Power connector system

Abstract

The supply charging device includes a supply power connector having a supply housing with a mating end mating with a receiving power connector of the mobile device along a mating axis. The supply housing includes a front housing and a rear housing separate and discrete from the front housing, the rear housing coupled to the front housing at a separable interface. The rear housing includes a cable chamber and the front housing includes a contact chamber. The supply charging device includes a latch that is latchably coupled to the receiving power connector. The supply charging device includes a contact assembly held by the rear housing, wherein the pins of the contacts are received in the contact cavities. The supply charging device includes a cable assembly coupled to the contact assembly and extending from the cable end.

Description

Technical Field

[0001] The subject matter herein relates generally to power connectors. Background Art

[0002] A mobile device, such as an autonomous vehicle, a mobile robot, or other type of rechargeable mobile vehicle, can move within an environment to perform tasks. The mobile device needs to be recharged from time to time. The mobile device returns to a charging station to supply power to the mobile device and recharge the battery of the mobile device. The charging connector can be inserted into the power connector of the mobile device to recharge the battery of the mobile device. The charging connector is provided at the end of a power cable. The power cable is susceptible to damage, such as stress and strain caused by bending of the cable, pulling of the cable, or impact on the connector. Different customers inevitably expect different types of charging connectors for their specific applications. It is expensive to completely redesign all components of the various charging connectors.

[0003] There remains a need for a robust and configurable charging connector for a mobile device. Summary of the invention

[0004] In one embodiment, a supply charging device for a mobile device is provided. The supply charging device includes a supply power connector having a supply housing extending between a front and a rear portion. The power connector has a mating end at the front. The mating end is configured to mate with a receiving power connector of the mobile device along a mating axis. The supply power connector has a cable end at the rear. The supply housing includes a front housing and a rear housing separated and discrete from the front housing. The rear housing is coupled to the front housing at a detachable interface. The rear housing includes a cable chamber at the cable end. The front housing includes a contact chamber at the mating end. The supply charging device includes a latch pivotally coupled to the supply housing. The latch includes a latch finger configured to be latchably coupled to the receiving power connector. The supply charging device includes a contact assembly held by the rear housing. The contact assembly includes a supply contact. The supply power contact has a pin received in the contact chamber of the front housing for mating with the receiving power connector. The contact assembly includes a supply data communication module held by the rear housing. The supply data communication module includes a signal contact at a mating end for electrically connecting to a receiving power connector. The supply charging device includes a cable assembly coupled to the contact assembly. The cable assembly includes a power cable terminated to a corresponding supply contact. The power cable extends from the cable end.

[0005] In another embodiment, a supply charging device for a mobile device is provided. The supply charging device includes a power connector having a supply housing extending between a front and a rear portion. The power connector has a mating end at the front. The mating end is configured to mate with a receiving power connector of the mobile device along a mating axis. The power connector has a cable end at the rear. The supply housing includes a front housing and a rear housing separated and discrete from the front housing. The rear housing is coupled to the front housing at a detachable interface. The front housing includes a contact chamber extending along the mating axis at the mating end. The rear housing includes a cable chamber at the cable end, which extends along a cable outlet axis oriented not parallel to the mating axis. The supply charging device includes a contact assembly held by the rear housing. The contact assembly includes a supply power contact and a signal contact. The supply power contact has a pin received in the contact chamber of the front housing for mating with the receiving power connector. Each pin is bent between the front end and the rear end. The front end extends parallel to the mating axis. The rear end does not extend parallel to the mating axis. The supply charging device includes a cable assembly coupled to the contact assembly. The cable assembly includes a power cable terminated to a rear end portion of a corresponding supply power contact. The power cable extends from a cable end along a cable outlet axis.

[0006] In another embodiment, a charging system is provided, the charging system including a mobile charging device having a receiving housing extending between a front and a rear. The receiving housing has a top and a bottom. The receiving power connector has a mating end at the front. The receiving power connector has a cable end. The receiving housing includes a receiving contact chamber at the mating end and a receiving cable chamber at the cable end. The receiving power connector includes a receiving power contact in the receiving contact chamber. The receiving power connector includes a receiving data communication module at the mating end. The mobile charging device includes a receiving cable assembly coupled to the receiving power connector and extending from the cable end. The receiving cable assembly includes a receiving power cable terminated to a corresponding receiving power contact. The charging system includes a supply charging device, the supply charging device including a supply power connector having a supply housing extending between the front and the rear. The supply housing has a top and a bottom. The supply power connector has a mating end at the front. The mating end is mated with the mating end of the receiving power connector along the mating axis. The supply power connector has a cable end opposite to the mating end. The supply housing includes a supply contact chamber at the mating end and a supply cable chamber at the cable end. The supply power connector includes a supply power contact in the supply power contact chamber for mating with a corresponding receiving power contact along a mating axis. The supply power connector includes a supply data communication module at the mating end for electrically connecting to a receiving data communication module of the receiving power connector. The supply charging device includes a supply cable assembly coupled to the supply power connector and extending from the cable end. The supply cable assembly includes a supply power cable terminated to the corresponding supply power contact. The supply power cable extends along a cable axis that is not parallel to the mating axis, wherein the supply housing includes a front housing and a rear housing that is separated and discrete from the front housing. The rear housing is coupled to the front housing at a detachable interface. The front housing includes a supply contact chamber. The rear housing includes a supply cable chamber. The rear housing holds the supply power contact and the supply data communication module. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Figure 1 A charging system for charging a mobile device according to an exemplary embodiment is shown.

[0008] Figure 2 A charging system for charging a mobile device according to an exemplary embodiment is shown.

[0009] Figure 3 A charging system according to an exemplary embodiment is shown.

[0010] Figure 4 A front view of a mobile charging device according to an exemplary embodiment is shown.

[0011] Figure 5A front view of a supply charging device according to an exemplary embodiment is shown.

[0012] Figure 6 is a front perspective view of a supply charging device according to an exemplary embodiment showing two of the interchangeable rear end portions configured to couple to a common front end portion.

[0013] Figure 7 is a rear perspective view of a supply charging device according to an exemplary embodiment showing two of the interchangeable rear end portions configured to couple to a common front end portion.

[0014] Figure 8 is a perspective view of one of the supply power contacts according to an exemplary embodiment.

[0015] Fig. 9 is a side perspective view of a contact assembly according to an exemplary embodiment.

[0016] Fig.10 is a front perspective view of a contact assembly according to an exemplary embodiment.

[0017] Fig.11 is a rear perspective view of a portion of a supply charging device according to an exemplary embodiment.

[0018] Fig.12 is a perspective view of a latch feature according to an exemplary embodiment.

[0019] Fig.13 is a rear perspective view of a portion of a front end of a supply charging device showing a latch feature received in a latch recess of a front housing according to an exemplary embodiment.

[0020] Fig.14 is a front perspective view of a portion of a rear end portion of a supply charging device according to an exemplary embodiment, illustrating the rear end of the supply charging device.

[0021] Fig.15 is a front perspective view of a supply charging device showing a front end portion coupled to a rear end portion according to an exemplary embodiment.

[0022] Fig.16 is a cross-sectional view of a supply charging device taken along one of the supply power contacts according to an exemplary embodiment.

[0023] Fig.17 is a cross-sectional view of a supply charging device taken along a latch feature according to an exemplary embodiment.

[0024] Fig.18 is a rear perspective exploded view of a portion of a supply charging device according to an exemplary embodiment.

[0025] Fig.19 is a top view of a portion of a supply charging device according to an exemplary embodiment.

[0026] Fig. 20 is a front perspective view of a portion of a supply charging device according to an exemplary embodiment, showing a rear end portion of the supply charging device.

[0027] Fig.21 is a front perspective view of a supply charging device showing a front end portion coupled to a rear end portion according to an exemplary embodiment.

[0028] Fig. 22 is a perspective view of one of the angled patterns supplying power contacts according to an exemplary embodiment.

[0029] Fig.23 is a perspective view of a contact assembly according to an exemplary embodiment.

[0030] Fig.24 is a cross-sectional view of a supply charging device taken along one of the supply charging contacts according to an exemplary embodiment.

[0031] Fig.25 is a cross-sectional view of a supply charging device taken along a latch feature according to an exemplary embodiment.

[0032] Fig.26 is a front perspective view of a supply charging device showing a plurality of interchangeable handles configured to be coupled to a supply housing according to an exemplary embodiment.

[0033] Fig. 27 is a front perspective view illustrating a mobile charging device according to an exemplary embodiment.

[0034] Fig.28 is a rear perspective exploded view of a portion of a mobile charging device according to an exemplary embodiment.

[0035] Fig.29 is a cross-sectional view of a mobile charging device taken along one of the receiving power contacts according to an exemplary embodiment.

[0036] Fig.30 is a cross-sectional view of a mobile charging device taken along a latch feature according to an exemplary embodiment. DETAILED DESCRIPTION

[0037] Figure 1A charging system 10 for charging a mobile device 12 according to an exemplary embodiment is shown. The charging system 10 includes a supply charging device 20 and a mobile charging device 30. The mobile charging device 30 is disposed on the mobile device 12. The supply charging device 20 is disposed on a charging assembly 14. The charging assembly 14 may extend from a wall outlet or a charging station 16. The charging assembly 14 may be located at a docking station of the mobile device 12. The charging assembly 14 may include a charging plug at the end of a cable bundle that is inserted into the mobile charging device 30 to charge the battery of the mobile device 12. The charging assembly 14 may be disposed at a fixed location in a room or building, and the mobile device 12 may be moved within the room or building and returned to the vicinity of the charging station 16 to connect to the charging assembly 14 to recharge the mobile device 12. The supply charging device 20 receives power from a power source 40.

[0038] In an exemplary embodiment, the mobile device 12 may be an autonomous mobile device that can move within an environment to perform tasks and return to a supply charging device 20 to charge the autonomous mobile device 12. In various embodiments, the mobile device 12 may be a forklift. In other various embodiments, the mobile device 12 may be a mobile robot, such as for performing tasks in a factory, a hotel, a store, or another environment. For example, a mobile robot may be used to scan items on a shelf, deliver items from one location to another, or perform other tasks. The mobile charging device 30 is mounted to the body 18 of the mobile device 12.

[0039] Figure 2 A charging system 100 for charging a mobile device 102 is shown according to an exemplary embodiment. Figure 3 A charging system 100 according to an exemplary embodiment is shown. The charging system 100 includes a charging device 200 and a mobile charging device 300. Figure 2 A straight version is provided for charging device 200 , wherein the power cable is oriented parallel to mating axis 110 . Figure 3 The angled version of the supply charging device 200 is shown with a handle. However, either version may be used with or without a handle. Additionally, various types of handles may be used interchangeably with the supply charging device 200. When coupled to the supply charging device 200, the mobile charging device 300 receives power from the supply charging device 200 to charge the battery of the mobile device 102.

[0040] The mobile charging device 300 is disposed on the mobile device 102 and includes a mating end 302 configured to mate with the supply charging device 200. For example, the mobile charging device 300 is configured to be coupled to a body or panel of the mobile device 102. The supply charging device 200 is part of the charging assembly 104 and includes a mating end 202 configured to mate with the mobile charging device 300. The mating end 202 is the same for both the straight version and the angled version of the supply charging device 200. The mating end 202 of the supply charging device 200 is configured to be inserted into the mating end 302 of the mobile charging device 300. In this way, both the straight version and the angled version of the supply charging device 200 are configured to be inserted into the same mating end 302 of the mobile charging device 300.

[0041] Additional references Figure 4 and Figure 5 , Figure 4 and Figure 5 1 and 2 show front views of the mobile charging device 300 and the supply charging device 200, respectively. Figure 4 ) includes a receiving power connector 310 having a receiving housing 312. The receiving housing 312 includes a latching feature 390 to secure the supply charging device 200 to the mobile charging device 300. The receiving power connector 310 includes a receiving contact assembly 322 having a plurality of receiving power contacts 320. The receiving contact assembly 322 is coupled to the receiving housing 312. The receiving power connector 310 includes a cable assembly 332 having a plurality of receiving power cables 330 terminated to corresponding receiving power contacts 320. The receiving power connector 310 includes a receiving data communication module 380 ( Figure 4 ).

[0042] Supply charging device 200 ( Figure 5 ) includes a supply power connector 210 having a supply housing 212. The supply housing 212 includes a latching feature 290 to secure the supply charging device 200 to the receiving charging device 300. The supply power connector 210 includes a supply contact assembly 222 having a plurality of supply power contacts 220. The supply contact assembly 222 is coupled to the supply housing 212. The supply power connector 210 includes a cable assembly 232 having a plurality of supply power cables 230 terminated to corresponding supply power contacts 220. The supply power connector 210 includes a supply data communication module 280 ( Figure 5 ), the supply housing 212 is configured to be coupled to a receiving data communication module 380.

[0043] The mating end 202 of the supply charging device 200 is coupled to the mating end 302 of the receiving charging device 300 along the mating axis 110. For example, the mating end 202 is inserted into the mating end 302. The supply power connector 210 is mated with the receiving power connector 310. For example, the supply contacts of the supply contact assembly 222 are mated with the receiving contacts of the receiving contact assembly 322. In the illustrated embodiment, the supply contacts are pin contacts and the receiving contacts are socket contacts; however, other types of contacts may be used in alternative embodiments. When mated, the supply data communication module 280 is mated with the receiving data communication module 380. For example, the signal contacts of the supply data communication module 280 are mated with corresponding signal contacts of the receiving data communication module 380. In the illustrated embodiment, the signal contacts of the supply data communication module 280 are pin contacts and the signal contacts of the receiving data communication module 380 are socket contacts; however, other types of contacts may be used in alternative embodiments. When mated, latch features 290 of donor charging device 200 couple to latch features 390 of recipient charging device 300 to securely couple donor charging device 200 to recipient charging device 300 .

[0044] In an exemplary embodiment, the supply charging device 200 includes interchangeable components for changing the direction of the cable outlet. For example, the rear end portion 205 of the supply charging device 200 can be interchangeable to change the direction of the cable outlet. The front end portion 203 of the supply charging device 200 is universal and is configured to couple to the interchangeable rear end portion 205. In the illustrated embodiment, the straight version ( Figure 2 ) orients the supply power cable 230 to be in line with or parallel to the mating axis 110, while the angled pattern ( Figure 3 ) Orient the supply power cable 230 transverse to or non-parallel to the mating axis, such as oriented 45° downward. In alternative embodiments, other angles are possible, such as at an angle between 30° and 60° or at 90° (a right-angle pattern). The supply power cable 230 extends along a cable axis 231. The rear end of the supply housing 212 maintains the cable axis 231 parallel to the mating axis 110 in a straight pattern. The rear end of the supply housing 212 maintains the cable axis 231 non-parallel to the mating axis 110 in an angled pattern, which may be more convenient or easier for a user to maintain. The rear portion of the supply housing 212 is angled to orient the supply power cable 230 in an angled orientation so that the supply power cable 230 does not need to be bent, which reduces internal strain on the supply power cable 230.

[0045] Figure 6is a front perspective view illustrating a supply charging device 200 according to an exemplary embodiment showing two of the interchangeable rear end portions 205 configured to couple to a universal front end portion 203 . Figure 7 is a rear perspective view of a supply charging device 200 according to an exemplary embodiment, showing that two of the interchangeable rear end portions 205 are configured to be coupled to a common front end portion 203. Any of the rear end portions 205 (e.g., a straight pattern or an angled pattern) can be coupled to the front end portion 203 to change the cable outlet orientation compared to the mating direction. The mating interfaces of the two rear end portions 205 are similar or identical so that the two rear end portions 205 can be engaged with the same front end portion 203. Thus, a modular system is provided that utilizes interchangeable components to reduce the number of overall components, which reduces the overall cost of manufacturing.

[0046] The supply charging device 200 includes a supply power connector 210, a supply contact assembly 222, a supply cable assembly 232, and a supply data communication module 280. The supply power connector 210 includes a supply housing 212. In an exemplary embodiment, the supply housing 212 is a multi-piece housing including a front housing 214 and a rear housing 216. The front housing 214 is part of the front end 203 of the supply charging device 200. The rear housing 216 is part of the rear end 205 of the supply charging device 200. Different types of devices (e.g., straight types and angled types) have rear housings 216 of different shapes (e.g., straight and angled).

[0047] The supply housing 212 includes a front portion 240 and a rear portion 242. The front housing 214 includes the front portion 240, and the rear housing 216 includes the rear portion 242. The rear housing 216 is connected to the front housing 214 at an interface 241 located between the front portion 240 and the rear portion 242. The interface of the straight type and the angled type of the rear housing 216 can be similar or identical to allow for engagement with the front housing 214. The supply housing 212 includes a top 244 and a bottom 246. In an exemplary embodiment, the mating end 202 is at the front portion 240 of the supply housing 212 (e.g., at the front housing 214), and the cable end 204 of the supply power connector 210 is at the rear portion 242 of the supply housing 212 (e.g., at the rear housing 216). The cable 230 enters / exits the supply housing 212 at the cable end 204. The cable 230 exits the supply housing 212 along the cable exit axis. In the case of a straight pattern, the cable 230 exits parallel to the mating axis. In the case of an angled pattern, the cable 230 exits at an angle that is transverse or non-parallel to the mating axis. In the illustrated embodiment, the cable 230 exits the angled pattern at an angle between 30° and 60°, such as at approximately 45°.

[0048] In an exemplary embodiment, the supply housing 212 includes a supply contact chamber 206 that receives the supply power contact 220 and a supply cable chamber 208 that receives the supply power cable 230. In an exemplary embodiment, the front housing 214 includes the contact chamber 206. The rear housing 216 may include a portion of the contact chamber 206. For example, the supply power contact 220 may be located in both the front housing 214 and the rear housing 216. The supply cable chamber 208 is located in the rear housing 216. For example, the power cable 230 may extend into the rear housing 216 and terminate to a corresponding power contact 220 in the rear housing 216. Optionally, a portion of the supply power contact 230 may be located within the supply cable chamber 208 to connect with the supply power cable 230. The supply cable chamber 208 is located at the rear 242. The supply cable chamber 208 may be opened at the rear 242 to receive the cable 230. In the illustrated embodiment, the supply cable chamber 208 extends generally horizontally in the straight version and at an angle (e.g., 45°) in the angled version. In the exemplary embodiment, the supply power cable 230 extends along a linear path through the supply cable chamber 208. The supply power cable 230 does not include a bend within the supply housing 212.

[0049] Figure 8 is a perspective view of one of the supply power contacts 220 according to an exemplary embodiment. The supply power contact 220 can be used in a straight version of the device. The supply power contact 220 includes a body 224 extending between a mating end 226 and a terminating end 228. The supply power contact 220 includes a groove 227 between the mating end 226 and the terminating end 228. The groove serves as a positioning feature to position the supply power contact 220 within the supply housing 212. In an exemplary embodiment, the body 224 is a machined part. However, the body 224 can be extruded, stamped and formed, milled, die cast, or formed by other manufacturing techniques. The mating end 226 is configured to mate with the receiving power connector 310 ( Figure 4 ) is mated. In the illustrated embodiment, the mating end 226 is a pin contact 225. The body 224 is cylindrical at the mating end 226. Other types of contacts, such as blades, sockets, spring beams, etc., may be provided at the mating end 226. In an exemplary embodiment, the terminating end 228 includes a crimp barrel that is configured to be crimped to the power cable 230. In alternative embodiments, the terminating end 228 may include a pad or other type of termination.

[0050] Fig. 9 is a side perspective view of a contact assembly 222 according to an exemplary embodiment. Fig.102 is a front perspective view of a contact assembly 222 according to an exemplary embodiment. In the illustrated embodiment, the contact assembly 222 includes a pair of supply power contacts 220. In alternative embodiments, the contact assembly 222 may include more or fewer supply power contacts 220. In an exemplary embodiment, the contact assembly 222 includes a contact holder 250 for holding the supply power contacts 220. The contact holder 250 is made of a dielectric material, such as a plastic material, to isolate the supply power contacts 220 from each other. In various embodiments, the contact holder 250 is a molded plastic component.

[0051] In an exemplary embodiment, the contact holder 250 includes a contact channel 252 that receives a corresponding supply power contact 220. Optionally, the contact channel 252 includes an opening 254 at a side of the contact holder 250 to receive the supply power contact 220. For example, the supply power contact 220 can be loaded sideways into the contact channel 252 through the opening 254. In an exemplary embodiment, the contact holder 250 includes a shoulder 256 extending into the contact channel 252. The shoulder 256 is configured to be received in the groove 227 to position the supply power contact 220 in the contact channel 252. Other types of positioning and / or fixing features, such as latches, clips, fasteners, etc., can be used in alternative embodiments. In an exemplary embodiment, the terminating end 228 of the power contact 220 is located in the contact channel 252, while the mating end 226 extends in front of the contact holder 250. However, in alternative embodiments, the mating end 226 may additionally or alternatively be located in the contact channel 252. In an exemplary embodiment, the contact holder 250 includes a front recess 258 at the front of the contact holder 250. The front recess 258 may be located between the contact channels 252. The front recess 258 may be configured to receive a latch and / or data communication module 280 (in Figure 5 ).

[0052] Fig.11 is a rear perspective view of a portion of a supply charging device 200 according to an exemplary embodiment. Fig.11 The front housing 214 , latch feature 290 , and data communications module 280 are shown.

[0053] In an exemplary embodiment, the latch feature 290 is coupled to the front housing 214. A portion of the latch feature 290 can extend behind the front housing 214. For example, the front housing 214 includes a latch recess 260 that receives the latch feature 290. The front housing 214 may include other openings to receive other components. For example, the front housing 214 includes a contact hole 262 that receives a portion of the supply power contact 220, such as a pin at the mating end of the supply power contact 220. In an exemplary embodiment, the front housing 214 includes a rear recess 264 located at the rear of the front housing 214. The rear recess 264 is configured to receive a portion of the data communication module 280. Optionally, a portion of the data communication module 280 can be received in the rear housing 216 (e.g., Figure 6 shown).

[0054] The data communication module 280 includes a data communication module housing 282 that holds data communication module contacts 284 and data communication module wires 286 extending from the data communication module contacts 284. In an exemplary embodiment, the data communication module contacts 284 are pin contacts. However, the data communication module contacts 284 may be other types of contacts, such as socket contacts, blade contacts, spring contacts, etc.

[0055] In an exemplary embodiment, the data communications module housing 282 includes contact channels 288 that receive corresponding data communications module contacts 284. Optionally, the contact channels 288 include openings at the sides of the data communications module housing 282 to receive the data communications module contacts 284. For example, the data communications module contacts 284 can be loaded into the data communications module housing 282 laterally through the openings. In an exemplary embodiment, the data communications module housing 282 includes shoulders or other types of locating features that extend into the contact channels 288 to locate the data communications module contacts 284 in the contact channels 288. In an exemplary embodiment, the mating ends of the data communications module contacts 284 extend in front of the data communications module housing 282 for mating with a receiving data communications module.

[0056] Fig.12 is a perspective view of a latch feature 290 according to an exemplary embodiment. Fig.13 is a rear perspective view of a portion of the front end 203 of the supply charging device 200 illustrating the latch feature 290 received in the latch recess 260 of the front housing 214 .

[0057] In an exemplary embodiment, the latch feature 290 includes a deflectable latch 292. The latch 292 includes an actuator 293 and a latch beam 294 extending from the actuator 293. The latch beam 294 includes a latch finger 295 at a distal end of the latch beam 294. The actuator 293 is actuated to release the latch finger 295. In an exemplary embodiment, the latch 292 includes a support arm 296 extending from opposite sides of the latch beam 294. The support arm 296 includes a positioning tab 297 for positioning the latch 292 in the front housing 214. In an exemplary embodiment, the latch feature 290 includes one or more biasing members 298 configured to engage the front housing 214 to hold the latch 292 in the loaded position. In the illustrated embodiment, the biasing member 298 is integral with the latch 292. For example, the biasing member 298 can be disposed at the distal end of the support arm 296. When the latch feature 290 is loaded in the latch recess 260, the biasing member 298 deflects, thereby generating an internal biasing force that holds the latch 292 in the loaded position. For example, the biasing member 298 can force the latch finger 295 to engage with the latch feature 390 of the receiving power connector 310 in a downward direction (e.g., in a latched position). The actuator 293 can press downward to lift the latch finger 295 in an upward direction (e.g., to an unlocked position) to release the latch feature 290 from the latch feature 390. When the actuator 293 is released, the biasing member 298 returns the latch 292 in a downward direction to the latched position.

[0058] Fig.14 is a front perspective view of a portion of the supply charging device 200 , illustrating the rear end 205 of the supply charging device 200 . Fig.15 is a front perspective view of the supply charging device 200 showing the front end 203 coupled to the rear end 205 . Fig.16 is a cross-sectional view of the supply charging device 200 taken along one of the supply power contacts 220 . Fig.17 is a cross-sectional view of the supply charging device 200 taken along the latch feature 290 . Figure 14-17 A straight version of the supply charging device 200 is shown, with the power cable 230 extending from the cable end 204 and the cable exit direction parallel to the mating axis.

[0059] When assembled, the contact assembly 222 and the data communication module 280 are received in the supply contact chamber 206 of the rear housing 216. The contact holder 250 and the data communication module housing 282 are coupled to the rear housing 216. The contact holder 250 holds the supply power contact 220 relative to the rear housing 216. The pins at the mating end 226 of the supply power contact 220 extend in front of the rear housing 216. The pins of the supply power contact 220 are received in the contact holes 262 of the front housing 214. The contact holes 262 form a socket around the pins, which is configured to receive the socket contacts of the receiving power connector 310. The data communication module housing 282 holds the data communication module contacts 284 relative to the rear housing 216. The pins of the data communication module contacts 284 extend in front of the data communication module housing 282. The pins of the data communication module contacts 284 are received in the supply contact chamber 206 of the front housing 214. For example, the pins of the data communications module contacts 284 are received in the recesses 264 at the bottom of the contact chamber 206 for mating with the data communications module 380 of the mobile charging device 300 .

[0060] The latch feature 290 is coupled to the supply housing 212. For example, the latch feature 290 is received in the latch recess 260 of the front housing 214. The latch beam 294 extends into the chamber 206 at the front of the front housing 214 to dock with the mobile charging device 300. The actuator 293 is located at the rear of the latch 292 and can extend rearward from the front housing 214. In an exemplary embodiment, the actuator 293 is received in the latch recess 266 of the rear housing 216. The top of the actuator 293 is exposed and accessible at the top of the supply housing 212. The user can press down on the actuator 293 to release the latch feature 290.

[0061] Fig.18 is a rear perspective exploded view of a portion of a supply charging device 200 according to an exemplary embodiment. Fig.19 is a top view of a portion of a supply charging device 200 according to an exemplary embodiment. Fig.18 and Fig.19A cable assembly 232 is shown coupled to the supply housing 212. In an exemplary embodiment, the cable assembly 232 includes a cable strain relief 234 that provides strain relief for the power cable 230. The cable strain relief 234 is coupled to the mounting tabs 270 at the rear of the rear housing 216. In an exemplary embodiment, the cable strain relief 234 includes cable retainers 236 that are configured to be secured together using fasteners. The cable retainers 236 are disposed on opposite sides of the power cable 230, such as above and below the power cable 230. Alternatively, the cable retainers 236 may be identical pieces that are inverted 180° relative to (e.g., only) one another. Each cable retainer 236 includes a cable channel 238 that receives a corresponding power cable 230. When the cable strain relief 234 is coupled to the mounting tabs 270, the power cable 230 is secured between the cable retainers 236. The cable retainer 236 may clamp or squeeze the power cable 230 to provide strain relief and prevent pulling on the supply power contacts 220 .

[0062] Fig. 20 is a front perspective view of a portion of the supply charging device 200 , illustrating the rear end 205 of the supply charging device 200 . Fig.21 is a front perspective view of the supply charging device 200 showing the front end 203 coupled to the rear end 205 . Fig. 20 and Fig.21 An angled version of the charging device 200 is shown, wherein the power cable 230 extends from the cable end 204 in a cable exit direction that is non-parallel to the mating axis. For example, the cable exit direction is angled downward at an angle between 30° and 60°, such as approximately 45°.

[0063] When assembled, the contact assembly 222 and the data communication module 280 are received in the supply contact chamber 206 of the rear housing 216. The angled pattern ( Fig.21 ) can be connected to the straight type ( Fig.15 ) are identical to the mating interface at the front of the front housing 214. The contact retainer 250 and the data communication module housing 282 are coupled to the rear housing 216. The contact retainer 250 holds the supply power contact 220 relative to the rear housing 216. The pins at the mating end 226 of the supply power contact 220 extend in front of the rear housing 216. The pins of the supply power contact 220 are received in the contact holes 262 of the front housing 214. In the straight version ( Fig.15 ) and angled types ( Fig.21) The same front housing 214 is used on both. The data communication module housing 282 holds the data communication module contacts 284 relative to the rear housing 216. The pins of the data communication module contacts 284 extend in front of the data communication module housing 282. The pins of the data communication module contacts 284 are received in the supply contact chamber 206 of the front housing 214. For example, the pins of the data communication module contacts 284 are received in the recesses 264 at the bottom of the contact chamber 206 for mating with the data communication module 380 of the mobile charging device 300.

[0064] Fig. 22 is a perspective view of one of the angled versions of the supply power contact 220 according to an exemplary embodiment. The supply power contact 220 includes a body 224 extending between a mating end 226 and a terminating end 228. In an exemplary embodiment, the body 224 includes a bend 229 that angles the terminating end 228 relative to the mating end 226. The bend controls the cable exit direction. In various embodiments, the bend 229 can be between 30° and 60°, such as approximately 45°. The supply power contact 220 includes a groove 227 between the mating end 226 and the terminating end 228. The groove 227 is used as a positioning feature to position the supply power contact 220 within the supply housing 212. The mating end 226 is configured to mate with the receiving power connector 310 ( Figure 4 ) mate. In the illustrated embodiment, the mating end 226 is a pin contact. However, in alternative embodiments, other types of contacts, such as blades, sockets, spring beams, etc., may be provided at the mating end 226. In an exemplary embodiment, the termination end 228 includes a crimp barrel that is configured to be crimped to the power cable 230. In alternative embodiments, the termination end 228 may include a pad or other type of termination.

[0065] Fig.23 2 is a perspective view of a contact assembly 222 according to an exemplary embodiment. In the illustrated embodiment, the contact assembly 222 includes a pair of supply power contacts 220 (having a bend 229). In alternative embodiments, the contact assembly 222 may include more or fewer supply power contacts 220. In an exemplary embodiment, the contact assembly 222 includes a contact holder 250 for holding the supply power contacts 220. The contact channels 252 receive corresponding supply contacts 220. The shoulders 256 are configured to be received in the grooves 227 to position the supply power contacts 220 in the contact channels 252. Other types of positioning and / or fixing features, such as latches, clips, fasteners, etc., may be used in alternative embodiments. In an exemplary embodiment, the mating end 226 (e.g., a pin) extends in front of the contact holder 250.

[0066] Fig.24is a cross-sectional view of the supply charging device 200 taken along one of the supply power contacts 220 . Fig.25 is a cross-sectional view of the supply charging device 200 taken along the latch feature 290 . Figures 24 to 25 An angled version of the supply charging device 200 is shown, wherein the power cable 230 extends from the cable end 204 in a cable exit direction that is non-parallel to the mating axis.

[0067] The contact assembly 222 and the data communication module 280 are received in the supply contact chamber 206 of the rear housing 216. The contact holder 250 and the data communication module housing 282 are coupled to the rear housing 216. The pins at the mating ends 226 of the supply power contacts 220 extend forward from the rear housing 216 into the contact holes 262 of the front housing 214. The pins of the data communication module contacts 284 extend forward from the data communication module housing 282 into the contact channels in the front housing 214.

[0068] The latch feature 290 is coupled to the supply housing 212. For example, the latch feature 290 is received in the latch recess 260 of the front housing 214 and the latch recess 266 in the rear housing 216. The latch beam 294 extends into the cavity 206 at the front of the front housing 214 to interface with the mobile charging device 300.

[0069] Fig.26 is a front perspective view of the supply charging device 200 illustrating a plurality of interchangeable handles 400 configured to be coupled to the supply housing 212 . Fig.26 Different types of handles 400 are shown. Each of the handles 400 includes an identical mounting bracket 402 so that different handles 400 can be interchangeably coupled to the supply housing 212. The mounting bracket 402 includes mounting arms 404 extending along opposite sides of the supply housing 212 and a connecting portion 406 between the mounting arms 404. The mounting arms 404 can be secured to the supply housing 212 using fasteners, clips, latches, or other securing devices. In the illustrated embodiment, the connecting portion 406 stands across the top of the supply housing 212. The connecting portion 406 includes a latch recess 408 that receives a portion of the latch feature 290, such as the actuator 293. In the illustrated embodiment, the mounting bracket 402 is open at the bottom so that the handle 400 can be mounted to the supply housing 212 from above. However, in alternative embodiments, the mounting bracket 402 can extend completely circumferentially around the supply housing 212.

[0070] In an exemplary embodiment, different handles 400 have different gripping portions 410 extending from mounting bracket 402. Different gripping portions 410 allow for different gripping orientations of charging device 200. For example, gripping portion 410 can be oriented parallel to the mating direction or perpendicular to the mating direction or at other angles. Gripping portion 410 can surround or wrap around the user's hand for better control. Gripping portion 410 can include finger grips 412 to allow the user to grip more conveniently.

[0071] Fig. 27 is a front perspective view showing a mobile charging device 300 according to an exemplary embodiment. The mobile charging device 300 has a mating interface configured for mating with both straight and angled versions of the supply charging device 200. The interchangeable front housing 214 of the supply charging device allows both versions to mate with the same mobile charging device 300.

[0072] The mobile charging device 300 includes a receiving power connector 310 , a receiving contact assembly 322 , a receiving cable assembly 332 , and a receiving data communication module 380 . The receiving power connector 310 includes a receiving housing 312 .

[0073] The receiving housing 312 includes a front portion 340 and a rear portion 342. The receiving housing 312 includes a top portion 344 and a bottom portion 346. In an exemplary embodiment, the receiving housing 312 includes a flange 314 located at the front portion, which can be used to fix the receiving housing 312 to a mobile device, such as a housing or a shell or a mobile device. In an exemplary embodiment, the mating end 302 is located at the front portion 340 of the receiving housing 312, and the cable end 304 of the receiving power connector 310 is located at the rear portion 342 of the receiving housing 312. The cable 330 enters / exits the receiving housing 312 at the cable end 304. The cable 330 exits the receiving housing 312 along the cable outlet axis. In various embodiments, the cable 330 can exit the receiving housing parallel to the mating axis. However, in alternative embodiments, the cable 330 can exit at other angles, such as perpendicular to the mating axis (e.g., right angles) or at other angles (e.g., 45°).

[0074] In an exemplary embodiment, the receiving housing 312 includes a receiving contact chamber 306 for receiving the receiving power contact 320 and a receiving cable chamber 308 for receiving the power cable 330. The receiving contact chamber 306 is located at the front 340. The receiving cable chamber 308 is located at the rear 342. The receiving cable chamber 308 can be opened at the rear 342 to receive the cable 330.

[0075] Fig.28 is a rear perspective exploded view of a portion of a mobile charging device 300 according to an exemplary embodiment. Fig.28A data communication module 380 is shown. The data communication module 380 includes a data communication module housing 382 that holds data communication module contacts 384 and data communication module wires 386 extending from the data communication module contacts 384. In an exemplary embodiment, the data communication module contacts 384 are socket contacts. However, the data communication module contacts 384 can be other types of contacts, such as pin contacts, blade contacts, spring contacts, etc. In an exemplary embodiment, the data communication module housing 382 includes contact channels 388 that receive corresponding data communication module contacts 384. During assembly, the data communication module 380 is loaded into the receiving housing 312, such as through the rear portion 342. The data communication module 380 can be positioned near the bottom 346 of the receiving housing 312.

[0076] Fig.29 is a cross-sectional view of the mobile charging device 300 taken along one of the receiving power contacts 320 . Fig.30 390 is a cross-sectional view of the mobile charging device 300 taken along the latch feature 390. When assembled, the contact assembly 322 and the data communication module 380 are received in the receiving contact chamber 306 of the receiving housing 312. The contact holder 350 holds the receiving power contact 320 relative to the receiving housing 312. The data communication module housing 382 holds the data communication module contacts 384 relative to the receiving housing 312.

[0077] A latch feature 390 is located in the chamber 306. In the illustrated embodiment, the latch feature 390 is integral with the receiving housing 312, such as being co-molded with the receiving housing 312. In the exemplary embodiment, the latch feature 390 includes a latch element 392 having a ramp surface 394 and a latch surface 396. The latch element 392 is configured to interface with the latch 292 of the supply charging device 200 to latchably secure the supply charging device 200 to the mobile charging device 300. Other types of securing features may be used in alternative embodiments.

[0078] In an exemplary embodiment, the receiving power contact 320 is a socket contact. The receiving power contact 320 includes a body 324 extending between a mating end 326 and a terminating end 328. The receiving power contact 320 includes a groove 327 between the mating end 326 and the terminating end 328. The groove 327 serves as a positioning feature to position the power receiving contact 320 within the contact holder 350. In an exemplary embodiment, the body 324 is a machined component. However, the body 324 can be extruded, stamped and formed, milled, die-cast, or formed by other manufacturing techniques. The body 324 is cylindrical at the mating end 326. The mating end 326 includes a socket 325, which is configured to receive the supply contact 220 ( Figure 5). Other types of contacts may be provided at the mating end 326, such as blades, sockets, spring beams, etc. In an exemplary embodiment, the terminating end 328 includes a crimp barrel that is configured to be crimped to the power cable 330. In alternative embodiments, the terminating end 328 may include a pad or other type of termination.

[0079] When assembled, the mating end 326 of the receiving power contact 320 is received in the contact hole 362 of the receiving housing 312. The contact hole 362 is open at the front to receive the pins of the supply contact 220. The hole 362 guides the pins of the supply power contact 220 into the socket 325 to electrically connect the receiving power contact 320 and the supply power contact 220.

Claims

1. A supply and charging device for a mobile device, the supply and charging device comprising: a supply power connector having a supply housing extending between a front portion and a rear portion, the supply power connector having a mating end portion at the front portion, the mating end portion being configured to mate with a receiving power connector of the mobile device along a mating axis, the supply power connector having a cable end portion at the rear portion, the supply housing comprising a front housing and a rear housing separate and distinct from the front housing, the rear housing being coupled to the front housing at a separable interface, the rear housing comprising a cable chamber at the cable end portion, and the front housing comprising a contact chamber at the mating end portion; a latch pivotally coupled to the supply housing, the latch including a latch finger configured to latchably couple to the receiving power connector; a contact assembly held by the rear housing, the contact assembly including a supply power contact having a pin received in the contact cavity of the front housing for mating with the receiving power connector, the contact assembly including a supply data communication module held by the rear housing, the supply data communication module including a signal contact at the mating end for electrically connecting with the receiving power connector; as well as A cable assembly is coupled to the contact assembly, the cable assembly including a power cable terminated to corresponding supply contacts, the power cable extending from the cable end.

2. The supply charging device of claim 1, wherein the rear housing includes a cable chamber at the end of the cable, the cable chamber extending along a cable outlet axis that is not oriented parallel to the mating axis.

3. The supply charging device according to claim 1, wherein each pin is bent between a front end portion and a rear end portion, the front end portion of the pin extends parallel to the mating axis, and the rear end portion of the pin does not extend parallel to the mating axis.

4. The supply charging device according to claim 1, wherein the socket housing is one of a straight socket housing or an angled socket housing, the straight socket housing keeps the pins and the cable parallel to the mating axis, and the angled socket housing keeps the pins parallel to the mating axis and keeps the cable non-parallel to the mating axis. 5 . The supply charging device of claim 4 , wherein the straight socket housing and the angled socket housing are interchangeably configured to be coupled to the front housing. 6 . The supply charging device of claim 1 , wherein the supply power connector comprises a handle removably coupled to the rear housing. 7 . The supply charging device of claim 1 , wherein the supply power connector includes a plurality of handles that are interchangeably coupled to the rear housing.

8. The supply charging device of claim 1, wherein the latch comprises an actuator and a latch beam, the latch beam being located in a latch recess of the front housing, and the actuator being received in a latch slot in the rear housing.

9. The supply charging device according to claim 1, wherein the contact assembly includes a contact holder that holds the supply power contact, the contact holder is received in the rear housing, and the contact holder positions the pins of the supply power contact in the front housing.

10. The supply charging device of claim 1, wherein the front housing includes a contact hole in which a pin of the supply power contact is received.

11. The supply charging device of claim 1, wherein the cable assembly includes a cable strain relief coupled to a rear portion of the supply housing, the cable strain relief coupled to the power cable to secure the power cable relative to the supply housing.

12. A supply and charging device for a mobile device, the supply and charging device comprising: A supply power connector having a supply housing extending between a front and a rear, the supply power connector having a mating end at the front, the mating end being configured to mate with a receiving power connector of the mobile device along a mating axis, the supply power connector having a cable end at the rear, the supply housing comprising a front housing and a rear housing separate and distinct from the front housing, the rear housing being coupled to the front housing at a detachable interface, the front housing comprising a contact chamber extending along the mating axis at the mating end, the rear housing comprising a cable chamber extending along a cable outlet axis oriented non-parallel to the mating axis at the cable end; a contact assembly held by the rear housing, the contact assembly comprising a supply power contact and a signal contact, the supply power contact having a pin received in a contact cavity of the front housing for mating with the receiving power connector, each pin being bent between a front end portion and a rear end portion, the front end portion extending parallel to the mating axis and the rear end portion extending non-parallel to the mating axis; as well as A cable assembly is coupled to the contact assembly, the cable assembly including a power cable terminated to a rear end portion of a corresponding power supply contact, the power cable extending from the cable end along the cable exit axis. 13 . The supply charging device of claim 12 , wherein the supply power connector comprises a plurality of handles that are interchangeably coupled to the rear housing.

14. The supply charging device of claim 12, further comprising a latch pivotally coupled to the supply housing, the latch including a latch finger configured to latchably couple to the receiving power connector.

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