whole.
Therefore, for example, in relation to the mounting configuration 112, the first charging contact 111a may be the first charging contact 111a of the battery charging system 1, and the second charging contact 111b may be the second charging contact of the battery charging system 1, and, in relation to the mounting assembly 14, the first charging contact 13a may be the third charging contact 13b of the battery charging system 1, and the second charging contact 13b may be the fourth charging contact 13b of the battery charging system 1.
Similarly, the first signal contact 1111a of the mounting configuration 112 may be the first signal contact 1111a of the battery charging system 1, and the first signal contact 131a of the mounting assembly 14 may be the second signal contact 131a of the battery charging system 1. The second signal contact 1111b of the mounting configuration 112 may be the third signal contact 1111b of the battery charging system 1, and the second signal contact 131b of the mounting assembly 14 may be the fourth signal contact 131b of the battery charging system 1. The same may apply, of course, to the data contacts 132,1112.
As will be appreciated, some embodiments provide relatively fragile engagement of some of the contacts (particularly the signal 131,1111 and/or the data 132,1112 contacts). This fragility is relative to the engagement of the charging contacts 13,111 and is such that if the battery 11 and the charging station 12 are moved into connection with each other (by engagement of the mounting configuration 112 and mounting assembly 14) then the charging contacts 13,111 will engage before the signal 131,1111 and/or data 132,1112 contacts engage each other. Similarly, if the battery 11 and the charging station 12 are moved out of connection with each other (by disengagement of the mounting configuration 112 and mounting assembly 14) then the signal 131,1111 and/or data 132,1112 contacts disengage each other before the charging contacts 13,111 disengage each other. In other words, the charging contacts 13,111 are the first to engage and the last to disengage typically. Equally, the signal and/or data contacts 131,132,1111,1112 are the last to engage each other and the first to disengage each other. This helps to ensure that a charging current is not delivered to the battery 11 , and/or the battery 11 does not draw a charging current, from the charging station 12 (over the charging contacts 12) unless the battery 11 and charging station 12 are properly engaged. This also ensures that any charging does not occur until the battery 11 and charging station 12 are properly engaged, and ceases to occur before the battery 11 and charging station 12 are full disengaged. Some embodiments of the present invention are particularly useful in relation to applications which use relatively high electric currents and with which there are, therefore, safety concerns. Although embodiments have been describe with reference to a battery charging system 1, it will be appreciated that the mounting configuration 112 and mounting assembly 14 could be used in other applications - which may or may not include the charging of a battery 11. Therefore, in some embodiments, it charging contacts 111,13 could be power contacts 111,13, and the above described elements are to be construed accordingly - with the charge confirmation sub-system 114 and charge actuation sub-system 1231 being a power confirmation sub-system 114 and power actuation sub-system 1231 respectively. Of course, in such embodiments, the operation of these sub-systems 1231,114 may be altered so that correct operation is achieved (i.e. the delivery of power through the power contacts 111,13 only when both the power contacts 111,13 and the or each signal contact 131,1111 (and/or data contact 132,1112) are engaged with their corresponding contacts on the other of the mounting assembly 14 and mounting configuration 112, as the case may be. The charge or power current which may be delivered through the charge/power contacts 13,111 may be greater than or equal to 10A, greater than or equal to 30A, or greater than or equal to 300A. The voltage across the charge/power contacts 13,111 may be between 5V and 400V. In some embodiments, the current and/or voltage may be greater than these ranges - particular in relation to the charging of larger capacity batteries 11 as might be used in a vehicle, for example.
In some embodiments, the roles of the data and signal contacts 1111,1112,131,132 are interchanged and/or mixed.
The data and/or signal contacts 1111,1112,131,132 may use any of the communication protocol disclosed herein (or others) to provide communication between the battery 11 and charging station 12. This communication may include information such as encryption keys, encrypted data, and/or the parameters discussed above. The date and/or signal contacts 1111,1112,131,132 (and the associated parts of the battery charger 11 and charging station 12) may be configured to use an analog or a digital communication protocol in some embodiments.
In some embodiments, the battery 11 and charging station 12 are locked together - in particular, the mounting configuration 112 and mounting assembly 14 are locked together - during charging of the battery 11. This locking may be achieved by use of the electromagnet(s) 19 in embodiments including this feature. In other embodiments, a mechanical locking mechanism may be provided - such as in the form of a latch of the battery 11 or charging station 12 which is configured to engage a part of the other of the battery 11 or charging station 12. Operation of the electromagnet(s) 19 or other locking mechanism (the electromagnet(s) 19 being an example of a locking mechanism in such embodiments) may be controlled by one or both of the charging controller 115 of the battery 11 and/or the charging controller 123 of the charging station 12 - and may be based on one or more signals or other data transmitted through the data and/or signal contacts 1111,1112,131,132. So for example, at the end of a charging process, the battery 11 may be released by disengagement or deactivation of the locking mechanism and at the start (and during) a charging process the locking mechanism may be engaged or activated.
As part of the operation of the lock mechanism, data may be sent via the data and/or signal contacts 1111,1112,131,132 to prevent or limit operation of a device or of equipment to which the battery 11 is attached or of which it forms a part during charging. This may occur even if there is no physical or electromagnetic locking of the battery 11 and charging station 12 together.
In some embodiments, the power regulation sub-system 122 may be configured to impose a current limit on the current drawn from the charging station 12 by the battery 11. This may, for example, act to filter or reduce current spikes which may occur during operation.
In some embodiments, the charging station 12 includes a discharge system which is configured to take electrical power from the battery 11 and do one or both of convert that electrical power to heat which is then exhausted (e.g. to the atmosphere) or to return that electrical power to the power supply (or use the power to charge another battery 11). The charging station 12 may, therefore, operate in a first mode of operation (the charging mode) and a second mode of operation (the discharging mode). Actuation between the two modes may be controlled by a user interface of the charging station 12 and/or via data received at the charging station from another source (e.g. over the data and/or signal contactsl 111,1112,131,132.
As will be appreciated, through the description reference has been made to the battery 11. The battery 11 may form part of another device or of other equipment and the description is to be construed accordingly. In some embodiments, the battery 11 is an auxiliary or secondary battery but this need not be the case.
When used in this specification and claims, the terms "comprises" and "comprising" and variations thereof mean that the specified features, steps or integers are included. The terms are not to be interpreted to exclude the presence of other features, steps or components. The features disclosed in the foregoing description, or the following claims, or the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for attaining the disclosed result, as appropriate, may, separately, or in any combination of such features, be utilised for realising the invention in diverse forms thereof. Each feature disclosed in the description, and (where appropriate) the claims and drawings may be provided independently or in any appropriate combination. It will be understood that the present invention has been described above purely by way of example, and modifications of detail can be made within the scope of the invention.
Reference numerals appearing in the claims are by way of illustration only and shall have limiting effect on the scope of the claims.

Claims

Claims
1. A battery charging system including a battery and a charging station, wherein:
the battery includes a mounting configuration having a first charging contact, a second charging contact, and a first signal contact, and
the charging station includes a mounting assembly having a third charging contact, a fourth charging contact, and a second signal contact,
the mounting configuration and mounting assembly are configured to connect to each other such that:
the first and third charging contacts engage in electrical communication;
the second and fourth charging contacts engage in electrical communication; the first and second signal contacts engage in electrical communication, and wherein:
during connection of the mounting configuration and mounting assembly, the charging contacts engage before the signal contacts; and
during disconnection of the mounting configuration and mounting assembly the signal contacts disengage before the charging contacts;
whereby the engagement of the first and second signal contacts is more fragile than the engagement of the charging contacts.
2. A system according to claim 1 configured to deliver a charging current to the battery using the charging contacts when the charging contacts and signal contacts are engaged and not to deliver the charging current to the battery when the signal contacts are disengaged and the charging contacts are engaged.
3. A system according to claim 1 or 2, wherein:
one or more of the charging contacts includes at least a portion which is magnetic such that the first and third charging contacts are attracted to each other and/or the second and fourth charging contacts are attracted to each other.
4. A system according to any preceding claim, wherein the first and second charging contacts are carried by a base member of the mounting configuration and at least one of the first and second charging contacts is configured to move between an extended and a retracted position with respect to the base member of the mounting configuration.
5. A system according to claim 4, wherein the contacts are configured to move between 0.1 mm and 5 mm between an extended and a retracted position, preferably between 0.5 mm and 2 mm, and more preferably approximately 1 mm.
6. A system according to claim 4 or 5, wherein the mounting configuration further includes a resilient biasing arrangement which is configured to bias the at least one charging contact towards the extended position.
7. A system according to any preceding claim, wherein the third and fourth charging contacts are carried by a base member of the mounting assembly and at least one of the first and second charging contacts is configured to move between an extended and a retracted position with respect to the base member of the mounting assembly.
8. A system according to claim 7, wherein the contacts are configured to move between 0.1 mm and 5 mm between an extended and a retracted position, preferably between 0.5 mm and 2 mm, and more preferably approximately 1 mm.
9. A system according to claim 7 or 8, wherein the mounting assembly further includes a resilient biasing arrangement which is configured to bias the at least one charging contact towards the extended position.
10. A system according to any preceding claim, wherein the first signal contact is carried by a base member of the mounting configuration and is configured to move between an extended and a retracted position with respect to the base member of the mounting configuration.
11. A system according to claim 10, wherein the mounting configuration further includes a resilient biasing arrangement which is configured to bias the first signal contact towards the extended position.
12. A system according to any preceding claim, wherein the second signal contact is carried by a base member of the mounting assembly and is configured to move between an extended and a retracted position with respect to the base member of the mounting assembly.
13. A system according to claim 12, wherein the mounting assembly further includes a resilient biasing arrangement which is configured to bias the second signal contact towards the extended position.
14. A system according to any preceding claim, wherein the first signal contact is configured to extend from a surface of the mounting configuration by a shorter distance than the first and second charging contacts extend from the surface of the mounting configuration.
15. A system according to any preceding claim, wherein the second signal contact is configured to extend from a surface of the mounting assembly by a shorter distance than the third and fourth charging contacts extend from the surface of the mounting assembly.
16. A system according to any preceding claim, wherein the first and second power contacts are be moveable to a greater extent with respect to a surface of the mounting configuration than the first signal contact is moveable with respect to the surface of the mounting configuration.
17. A system according to any preceding claim, wherein the third and fourth charging contacts are be moveable to a greater extent with respect to a surface of the mounting assembly than the second signal contact is moveable with respect to the surface of the mounting assembly.
18. A system according to any preceding claim, wherein one or more of the charging and signal contacts is tiltable.
19. A system according to any preceding claim, wherein one or more of the charging contacts includes at least a portion which is magnetic such that the first and third charging contacts are attracted to each other and/or the second and fourth charging contacts are attracted to each other, and the charging station is configured to deliver a charging current to the battery using the charging contacts.
20. A battery charging system including a battery and a charging station, wherein:
the battery includes a mounting configuration having a first charging contact, a second charging contact, and optionally a first signal contact, and
the charging station includes a mounting assembly having a third charging contact, a fourth charging contact, and optionally a second signal contact,
the mounting configuration and mounting assembly are configured to connect to each other such that:
the first and third charging contacts engage in electrical communication;
the second and fourth charging contacts engage in electrical communication;
the first and second signal contacts engage in electrical communication, and wherein one or more of the charging contacts includes at least a portion which is magnetic such that the first and third charging contacts are attracted to each other and/or the second and fourth charging contacts are attracted to each other, and the charging station is configured to deliver a charging current to the battery using the charging contacts.
21. A system according to claim 19 or 20, wherein one or more of the charging and signal contacts includes a portion made from a ferrous metal and/or a ferromagnetic material and/or an electromagnet.
22. A system according to claim 21, wherein one or more of the charging and signal contacts includes an electromagnet powered in proportion to a power flowing through the charging contacts.
23. A system according to any of claims 19 to 22, wherein each charging contact only includes a magnetic portion.
24. A system according to any of claims 19 to 23, wherein one or more of the charging and signal contacts includes a contact tab or a cap of an electrically conductive material.
25. A system according to claim 24, wherein the contact tab or cap is of a non-ferromagnetic material.
26. A system according to claim 24 or 25, wherein the contact tab or cap comprises copper, optionally with a coating, optionally with a nickel-gold coating.
27. A system according to any of claims 24 to 26, wherein the contact tab comprises a cavity for housing a magnetic portion.
28. A system according to claim 27, wherein the cavity is arranged such that the magnetic part is housed beneath an engagement surface of the contact tab or cap intended to engage with another contact.
29. A system according to any of claims 19 to 28, wherein one or more of the signal and charging contacts includes an insulation sleeve which surrounds at least a portion of the or each contact.
30. A system according to any of claims 19 to 29, wherein:
one or more of the signal contacts includes at least a portion which is magnetic such that at least the first and second signal contacts are attracted to each other.
31. A system according to any preceding claim, wherein the battery further includes a charge confirmation sub-system and the charging station further includes a charge actuation sub-system, and the charge confirmation sub-system and charge actuation sub-system are configured to communicate using the or each signal contact to confirm that the mounting configuration and mounting assembly are connected such that the respective signal contacts engage each other in electrical communication.
32. A mounting configuration/member including:
a base member,
a plurality of power contacts carried by the base member,
a first signal contact carried by the base member, wherein the first signal contact and charging contacts are configured such that:
the charging contacts extend a greater distance from a surface of the mounting configuration/member than the signal contact; and/or
the charging contacts are moveable to a greater extent with respect to the base member than the signal contact is moveable with respect to the base member.
33. A mounting configuration/member according to claim 32, further including a resilient biasing arrangement configured to bias one or more of the charging contacts into an extended position.
34. A mounting configuration/member according to claim 32 or 33, wherein one or more of the contacts is magnetic.
35. A mounting configuration/member including:
a base member,
a plurality of charging contacts carried by the base member,
optionally a first signal contact carried by the base member,
wherein one or more of the contacts is magnetic.
36. A mounting configuration/member according to claim 34 or 35, wherein one or more of the contacts includes a permanent magnet.
37. A mounting configuration/member according to any of claims 34 to 36, wherein one or more of the contacts includes an electromagnet.
38. A mounting configuration/member according to claim 37, wherein the electromagnet is adapted to be powered in proportion to a power flowing through the power contacts.
39. A mounting configuration/member according to any of claims 34 to 38, wherein one or more of the contacts includes a contact tab.
40. A mounting configuration/member according to any of claims 34 to 39, wherein one or more of the contacts includes a cap of an electrically conductive material.
41. A battery including a mounting configuration/member according to any of claims 32 to 40.
42. A charging station including a mounting configuration/member according to any of claims 32 to 40.
43. A device including a mounting configuration/member according to any of claims 32 to 40.
44. A vehicle or item of furniture including a mounting configuration/member according to any of claims 32 to 40.
45. A battery charging system including a battery and a charging station, wherein the battery includes a charge confirmation sub-system and the charging station includes a charge actuation sub-system, and the charge confirmation sub-system and charge actuation sub-system are configured to communicate using signal contacts arranged to engage each other in electrical communication to confirm that the battery and the charging station are connected.
46. A battery charging system substantially as herein described with reference to the accompanying drawings.
47. A mounting configuration and mounting assembly combination substantially as herein described with reference to the accompanying drawings.
48. A mounting configuration/member substantially as herein described with reference to the accompanying drawings.
49. A battery substantially as herein described with reference to the accompanying drawings.
50. A charging station substantially as herein described with reference to the accompanying drawings.
51. A device substantially as herein described with reference to the accompanying drawings.
52. A vehicle or item of furniture substantially as herein described with reference to the accompanying drawings.
PCT/GB2016/053344 2015-10-27 2016-10-27 A battery charging system and associated elements WO2017072516A1 (en)

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GB2557853B (en) 2021-09-08
GB201519005D0 (en) 2015-12-09
GB201806870D0 (en) 2018-06-13

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