CROSS-REFERENCE TO RELATED APPLICATION(S)

[0001] This application claims the benefit of priority under 35 U.S.C. § 119(e) to U.S. Provisional Patent Application No.: 63/418,163 filed on 21 October 2022, which is herein incorporated by reference.

TECHNICAL FIELD

[0002] The present disclosure relates to an electrical coupling apparatus for connecting together electronic and/or electrical parts having multiple current paths.

BACKGROUND

[0003] In an electronic system, it is typically necessary to establish electrical connections between constituent parts of the system. In some situations, the parts to be connected together have multiple current paths. The multiple current paths may be low voltage data or control signals and/or power flows. Connectors for multiple path parts, i.e., multi-path connectors, are typically plug and socket connections that are difficult and, thus, expensive to manufacture. Moreover, conventional multi-path connectors tend to be susceptible to wear and tear and do not accommodate the misalignment of the parts being connected together. More specifically, conventional multi-path connectors typically do not accommodate angular misalignment, i.e., components of a conventional multi-path connector must be in a particular angular position relative to each other in order to be connected together. However, in some applications, it would be desirable to connect together the components regardless of their angular orientation relative to each other.

[0004] Based on the foregoing, it would be desirable to provide an improved electrical coupling apparatus for electrically connecting together multi-path parts.

SUMMARY

[0005] A coupling apparatus is disclosed having first and second connector parts. The first connector part includes a plurality of canted coils arranged concentrically. A first housing holds the canted coils and includes a socket within which a first ground conductor is disposed. The second connector part includes a plurality of annular bus bars arranged concentrically. A second housing holds the bus bars and includes a plug. At least one engaging portion of a second ground conductor protrudes from the plug. The first and second connector parts are configured to be coupled together to electrically connect the canted coils to the busbars and to have the plug received in the socket to electrically connect the first ground conductor to the second ground conductor. The connection of the canted coils to the busbars allows power to flow through the coupling apparatus and the connection of the first ground conductor to the second ground conductor forms a grounding path through the coupling apparatus.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] The features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:

[0007] Fig. 1 is a top perspective view of a coupling apparatus having first and second connector parts;

[0008] Fig. 2 is a bottom perspective view of the coupling apparatus of Fig. 1;

[0009] Fig. 3 is a bottom perspective view of retaining rings and canted coils of the first connector part of the coupling apparatus of Figs. 1 and 2;

[0010] Fig . 4 is a sectional view of the first connector part of the coupling apparatus of Figs. 1 and 2, wherein a lower plate of the first connector has been removed;

[0011] Fig. 5 is a top perspective view of a portion of the first connector part of the coupling apparatus of Figs. 1 and 2, wherein the portion includes conductors connected to conductive strips, a ground sleeve, sense rings and a force sensor;

[0012] Fig. 6 is a bottom perspective view of the coupling apparatus of Figs. 1 and 2, wherein a mount and a lower plate of the first connector part have been removed;

[0013] Fig. 7 is a bottom perspective view of the second connector part of the coupling apparatus of Figs. 1 and 2; [0014] Fig. 8 is a bottom perspective view of a portion of the second connector part of the coupling apparatus of Figs. 1 and 2, wherein the portion includes bus bars, a ground sleeve and inner and outer ring structures;

[0015] Fig . 9 shows a bottom perspective view of an upper shell of the second connector part of the coupling apparatus of Figs. 1 and 2; and

[0016] Fig. 10 shows a perspective view of the ground sleeve and the inner and outer ring structures of the second connector part of the coupling apparatus of Figs. 1 and 2.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

[0017] It should be noted that in the detailed descriptions that follow, identical components have the same reference numerals, regardless of whether they are shown in different embodiments of the present disclosure. It should also be noted that for purposes of clarity and conciseness, the drawings may not necessarily be to scale and certain features of the disclosure may be shown in somewhat schematic form.

[0018] Referring now to Fig. 1 , there is shown a coupling apparatus 210 constructed in accordance with this disclosure. The coupling apparatus 210 generally includes a lower or first connector part 212 configured for connection to an upper or second connector part 214. The first connector part 212 has a mount 216 that is configured for connection to a docking structure of a larger device. The docking structure may be movable in an X-Z plane and/or the Y-direction and/or may be angularly movable. The mount 216 may have an outer rubber sheath that helps retain the mount 216 in a bore of the docking structure. The first connector part 212 is connected to conductors 222, while the second connector part 214 is connected to conductor terminals 224. Thus, when the first and second connector parts 212, 214 are connected together, the conductors 222 are electrically connected to the terminals 224, respectively. The conductors 222 and the terminals 224 may carry electric power and/or low voltage data and/or control signals, as described below. [0019] For purposes of facilitating description, components of the coupling apparatus 210 may be described with regard to X, Y, Z spatial coordinates, which are as follows: the X-axis extends in the direction of the conductors 222; the Y-axis extends through the first and second connector parts 212, 214; and the Z-axis extends between side edges of the first connector part 212, wherein each side edge extends in the direction of the X-axis.

[0020] Referring now also to Figs. 3-6, the first connector part 212 includes a plastic housing 230, which may have a main body 232 connected to a lower plate 234 and an upper cover 236. The main body 232 has an inner socket 238 and an annular outer wall 240 joined to a circular plate 242. The socket 238 includes a cylindrical side wall. The plate 242 has a plurality of concentric grooves 241 formed therein, which give the plate 242 a crenellated cross-section. A plurality of concentric annular structures or retaining rings 246 is secured to and extend outwardly from the plate 242. Each retaining ring 246 has a generally T-shaped cross-section and includes a wall 248 joined to a center of a top flange 250. A plurality of snap-fit projections 245 extend downwardly from a bottom edge of the wall 248. The projections 245 may be arranged in pairs, wherein the pairs are arranged in a spaced-apart manner around the circumference of the bottom edge of the wall 248. The projections 245 may be releasably secured in slots formed in the bottoms of the grooves 241 of the plate 242. The retaining rings 246, together with the socket 238 and the outer wall 240 define a plurality of concentric annular holding spaces 254. The holding spaces 254 have upper openings that are narrowed by at least one of the top flanges 250. A plurality of canted coils 260 is disposed in at least a portion of the holding spaces 254, respectively. In the embodiment best shown in Fig. 4, a canted coil 260 is disposed in the holding space 254 defined between each pair of the retaining rings 246. In addition, a canted coil 260 is disposed in the holding space 254 defined between an innermost one of the retaining rings 246 and the socket 238. In this embodiment, there are four canted coils 260. Of course, in other embodiments, more or less than four canted coils 260 may be used. [0021] The canted coils 260 each have an annular configuration and includes a plurality of coil contacts. Each coil 260 may be a single unitary coil having a series of adjacent turns or loops, each of which is a coil contact. Alternately, each coil 260 may include a plurality of arcuate unitary coils that are arranged to form an annular configuration. The coils 260 are formed from copper or, more preferably, a high conductivity, high temperature copper alloy, such as C18080, which is an alloy of copper, chromium, silicon, titanium, silver and iron. Another suitable copper alloy is C151 , which is an alloy of copper and zirconium. The coils 260 may be plated with silver. Each coil 260 is pre-loaded and canted in an axial direction.

[0022] The coils 260 may be mounted to the body 232 by disposing the coils 260 on top surfaces 264 of the plate 242 (between the grooves 241) and then securing the projections 245 in the slots of the plate 242. In this manner, the holding spaces 254 are formed around the coils 260. Since the diameter of the coils 260 is wider than the upper openings of the holding spaces 254, the coils 260 are trapped inside the holding spaces 254.

[0023] The coils 260 are electrically connected to conductors 222a,b,c,d by conductive strips 270, each of which has a straight first end portion 270a and an arcuate second end portion 270b (as best shown in Fig. 5). The strips 270 extend through openings in the plate 242 of the body 232, such that the second end portions 270b lie on or are flush with the top portions 264 of the plate 242. The first end portions 270a of the strips 270 may be secured to the conductors 222, such as by welding or soldering. The second end portions 270b of the strips 270 may be secured to the coils 260, such as by welding or soldering. The strips 270 are formed from a conductive metal, such as copper or a copper alloy. Thermistors 272 may be electrically connected to the strips 270 between the conductors 222 and the coils 260. The thermistors 272 may be connected to a sensing unit by wires 274.

[0024] A first ground conductor, which may take the form of a cylindrical metallic sleeve 276, is mounted inside the socket 238, adjacent to a side wall thereof. The sleeve 276 is formed from a conductive metal, such as copper or a copper alloy. A metallic strip 280 electrically connects the sleeve 276 to a conductor 222f, which is connected to ground. A sensing disc 282 is secured inside the bottom of the socket 238. At least one first sense conductor, such as concentric inner and outer sensing rings 284, 286, is mounted in the sensing disc 282 so as to be flush with a top surface of the sensing disc 282. The inner and outer sensing rings 284, 286 are connected by metallic strips 288, 290 to conductors 222e and 222g. The inner and outer sensing rings 284, 286 or the strips 288, 290 may be disposed in contact with or proximate to one or more sensors 294 for detecting and/or processing low voltage data and/or control signals. For example, the strips 288, 290 may be disposed proximate to the sensor 294 mounted below the sensing disc 282. The sensor 294 may be a circuit board (PCB) with Hall sensors mounted thereto. A force sensor 296 may be mounted below the sensor 294 to measure the force being applied to the first connector part 212, such as when the first and second connector parts 212, 214 are pressed together during coupling. In this manner, the force can be controlled to prevent the first and second connector parts 212, 214 from being damaged when they are being coupled together.

[0025] Referring now to Figs. 1-2 and 7-8, the second connector part 214 includes a housing comprising upper and lower shells 300, 302, which may be formed from plastic or other material. For example, the lower shell 302 may include a PCB having internal conductive traces connected to the terminals 224. The lower shell 302 includes a central plug 304 and an annular outer ring 306 joined to, and extending from, a plate 308. A leading exterior surface of the central plug 304 has a chamfered or rounded edge to facilitate self-alignment of the first and second connector parts 212, 214 when they are connected together (mated), but are initially out of alignment. In other embodiments, the central plug 304 may be conical to facilitate self-alignment. A plurality of annular bus bars 310 is secured to the plate 308, radially inward from the outer ring 306. The bus bars 310 are concentrically arranged and radially spaced apart. The bus bars 310 have latches 314 that extend through aligned slots in the plate 308 and the upper shell 300, thereby securing the bus bars 310 to the plate 308 and the upper shell 300. The bus bars 310 are formed from an electrically conductive metal, such as copper or a copper alloy.

[0026] Referring now also to Figs. 9 and 10, a hub 320 extends outwardly from a bottom surface of a plate 322 of the upper shell 300. An annular support 324 is joined to an end surface of the hub 320 and extends outwardly therefrom. The annular support 324 is disposed radially inward from an outer side surface of the hub 320. Radially inward of the annular support 324, a cylindrical pedestal 328 is joined to the end surface of the hub 320. Outer slots 332 are formed in the plate 322, adjacent to the outer side surface of the hub 320 and on opposite sides of the hub 320. Inner slots 334 are formed in the hub 320, adjacent to an inner surface of the annular support 324 and on opposite sides of the annular support 324.

[0027] A second ground conductor, such as cylindrical ground sleeve 338, is mounted to the hub 320 such that an inner surface of the ground sleeve 328 adjoins the outer side surface of the hub 320. The sleeve 338 is formed from an electrically conductive metal, such as copper or a copper alloy. Outwardly extending tabs 340 of the ground sleeve 338 are pressed into the outer slots 332 of the plate 322 to secure the ground sleeve 338 to the upper shell 300. A plurality of bent spring arms 342 are formed in the ground sleeve 338 and are arranged around its circumference. The spring arms 342 slope outwardly from an annular body of the ground sleeve 338 and the bends therein project radially outward. The bends in the spring arms form engaging portions of the second ground conductor, as discussed more fully below.

[0028] The second connector part 214 also includes at least one second sense conductor having at least one engaging portion that protrudes from the central plug 304. The at least one second sense conductor may include an inner sensing ring structure 346 and an outer ring structure 352.

[0029] The inner sensing ring structure 346 is supported on an end surface of the pedestal 328 and has an elongated tab 348 that is pressed into a bottom one of the inner slots 334 to secure the inner sensing ring structure 346 to the upper shell 300. The inner sensing ring structure 346 is formed from an electrically conductive metal, such as copper or a copper alloy. A pair of bent spring fingers 350 are formed in the inner sensing ring structure 346 and are arranged on opposite sides of the inner sensing ring structure 346. Bends in the spring fingers 350 project axially outward.

[0030] The outer ring structure 352 is supported on the annular support 324 and has an elongated tab 354 that pressed in a top one of the inner slots 334 to secure the outer ring structure 352 to the upper shell 300. The outer ring structure 352 is formed from an electrically conductive metal, such as copper or a copper alloy. A pair of bent spring fingers 356 are formed in the outer ring structure 352 and are arranged on opposite sides of the outer ring structure 352. Bends in the spring fingers 356 project axially outward. The bends of the spring fingers 356, together with the bends of the spring fingers 350 form the at least on engaging portion of the at least one second sense conductor.

[0031] The central plug 304 of the lower shell 302 has a hollow interior. The ground sleeve 338 mounted to the hub 320, the inner sensing ring structure 346 mounted to the pedestal 328 and the outer ring structure 352 mounted to the annular support 324 (as described above) are disposed inside the hollow interior of the central plug 304 such that the bends of the spring arms 342 protrude through openings in a side wall of the central plug 304 and the bends of the spring fingers 350, 356 protrude through openings in an end wall of the central plug 304. The bends of the spring arms 342 protruding from the side wall of the central plug 304 are biased radially outward but may be moved radially inward, and the bends of the spring fingers 350, 356 protruding from the end surface of the central plug 304 are biased axially outward but may be moved axially inward.

[0032] The bus bars 310, the ground sleeve 338 and the inner and outer sensing ring structures 346, 352 are electrically connected to terminals 224, respectively. The electrical connections may be through traces in one or more separate PCBs (not shown) mounted to the upper shell 300 and/or the lower shell 302 and/or through conductor wires (not shown) mounted to the upper shell 300 and/or the lower shell 302. Alternately, one or both of the upper shell 300 and the lower shell 302 may be at least partially constructed from a PCB having traces that connect the bus bars 310, the ground sleeve 338 and the inner and outer sensing ring structures 346, 352 to terminals 224.

[0033] The coupling apparatus 210 may be manipulated in different ways to connect the first connector part 212 to the second connector part 214. For example, if the first and second connector parts 212, 214 are substantially misaligned in the X-Z plane, the second connector part 214 may be held stationary while the first connector part 212 is moved into substantial alignment, or the first connector part 212 is held stationary while the second connector part 214 is moved into substantial alignment. When the first and second connector parts 212, 214 are in at least substantial alignment in the X-Z plane, one of or both of the first and second connector parts 212, 214 are moved (in the Y direction) into engagement with each other. In some embodiments, the first connector part 212 and/or the second connector part 214 may be fixed in the X-Z and is/are only movable in the Y direction.

[0034] When the first and second connector parts 212, 214 are at least substantially aligned in the X-Z plane, the holding spaces 254 of the first connector part 212 are at least substantially aligned with the bus bars 310 of the second connector part 214. In addition, the socket 238 of the first connector part 212 is at least substantially aligned with the central plug 304 of the lower shell 302. When they are at least substantially aligned, the first and second connectors 212, 214 are then brought together in the Y- direction. The first engagement between the first and second connectors 212, 214 is the central plug 304 entering the socket 238. If there is some misalignment between the first and second connector parts 212, 214, the chamfered or rounded edge of the central plug 304 will engage the side wall of the socket 238 and thereby cause self-alignment of the first and second connector parts 212, 214. As the first and second connectors 212, 214 are brought together, the protruding bends of the spring arms 342 of the ground sleeve 338 of the second connector part 214 engage the ground sleeve 276 of the first connector part 212 and then the bus bars 310 of the second connector part 214 come into physical and electrical contact with the canted coils 260, respectively. Finally, the bends of the spring fingers 350, 356 of the inner and outer sensing ring structures 346, 352 of the second connector part 214 press against the inner and outer sensing rings 284, 286 of the first connector part 212.

[0035] When the first and second connector parts 212, 214 are connected together (mated), as described above, the canted coils 260 of the first connector part 212 are electrically connected to the bus bars 310 of the second connector part 214, thereby allowing power to flow through the coupling apparatus 210. In addition, the ground sleeve 276 of the first connector part 212 is electrically connected to the ground sleeve 338 of the second connector part 214, thereby establishing a grounding path through the coupling apparatus 210. Still further, the inner and outer rings 284, 286 of the first connector part 212 are electrically connected to the inner and outer sensing ring structures 346, 352 of the second connector part 214, thereby establishing sensing lines extending through the first and second connector parts 212, 214 and through which low voltage data and/or control signals may be transmitted. The sensor 294 may, inter alia, detect whether the low voltage signals are being transmitted through the sensing lines. [0036] When the first and second connector parts 212, 214 are fully connected together and power is flowing through the coupling apparatus 210, the low voltage signals are transmitted through the sensing lines and are detected by the sensor 294. However, if the first and second connector parts 212, 214 start to decouple, the sensing lines are broken and the low voltage signals will not be transmitted through the sensing lines (and detected by the sensor 294), even if current is still flowing through the interconnected canted coils 260 and the bus bars 310. In this manner, a break in the sensing lines will provide an early indication that the first and second connector parts 212, 214 are becoming de-coupled. [0037] It should be appreciated from the foregoing that the first and second connector parts 212, 214 are especially constructed to make electrical connections in a particular order during mating and to make electrical disconnections in a reverse order during un-mating. More specifically, when the first and second connector parts 212, 214 are mated, the ground sleeves 276, 338 are electrically connected together first, followed by the electrical connection of the bus bars 310 with the canted coils 260 and then the electrical connection of the inner and outer sensing rings 284, 286 with the inner and outer sensing ring structures 346, 352. When the first and second connector parts 212, 214 are un-mated, the electrical connections are broken in the reverse order, namely the inner and outer sensing rings 284, 286 are disconnected from the inner and outer sensing ring structures 346, 352 first, followed by the disconnection of the bus bars 310 from the canted coils 260 and then the disconnection of the ground sleeves 276, 338. The purpose of this ordering is to permit detection (through the sensing lines) of the start of a de-coupling of the first and second connector parts 212, 214 before electrical connections are lost between the bus bars 310 and the canted coils 260 and between the ground sleeves 276, 338, thereby permitting corrective action to quickly be taken to avoid arcing, e.g., moving the first connector part 212 to maintain the electrical connection between the canted coils 260 of the first connector part 212 and the bus bars 310 of the second connector part 214.

[0038] It should also be appreciated that the pitch of the coil contacts can be selected to provide a desired vertical force, which is preferably the lowest force required to make a good electrical connection between the bus bars 310 of the second connector part 214 and the canted coils 260 of the first connector part 212. Using a limited amount of feree reduces the amount wear the bus bars 310, the canted coils 260 and the other components of the first and second connector parts 212, 214 become subjected to during repeated use of the coupling apparatus 210.

[0039] The coupling apparatus 210 is particularly well suited for applications where the first and second connector parts 212, 214 need to be connected together when they are at any angular position relative to each other. One such application is use of the coupling apparatus 210 in a battery charging system for electric vehicles. In such a system, the second connector part 214 may be mounted to the underside of an electric vehicle and electrically connected to the battery cells of the vehicle, while the first connector part 212 may be mounted to the docking structure of a charging station with a control system. The first connector part 212 may be connected to the charging station to permit low voltage signals to be transmitted between the first connector part 212 and the control system of the charging station. For example, the control system may be electrically connected to the sensor 294 and the force sensor 296 and may monitor the low voltage signals in the sensing lines. The vehicle may be maneuvered to position the second connector part 214 over the first connector part 212. The docking structure is then moved to connect the first connector part 212 to the second connector part 214. Measurements from the force sensor 296 (which may be transmitted to the control system of the charging station) may be used to control movement of the docking structure (and the first connector part 212) to ensure the proper connection of the first and second connector parts 212, 214 and prevent them from being damaged. In addition, the force sensor 296 may be used to detect if the vehicle moves during use (e.g. a person enters/exits the car while it is charging), which signals the charging station to dynamically adjust the height of the docking structure to maintain contact, or to prevent damage from being overly-compressed.

[0040] It is to be understood that the description of the foregoing exemplary embodiment(s) is (are) intended to be only illustrative, rather than exhaustive. Those of ordinary skill will be able to make certain additions, deletions, and/or modifications to the embodiment(s) of the disclosed subject matter without departing from the spirit of the disclosure or its scope.