WO2020058709A1

WO2020058709A1 - Modular power and socket assembly

Info

Publication number: WO2020058709A1
Application number: PCT/GB2019/052628
Authority: WO
Inventors: Timothy Richard Hobbs
Original assignee: Oe Electrics Limited
Priority date: 2018-09-18
Filing date: 2019-09-18
Publication date: 2020-03-26
Also published as: GB201815161D0; GB2578956A; GB201913157D0

Abstract

The invention relates to a modular system which allows the selective configuration and provision of an assembly which includes a plurality of power sockets (16) to be made available to allow DC voltage power to be provided to one or more items of apparatus to be charged by the selective electrical connection of the same with a respective socket. Modules (2) include at least one said socket, mechanical engagement means (22, 24) to allow the modules to be selectively engaged in a number of different configurations and input and output electrical connections (18, 20) which allow an incoming power supply to be transferred between said modules and then made available at the said sockets. The output power supply may be at a voltage lower than the said incoming power supply and the particular voltage may be selectable from a range of possible voltages.

Description

Modular power and Socket Assembly

The invention to which this application relates is the provision of a modular system to allow the selective configuration and provision of at least one, but typically a plurality, of charging power sockets to be made available for use as part of an assembly to thereby allow DC voltage power to be provided to one or more items of apparatus to be charged by the insertion of a plug into respective sockets and the plug is typically connected to the item via a cable connection to allow the provision of power to charge and/or operate the same.

Although the invention is herein described with reference to the use of sockets of a USB type A or USB-C configuration, it should be appreciated that the same principles of the application can be applied to an assembly using different forms of charging sockets and/or combinations of charging sockets of different configurations.

The charging and/ or operation of items of apparatus such as mobile phones and tablet computers by providing electrical power thereto has been typically achieved by way of fixed configuration AC to DC conversion and control apparatus such as a plug top charger with a single USB outlet port or an electrical socket unit with one or two outlet ports in a fixed location such as a wall or item of furniture which typically requires the provision of AC power locally to the AC to DC conversion and control apparatus. The incorporation of AC to DC conversion means within the same apparatus as the USB outlet ports and their control means creates restrictions on the minimum size of the device for a given DC output and in addition high levels of heat can be generated by the AC to DC conversion process which independently or together can restrict where the charging assemblies can be installed.

In addition whereas traditionally USB charging was provide by a USB Type A connector at a fixed 5V DC output the recent implementation of USB charging at variable output voltages via a new Type C USB connector will extend the use of USB charging to devices such as laptop computers that require much higher charging currents than previously supplied via a USB interface, the selection of the particular voltage which is supplied made as a result of a signal received from the particular item of apparatus which is connected to the USB socket at that time. However it is expected that USB charging capability via both USB type A and USB type C outlets will be required for a sufficient period o f time to meet the needs of users of both new and old devices. This extended use of USB charging in turn requires the components of the USB charging apparatus in particular the AC to DC conversion components to be larger in order to be able to deliver higher charging currents which again means more heat is generated within the apparatus.

There is however increasing demand for the installation of USB charging apparatus in confined spaces within commercial furniture in particular seating which thus may not be possible with USB charging apparatus with built in AC to DC conversion means and in addition the bringing of AC power to such apparatus and thus in close proximity to the outlet port could have safety implications in some situations. There is also interest in providing low voltage DC power circuits not just for LED lighting but also to provide USB type charging facilities, in particular as low voltage DC current is actually the primary source of electricity from solar panel and in trains so greater efficiency as well as safety would be obtained by providing said low voltage DC power direct to an apparatus for providing USB charging.

At present, the USB charging assemblies for application such as installation in commercial furniture can typically be provided as part of a standard configuration power assembly which is manufactured under factory conditions and the unit is then sold to the end user or installer with one or more Type A or Type C USB charging ports and control and conversion means for the same embedded within the unit and attachment means for an AC electricity supply. This form of unit is fixed in its configuration and cannot be converted subsequently by the user to suit their specific requirements. Alternatively, a customer may specify a particular charging assembly requirement and the manufacturer then makes the assembly to match that particular arrangement. However, this is an expensive, low volume solution.

While these different forms of the charging assemblies suit particular purposes, neither provide a solution to the problem currently faced by installers and/or operators of charging assemblies for industrial and commercial use such as, for example, for use in offices, factories, transport vehicles or public utility spaces, such as airports, railway stations and the like. In these environments it is not attractive to install factory configured units as this means that the installer cannot configure the units to suit the particular demands in a particular installation environment or to suit the particular item in which the same is to be installed, such as in an item of furniture and in addition the size of such units, the heat output generated by the AC to DC conversion means and/or safety considerations of requiring an AC power supply connection may also be negative factors. This therefore limits their installation options. Also, the use of charging assemblies which are free standing whether on desk/table top or floor are susceptible to theft by members of the public or may be adapted for use but in a potentially hazardous manner.

An aim of the present invention is therefore to provide a compact configurable modular charging assembly system for connection which can include a plurality of different outlet port type and output voltage modules, each of the modules capable of being used alone, or in combination with at least one other module, to allow the formation of a particular selected configuration of the modular power charging assembly.

In a first aspect of the invention, there is provided an electrical power charging assembly, said charging assembly including a number of modules, each with mechanical engagement means to allow the selective engagement of respective modules, and electrical connection means to allow the transfer of DC electrical power between an input and at least one output of said connected modules and wherein the module includes at least one outlet port from which DC power is available to provide power to an item of apparatus and, control means to control the DC power which is supplied from the said outlet port, said control means including means to convert the DC electrical power provided to the module to a DC voltage level suitable for an attached item of apparatus.

In one embodiment the said DC voltage level is suitable for charging the said attached item of apparatus.

In one embodiment the power which is transferred between the said connected modules is a DC power supply at a voltage level which is higher than that supplied from the outlet ports of the modules.

Typically the connection of the DC power supply to the electronic circuitry means in a module allows lower voltage DC power to be provided from the electronic circuitry means to the outlet port of that module.

In one embodiment each input for the DC power supply connection between modules is by a male electrical connector and each output by a female electrical connector and the respective input/ outputs are electrically connected within the module to allow the passage of the DC power supply therebetween.

In one embodiment both the input and output electrical connector types for the DC power supply in the module are male connectors and a connecting component is provided which has a female connector to be placed into the input/ output of a first module and a second female connector to be placed into the input/output of a second module. Thus, by using the connectors as herein described, the DC power supply to a first module may be transferred to a further module via the connecting component. In one embodiment the power charging assembly has a separate DC input connector for connection of an external DC power supply which then provides DC current throughout the interconnected modules.

In one embodiment the power charging assembly is combined with a dedicated AC to DC conversion means within a common housing, or mechanically and electrically connected housings, to provide DC current to the power charging apparatus.

In one embodiment the above said dedicated AC to DC conversion means is within a housing that can be both mechanically and electrically connected to one of the modules by using the same mechanical and electrical interface components as fitted to the modules

In one embodiment the power charging assembly includes electronic circuitry means to allow the mains AC power supply to be transformed to the DC power supply which is then provided throughout interconnected modules.

In one embodiment, a number of said male and/or female electrical connectors are provided on one or more faces of each module so as to allow a user to select the particular configuration of connection of the respective modules by placing the modules in the desired positions and placing the electrical connecting components into selected input/outputs of the modules to electrically connect the same.

Typically, in whichever configuration the modules are connected, an outlet port is available for use from each of the modules. In one embodiment the said outlet port on each module is provided in the form of a USB socket and more typically a USB Type A or a USB-C socket.

Typically, when the modules have been placed into the required configuration, the same are received within a housing so as to allow the housing and hence the power charging assembly to then be securely retained in position for subsequent use by the end user.

In one embodiment, the outlet port of the module is p ositioned at an external face of the module for selection by a user to charge an item of apparatus. Alternatively, the outlet port which is available for use by the end user is provided on a separate user interface component which includes an outlet port at an external face of the interface component and a plug which is provided to be connected to the outlet port of the module. This embodiment allows the said interface part to be sacrificial in that the same can be removed and replaced if damaged or to change the format of outlet port to be provided to the user, without having to alter or remove the module to which it is connected.

Typically, the modules include mechanical location means in addition to the mechanical location which is provided by the engagement of the connecting components and inlet/ outlets. This therefore avoids the reliance on the electrical connection component to maintain the modules in a particular configuration and therefore avoids possible damage being caused to the same.

In one embodiment, the mechanical location means include matching male and female formations on the housing of the module. It will therefore be appreciated that in accordance with the invention, the respective modules may be placed in a side by side configuration and attached to each other, may be stacked one on the other and attached to each other and/ or any combination of the same.

Typically, each of the modules is independently controlled so as to allow the particular DC voltage from the outlet port to be selected for that particular module, so that, for example, the outlet ports of respective modules in the same assembly may provide different DC voltage levels therefrom.

In one embodiment, the outlet ports are USB Type C p orts and the control means in the module allows the selective supply of a DC voltage at a specified level from the outlet port of that module.

In one embodiment, the particular DC voltage level is one of a range of possible DC voltage levels which can be provided and in one embodiment the particular voltage level is determined in response to detection of the particular item of apparatus which is connected to the outlet port at that time.

In one embodiment, once the configuration of the modules is selected, the modules are securely retained in position, such that removal or adaptation of the configuration is only possible using one or more tools. In one embodiment the retention is achieved by placing the modules in the selected configuration into a housing or specially adapted fixing means are provided to mechanically locate the modules and which fixing means can only be removed using a particular form of tool. In one embodiment sufficient male / female connectors for the transfer of DC power between modules are provided to allow each module to be selectively connected to another module in at least two different positions.

In a further aspect of the invention there is provided An electrical power charging module, said module including at least one electrical connector to receive a DC power supply and at least one electrical connector to pass the DC power supply therefrom to another module, at least one outlet port from which a DC power supply at a voltage level defined by control means in the module which control the power supply is provided, and electronic circuitry means to convert the DC power supply which enters the module to the required DC power supply level for the at least one outlet port.

Typically, connection means on the module allow the selective engagement of the module with another of the said modules and the passage of DC power therebetween.

In one embodiment, each module is independently controlled with respect to the DC voltage level which is available from its outlet port.

Typically, the level of the DC voltage made available from an outlet port of a module is unaffected by the DC voltages available from outlet ports of other interconnected modules in the power assembly.

In one embodiment, the power assembly comprises a plurality of modules, which are independently controllable to transform a received DC voltage supply to DC voltage levels which are made available simultaneously from outlet ports of the respective modules.

In a further aspect of the invention there is provided A method of providing a power assembly, the said method comprising providing a series of modules, each module having at least one outlet port from which DC power at a selected voltage level is made available to a connected item of apparatus, providing a connector interface by which a fixed voltage DC power supply from a source external to the assembly is received, transferring said fixed voltage DC power supply to said other module by selectively connecting an output connector of one module to an input connector of another module, and repeating these connecting step s with further modules until a required power assembly configuration of modules is achieved in which the modules are mechanically located and wherein at least one of the modules is capable of being selectively connected to another module in at least two different positions.

In one embodiment, once the particular configuration of modules has been selected, the assembly is placed into or used with securing means which allow the said assembly to be retained in the selected configuration.

In one embodiment, the assembly is placed into an item of furniture.

Thus, in accordance with the invention there is provided an assembly which can be attached to a DC supply source or, in another embodiment the assembly has an integral or attached AC to DC conversion device or one of the modules is an AC-DC conversion module with the same mechanical and electrical interfaces as the other modules.

Specific embodiments of the invention are now described with reference to the accompanying drawings; wherein

Figure 1 illustrates a module in accordance with one embodiment of the invention;

Figure 2 illustrates a module in accordance with a second embodiment of the invention;

Figures 3a-b illustrates a further embodiment of the use of the module of Figure 2;

Figures 4a-e illustrate a plurality of the modules of Figure 2 in selected configurations for use.

Referring firstly to Figures 1 and 2 there are illustrated two embodiments of a module 2 in accordance with the invention. In each embodiment there is provided a housing which has a top 4, bottom 6, front and rear walls 8,10 and side walls 12,14. There are also provided mechanical location formations on the housing and some of these are shown, with for example, female indents 22 on the top face 4 and a male protrusion 24 on the side wall 14. It will be appreciated that matching male protrusions 24 and female indents 22 will be provided on matching walls of other modules in the set of modules so as to allow the same to be selectively brought into engagement.

In both embodiments of the modules there is provided an outlet port 16, in this embodiment in the form of a USB Type-C socket, for the selective receipt of a USB plug therein in order to provide a DC power supply at the required voltage to be provided therefrom to charge an item of apparatus connected to the USB plug. Also provided are input/output connectors 18 and 20 which are used for the receipt of DC power typically at a fixed voltage such as from separate AC to DC conversion apparatus into the module and provision of said DC power from the module to an adjacent connected module. In the embodiment shown in Figure 2 there is provided a further input/ output 26 on the top face 4 and an input/ output 28 on the bottom face 6 of the housing and all of these inputs/ outputs are electrically connected together within the module housing so as to allow the passage of the DC power supply between the same.

In these embodiments the inputs/ outputs 18,20,26,28 are able to selectively receive a connecting component 30 therein. The connecting component is provided with a first interface 32 which allows electrical connection with one of the input/ output ports 18,20,26,28 of a first module and a second interface 34 which allows electrical connection with one of the input/ output ports 18,20,26,28 of another module to allow the transfer of the DC power supply between the modules.

In each module the incoming DC power supply is connected to control means within the same which allow the appropriate DC power supply level to be available from the outlet port 16. The control means includes electronic circuitry means which transforms the incoming DC power supply, typically by reducing the DC voltage level so as to allow the provision at a given time, of one of a range of possible voltage levels, with the particular voltage level being dependent upon the detected format and requirements of the item of apparatus connected to the module 2 via the outlet port 16 at that time.

In accordance with the invention, the modules can be selectively electrically and mechanically connected to suit a particular usage configuration for a particular location of use, environment and/or physical space which is available. In accordance with the invention, as there are provided a plurality of spaced apart input/ output connectors 18,20,26,28 and only two are required to be used to allow a further module to be connected then the installer has a range of possible configurations available to them.

Some of the configuration possibilities are illustrated in Figures 4a-e. In Figures 4a and b there is shown plan and elevation views of first and second modules 2, 2’ which are mechanically and electrically connected and a third module 2” is shown in the process of being moved into connection in the direction of arrow 36. The two modules 2,2’ which are connected are electrically connected so that the output 20 is connected to the input 18’ via connecting component 30 and are mechanically connected by the receipt of male protrusion 24 in the female indent 22’. The module 2” will be connected electrically to the module 2 by the connection of input 18 to the output 20” via another connecting component 30 and mechanically by the connection of the protrusion 24” in the indent 22.

Also shown in Figure 4b is that DC power from an external supply source is provided to the assembly via power cable 36 fitted with a connection component 38 which is received in the input 18” of the module 2” the DC voltage supply is transferred to each of the connected modules. Thus, in this embodiment there is provided a power assembly formed by the interconnected modules, with three outlet ports in the form of USB-C sockets 16, 16’, 16” and, as each module will have its own control means for the power supplied to the respective outlet port, it is p ossible that the outlet ports 16, 16’, 16” will provide different DC power at different DC voltage levels.

In Figure 4c there is illustrated a first stack of module s 2, 2’, 2” and in Figure 4d there are provided two stacks of modules 2,2’2” with the two stacks electrically and mechanically j oined together so that in total there are six modules, each of which provides an outlet port 16 available for use.

The modules 2, 2’, 2” are provided in a stack by using connecting components 30 to j oin, respectively output 28 to input 26’ and output 28’ to input 26”. Mechanical engagement is achieved by the provision of protrusions 24 in indents 22’ and protrusions 24’ in indents 22”. As shown in Figure 4d, the stacks can then be electrically j oined together using further connecting components 30 between outlet 20 and inlet 18, outlet 20’ and inlet 18’ and outlet 20” and inlet 18”and in each case DC power from an external supply source is provided via power cable 36 fitted with a connection component 38.

In figure 4e there is provided a stack of two modules 2,2’, similar to those shown in Figure 4c, and in this embodiment these modules are provided along with an AC to DC conversion module 39 with a female DC output connector 40 attaching to connector 26’ on module 2’ and an external source of AC power is connected to module 39 via power cable 42’ fitted with an AC power connection component 43’ which can be located internally of the module 39 as shown in broken lines or via cable 42 fitted with an AC power connection component 43 which is positioned and plugged in externally as shown in full lines, and in either embodiment connected on to DC output connector 40.

In Figures 3a and b there is illustrated a further embodiment of a module 2 in accordance with the invention. In this case the module 2 includes all of the features of the module shown in Figure 2 but in this case the socket 16 and face 8 are provided to receive an interface part 40 which has a connector 42 for receipt in the outlet port 16 of the module and a socket 44 connected to the connector 42 which, when the part 40 is connected to the module 2 is located on the external face 46 and available for use by the user. The part 40 is typically held in position mechanically by the jacking screw 48 which passes through the part and into a threaded aperture 50. This arrangement allows the component 40 to be sacrificial in as much as it can be replaced if it is damaged or , as illustrated in Figure 3a a component 40 with a first outlet port type 16 can be replaced by a component 40’ with a different outlet port type 16’. The provision of the jacking screw 48 allows the component 40 to be retained in position and not easily removable whilst allowing the adaptability of the configuration of the modules to be achieved.

Claims

1.An electrical power charging assembly, said charging assembly including a number of modules, each with mechanical engagement means to allow the selective engagement of respective modules, and electrical connection means to allow the transfer of DC electrical power between an input and at least one output of said connected modules and wherein the module includes at least one outlet port from which DC power is available to provide power to an item of apparatus and, control means to control the DC power which is supplied from the said outlet port, said control means including means to convert the DC electrical power provided to the module to a DC voltage level suitable for an attached item of apparatus.

2. An assembly according to claim 1 wherein the said DC voltage level is suitable for charging the said attached item of apparatus.

3. An assembly according to claim 1 wherein the voltage level of the DC electrical power supply provided to the modules is higher than the voltage of the DC power supplied from the at least one outlet port of the modules.

4. An assembly according to claim 3 wherein the connection of the DC electrical p ower supply to electronic circuitry means in a module creates the lower voltage DC power which is supplied from the same to the at least one outlet port of that module.

5. An assembly according to claim 1 wherein each input for the DC electrical power supply connection between modules is a male electrical connector and each output is a female electrical connector and the respective input/outputs are electrically connected to allow the passage of the DC electrical power supply therebetween.

6 An assembly according to claim 1 wherein both the input and output electrical connector types for the DC electrical power supply in the module are male connectors and a connecting component is provided which has a first female connector to be connected to the input/output of a first module and a second female connector to be placed into the other of the input/ output of a second module and thereby allow the DC electrical power supply to be transferred from a first module to the second module via the connecting component.

7 An assembly according to any of the preceding claims wherein a DC input connector is provided for connection therewith of an external DC power supply which then provides DC current throughout the interconnected modules.

8 An assembly according to claim 7 wherein the assembly is combined with an AC to DC conversion means so as to provide DC current to the power charging apparatus.

9 An assembly according to claim 8 wherein the said AC to DC conversion means is within a housing that can be both mechanically and electrically connected to one of the modules.

10 An assembly according to any of the preceding claims wherein the assembly includes a electronic circuitry means to allow a mains AC power supply to be transformed to the DC power supply which is then provided throughout interconnected modules.

11. An assembly according to any of the preceding claims wherein a number of said male and/or female electrical connectors are provided on one or more faces of each module so as to allow a user to select the particular configuration of connection of the respective modules by placing the modules in the desired positions and electrically connecting the same.

12. A n assembly according to claim 11 wherein the electrical connection is made by placing the electrical connecting components into selected input/outputs of the modules to electrically connect the same.

13 An assembly according to any of claims 11 or 12 wherein in whichever configuration the modules are connected, an outlet port is available for use from each of the modules.

14 An assembly according to any of the preceding claims wherein the said outlet port on each module is provided in the form of a USB socket and more typically a USB Type A or a USB-C socket.

15. An assembly according to any of the preceding claims wherein when the modules have been placed into the required configuration, the same are received within a housing.

16 An assembly according to claim 15 wherein the housing is securely retained in position for subsequent use by the end user.

17. An assembly according to any of the preceding claims wherein the at least one outlet port o f the module is po sitioned at an external face of the module for selection by a user to charge an item of apparatus.

18 An assembly according to any of the claims 1 - 16 wherein the at least one outlet port receives a user interface component which includes an outlet port and a plug which is provided to be connected to the outlet port of the module.

19 An assembly according to claim 1 8 wherein the said interface component is sacrificial in that the same can be removed and replaced if damaged or to change the format of outlet port to be provided to the user, without having to alter or remove the module to which it is connected.

20 An assembly according to any of the preceding claims wherein the modules include mechanical location means in addition to the mechanical location which is provided by the engagement of the connecting components and inlet/outlets.

21. An assembly according to claim 20 wherein the mechanical location means include matching male and female formations on the housing of the module.

22. An assembly according to any of the preceding claims wherein each of the modules is independently controlled so as to allow the particular DC voltage level of the power supply which is made available from the outlet p ort to be selected for that particular module.

23 An assembly according to any of the preceding claims wherein the particular DC power supply voltage level is one of a range of possible DC voltage levels which can be selected.

24 An assembly according to claim 23 wherein the particular voltage level is determined in resp onse to detection of the particular item of apparatus which is connected to the outlet port at that time.

25 An assembly according to any of the preceding claims wherein once the configuration of the modules is selected, the modules are securely retained in position and removal or adaptation of the configuration is only possible using one or more tools.

26 An assembly according to claim 25 wherein the retention is achieved by placing the modules in the selected configuration into a housing or specially adapted fixing means are provided to mechanically locate the modules and which fixing means can only be removed using a particular form of tool.

27 An assembly according to any of the preceding claims wherein the modules are selectively connectable to each other in at least two different positions.

28. A n assembly according to any of the preceding claims wherein DC power supplies are provided simultaneously from outlet ports of the respective modules .

29. An electrical p ower charging module, said module including at least one electrical connector to receive a DC power supply and at least one electrical connector to pass the DC power supply therefrom to another module, at least one outlet port from which a DC power supply at a voltage level defined by control means in the module which control the power supply is provided, and electronic circuitry means to convert the DC power supply which enters the module to the required DC power supply level for the at least one outlet port.

30. A module according to claim 29 wherein each module is independently controlled with respect to the DC voltage level which is available from its outlet port.

31 A method of providing a power assembly, the said method comprising providing a series of modules, each module having at least one outlet port from which DC power at a selected voltage level is made available to a connected item of apparatus, providing a connector interface by which a fixed voltage DC power supply from a source external to the assembly is received, transferring said fixed voltage DC power supply to said other module by selectively connecting an output connector of one module to an input connector of another module, and repeating these connecting step s with further modules until a required power assembly configuration of modules is achieved in which the modules are mechanically located and wherein at least one of the modules is capable of being selectively connected to another module in at least two different positions.

32. A method according to claim 31 wherein once the particular configuration of modules has been selected, the assembly is placed into or used with securing means which allow the said assembly to be retained in the selected configuration.

33 A method according to claim 31 wherein the fixed voltage DC power supply is provided from an AC to DC conversion device.

34 A method according to any of claims 31 -33 wherein the modules include electronic circuitry means to allow the voltage level of the said DC power supply to the at least one outlet o f the module to be selected.

35 A method according to claim 34 wherein user selection means, and/ or apparatus type detection means are provided in the module to allow the DC power supply voltage level suitable for the outlet port at that time to be selected.