U.S. patent application number 09/728869 was filed with the patent office on 2001-06-07 for waterproof inductive charging paddle.
Invention is credited to Koike, Yasuhiro.
Application Number | 20010002788 09/728869 |
Document ID | / |
Family ID | 18382066 |
Filed Date | 2001-06-07 |
United States Patent
Application |
20010002788 |
Kind Code |
A1 |
Koike, Yasuhiro |
June 7, 2001 |
Waterproof inductive charging paddle
Abstract
An induction type charging paddle engages a receptacle to charge
a battery. The charging paddle has a housing, and a circuit board
is located in the housing to control the charging operation. A case
is located in the housing to accommodate the circuit board. The
case is sealed to prevent the circuit board from becoming wet.
Inventors: |
Koike, Yasuhiro;
(Kariya-shi, JP) |
Correspondence
Address: |
Kurt E. Richter
Morgan & Finnegan, L.L.P.
345 Park Avenue
New York
NY
10154
US
|
Family ID: |
18382066 |
Appl. No.: |
09/728869 |
Filed: |
December 1, 2000 |
Current U.S.
Class: |
320/108 |
Current CPC
Class: |
Y02T 10/7072 20130101;
Y02T 90/14 20130101; H02J 50/10 20160201; Y02T 90/12 20130101; Y02T
90/16 20130101; B60L 53/12 20190201; Y02T 10/70 20130101; B60L
53/34 20190201 |
Class at
Publication: |
320/108 |
International
Class: |
H02J 007/00 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 6, 1999 |
JP |
11-346239 |
Claims
What is claimed is:
1. An induction type charging paddle for engaging a receptacle to
charge a battery, the charging paddle comprising: a housing; a
circuit board used for controlling the charging of the battery; and
a case located in the housing to accommodate the circuit board,
wherein the case is sealed to prevent the circuit board from
becoming wet.
2. The charging paddle according to claim 1, wherein the receptacle
has an infrared communication device, wherein an infrared
communication device is located on the circuit board to communicate
the infrared communication device of the receptacle.
3. The charging battery according to claim 2, wherein the housing
and the case is formed with a resin that transmits infrared
light.
4. The charging battery according to claim 3, wherein the housing
has a first side and a second side, wherein the second side is
substantially parallel to the first side, and wherein a prism is
located in the charging paddle, and the prism causes the infrared
light radiated from the communication device to exit from both of
two opposite sides of the charging paddle, and the prism leads
infrared radiation from either of the two opposite sides of the
paddle to the communication device.
5. The charging battery according to claim 4, wherein the prism is
attached to the case.
6. The charging battery according to claim 1, wherein the shape of
the case substantially conforms to that of the circuit board.
7. The charging battery according to claim 1, wherein an opening is
defined in the case, and the opening is sealed by a sealing
resin.
8. The charging battery according to claim 1, wherein the case has
a first case component and a second case component, which are
fitted each other, wherein a peripheral seal member is located
between the first case component and the second case component.
9. The charging battery according to claim 8, wherein a fastener
fixes the case to the housing, wherein the fastener is located
outside of the seal member.
10. The charging battery according to claim 1, wherein the case is
transparent to infrared light.
11. An induction type charging paddle for cooperating with a
receptacle to charge a battery, wherein the receptacle has an
infrared communication device, the charging paddle comprising: a
housing; a circuit board used for controlling the charging of the
battery, wherein the circuit board has an infrared communication
device to communicate with the infrared communication device of the
receptacle; and a case located in the housing to accommodate the
circuit board, wherein the case is made with an
infrared-transmitting resin, and the case is colorless and
transparent, and wherein the case is sealed to prevent moisture
from reaching the circuit board.
12. The charging battery according to claim 11, wherein an opening
is defined in the case, and the opening is sealed by a sealing
resin.
13. The charging battery according to claim 11, wherein the case
has a first case component and a second case component, which are
fitted each other, wherein a peripheral seal member is located
between the first case component and the second case component.
14. The charging battery according to claim 13, wherein a fastener
fixes the case to the housing, wherein the fastener is located
outside of the seal member.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a waterproof structure for
charging paddles used in inductive battery chargers.
[0002] Generally, there is an induction method for charging
batteries in electric vehicles. According to this charging method,
as shown in FIG. 6, a charging paddle 50 is connected to a cable 63
extending from a power supply unit. The paddle 50 is inserted to a
receptacle 51 of a vehicle to charge a battery.
[0003] The charging paddle 50 is provided with a primary core 52
and a primary coil 53. The receptacle 51 is provided with a
secondary core 54 and a secondary coil 55. The charging paddle 50
is inserted to a slot 56 of the receptacle 51. An alternating
current supplied from the power supply unit flows through the
primary coil 53 to generate an electromotive force in the secondary
coil 55 by electromagnetic induction. The battery in the vehicle is
charged based on this electromotive force.
[0004] The charging paddle 50 has an insert head 57 that is
inserted in the slot 56 of the receptacle 51 and a grip 58, which
is gripped by an operator. The insert head 57 includes the primary
core 52, the primary coil 53 and a circuit board 59 having a
communication device. The communication device carries out wireless
communication with a communication device 60 in the receptacle 51.
The communication device in the charging paddle 50 receives
information about the vehicle, including the battery capacity,
through this communication.
[0005] The charging paddle 50 has a housing 62 formed by welding
two housing components 61. The cable 63 is introduced into the
housing 62 through a lead-in hole defined in the grip 58. A
waterproof grommet 64 is fitted in the lead-in hole. The grommet 64
prevents water from entering the housing 62.
[0006] However, for example, if it happens that an operator drops
the charging paddle 50 and cracks the housing 62, water may
penetrate the housing 62. Also, if the cable 63 is pulled very
strongly, the waterproof grommet 64 fails to fully seal the lead-in
hole, and water may enter the housing 62 through the lead-in hole.
Therefore, the circuit board 59 may get wet.
SUMMARY OF THE INVENTION
[0007] It is an objective of the present invention to provide a
waterproof structure for an inductive charging paddle, which
prevents the circuit board from becoming wet, even if water enters
the housing of the charging paddle.
[0008] In order to attain the above objective, the present
invention provides an induction type charging paddle for engaging a
receptacle to charge a battery. The charging paddle comprises a
housing. A circuit board is used for controlling the charging of
the battery. A case is located in the housing to accommodate the
circuit board. The case is sealed to prevent the circuit board from
becoming wet.
[0009] Other aspects and advantages of the invention will become
apparent from the following description, taken in conjunction with
the accompanying drawings illustrated by way of examples the
principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The invention together with the objects and advantages
thereof, may best be understood by reference to the following
description of the presently preferred embodiments together with
the accompanying drawings in which:
[0011] FIG. 1 is a cross-sectional view showing the charging paddle
according to a first embodiment of the present invention;
[0012] FIG. 2 is a perspective view of the receptacle and the
charging paddle shown in FIG. 1;
[0013] FIG. 3 is a cross-sectional view taken along the line 3-3 in
FIG. 1;
[0014] FIG. 4 is an exploded perspective view of the case for the
circuit board shown in FIG. 1;
[0015] FIG. 5 is an enlarged cross-sectional view taken along the
line 5-5 in FIG. 1; and
[0016] FIG. 6 is a perspective view showing the receptacle and the
charging paddle of the prior art.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] A first embodiment of the present invention will be
described below referring to FIGS. 1 to 5.
[0018] FIG. 2 shows a charging paddle 10 connected to a cable 21
extending from a stationary power supply unit and a receptacle 11
incorporated to a vehicle.
[0019] The receptacle 11 is provided with a secondary core 12 and a
secondary coil 13, which is wound around a cylindrical magnetic
pole 12a of the core 12. The receptacle 11 has a circuit board 14
on which a wireless communication device is mounted.
[0020] The charging paddle 10 has a housing 15, as shown in FIG. 2.
The charging paddle 10 includes an insert head 16, which is
inserted to a slot 11a of the receptacle 11, and a grip 17, which
is to be gripped by an operator. The housing 15 has a pair of
housing members 18a and 18b. The housing members 18a and 18b are
each integrally molded using an infrared-transmitting resin (e.g.,
a polycarbonate resin), which is colored using an
infrared-transmitting pigment.
[0021] The insert head 16 includes a cylindrical primary core 19
and an annular primary coil 20, which is fitted around the primary
core 19.
[0022] As shown in FIG. 1, the grip 17 has a lead-in hole 17a, in
which a waterproof grommet 25 is fitted. The cable 21, which
extends from the power supply unit, is inserted through the
waterproof grommet 25 into the housing 15.
[0023] As shown in FIGS. 1 and 3, the insert head 16 is provided
with a circuit board 22 for communication. The circuit board 22
confirms whether the charging paddle 10 is correctly connected to
the receptacle 11. Further, information about the vehicle,
including the battery capacity, is transmitted through the circuit
board 22.
[0024] In this embodiment, infrared communication is employed as
the communication method. The circuit board 22 includes a
communication integrated circuit 23 and an infrared communication
element 24.
[0025] The cable 21 includes electric supply lines 26 connected to
the primary coil 20, power source lines 27 and signal lines 28,
which are connected to the circuit board 22 with the power supply
unit.
[0026] Next, the characteristics of the present invention will be
described specifically.
[0027] The circuit board 22 is contained in a water-proof case 29.
The case 29 is made of a colorless and transparent infrared
transmitting resin. The case 29 substantially conforms to the
circuit board 22, as shown in FIG. 1.
[0028] As shown in FIG. 4, the case 29 has a first case component
30, a second case component 31 and an annular gasket 32 located
between these two cases 30 and 31.
[0029] The first case component 30 has an upright guide wall 30a.
The first case component 30 also has an peripheral groove 30b
formed along the outer surface of the guide wall 30a. The gasket 32
is fitted in this groove 30b. The second case component 31 is
fitted about the guide wall 30a. The first case component 30
contacts the gasket 32. The circuit board 22 is contained in the
first case component 30 and is positioned by the guide wall
30a.
[0030] A notch 30c is formed in the guide wall 30a. An opening 33
is defined in the second case component 31 to oppose the notch 30c.
As shown in FIG. 5, the power source lines 27 and signal lines 28
connected to the circuit board 22 are led out through the notch 30c
and the opening 33 to the outside of the case 29.
[0031] As shown in FIG. 4, a notch 30d is defined in the first case
component 30 to oppose a light-emitting section and a
light-receiving section of the communication element 24. A prism 34
is supported by a pair of pins 30e on the external side of the
guide wall 30a to oppose the notch 30d. The second case component
31 has a pair of regulating pieces 31a for engaging the prism 34.
The prism 34 causes the infrared light radiated from the
communication element 24 to exit from both sides of the charging
paddle 10. The prism 34 also leads the infrared radiation coming in
from either side of the paddle 10 to the communication element 24.
This enables communication when the charging paddle 10 is inserted
to the slot 11a (see FIG. 2) in both possible orientations of the
paddle 10 with respect to the receptacle 11.
[0032] The inner surface of the housing member 18a has protrusions,
such as ribs (not shown), for locating the first case component 30
in a predetermined position. As shown in FIG. 4, a plurality of
fixing pieces 31b are formed at the periphery of the second case
component 31 to protrude horizontally. Each fixing piece 31b
contains a hole 36 for receiving a fastener such as a screw 35 (see
FIG. 1). A plurality of bosses 37 are formed to protrude from the
inner surface of the housing member 18a, at sites corresponding to
the fixing pieces 31b of the second case component 31, respectively
(only one boss 37 is shown in FIGS. 1 and 5).
[0033] The circuit board 22 is contained in the case 29, and with
the lines 27 and 28 are led out from the notch 30c and the opening
33. The case 29 is located in a predetermined position in the
housing member 18a. The screws 35 secure the fixing pieces 31 to
the bosses 37, respectively, to fix the case 29 to the housing
member 18a. Since the screws 35 are outside of the gasket 32, the
case 29 is hermetically sealed. Further, the notch 30c and the
opening 33 are hermetically sealed by a sealing resin (e.g.,
potting material) 38.
[0034] As described above, the joint between the first case
component 30 and the second case component 31 of the case 29 is
sealed by the gasket 32, and the opening 33 is sealed by the
sealing resin 38 to form water-proof seals.
[0035] This embodiment has the following effects.
[0036] If water enters the housing 15 through cracks formed in the
charging paddle 10 or through the lead-in hole 17a of the cable 21,
the circuit board 22 is protected in the hermetically sealed and
water-proof case 29.
[0037] The communication element 24 on the circuit board 22
performs reliable infrared communication with the receptacle 11
through the housing 15 and case 29. Further, since the case 29 is
colorless and transparent, whether or not the circuit board 22 is
set properly in the case 29 can be visually confirmed from the
outside of the case 29. Thus, a defect in the position of the
circuit board 22 in the case 29 can be eliminated before the
housing members 18a and 18b are welded.
[0038] The sealing resin 38 is poured into the opening 33 to seal
it, so that the case 29 is fully sealed against moisture.
[0039] Since the screws 35 are on the external side of the gasket
32, they do not impair the gasket 32. For example, if a screw is
driven into a location inside the gasket 32, that location must be
additionally sealed. However, such a complicated sealing structure
is not necessary.
[0040] The shape the case 29 substantially conforms to that of the
circuit board 22. This reduces the size of the case 29 to
facilitate incorporation of the case 29 into the housing 15.
Further, the circuit board 22 is correctly positioned by the guide
wall 30a.
[0041] Since the prism 34 is attached to the case 29, the prism 34
can be easily positioned with respect to the communication element
24 by merely setting the circuit board 22 in the case 29.
[0042] The above embodiment can be modified as follows.
[0043] The gasket 32 may be replaced with a sealing resin, or a
liquid sealing material may be applied to the joint faces.
[0044] The case 29 may be fixed to the housing 15 using, for
example, an adhesive.
[0045] The opening 33 may be sealed with a sealing material such as
a rubber.
[0046] While the case 29 includes the first case component 30 and
the second case component 31, the lid-like case component may be
bonded to the housing 15 with a sealing material.
[0047] The case may contain a plurality of circuit boards.
[0048] The method of communication is not limited to infrared
communication. For example, an antenna may be contained in the
housing 15 to enable radio communication. In this case, the
material of the case 29 is not limited to infrared transmitting
resin, and the case 29 may be opaque. Further, a combination of
infrared communication and radio wave communication may be used as
the communication method.
[0049] Circuit boards for charging control devices other than the
communication device may be contained in the case 29. Also, more
than one case 29 may be incorporated, as necessary.
[0050] The present invention may be applied not only to a vehicle
charging paddle but also to various kinds of battery-powered
apparatuses, such as self-propelled robots.
[0051] It should be apparent to those skilled in the art that the
present invention may be embodied in many other specific forms
without departing from the spirit or scope of the invention.
[0052] Therefore, the present examples and embodiments are to be
considered as illustrative and not restrictive, and the invention
is not to be limited to the details given herein, but may be
modified within the scope of the appended claims.
* * * * *