U.S. patent application number 09/731967 was filed with the patent office on 2001-06-21 for vehicle battery charger with wiring opening.
Invention is credited to Kajiura, Katsuyuki.
Application Number | 20010004201 09/731967 |
Document ID | / |
Family ID | 18453230 |
Filed Date | 2001-06-21 |
United States Patent
Application |
20010004201 |
Kind Code |
A1 |
Kajiura, Katsuyuki |
June 21, 2001 |
Vehicle battery charger with wiring opening
Abstract
A charger includes a power source device having an outer casing
constructed by housing, an upper housing and a side cover, which
are formed of metal. Circuit boards and electric components are
mounted to the lower housing. An indicator, a coupler resting case
and a sensor are mounted on the upper housing. An opening is formed
in the upper housing so that wires extending from the indicator and
the sensor can be connected to wires extending from the circuit
board through the opening of the upper housing, after the upper
housing is placed on the lower housing. The opening is closed by a
cover and is electromagnetically sealed.
Inventors: |
Kajiura, Katsuyuki;
(Kariya-shi, JP) |
Correspondence
Address: |
WOODCOCK WASHBURN KURTZ MACKIEWICZ & NORRIS LLP
One Liberty Place, 46th Floor
Philadelphia
PA
19103
US
|
Family ID: |
18453230 |
Appl. No.: |
09/731967 |
Filed: |
December 7, 2000 |
Current U.S.
Class: |
320/109 |
Current CPC
Class: |
Y02T 90/14 20130101;
Y02T 10/7072 20130101; Y02T 10/70 20130101; B60L 53/31 20190201;
Y02T 90/12 20130101 |
Class at
Publication: |
320/109 |
International
Class: |
H02J 007/00 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 16, 1999 |
JP |
11-357263 |
Claims
1. A charger for a vehicle, comprising a power source unit and a
feeding coupler connected to the power source unit via a cable and
adapted to be coupled to a receiver of a vehicle, said power source
unit comprising: an outer casing including a metallic base having
an electric circuit component mounted thereon and a metallic
tubular member having a closed end and placed on said metallic base
so as to cover said electric circuit component; an electric member
mounted on said tubular member in an electromagnetically shielded
state; said tubular member having an opening for connecting wires
between said electric member and said electric circuit component
through said opening; and an electromagnetically shielding material
covering said opening.
2. A charger as set forth in claim 1, wherein said electric member
is mounted on said tubular member such that said electric member is
at least partially exposed from an external surface of said tubular
member.
3. A charger as set forth in claim 1, wherein said tubular member
has a bulge portion integrally formed with said tubular member in
which said electric member is accommodated in such a manner as to
be partially exposed from the external surface of said tubular
member, said opening being formed in said bulge portion.
4. A charger as set forth in claim 1, wherein said electric member
is mounted on the outside of said tubular member in an
electromagnetically shielded state.
5. A charger as set forth in claim 4, wherein said wires include
electrically shielded wiring extending to the outside of said
tubular member and connected to said electric member.
6. A charger as set forth in claim 1, wherein said
electromagnetically shielding material comprises a metallic housing
cover mounted on said tubular member in a such a manner as to cover
said electric member and said wiring exposed from the external
surface of said tubular member, or is located on the outside of
said tubular member, and said opening.
7. A charger as set forth in claim 1, wherein said electric member
is an indicator.
8. A charger as set forth in claim 1, wherein said electric member
is a detector for detecting insertion or removal of said feeding
coupler into or from a coupler rest portion provided on the outside
of said tubular member.
9. A charger for a vehicle, comprising a power source unit, and a
feeding coupler connected to said power source unit via a cable and
adapted to be coupled to a receiver of a vehicle, said power source
unit comprising: an outer casing including a metallic base having
an electric circuit component mounted thereon, and a metallic
tubular member having a closed end and placed on said metallic base
so as to cover said electric circuit component; and an electric
member provided on said metallic base.
10. A charger as set forth in claim 9, wherein said electric member
is an indicator.
11. A charger as set forth in claim 9, wherein said electric member
is a detector for detecting insertion or removal of said feeding
coupler into or from a coupler rest portion provided on the outside
of said tubular member.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a battery charger for a
vehicle having a feeding coupler adapted to be coupled to a
receiver in the vehicle for charging the battery provided on the
vehicle such as an electric automobile or the like.
[0003] 2. Description of the Related Art
[0004] In a charger for a vehicle, charging is performed by
coupling a feeding coupler connected via a cable to a power source
device (a power supply device) to a receiver (a receiving charging
port) provided on a vehicle. Conventionally, an inductive system
(an electromagnetic system induction) charger and a conductive
system using different charging methods, are known.
[0005] For example, there has been proposed a charger for an
inductive system as shown in FIG. 7.
[0006] The charger 71 comprises a power source device (a power
supply device) 72 and a feeding coupler 74 attached to a distal end
of a cable 73 extending from the power source device 72. The power
source device 72 converts an alternating current supplied from a
commercial alternating current power source into a charging
alternating current (a predetermined frequency, a predetermined
voltage) and outputs the alternating current so converted to the
cable 73. A primary coil is built in the feeding coupler 74, and
when the feeding coupler 74 is inserted in a receiver in the
vehicle, an alternating current flows through the primary coil, and
then current is induced in a secondary coil in the receiver under
the action of electromagnetic induction, whereby charging is
done.
[0007] A housing (outer casing) 75 of the power source device 72 is
made of metal and comprises a base 76 and a bottomed tubular upper
housing 77. Various electric circuit components for power and
control systems (for example, a circuit board)(not shown) are
mounted on the base 76. On the other hand, an indicator 78 and a
coupler rest portion 79 where the feeding coupler 74 is inserted
for rest are provided on the upper housing 77, and the indicator 78
is electrically connected to the electric circuit component,
attached to the base 76, via wiring. A communication device is
built in the feeding coupler 74 for communication with the receiver
on the electric automobile to obtain information on the residual
capacity of the battery when the coupler 74 is connected to the
receiver on the vehicle. The communication device is controlled so
as to be powered in a state in which the feeding coupler 74 is
removed from the rest portion 79, and there is provided a sensor 80
for detecting the insertion or removal of the feeding coupler 74
into or from the rest portion 79. The sensor 80 is conventionally
attached to the inner surface of the housing 75 for detecting the
magnetism of a magnet located at a predetermined position in the
feeding coupler 74.
[0008] The reason why the indicator 78 and the sensor 80 are
mounted on the internal surface of the upper housing 77 is because
the electric circuit components and electric apparatuses 78, 80 are
completely covered with the metallic housing 75 for electromagnetic
shielding.
[0009] Assembling the power source device 72 is done by placing the
upper housing 77 on the base 76 so as to cover components to be
accommodated therein such as the electric circuit components. When
this occurs, the electric circuit components provided on the base
76 are required to be connected to the indicator 78 and the sensor
80 provided on the upper housing 77 via wiring before the upper
housing 77 is completely placed on the base 76. To this end, for
example, electric wires have to be made sufficiently long to
complete the connection of the components before the upper housing
77 is placed on the base 76, or the connection has to manually be
completed within the upper housing 77 which is being placed on the
base 76. However, the longer electric wires cause a problem that
the wires get entangled with the components and that the position
of the wires changes within the housing 75. Additionally, with the
method in which the electric wires are made short for connection at
an intermediate position, not only it is difficult to connect the
wires to each other but also there may be a risk that the wires
become disconnected due to a load that would be applied thereto
unless the upper housing is handled carefully. With both methods,
the assembling operation has to be carried out carefully, and this
makes assembling the power source device 72 very troublesome,
decreasing the production efficiency (decreasing the productivity)
of the chargers 71.
SUMMARY OF THE INVENTION
[0010] The present invention is made to solve the aforesaid
problems, and an object thereof is to provide a charger for a
vehicle which can facilitate the assembling work of a power source
unit by reducing labor hours in assembling an outer casing even if
a construction is adopted in which an electric member is mounted on
the outer casing of the charger and hence which can increase the
production efficiency of chargers.
[0011] With a view to attaining the above object, according to the
present invention, there is provided a charger for a vehicle,
comprising a power source unit and a feeding coupler connected to
the power source unit and adapted to be coupled to a receiver of a
vehicle. The power source unit comprises an outer casing including
a metallic base having an electric circuit component mounted
thereon and a metallic tubular member having a closed end and
placed or fitted on the metallic base so as to cover the electric
circuit component, an electric member mounted on the tubular member
in an electromagnetically shielded state, the tubular member having
an opening for connecting wires between the electric member and the
electric circuit component through the opening, and an
electromagnetically shielding material covering the opening.
[0012] According to this structure, the electric wires of the
electric member and the electric circuit component can be connected
to each other through the opening in the tubular member after the
tubular member is placed on the base so that the electric component
is covered. Consequently, the assembling work of the power source
unit can be facilitated. In addition, since the opening is covered
by the electromagnetically shielding material, the components
accommodated in the power supply unit can be electromagnetically
shielded by the outer casing comprising the metallic base and the
tubular member.
[0013] Preferably, the electric member is mounted on the tubular
member such that the electric member is at least partially exposed
at an external surface of the tubular member.
[0014] In this structure, in a case where the electric member needs
to be mounted in such a manner as to be partially exposed from the
external surface of the tubular unit or needs to be mounted on the
outside of the tubular unit, although there is no way but to
assembly the electric member to the tubular member side, the
assembling work of the power source unit can be facilitated.
[0015] Preferably, a bulge portion is formed integrally with the
tubular member in which the electric member is accommodated in such
a manner as to be partially exposed from the external surface of
the tubular member, and the opening is formed in the bulge
portion.
[0016] In this structure, in assembling the electric member in such
a manner that the electric member is accommodated in the bulge
portion of the tubular member, since there is provided the opening,
the assembling of the electric member and connection of the
electric wires can be facilitated, and moreover, since the electric
member is accommodated in the bulge portion, both the electric
member and wiring can be disposed within the tubular member in the
electromagnetically shielded state. Due to this, no separate
electromagnetically shielding construction has to be adopted
individually for the electric apparatus and wiring.
[0017] Preferably, the electric member is mounted on the outside of
the tubular member in an electromagnetically shielded state.
[0018] In this structure, although the electric member is mounted
on the outside of the tubular member, since it is
electromagnetically shielded, the leakage of electromagnetic waves
can be prevented.
[0019] Preferably, the wires includes an electrically shielded
wiring extending from the outside of the tubular member and
connected to the electric member.
[0020] In this construction, since the wiring extending from the
outside of the tubular member for connection to the electric member
is the electrically shielded wiring, the wiring does not constitute
a source from which electromagnetic waves are irradiated, whereby
the leakage of electromagnetic waves can be prevented.
[0021] Preferably, the electromagnetically shielding material
comprises a metallic housing cover mounted on the tubular member in
such a manner as to cover the electric member and the wiring
exposed from the external surface of the tubular member or is
located on the outside of the tubular member, and the opening.
[0022] In this construction, the electric member and the wiring
exposed from the external surface of the tubular member or the
electric member, and the opening which are located on the outside
of the tubular member are covered by and electromagnetically
shielded by the metallic housing cover mounted on the tubular
member, and also covering the power source unit with the housing
cover can provide a better external appearance to the power source
main body.
[0023] According to another aspect of the present invention, there
is provided a charger, for a vehicle, comprising a power source
unit and a feeding coupler connected to the power source unit and
adapted to be coupled to a receiver of a vehicle, the power source
unit comprising an outer casing, a metallic base having an electric
circuit component mounted thereon and a metallic tubular member
having a closed end and placed on the metallic base so as to cover
the electric circuit component, and an indicator provided on the
metallic base.
[0024] In this structure, since the electric member is mounted on
the base, even in the event that the electric member and the
electric circuit component are connected in advance, the wiring
does not interrupt the placement of the tubular member on the base
for the purpose of covering the electric component, facilitating
the assembly work of the power source unit. In addition, the
components accommodated in the power source unit can be
electromagnetically shielded by the outer casing comprising the
metallic base and the tubular member.
[0025] Preferably, the electric apparatus is an indicator, and/or a
sensor for detecting the insertion or removal of the feeding
coupler into or from a coupler resting portion where the feeding
coupler is removably inserted which is mounted on the outside of
the tubular member.
[0026] In this construction, even in the event that the indicator
or the sensor is mounted on the tubular unit, the assembly work of
the power source unit can be facilitated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] The present invention will become more apparent from the
following description of the preferred embodiments, with reference
to the accompanying drawings, in which:
[0028] FIG. 1 is a partially exploded front view of a power source
unit constituting an electromagnetic induction non-contact type
battery charger according to an embodiment of the present
invention;
[0029] FIG. 2 is a side view of the power source unit, with the
side cover removed;
[0030] FIG. 3 is an enlarged side view of the power source unit of
FIG. 2;
[0031] FIG. 4 is an exploded perspective view of the power source
unit;
[0032] FIG. 5 is a perspective view of the electromagnetic
induction non-contact type charger battery charger and a
vehicle;
[0033] FIG. 6 is a partially exploded front view of a power source
unit according to another embodiment of the present invention;
and
[0034] FIG. 7 is a front view showing a conventional charger.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0035] Referring to FIGS. 1 to 5, an embodiment of the present
invention will be described below in which the invention is
embodied as an electromagnetic induction non-contact type battery
charger for a vehicle.
[0036] As shown in FIG. 5, the electromagnetic induction
non-contact type battery charger (hereinafter, referred to as a
charger) 1 comprises a power source device (a power supply device)
2 as a power source unit and a paddle-type (flat shaped) feeding
coupler 4 provided at a distal end of a cable 3 extending from the
power source device 2. The power source device 2 is supported by a
stand 5 arranged upright on the ground.
[0037] The feeding coupler 4 has an inserting portion 4a adapted to
be removably inserted into a coupler inserting opening 7a of a
receiving charge port (a receiving coupler) 7 as a receiver
arranged at a selected position (for example, at a front portion of
a bonnet) of an electric automobile 6 as a vehicle.
[0038] In charging the electric automobile 6, the inserting portion
4a of the feeding coupler 4 is inserted into the coupler inserting
opening 7a of the charge port 7, as indicated by chain lines in
FIG. 5. When the feeding coupler 4 is connected to the charge port
7, communication is established between them, and the power source
device 2 sets a preferred charging condition based on information
obtained from the electric automobile 6 on the residual capacity of
a battery, converts a commercial alternating current into a
charging alternating current (a predetermined voltage, a
predetermined frequency) and outputs the alternating current so
converted to the feeding coupler 4. The alternating current is
supplied from the power source device 2 to the battery 8, while the
alternating current is transmitted from a primary coil in the
feeding coupler 4 a secondary coil in the charge port 7 under the
action of electromagnetic induction, whereby the battery 8 on the
electric automobile 6 is charged.
[0039] The construction of the power source device 2 will be
described. As shown in FIG. 4, a metallic (for example, iron or
aluminum) housing 10 as an outer casing constituting the power
source device 2 comprises a lower housing 11 as a base supported on
the upper surface of the stand 5, a rectangular tubular upper
housing 12 with the upper end thereof closed, and a side cover 13,
which acts as an electromagnetic shielding material and a housing
cover covering the right-hand side of the upper housing 12.
[0040] A rectangular tubular duct 16 is attached to the front side
of a back board 15, which is welded to and integral with the lower
housing 11, and a power system circuit board 21 and a
control-system circuit board 22 are directly attached to the front
side and one side (right-hand side) of the duct 16, respectively.
Electric components (electronic components) 23 constituting a
power-system circuit such as a rectification circuit, a power
factor improving circuit and a resonance converter are installed on
the power system circuit board 21. A capacitor 24 and a coil (a
resonance coil) 25, which constitute the power-system circuit and
are relatively heavy, are supported by the back board 15 and
disposed on the power-system circuit board 21 (on the left-hand
side thereof). The power-system circuit is designed to rectify an
alternating current supplied from an external commercial
alternating current power source and convert the convert obtained
direct current into a charging alternating current of, for example,
several tens of kHz in order to output it to the cable 3 (FIG. 5).
Note that the electric circuit components are constituted by the
circuit boards 21 and 22, the capacitor 24, the coil 25 and
others.
[0041] In addition, electronic components (including a CPU) (not
shown) constituting various control circuits for governing the
control of the power-system circuit and the control of
communication of a communication device (for example, an infrared
communication device or a radio communication device) built in the
feeding coupler 4 are installed on the control-system circuit board
22. The control circuits include an indication control circuit and
a communication power source control circuit for switching on and
off the power source of the communication device.
[0042] As shown in FIG. 4, the duct 16 has at the top thereof an
approximately rectangular tubular hood 26 the size of which
increases toward its top, and a pair of left and right blowers (fan
units) 27 are disposed in the upper opening portion of the hood 26.
The blowers 27 are secured by the back board 15 with screws. The
blowers 27 are driven when a temperature detected by a temperature
sensor (not shown) for detecting the temperature in the housing 10
reaches or exceeds a set temperature. The blowers 27 are designed
to generate a flow of cooling air in the housing 10, by forcibly
introducing cooling air from above the duct 16.
[0043] The duct 16 is constructed by an angled, cooling fin plate
28 having inner fins and formed into a duct, and the circuit boards
21 and, 22 are directly attached to the cooling fin plate 28. The
duct 16 is covered by a box-like cover 29 at the lower part of the
cooling fin plate 28, so that the duct 16 communicates with an
exhaust port (not shown) provided in the bottom of the lower
housing 11. An intake port (not shown) is formed in the bottom of
the lower housing 11 at a position in front of the exhaust port,
and when the blower devices 27 are driven, a flow of air is
generated wherein an external air is taken into the housing 10
through the intake port, passes upwardly along front sides of the
circuit boards 21 and 22, and through the fans 27 into the duct 16,
and is then discharged from the exhaust port.
[0044] As shown in FIGS. 1 to 4, a box portion 30 is integrally
formed with the right-hand side surface of the upper housing 12 as
a bulge portion, and an indicator 31 as an electric component is
incorporated in the front surface of the box portion 30. The
indicator 31 indicates a residual capacity (a charged condition) of
the battery obtained from the electric automobile 6 as a result of
communication. An opening 30a is formed in the right-hand side
surface of the box portion 30. The opening 30a is closed by a
metallic cover 32 as an electromagnetically shielding material, the
cover being fixed to the box portion 30 with screws.
[0045] Also, a coupler resting case 34 is disposed on the
right-hand side surface of the upper housing 12 below the box
portion 30 in an inserted coupler securely receiving case 34, as a
coupler inserting and removing portion where the feeding coupler 4
is removably inserted. A coupler inserting opening 34a is disposed
in the front side of the coupler resting case 34 for insertion of
the feeding coupler 4 therein, and a pair of locking springs 35 are
disposed at upper and lower positions of the coupler inserting
opening 34a. The feeding coupler 4 is lightly locked with the pair
of locking springs 35 in a state in which the feeding coupler 4 is
fully inserted in the coupler inserting opening 34a so that the
coupler 4 does not fall down from the coupler resting case 34.
[0046] In addition, as shown in FIGS. 1 and 4, openings 13a and 13b
are formed in the side cover 13 for allowing the indicator 31 and
the coupler inserting opening 34a of the coupler resting case 34 to
be exposed from the front side of the housing 10.
[0047] Also, as shown in FIGS. 2 and 3, a sensor (for example, a
magnetic sensor) 36 as an electric member and a detector for
detecting that the feeding coupler 4 is fully inserted in the
coupler inserting opening 34a are mounted on the coupler resting
case 34. A magnet (not shown) is embedded in the feeding coupler 4
at a predetermined position, and the sensor 36 is arranged to
detect magnetism of the magnet when the feeding coupler 4 is fully
inserted in the coupler inserting opening 34a.
[0048] An electromagnetically shielded wire 37 extends outward from
the box portion 30 as wiring for electrically connecting the
circuit board 22 in the housing 10 to the sensor 36, since the
sensor 36 is mounted on the outside of the upper housing 12. The
electromagnetically shielded wire 37 has therein a shielding layer
37a comprising, for example, an aluminum wire. A wiring portion
(non-electromagnetically shielded wire portion) 39 connecting the
sensor 36 with wires (bare wires) of the electromagnetically
shielded wire 37 via terminals 38 and the sensor 36 are disposed in
an aluminum case 40, and the aluminum case 40 is fixed to the side
surface of the coupler resting case 34 with screws 41. Thus, the
sensor 36 is mounted on the outside of the upper housing 12. Note
that the aluminum case 40 is illustrated in section.
[0049] As shown in FIG. 3, the other end of the electromagnetically
shielded wire 37 is connected to a connector 43 supported by a
bracket 42 within the box portion 30. In addition, within the
interior of the box portion 30, wiring 45 having a connector 44
provided at the distal end thereof extends from the back side of
the indicator 31.
[0050] On the other hand, as shown in FIG. 4, two wires 48 and 49
having connectors 46 and 47 provided at the distal ends thereof
extend from the circuit board 22. The connector 46 is electrically
connected to the indication control circuit, whereas the connector
47 is electrically connected to the input part of the communication
power source control circuit. The connectors 46 and 47 are
connected to the connectors 44 and 43, respectively, whereby the
circuit board 22 and respective wires 45, 48, 37 and 49 of the
indicator 31 and the sensor 36 are connected to each other.
[0051] As shown in FIG. 3, the coupler resting case 34 is fixed to
the right-hand side surface of the upper housing 12 with screws 50,
and a plurality of screw holes 51 are formed in the periphery of
the opening 30a in the box portion 30 so that screws 33 are
securely screwed thereinto. The indicator 31 is secured to the
front surface of the box portion 30a with screws 52. Additionally,
as shown in FIGS. 1 to 3, seat portions 53 into which screws for
fixing the side cover 13 to the upper housing 12 are securely
screwed are welded to the right-hand side surface of the upper
hosing 12. The upper housing 12 is constructed so as to be fixed to
the lower housing 11 by securely screwing screws into the back
board 15 in a state in which the upper housing 12 is placed on the
lower housing 11. In addition, as shown in FIGS. 1 and 2, the cable
3 is connected to the bottom of the lower housing 11 at a position
closer to the right-hand side thereof and a power source cable 54
is connected to the same bottom at a position closer to the
left-hand side thereof for supplying a commercial alternating
current.
[0052] The assembling procedure of the charger 1 will now be
described.
[0053] The indicator 31, the sensor 36 and the electromagnetically
shielded wire 37 are assembled to the upper housing 12 in advance.
The upper housing 12 is assembled to the lower housing 11 after all
the components that are to be assembled to the lower housing 11
have been so assembled. In this instance, the connectors 46 and 47
are provisionally fixed at positions facing to or close to the
opening 30a with clips.
[0054] As shown in FIG. 4, the upper housing 12 is placed or fitted
on the lower housing 11 in such a manner as to cover the circuit
boards 21 and 22 and the blower devices 27 that are assembled to
and supported by the back board 15. Thereafter, as shown in FIG. 3,
the respective connectors 46, 47, 43 and 44 are connected to each
other through the opening 30a to connect the respective wires 48,
49, 45 and 37. After the connecting work has been completed, as
shown in FIG. 4, the cover 32 is fixed to the box portion 30 with
the screws 33 so as to close the opening 30a. Thereafter, the upper
housing 12 and the lower housing 11 are fixed to each other by
securely screwing screws into the back board 15 from the outside of
the back of the upper housing 12. Then, when the assembly in the
state shown in FIGS. 1 and 2 has been completed, the side cover 13
is next disposed to cover the entirety of the right-hand side
surface of the upper housing 12, and the side cover 13 is fixed to
the upper housing 12 by securely screwing the screws inserted from
the outside of the side cover 13 into the seat portion 53.
[0055] Since the opening 30a through which the connecting work of
the wires 45, 48, 37 and 49 for the indicator 31 and the sensor 36
is carried out is formed in the box portion 30, the connecting work
can be carried out after the upper housing 12 has been placed on
the lower housing 11. Since this allows the placement of the upper
housing 12 on the lower housing 11 to be carried out without regard
to the wires 45, 48, 37 and 49, the working efficiency can be
improved.
[0056] In addition, since the opening 30a is electromagnetically
shielded by being closed by the metallic cover 32, electromagnetic
waves emitted from the circuit boards 21 and 22 and the various
electric components 24 and 25 can completely be shielded.
Additionally, since the electromagnetically shielded wire 37 is
used for the extension line for the sensor 36 mounted on the
outside of the housing 10 and moreover the sensor 36 and the wiring
portion 39 are protected within the aluminum case 40, there is no
risk of electromagnetic waves leaking from the extension line 37
and the sensor 36. Furthermore, since the entirety of the
right-hand side surface of the upper housing 12 is covered with the
metallic side cover 13 in such a manner as to completely cover the
box portion 30, the coupler resting portion 34 and the like, double
electromagnetic shielding is provided by the side cover 13.
[0057] As has been described in detail heretofore, according to the
embodiment of the present invention, the following advantages can
be obtained.
[0058] (1) The wires 45, 48, 37 and 49 connecting the indicator 31
and the sensor 36 to the circuit board 22 can be connected together
through the opening 30a after the upper housing 12 is placed on the
lower housing 11 to cover the circuit boards 21 and 22. Thus, the
assembling work of the power source device 2 can be
facilitated.
[0059] (2) Since the indicator 31 and the wires 45 and 48 thereof
are located within the box portion 30 closed by the cover 32 and
are accommodated within the housing 10 in an electromagnetically
shielded state, there is no need to adopt individually separate
electromagnetically shielding constructions for the indicator 31
and the wires 45 and 48 thereof.
[0060] (3) Since the extension line taken out to the outside of the
upper housing 12 for connection to the sensor 36 is the
electromagnetically shielded wire 37, the leakage of
electromagnetic waves from the extension line 37 can be prevented.
Additionally, since the sensor 36 and the wiring portion 39
therefor are protected within the aluminum case 40, electromagnetic
waves leaking from the sensor 36 and the wiring portion 39 are
prevented from leaking to the outside of the aluminum case 40.
Consequently, even if a construction is adopted in which the sensor
36 is mounted on the outside of the housing 10, good
electromagnetic shielding properties can be secured.
[0061] (4) Since the circuit board 22 is located at a position
closer to the opening 30a in the housing 10, the length of the
wires 48 and 49 can be made relatively short.
[0062] (5) Since the metallic cover 13 is mounted on the upper
housing to cover the entirety of the right-hand side surface of the
upper housing, not only can double electromagnetic shielding be
provided so as to improve the electromagnetically shielding effect
but also the box portion 30, the coupler resting case 34, the
wiring 37 and the like can be concealed to thereby improve the
external appearance of the power source device 2.
[0063] Note that the present invention is not limited to the
embodiment described above but may be modified as follows, for
example:
[0064] FIG. 6 shows a charger 1 wherein an indicator 60 as an
electric member is mounted on a lower housing 11 as a base. The
construction of the charger 1 is identical to that of the previous
embodiment except for the mounting position of the indicator 60. An
opening 30a in a box portion 30 is used for connection of wires for
a sensor 36. The indicator 60 is mounted on the lower housing 11 in
a posture in which an indicating surface of the indicator 60 is
oriented obliquely upwardly. According to this construction, since
the indicator 60 is mounted on the lower housing 11, even if the
indicator 60 and a circuit board 22 (see FIG. 4) are connected to
each other in advance, the wiring for the indicator and the circuit
board does not interrupt the assembly of a power source device 2,
whereby the assembling work thereof can be facilitated.
[0065] The electric member which is mounted on the housing 11 is
not limited to the indicator and the detector. For example, the
electric member may be a speaker, an illuminating lamp or a power
rate meter.
[0066] The use of the indicator does not have to be limited to
indicate the residual capacity (the charged condition) of the
battery, and therefore the indicator may be used to indicate other
information (for example, charging rate, diagnostic information
obtained from an electric automobile through communication
therewith, or the like).
[0067] The use of the detector does not have to be limited to
detect the insertion and/or removal of the feeding coupler into
and/or from the coupler resting case, and therefore, the detector
may be a sensor for performing another sensing or detecting
function or a switch.
[0068] There may be provided no detector in the construction of the
previous embodiment. Namely, the communication power source may be
left switched on at all times. Even in such an embodiment, the
construction of the indicator 31 (60) described in the previous
embodiment or in FIG. 6 may be adopted for an indicator according
to the embodiment, whereby the assembling work of a power source
device 2 can be facilitated.
[0069] In the previous embodiment, the sensor 36 can be mounted on
the upper housing 12 in such a manner that only a detecting portion
thereof is exposed from the side surface of the upper housing 12.
In this case, since the extension line is not needed, a special
electric wire such as the electromagnetically shielded wire does
not have to be used.
[0070] In addition, the side cover 13 may be deleted. Namely, the
opening is closed with only the cover 32 as the electromagnetically
shielding material. The external appearance may be deteriorated
slightly, but the assembling work of the power source device 2 can
be further facilitated.
[0071] The mounting position of the electric apparatus to the upper
housing is not limited to the side surface of the upper housing.
For example, the electric apparatus may be mounted on the front
surface of the upper housing. In addition, a plurality of electric
members may be mounted on different surfaces of the upper housing
(for example, left-hand side and right-hand side surfaces, the side
surface and the front surface, or the like).
[0072] The cover 32 for closing the opening 30a may be deleted.
Namely, only the side cover 13 (the housing cover) may be used to
provide electromagnetic shielding. Devising the configuration of
the side cover 13 may be able to modify the gap between the upper
housing 12 and the side cover 13 or the gap at the coupler
pass-through opening 34a to a gap configuration (gaps at bending
paths) or a space that can be electromagnetically shielded, whereby
the electromagnetic shielding can be provided by the side cover 13
only. It goes without saying that a metallic member or the like may
be mounted over the gap to improve the electromagnetically
shielding effect.
[0073] The material of the cover 32 is not limited to metal. For
example, ferrite (sintered ferrite or ferrite resin) may be used as
a material for the cover. In short, any material having
electromagnetic shielding properties may be used as a material for
the cover. For example, a metallic-coated or ferrite-coated resin
plate may be used.
[0074] The tubular unit having one closed end may be constituted by
a plurality of members, not by a single member such as the upper
housing. For example, the tubular unit may be constituted by two
members such as a tubular member and a bottomed tubular member. In
addition, the tubular unit may be constituted by two members such
as a front board and a back board. It goes without saying that the
bottomed tubular unit may be constituted by a plurality of members
such as three or more members. In short, any member formed into a
housing portion that can cover the electric circuit components
assembled to and supported by the base may be used as a member for
the bottomed tubular unit.
[0075] The mode for connecting the feeding coupler constituting the
charger to the receiver of the automobile is not limited to
insertion. In short, any connecting construction may be used in
which the primary coil and the secondary coil can be disposed close
to each other so that an electromagnetic induction can be
ensured.
[0076] The present invention is not limited to the charger of the
electromagnetic induction system (the inductive system). The
present invention may also be applied to a charger of the
conductive system.
[0077] The present invention is not limited to electric automobiles
but the present invention may be applied to any type of automobiles
using a battery. For example, the present invention may be applied
to an industrial vehicle such as a battery-type forklift truck or a
battery-type carrier.
[0078] Note that a technical concept derived from the previous
embodiment but not claimed will be described below.
[0079] The electromagnetically shielding material is constituted by
the housing cover and the cover closing the opening within the
housing cover. In this case, since the opening is double
electromagnetically shielded, the leakage of electromagnetic waves
can be prevented more securely.
[0080] According to the present invention, since the wires of the
electric members and the electric circuit components can be
connected to each other after the bottomed tubular unit is placed
on the base so as to cover the electric circuit components, the
assembling work of the power source device can be facilitated.
[0081] Since both the electric member and the wiring therefor are
accommodated in the bulge portion of the bottomed tubular unit,
there is no need to adopt separate electromagnetic shielding
construction individually for the electric components and the
wiring.
[0082] In addition to the effects provided previously, since the
extension line taken out to the outside of the bottomed tubular
unit for connection with the electric member is the
electromagnetically shielded wire, the leakage of electromagnetic
waves can be prevented.
[0083] The electric member and the wiring exposed from the external
surface of the bottomed tubular unit or located on the outside
thereof, and the opening are covered with the metallic housing
cover for electromagnetic shielding, and the external appearance of
the power source main body can be improved.
[0084] Since the electric member is mounted on the base, even if
the electric member and the electric circuit component are
connected to each other in advance, the wiring interrupts the
assembly work of the power source unit, whereby the assembling work
of the power source unit can be facilitated.
* * * * *