U.S. patent number RE36,225 [Application Number 08/504,601] was granted by the patent office on 1999-06-08 for battery recharge interconnection system with safety cut-out.
This patent grant is currently assigned to Mattel, Inc.. Invention is credited to Timothy S. Harris.
United States Patent |
RE36,225 |
Harris |
June 8, 1999 |
Battery recharge interconnection system with safety cut-out
Abstract
A battery recharge interconnection system is provided for use on
an electric toy vehicle or other load device powered by a
rechargeable battery. The interconnection system includes a charger
receptacle, operatively connected to a rechargeable battery,
covered by a rotatable disc. An opening in the disc permits a plug
from an external charger to be inserted through the opening and
into the charger receptacle whenever the disc is rotated to a
predetermined position in which the opening overlies the
receptacle. The rotatable disc is also mechanically coupled to an
actuator which engages and operates a cut-out switch or other
device. During normal operation of the battery-operated device, the
disc is rotated to a first position in which the charger receptacle
is obstructed by the disc and the cut-out switch is disengaged. To
recharge the device, the disc is rotated to a second position in
which the opening in the disc overlies the receptacle, permitting a
recharger plug to be inserted in the receptacle When the disc is in
the second position, the cut-out switch is engaged, preventing
operation of the device. A current protection fuse in the charging
circuit is also disclosed.
Inventors: |
Harris; Timothy S. (Fort Wayne,
IN) |
Assignee: |
Mattel, Inc. (El Segundo,
CA)
|
Family
ID: |
25264085 |
Appl.
No.: |
08/504,601 |
Filed: |
July 20, 1995 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
Reissue of: |
833320 |
Feb 10, 1992 |
05229703 |
Jul 20, 1993 |
|
|
Current U.S.
Class: |
320/104;
320/113 |
Current CPC
Class: |
B60L
53/30 (20190201); H02J 7/00304 (20200101); H02J
7/0031 (20130101); H02J 7/0045 (20130101); B60L
2200/20 (20130101); Y02T 10/70 (20130101); Y02T
90/14 (20130101); Y02T 90/12 (20130101); Y02T
10/7072 (20130101) |
Current International
Class: |
H02J
7/00 (20060101); H01M 010/46 (); H02J 007/00 () |
Field of
Search: |
;320/2,5,14,49,62,107,104,109,111,113,123 ;180/65.1,65.3 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Primary Examiner: Tso; Edward
Attorney, Agent or Firm: Kolisch, Hartwell, Dickinson,
McCormack & Heuser
Claims
What is claimed is:
1. A battery recharge interconnection system for an electric
vehicle powered by a rechargeable battery, comprising:
a cut-out switch operatively connected to the vehicle wiring for
rendering the vehicle inoperable when the cut-out switch is engaged
and for permitting operation of the vehicle when the cut-out switch
is disengaged,
a charger receptacle operatively connected to the rechargeable
battery of the vehicle for mating with an external recharger to
recharge the battery, and
a movable receptacle cover on the vehicle for selectively
obstructing the charger receptacle, the cover being operatively
connected to the cut-out switch and being movable between a first
position in which the cover blocks the charger receptacle to
prevent an external charger from mating with the charger receptacle
and in which the cut-out switch is disengaged to permit operation
of the vehicle, and a second position in which the cover unblocks
the charger receptacle to permit an external charger to be mated
with the charger receptacle and in which the cut-out switch is
engaged to prevent operation of the vehicle, whereby the vehicle is
inoperable during recharging of the battery.
2. A battery recharge interconnection system for an electric
vehicle powered by a rechargeable battery, comprising:
a cut-out switch operatively connected to the vehicle wiring for
rendering the vehicle inoperable when the cut-out switch is engaged
and for permitting operation of the vehicle when the cut-out switch
is disengaged,
a female charger receptacle operatively connected to the
rechargeable battery of the vehicle for mating with a charger plug
from an external charger which is insertable into the charger
receptacle along an insertion axis to recharge the battery, and
a cover for the charger receptacle operatively connected to the
cut-out switch, the cover being mounted for movement between first
and second positions in a direction transverse to the insertion
axis of the charger receptacle, wherein when the cover is in the
first position the cut-out switch is disengaged and the cover
prevents an external charger from mating with the charger
receptacle, and when the cover is in the second position the
cut-out switch is engaged and the cover is moved to a nonblocking
position relative to the charger receptacle permitting an external
charger to be mated with the charger receptacle, whereby the
vehicle is inoperable during recharging of the battery.
3. A battery recharge interconnection system as in claim 2 in which
the cover includes an opening through which a charger plug is
extendable to mate with the charger receptacle, the opening being
movable with the cover between a first position in which the
opening is out of alignment with the charger receptacle and the
cover obstructs the charger receptacle, and a second position in
which the opening overlies the charger receptacle to permit a
charger plug to be inserted into the charger receptacle through the
opening in the cover.
4. A battery recharge interconnection system as in claim 3 in which
the cover is supported over the charger receptacle on a pivot, the
cover being rotatable between the first and second positions.
5. A battery recharge interconnection system as in claim 4 in which
the cover includes a generally circular disc supported over the
charger receptacle on the pivot for rotation between the first and
second positions.
6. A battery recharge interconnection system as in claim 1
including a current-limiting fuse in the connection between the
charger receptacle and the rechargeable battery for limiting the
charging current supplied to the battery.
7. A battery recharge interconnection system for use in the
electrical circuitry of a load device powered by a rechargeable
battery, the interconnection system comprising:
a cut-out switch operatively connected to the electrical circuitry
for interrupting the power to the load device from the rechargeable
battery when the cut-out switch is engaged and for permitting power
from the battery to energize the load device when the cut-out
switch is disengaged,
a charger receptacle for mating with an external recharger, the
charger receptacle being operatively connected to the electrical
circuitry to supply recharging current to the battery, and
a movable receptacle cover adjacent the charger receptacle for
selectively blocking the charger receptacle, the cover being
operatively connected to the cut-out switch and mounted for
movement relative to the charger receptacle between a first
position, in which the cover blocks the charger receptacle and
prevents an external charger from mating with the charger
receptacle to recharge the battery and also disengages the cut-out
switch, and a second position in which the cover unblocks the
charger receptacle permitting an external charger to be mated with
the charger receptacle and the cut-out switch is engaged, whereby
the load device is inoperable during recharging of the battery.
8. A battery recharge interconnection system for use in the
electrical circuitry of a load device powered by a rechargeable
battery, the interconnection system comprising:
a cut-out switch operatively connected to the electrical circuitry
for interrupting the power to the load device from the rechargeable
battery when the cut-out switch is engaged and for permitting power
from the battery to energize the load device when the cut-out
switch is disengaged,
a female charger receptacle having an opening into which a charger
plug from an external charger is inserted along an insertion axis
when the receptacle is mated with an external recharger to recharge
the battery, the charger receptacle being operatively connected to
the electrical circuitry to supply recharging current to the
battery, and
an obstruction for selectively blocking the charger receptacle
operatively connected to the cut-out switch and mounted for
movement relative to the charger receptacle in a direction
transverse to the insertion axis of the charger receptacle between
a first position, in which the obstruction prevents an external
charger from mating with the charger receptacle to recharge the
battery and also disengages the cut-out switch, and a second
position in which the obstruction is removed from the charger
receptacle permitting an external charger to be mated with the
charger receptacle and the cut-out switch is engaged, whereby the
load device is inoperable during recharging of the battery.
9. A battery recharge interconnection system as in claim 8 in which
the obstruction is a cover for the charger receptacle mounted for
movement between first and second positions corresponding to the
first and second positions of the obstruction, the cover including
an aperture therethrough which is out of alignment with the
insertion axis of the charger receptacle when the cover is in its
first position, whereby the cover obstructs the charger receptacle,
and is aligned with the insertion axis of the charger receptacle
when the cover is in its second position, permitting a charger plug
to be inserted into the charger receptacle through the
aperture.
10. A battery recharge interconnection system as in claim 9 in
which the cover is supported over the charger receptacle on a
pivot, the cover being rotatable between the first and second
positions.
11. A battery recharge interconnection system as in claim 10 in
which the cover which forms the obstruction includes a generally
circular disc supported over the charger receptacle on the pivot
for rotation about the pivot between the first and second
positions.
12. A battery recharge interconnection system as in claim 7
including a fuse in the operative connection between the charger
receptacle and the battery for limiting the charging currents
applied to the battery.
13. A receptacle and actuator assembly for permitting electrical
interconnections to be selectively made when the actuator portion
of the assembly is moved to a predetermined position,
comprising:
an electrical receptacle having an opening into which a plug is
insertable to complete one or more electrical interconnections,
a cover for the receptacle rotatably mounted adjacent the
receptacle, the cover being rotatable between a first position in
which the cover blocks the opening of the receptacle to prevent
insertion a plug into the receptacle and a second position in which
the cover is rotated out of its blocking position, thereby
permitting insertion of a plug into the receptacle, and
an actuator operatively coupled to the cover for operating a device
separate from the electrical receptacle, the actuator being movable
between first and second states in response to rotational movement
of the cover between its respective first and second positions,
whereby a plug is insertable in the receptacle only when the
actuator is moved to its second state.
14. A receptacle and actuator assembly for permitting electrical
interconnections to be selectively made when the actuator portion
of the assembly is moved to a predetermined position,
comprising:
an electrical receptacle having an opening into which a plug is
insertable to complete one or more electrical interconnections, the
receptacle opening having an insertion axis along which the plug is
insertable,
a rotatable obstruction mounted adjacent the receptacle including a
rotatable disc mounted for rotation about a pivot axis which is
generally parallel with the insertion axis of the receptacle, the
disc including an aperture therethrough through which a plug is
extendable for insertion into the receptacle, the aperture being
movable into and out of alignment with the receptacle, and the disc
being rotatable about its pivot axis between a first position in
which the aperture is out of alignment with the receptacle, whereby
when the disc is in its first position the disc covers and blocks
the receptacle opening and prevents insertion of a plug into the
receptacle, and a second position in which the disc is rotated such
that the aperture is in alignment with the receptacle, thereby
permitting insertion of a plug into the receptacle through the
aperture, and
an actuator operatively coupled to the disc for operating a device
separate from the electrical receptacle, the actuator being movable
between first and second states in response to rotational movement
of the disc between its respective first and second positions,
whereby a plug is insertable in the receptacle only when the
actuator is moved to its second state.
15. A receptacle and actuator assembly as in claim 14 in which the
actuator is operatively coupled to the disc and operates a switch
mounted adjacent the disc, the switch being repositioned as the
actuator moves between its first and second states in response to
rotation of the disc between its respective first and second
positions.
16. A receptacle and actuator as in claim 13 in which the actuator
operates a switch, the receptacle and actuator including a mounting
plate for mounting the receptacle and switch, in which the
rotatable obstruction is a rotatable disc pivotally mounted on the
plate, the disc extends over the receptacle and the switch and
includes an aperture therethrough through which a plug is
extendable for insertion into the receptacle, the aperture being
movable into alignment with the receptacle when the disc is rotated
into its second position, and the actuator being an arm attached to
the disc for repositioning the switch when the disc is rotated
between its first and second positions. .Iadd.
17. A battery recharge interconnection system for an electric
children's riding vehicle powered by at least one rechargeable
battery, comprising:
a cut-out switch operatively connected to the vehicle wiring for
rendering the vehicle inoperable when the cut-out switch is engaged
and for permitting operation of the vehicle when the cut-out switch
is disengaged,
a charger receptacle operatively connected to the rechargeable
battery of the vehicle for mating with an external recharger to
recharge the battery, and
a movable receptacle cover on the vehicle operatively connected to
the cut-out switch and movable to a first position in which the
cut-off switch is dis-engaged to permit the operation of the
vehicle, and a second position in which the cut-off switch is
engaged to prevent operation of the vehicle, whereby the vehicle is
inoperable during recharging of the battery. .Iaddend..Iadd.18. The
system of claim 17, wherein the cover is supported on a pivot for
movement about a pivot axis between the first and second positions.
.Iaddend..Iadd.19. The system of claim 18, wherein the cover is
supported on the pivot adjacent the charger receptacle, and wherein
the external charger is insertable into the charger receptacle
along an insertion axis which is generally parallel to the pivot
axis.
.Iaddend..Iadd.20. The system of claim 19, wherein the cover
includes an opening and the external recharger is insertable
through the opening for mating with the charger receptacle.
.Iaddend..Iadd.21. The system of claim 20, wherein the opening is
an aperture which extends through the cover. .Iaddend..Iadd.22. A
battery recharge interconnection system for an electric children's
riding vehicle powered by at least one rechargeable battery,
comprising:
a cut-out switch operatively connected to the vehicle wiring for
rendering the vehicle inoperable when the cut-out switch is engaged
and for permitting operation of the vehicle when the cut-out switch
is disengaged;
a charger receptacle operatively connected to the rechargeable
battery of the vehicle for mating with an external recharger to
recharge the battery; and
a movable receptacle cover mounted for movement in a defined
direction between a first position in which the cut-out switch is
disengaged and a second position in which the cut-out switch is
engaged, and wherein the external recharger is insertable into the
charger receptacle along an insertion axis for recharging the
battery, such insertion axis being generally transverse the cover's
direction of movement.
.Iaddend..Iadd. The system of claim 22, wherein the cover is
mounted adjacent the charger receptacle. .Iaddend..Iadd.24. The
system of claim 23, wherein the cover is mounted adjacent the
charger receptacle and includes an opening, and wherein the
external recharger is insertable through the opening for mating
with the charger receptacle. .Iaddend..Iadd.25. The system of claim
24, wherein the opening is an aperture which extends through the
cover. .Iaddend..Iadd.26. The system of claim 22, wherein the cover
is supported on a pivot for movement about a pivot axis which is
generally parallel to the insertion axis.
.Iaddend..Iadd.27. A children's riding vehicle which is
electrically rechargeable comprising:
a body;
plural wheels rotatably mounted on the body;
a motor source on the vehicle operatively connected to at least one
of the wheels for rotatably driving the same;
at least one rechargeable battery with associated wiring, mounted
on the vehicle and operatively connected to the motor source for
supplying electrical power thereto;
a cut-out switch operatively connected to the wiring for rendering
the vehicle inoperable when the cut-out switch is engaged, and for
permitting operation of the vehicle when the cut-out switch is
disengaged;
a charger receptacle operatively connected to the rechargeable
battery for mating with an external recharger to recharge the
battery; and
a movable receptacle cover on the vehicle operatively connected to
the cut-out switch and movable to a first position in which the
cut-off switch is dis-engaged to permit the operation of the
vehicle, and a second position in which the cut-off switch is
engaged to prevent operation of the vehicle, whereby the vehicle is
inoperable during recharging of the battery. .Iaddend..Iadd.28. The
vehicle of claim 27, wherein the cover is supported on a pivot
adjacent the charger receptacle for movement about a
pivot axis between the first and second positions.
.Iaddend..Iadd.29. The vehicle of claim 28, wherein the external
charger is insertable into the charger receptacle along an
insertion axis which is generally parallel to the pivot axis.
.Iaddend..Iadd.30. The vehicle of claim 29, wherein the cover
includes an opening and the external charger is insertable through
the opening for mating with the charger receptacle.
.Iaddend..Iadd.31. The vehicle of claim 30, wherein the opening is
an aperture which extends through the cover. .Iaddend.
Description
BACKGROUND AND SUMMARY OF THE INVENTION
The invention relates generally to a recharging system for devices
such as a child's ride-on vehicle powered by a rechargeable
battery, and more specifically to a recharger receptacle used in a
battery recharge interconnection system which protects the battery
and prevents operation of the battery-powered vehicle or other
device while the battery is being recharged.
Battery powered vehicles such as children's ride-on cars or other
toy vehicles usually receive power from one or more rechargeable
batteries carried on the vehicle. In a typical electrical system
used in some models of toy ridable vehicles, the vehicle battery is
coupled to a connector plug which is mated with a cooperating
connector on the wiring harness of the vehicle. Power to operate
the vehicle is supplied through the wiring harness connector. To
recharge the battery, the two halves of the connector are separated
and the part connected to the battery is inserted into a
cooperating connector on an external recharger, which supplies
recharging current to the battery. When a recharging cycle is
completed, the cooperating connector on the charger is separated
from the battery connector plug and reconnected to the cooperating
plug on the wiring harness. Since the wiring harness must be
disconnected before the battery can be recharged, this prior art
system has the advantage of eliminating the possibility of
operating the vehicle during a recharging cycle. That is an
important safety feature because it avoids the possibility of a
child climbing on and operating the vehicle while it is recharging,
which might entangle the child in external wires or damage the
charger, the battery, or the vehicle.
The problem with the prior art charging system described above is
that it requires the separation and reconnection of the two halves
of the battery connector a minimum of three times for a single
charging cycle. It would be far more convenient to provide a
plug-type receptacle on the vehicle which is permanently connected
to the battery terminals and into which a battery recharger could
be plugged to recharge the battery. The risk with such a system is
that a child may attempt to operate the vehicle while it is
recharging.
Rechargeable batteries are recharged by feeding a charging current
through the battery terminals. Excessive charging current can
overheat and damage the battery and may present a leakage or
rupture hazard. It can also damage the external recharger, its cord
and the internal vehicle wiring. Excessive charging current can
result from numerous causes, including shorts in the recharger
cord, or shorts caused by foreign objects such as pins or paper
clips which can lodge across the battery or charger terminals. On
rechargeable toys such as children's ridable vehicles, it is
particularly important that hazards resulting from excessive
recharging current be eliminated. It would therefore be
advantageous if some type of protective system is provided for
limiting the recharger current supplied to the rechargeable battery
on a toy ridable vehicle.
It would be advantageous to have a battery recharge interconnection
system for use in toy riding vehicles, or in other battery-operated
load devices powered by rechargeable batteries, which incorporates
a receptacle assembly that is capable of disabling the vehicle or
can otherwise protect against improper use of the battery-operated
device during a recharging cycle.
It would be a further advantage If such a battery recharge
interconnection system included a cut-out switch operatively
connected to the electrical circuitry of the load device for
interrupting the supply of power from the battery to the device
whenever the battery is recharged.
It would be also be advantageous to have a battery recharge
interconnection system which both disables the operation of the
battery-operated device during recharging and which helps prevent
dust, dirt and other foreign matter from entering the recharge
receptacle.
Finally, it would be advantageous to have a battery recharge
interconnection system which protects against excessive current to
the battery by means of a current-limiting fuse that is simple and
inexpensive to replace.
Accordingly, the present invention provides a battery recharge
interconnection system for an electric vehicle, or for use in the
electrical circuitry of another type of load device powered by a
rechargeable battery. The interconnection system for an electric
vehicle comprises a cut-out switch operatively connected to the
vehicle wiring for rendering the vehicle inoperable when the
cut-out switch is engaged and for permitting operation of the
vehicle when the cut-out switch is disengaged. A charger receptacle
is provided which is operatively connected to the rechargeable
battery of the vehicle for mating with an external recharger to
recharge the battery. Finally, an interlock is provided between the
charger receptacle and the cut-out switch, in the form of an
obstruction for the charger receptacle. The interlock operates to
reposition the cut-out switch whenever the obstruction is moved,
either to block or unblock the charger receptacle. Specifically,
the obstruction is movable between a first position, in which the
cut-out switch is disengaged and the obstruction prevents an
external charger from mating with the receptacle, and a second
position in which the cut-out switch is engaged and the obstruction
is removed from blocking the charger receptacle. When the
obstruction is in its second position, an external charger can be
mated with the charger receptacle. Thus, whenever the battery is
recharged the cut-out switch renders the vehicle inoperable.
In the embodiment of the invention used in the electrical circuitry
of a load device powered by a rechargeable battery, the
interconnection system comprises a cut-out switch operatively
connected to the electrical circuitry for interrupting the power to
the load device from the rechargeable battery. The system provides
an obstruction for selectively blocking the charger receptacle. The
obstruction is operatively connected to a cut-out switch for the
device and is mounted for movement relative to the charger
receptacle between first and second positions. In the first
position, the cover prevents an external charger from mating with
the receptacle and also disengages the cut-out switch. In the
second position, the cover is removed from the charger receptacle,
allowing an external charger to be mated with the receptacle, and
it engages the cut-out switch. Whenever the cover is in its second
position, the load device is inoperable and the battery can be
recharged.
At the heart of the battery recharge interconnection system is a
receptacle and actuator assembly for permitting electrical
interconnections to be selectively made when the actuator portion
of the assembly is moved to a predetermined position. The
receptacle and actuator assembly comprises an electrical receptacle
having an opening into which a plug is insertable to complete one
or more electrical interconnections. When used with a battery
recharge interconnection system, the charger receptacle is
operatively connected to the electrical circuitry which supplies
recharging current to a battery. A rotatable obstruction is
pivotally mounted adjacent the receptacle for movement between a
first position, in which the obstruction blocks the opening of the
receptacle to prevent insertion of a plug into the receptacle, and
a second position, in which the obstruction is rotated out of its
blocking position. When the rotatable obstruction is in its second
position, it permits insertion of a plug into the receptacle. An
actuator is operatively coupled to the rotatable obstruction for
operating a device separate from the electrical receptacle. The
actuator is movable between first and second states in response to
rotational movement of the obstruction between its respective first
and second positions. A plug is insertable in the receptacle only
when the actuator is moved to its second state. In the battery
recharge interconnection system of the present invention, the
actuator is operatively coupled to the cut-out switch and engages
the cut-out switch when in its second state.
Finally, in the preferred embodiment of the invention, a
current-limiting fuse is installed in the circuitry between the
charger receptacle and the battery to prevent excessive charging
current from damaging the battery, the external battery charger or
the battery charger cord.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial, schematic, perspective view of a child's
ridable vehicle shown in phantom, with the major parts of the
wiring harness, incorporating the battery recharge interconnection
system of the present invention, shown with solid lines.
FIG. 2 is a partially schematic circuit diagram showing the major
elements of the vehicle wiring harness of FIG. 1 and also showing
the battery recharge interconnection system of the present
invention.
FIG. 3 is a partial perspective view, partially exploded, showing
the receptacle assembly of the present invention as used in the
battery recharge interconnection system of FIGS. 1 and 2.
FIG. 4 is a top plan view, partially in phantom, illustrating the
various parts of the receptacle assembly shown in FIG. 3.
FIGS. 5A and 5B are side plan views, partially in cross-section,
taken along lines 5A--5A of FIG. 4, on an enlarged scale,
illustrating how the actuator arm of the receptacle assembly of
FIGS. and 4 repositions the cut-out switch. FIG. 5A shows the
cut-out switch in its disengaged position and FIG. 5B shows the
cut-out switch in its engaged position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a child's ridable toy vehicle 10 is shown in
phantom. Certain parts of vehicle 10, such as the seats, trunk lid
and battery enclosure housing, have been deleted from the phantom
image to more clearly show the key parts of the vehicle wiring
harness 12. Wiring harness 12 includes the principal electrical
devices in the drive train or drive system used to power and drive
vehicle 10. The vehicle shown in FIG. 1 is a toy version of a
rear-engine car, such as a Porsche. Like the real car, vehicle 10
has its power unit, in the form of rechargeable battery 14, located
in the rear compartment 16 of the vehicle. Typically, in a
completely assembled version of vehicle 10, battery 14 will be
covered by a housing which resembles or simulates an automotive
engine.
Battery 14 is preferably an 18-volt, solid gel rechargeable
battery. The negative and positive terminals 18, 20, respectively
of battery 14 are operatively connected by electrical wires to the
various electrical components of wiring harness 12. Battery
terminals 18, 20 are also connected to a recharge interconnector 22
on the vehicle for recharging the battery. Interconnector 22 is at
the heart of the battery recharge interconnection system of the
present invention and is described in detail below.
The wires in wiring harness 12 include a negative battery line 24,
operatively connecting battery terminal 18 with recharge
interconnector 22. A negative wiring harness lead 26 extends from
interconnector 22 to the other parts of the wiring harness. A
positive wiring harness lead 30 operatively connects positive
battery terminal 20 with the other parts of wiring harness 12.
Electrical system 12 also include drive motors 32, 34, a
forward-reverse switch 40, and an on-off switch 48. The
forward-reverse switch 40 is preferably mounted near the driving
position of the vehicle, in the form of a simulated shift lever 39
which is moved in the direction of arrows 41, 42 (FIG. 2) to select
forward and reverse operation. On-off switch 48 is preferably
mounted on the floor and is covered by a simulated gas pedal 50
which is depressed by the driver's foot to energize drive motors
32, 34. Numerous other devices (not shown) may also be operatively
connected to the wiring harness of the vehicle, including a horn,
headlights, a speed selector or controller and other accessories.
The vehicle illustrated in the figures includes only the basic
elements necessary to fully describe the battery recharge
interconnection system of the present invention.
Forward-reverse switch 40 is a conventional double-pole
double-throw switch wired to offer selective reverse polarity. It
is illustrated schematically and pictorially in FIG. 2. Battery
voltage, supplied at a fixed polarity, is applied to common
parallel terminals 43, 44 on switch 40 via negative and positive
wiring harness leads 26, 30, respectively. When the double-pole
switch engages the forward terminals connected to switch output
lines 45, 46, the polarity of the output lines will be the same as
on wiring harness leads 26, 30. When switch 40 is placed in the
reverse position, engaging terminals 47, 48, switch 40 reverses the
battery polarity on output lines 45, 46.
The principal load devices on vehicle 10 are motors 32, 34, which
are conventional direct-current motors wired in parallel and
energized by battery 10 through forward-reverse switch 40 and
switch 48. Switch 48 is an on-off switch which is "on" when input
terminal 49 is electrically connected to middle terminal 55 on the
switch, which occurs whenever pedal 50 is depressed. Switch 48 is
preferably a double-pole switch which can also be used to make a
connection with a brake resistor 57 (shown in phantom in FIG. 2).
Whenever gas pedal 50 is released by the driver, an internal spring
in switch 48 opens the connection between terminals 49 and 55 and
closes the connection between terminals 55 and 56. If a brake
resistor 57 is provided, the voltage across motors 32, 34 is
shunted through the brake resistor which dissipates energy
generated by the motors and rapidly slows the vehicle to a stop.
The wiring configuration shown in FIG. 2 provides for only a single
speed of operation in which motors 32, 34 are selectively supplied
with full battery voltage, or supplied with zero voltage. An
alternative motor wiring configuration which allows for two-speed
operation of vehicle 10 is shown in FIG. 2 of co-pending patent
application Ser. No. 07/833,980, filed Feb. 10, 1992, entitled
ELECTRIC DRIVE SYSTEM FOR A CHILD'S RIDABLE VEHICLE, invented by
Timothy S. Harris, the disclosure of which is incorporated herein
by reference. The battery recharge interconnection system of the
present invention can be used with the single-speed or two-speed
motor wiring configuration, or with another motor wiring
configuration.
At the heart of the battery recharge interconnection system of the
present invention is a receptacle and actuator assembly 22, shown
in detail in FIGS. 2-4. Assembly 22 includes a female battery
charger plug receptacle 60 having a orifice 61 into which a
cooperating male battery charger plug 62 is inserted to complete
one or more electrical interconnections. Charger plug 62 is
connected to an external charger 64 by charger cord 63. FIG. 2
depicts receptacle 60 schematically, in cross section. Receptacle
60 has an outer sleeve portion 66 interconnected with the positive
terminal 20 of battery 14 by a first recharger current supply line
68. An axial pin disposed centrally within sleeve 66 forms the
other terminal 70 of charger receptacle 60. Central pin 70 is
connected to the opposite terminal of battery 14 via a second
recharger current supply line 72, which communicates with negative
battery connector line 24.
A male battery charger plug 62, designed to mate with receptacle
60, is shown in FIG. 3. Plug 62 is insertable into receptacle 60
along an insertion axis 78. The insertion axis of receptacle 60
extends through the center of receptacle orifice 61. Plug 62
includes an outer sleeve 74 (see FIG. 3) for engaging outer sleeve
66 of receptacle 60, and a inner sleeve 76 for encircling and
mating with pin 70. The external charger unit 64 (FIG. 2) is
designed to be energized by a household current and includes a
transformer to supply the necessary current to recharge battery 14
by conventional recharging processes well known to those skilled in
the art.
Charger receptacle 60 is mounted on a mounting plate 80 designed to
support the various parts of the receptacle and actuator assembly
of the present invention. Mounting plate 80, also referred to as a
mounting frame or mounting body, is designed to be mounted on the
wall of the trunk compartment 16 of vehicle 10. Mounting plate 80
is made of molded plastic and includes one or more snap hooks 81
and engaging flanges 83 at suitable locations along its periphery
to facilitate mounting.
Another part of assembly 22 is a cut-out switch 82 mounted on
mounting plate 80. Cut-out switch 82 is a conventional see-saw
switch which is pivotable between two positions to selectively open
or close a circuit. Cut-out switch 82 is illustrated schematically
in FIG. 2, below the charger receptacle, and in perspective in FIG.
3. It is electrically interconnected between the negative terminal
18 of battery 14 (via negative battery connector line 24) and
negative wiring harness lead 26. The purpose of cutout switch 82 is
to disable the vehicle, rendering it inoperable whenever the
battery is being recharged. In FIG. 2, cut-out switch 82 is
depicted in its engaged position, in which the switch is open,
meaning the "cut-out" is engaged. In its disengaged position,
switch 82 is closed, meaning there is no "cut-out" in the circuit.
Whenever switch 82 is engaged (i.e., open), vehicle 10 is
inoperable.
A pivotally-mounted circular disc 90 is mounted on plate 80 and
serves as an obstruction for selectively blocking charger
receptacle 60. Disc 90 is mounted for rotation about a pivot axis
91, the pivot axis being generally parallel with the insertion axis
78 of receptacle 60. The disc is preferably made of molded plastic
and is rotatable about a central pivot axis 9 (see FIG. 3). The
disc has a sufficient radius to extend over both charger receptacle
60 and cut-out switch 82. An opening or aperture 94 extends through
disc 90. Opening 94 is positioned on disc 90 so it can be moved
into registration with the insertion axis 78 of charger receptacle
60. In other words, the center of aperture 94 and the insertion
axis 78 of receptacle 60 are spaced the same distance from the
rotational axis 91 of the disc. Consequently, disc 90 can be
rotated about axis 91 until opening 94, which moves with disc 90,
is positioned directly over charger receptacle 60. Opening 94 is
large enough for the male charger plug 62 from external charger 64
to be extended or inserted through the opening into receptacle
60.
A raised central support post 92 extends outwardly from the face of
mounting plate 80. A retaining screw 93, extends through a central
opening 96 in the center of the disc. Screw 93 and a washer 95 hold
the disc on post 92 in a manner which allows for rotation of the
disc about pivot axis 91. When disc 90 is mounted on post 92, it is
movable across or over receptacle 60 in a direction transverse to
and intersecting with insertion axis 78 of the receptacle. Several
elements limit or control the rotational movement of disc 90 about
its pivotal axis. A pair of movement-limiting posts 101, 102 extend
outwardly from the face of mounting plate 80 toward disc 90. Posts
101, 102 are somewhat shorter than pivot support post 92 and are
designed to extend toward the underside 103 of disc 90. A tang 106
formed on or attached to the underside 103 of disc 90 is positioned
on the disc to strike posts 101, 102 to stop its rotation at
selected orientations.
With disc 90 mounted on post 92 and with tang 106 positioned
between posts 101 and 102, the disc can be rotated over a limited
angular range indicated at 100 in FIG. 2. The limit of
counterclockwise rotational movement for disc 90, in direction 107
(see FIGS. 2 and 4), occurs when tang 106 strikes post 102. That
position is called the first position 104 of the disc. The limit of
clockwise rotational movement for disc 90, in direction 108, occurs
when tang 106 strikes post 101. That position is called the second
position 105 of the disc. In its first position, disc opening 94 is
offset from charger receptacle 60. Consequently, disc surface 90
acts as an obstruction for the charger receptacle, preventing an
external charger from mating with the receptacle. When disc 90 is
in its second position, opening 94 is in registration or alignment
with charger receptacle 60 and the obstruction is removed, allowing
an external charger to mate with the charger receptacle through
aperture 94.
Disc 90 also serves as an actuator which repositions cut-out switch
82, selectively engaging or disengaging the switch as the disc is
rotated. That function is accomplished by means of an actuator arm
110 attached to the underside 103 of disc 90. Referring to FIGS. 3,
4, 5A and 5B, when the disc is assembled on mounting plate 82,
actuator arm 110 is located immediately adjacent or overlying
cut-out switch 82. The actuator arm 110 is a short, wedge-shaped
extension of molded plastic or another material formed integrally
with, or attached to, the underside of the disc. Arm 110 is long
enough to touch and engage see-saw switch 82 and to move it from
one position to the other as disc 90 rotates between its first and
second positions, 104, 105, respectively.
FIGS. 5A and 5B illustrate, in enlarged cross-sectional views, the
repositioning of cut-out switch 82 by actuator arm 110. In FIG. 5A,
disc 90 is in its first position 104 (see FIG. 2), having been
rotated in a counterclockwise direction 107 to the limit of its
rotational travel. When disc 90 is in its first position, actuator
arm 110 is in its first operational state, positioned over the
right half of cut-out switch 82 (as viewed in FIGS. 5A is and 5B).
When am 110 is in its first state, it depresses the right half of
switch 82, disengaging the cut-out. In that position, cut-out
switch 82 is electrically closed and lines 24 and 26 are connected
to one another to supply battery power to motors 32, 34. Thought of
in another way, the electrical connection posts 114, 115 at the
base of cut-out switch 82, used for making electrical connections
to the switch, are electrically coupled when switch 82 is in the
position shown in FIG. 5A.
In FIG. 5B, disc 90 is in its second position 105, having been
rotated in a clockwise direction 108 to the limit of its rotational
travel. When disc 90 is in its second position 105, actuator arm
110 is in its second state, positioned over the left half of
cut-out switch 82 (as viewed in FIG. 5B), which is the engaged
position of the cut-out switch. In that position, terminals 114 and
115 are disconnected and cut-out switch 82 is open. When cut-out
switch 82 opens, the power supply from battery 14 to the wiring
harness 12 of vehicle 10 is broken. Only when actuator 110 is in
its predetermined second state, shown in FIG. 5B, can charger plug
62 be inserted into receptacle 60 to make the necessary electrical
interconnections for recharging battery 14.
Cut-out switch 82 is preferably biased toward the closed (or
"disengaged") position shown in FIG. 5A. In other words, switch 82
has an internal spring which urges the left half of the rocker
switch (as viewed in FIG. 5A) in the direction of arrow 111. When
disc 90 is moved to first position 104, the switch automatically
returns to the position shown in FIG. 5A. When disc 90 is rotated
in clockwise direction 108, the leading edge 113 of actuating arm
110, which is angled and forms a ramp, engages the sloping face 116
on the left side of see-saw switch 82 and forces the left side of
the switch downwardly. No ramp is required on the right side of
actuating arm 110 because of the internal bias of switch 82.
To facilitate the rotation of disc 90, the outer periphery of the
disc preferably includes a widened edge 120 which is wider than the
thickness 122 of the disc itself (see FIGS. 3, 4, 5A and 5B).
Suitable grip contours such as knurls are provided on the outside
periphery of edge 120. Disc 90 has a diameter of approximately
21/2-inches, an overall thickness 122, in the region radially
inward from peripheral edge 120, of less than 1/8-inch. The outer
peripheral edge of disc 90 has a width 121 of approximately
1/2-inch (see FIG. 3). Disc 90 could alternatively be referred to
as a knob which is grasped and turned to control the obstruction of
charger receptacle 60 and to actuate cut-out switch 82.
Operation of the battery recharge interconnection system is simple
and safe. Whenever the user desires to recharge battery 14, disc 90
is rotated from its operating or first position 104, in a clockwise
direction 108, to second position 105. When in its second position,
the opening 94 in disc 90 is aligned with charger receptacle 60,
permitting a charger plug 62 from an external charger to be
inserted through disc opening 94 into receptacle 60. Also, when
disc 90 is in its second position, cut-out switch 82 is engaged and
the battery is disconnected from the vehicle wiring harness. When a
charging cycle has been completed, which generally requires a
period of hours, charger plug 62 is removed from receptacle 60 and
disc 90 is rotated in a counterclockwise direction 107, from second
position 105 to first position 104. Once the disc is in its first
position, opening 94 is offset from charger receptacle 60 and the
disc blocks and obstructs receptacle orifice 61, preventing a
charger plug from being inserted in the receptacle Also, the
actuator arm 110 disengages cut-out switch 82, permitting operation
of the vehicle.
The battery recharge interconnection system of the present
invention includes an additional protective feature in the form of
a fuse 140 in the charging circuit of battery 14 (see FIGS. 1 and
2). Fuse 140 is located in the positive side recharger current
supply line 68, which connects charger receptacle 60 and
interconnector 22 with battery terminal 20. Fuse 140 prevents
excessive current flow in the circuit extending from the external
charger to the battery. Preferably fuse 140 is a 5-amp fuse, which
limits the charging current supplied to battery 14 via charger 64,
charger cord 63, and plug 62 to 5-amps or less. Fuse 140 protects
against several hazards which might arise in a child's toy electric
vehicle. For example, if the recharger cord is accidentally shorted
due to a kinking, pinching, or fraying, fuse 140 would blow before
the battery, charger, or cord would be damaged. Alternatively,
should a child inadvertently insert a bobby pin, paper clip or
other conductive object into the charger receptacle, a short
circuit would develop across the battery which would immediately
blow fuse 140. Thus, the fuse protects the battery, the external
charger and persons using the vehicle from the danger and damage
caused by excessive current in the battery charging circuit. Prior
art recharge protection systems often used diodes or other types of
current-limiting devices. Such prior art current limiting devices
are effective, but are not as inexpensive and simple to replace as
a conventional fuse.
The battery recharge interconnection system of the present
invention simplifies the recharging process by proving an
easily-accessible charger receptacle permanently connected to the
battery. There is no need to disconnect and reconnect connector
plugs to recharge the battery. In order to use the charger
receptacle, the user only needs to rotate the disc to the position
which permits insertion of the charger plug into the receptacle 60.
Positioning the disc for recharging automatically engages the
cut-out switch, thereby eliminating the possibility of operating
the vehicle during a recharging cycle. Disc 90 also serves as a
cover for the charger receptacle opening, preventing dust and
debris from entering the receptacle.
The system of the present invention, while depicted for use in a
child's ridable vehicle, cap also be employed in electrical
circuitry for any other type of load device powered by a
rechargeable battery. Regardless of the type of load device, the
battery recharge interconnection system of the present invention
provides an automatic cut-out switch which interrupts the power to
the load device whenever the user recharges the battery. The
invention provides a unique receptacle and actuator assembly for
recharging a battery, or for performing other useful electrical
interconnections using a plug and receptacle. A rotatable
obstruction selectively blocks or unblocks the receptacle,
depending on the state of an operatively-coupled actuator. Unless
disc 90 is removed from mounting plate 80, the interlock between
cut-out switch 82 and access to charger receptacle 60 is assured.
Screw 93 could be replaced by a permanent rivet or other suitable
attachment to prevent disengagement of disc 90 from mounting plate
82, to ensure that the interlock is not tampered with.
The present invention is particularly adapted for use on
rechargeable electric toy vehicles of the type ridden by children.
In one such vehicle incorporating the present invention, an 18-volt
battery supplies two drive motors which move the vehicle at a
maximum speed of 8-miles-per-hour or less. Alternative types of
vehicles with different power supplies may also employ the battery
recharge interconnection system of the present invention.
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