Supply charging device comprising supply power connector

Abstract

A supply charging device (200) for a mobile device (102) includes a supply power connector (210) having a supply housing (212) with a mating end (202) mating with a receiving power connector (310) of the mobile device along a mating axis (110) at a front portion (240). The supply power connector has a cable end (204) at the bottom (246). A supply contact chamber (206) is located at the mating end and a supply cable chamber (208) is located at the cable end. The supply power connector includes supply power contacts (220) and a data communication module (380) at the mating end. The supply charging device (200) includes a cable assembly (232) extending from a cable end at a bottom of the supply housing. The supply power cable (230) extends along a cable axis (231) that is not oriented parallel to the mating axis.

Description

Technical Field

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

[0002] Mobile devices such as autonomous vehicles, mobile robots or other types of rechargeable mobile vehicles can move within an environment to perform tasks. Mobile devices need 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 arranged at the end of the power cable. The connection between the power contacts of the charging connector is susceptible to damage at the power cable, such as stress and strain caused by bending of the cable, pulling on the cable or impact on the connector. The connection between the power cable and the power contact is a permanent connection, such as welding or crimping. Therefore, it is impractical to reuse or repair the power cable and the power contact, so when other components are damaged, the components cannot be reused.

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

[0004] The solution is provided by a supply charging device for a mobile device. The supply charging device includes a supply power connector having a supply housing extending between a front and a rear portion. The supply housing has a top and a bottom. The supply 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 docking axis. The supply power connector has a cable end at the bottom. 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 contact chamber for mating with the receiving power connector along the mating axis. The supply power connector includes a data communication module at the mating end for electrically connecting to the receiving power connector. The supply charging device includes a cable assembly connected to the supply power connector and extending from the cable end at the bottom of the supply housing. The cable assembly includes a supply power cable terminated to a corresponding supply power contact. The supply power cable extends along a cable axis that is not parallel to the mating axis. BRIEF DESCRIPTION OF THE DRAWINGS

[0005] The present invention will now be described by way of example with reference to the accompanying drawings, in which:

[0006] Figure 1 A charging system for charging a mobile device according to an exemplary embodiment is shown.

[0007] Figure 2A charging system for charging a mobile device according to an exemplary embodiment is shown.

[0008] Figure 3 A charging system according to an exemplary embodiment is shown.

[0009] Figure 4 is a front perspective view of a supply charging device according to an exemplary embodiment.

[0010] Figure 5 is a rear perspective view of a supply charging device according to an exemplary embodiment.

[0011] Figure 6 is a cross-sectional view of a supply charging device according to an exemplary embodiment.

[0012] Figure 7 is an exploded partial cross-sectional view of a rear portion of a supply charging device according to an exemplary embodiment.

[0013] Figure 8 is a bottom perspective, partially cut-away view of a supply charging device according to an exemplary embodiment.

[0014] Fig. 9 is a rear perspective view of a data communication module according to an exemplary embodiment.

[0015] Fig.10 is a front perspective view of a data communication module according to an exemplary embodiment.

[0016] Fig.11 is a cross-sectional view of a supply charging device according to an exemplary embodiment, showing a supply data communication module.

[0017] Fig.12 is a front perspective view of a receiving charging device according to an exemplary embodiment.

[0018] Fig.13 is a rear perspective exploded view of a receiving charging device according to an exemplary embodiment.

[0019] Fig.14 is a rear perspective partial cross-sectional view of a receiving charging device according to an exemplary embodiment.

[0020] Fig.15 is a side cross-sectional view of a receiving charging device according to an exemplary embodiment.

[0021] Fig.16 is an end cross-sectional view of a receiving charging device 300 according to an exemplary embodiment.

[0022] Fig.17 is a cross-sectional view of a receiving charging device showing a receiving data communication module according to an exemplary embodiment.

[0023] Fig.18 is a perspective view of a portion of a charging system according to an exemplary embodiment showing a supply data communications module and a receiving data communications module ready to mate with each other.

[0024] Fig.19 is a cross-sectional view of a supplying data communications module and a receiving data communications module mating with each other according to an exemplary embodiment.

[0025] Fig. 20 is a cross-sectional view of a supplying data communications module and a receiving data communications module mating with each other according to an exemplary embodiment.

[0026] Fig.21 is a cross-sectional view of a portion of a charging system showing a supply charging device coupled to a mobile charging device according to an exemplary embodiment. DETAILED DESCRIPTION

[0027] 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 supply housing has a top and a bottom. The supply 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 docking axis. The supply power connector has a cable end at the bottom. 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 contact chamber for mating with the receiving power connector along the mating axis. The supply power connector includes a data communication module at the mating end for electrically connecting to the receiving power connector. The supply charging device includes a cable assembly connected to the supply power connector and extending from the cable end at the bottom of the supply housing. The cable assembly includes a supply power cable terminated to a corresponding supply power contact. The supply power cable extends along a cable axis that is not parallel to the mating axis.

[0028] In another 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 supply housing has a top and a bottom. The supply 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 docking axis. The supply power connector has a cable end at the bottom. 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 supply power contacts in the supply contact chamber for mating with the receiving power connector along the mating axis, each supply power contact including a cable clamp, the cable clamp including a cable space between a base and a clamping member. The clamping member is movable between a clamping position and a release position relative to the base, wherein the size of the cable space is smaller at the clamping position. The supply power connector includes a data communication module at the mating end for electrically connecting to the receiving power connector. The supply charging device includes a cable assembly connected to the supply power connector and extending from the cable end at the bottom of the supply housing. The cable assembly includes supply power cables terminated to corresponding supply power contacts. The supply power cables extend along a cable axis oriented non-parallel to the mating axis, each supply cable including an end portion received in a cable space of a corresponding cable clamp, wherein the ends of the supply cables are compressively connected between the base and the clamping member when in the clamped position.

[0029] In another embodiment, a charging system is provided, and the charging system includes 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, which is connected to the receiving power connector and extends 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, which includes a supply power connector, which has 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 mates with the mating end of the receiving power connector along the docking axis. The supply power connector has a cable end at the bottom. 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 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 that is connected to the supply power connector and extends from a cable end at the bottom of the supply housing. 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 oriented parallel to the mating axis.

[0030] Figure 1 A 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 component 14. The charging component 14 may be at a docking station. The charging component 14 may extend from a wall outlet or a charging station 16. The charging component 14 may include a charging plug at the end of a cable bundle. The charging component 14 may be provided in a fixed position in a room or building, and the mobile device 12 may be movable within the room or building and returned to the vicinity of the charging station 16 for connection to the charging component 14 to recharge the mobile device 12. The supply charging device 20 receives power from a power source 40.

[0031] 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, transport 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.

[0032] 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 supply charging device 200 and a mobile charging device 300. Figure 2 is a front view of the mobile charging device 300 . Figure 3 is a front view of the supply charging device 200. 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 coupled to a body or panel of the mobile device 102. The supply charging device 200 is a part of the charging component 104 and includes a mating end 202 configured to mate with the mobile charging device 300. The mating end 202 of the supply charging device 200 is configured to be plugged onto the mating end 302 of the mobile charging device 300.

[0033] The mobile charging device 300 receives power from the supply charging device 200 to charge the battery of the mobile device 102 when connected to the supply charging device 200. The mobile charging device 300 includes a receiving power connector 310 having a receiving housing 312. The receiving housing 312 includes a latch feature 390 to secure the supply charging device 200 to the mobile charging device 300. The receiving power connector 310 includes a plurality of receiving power contacts 320 ( Figure 2 ) of the receiving contact assembly 322. 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 coupled to the receiving housing 312.

[0034] The supply charging device 200 includes a supply power connector 210 having a supply housing 212. The supply housing 212 includes a latch feature 290 to secure the supply charging device 200 to the receiving charging device 300. The supply power connector 210 includes a plurality of supply power contacts 220 ( Figure 3 ) of the supply contact assembly 222. 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 source data communication module 280 coupled to the supply housing 212, and the supply housing 212 is configured to be coupled to the receiving data communication module 380.

[0035] In an exemplary embodiment, the supply power connector 210 is a right-angle connector having a supply power cable 230 that exits the supply housing 212 perpendicular to the mating end of the supply contact body 220. For example, the supply power cable 230 can extend along a cable axis 231 that is perpendicular to the mating axis 110. In this way, when inserted into the receiving power connector 310, the cable 230 can be cantilevered straight down from the supply power connector 210. In this way, the pressure and strain on the cable 230 are reduced compared to a connector having a cable that extends parallel to the mating axis and then bends 90° downward and back from the connector. Such a bend in the cable causes strain between the cable and the contact, which may cause failure over time. In other embodiments, the supply power cable 230 can exit the supply housing 212 at other angles relative to the mating axis 110. For example, the cable axis 231 can be oriented at an angle that is not parallel to the mating axis 110. The supply power cable 230 can exit at an angle that is angled downward relative to the mating axis 110. For example, the supply power cable 230 may exit the supply housing 212 at an angle between 30° and 60° relative to the mating axis 110. In various embodiments, the supply power cable 230 may exit the supply housing 212 at an angle of approximately 45° relative to the mating axis 110. In alternative embodiments, other orientations are possible.

[0036] Figure 4 is a front perspective view of a supply charging device 200 according to an exemplary embodiment. Figure 5 is a rear perspective view of a supply charging device 200 according to an exemplary embodiment. Figure 6 2 is a cross-sectional view of a supply charging device 200 according to an exemplary embodiment. 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 .

[0037] The supply housing 212 includes a body 214 and a cover 216 coupled to the body 214. In various embodiments, the cover 216 can be rotatably coupled to the body 214. The supply housing 212 includes a front 240 and a rear 242. The supply housing 212 includes a top 244 and a bottom 246. In an exemplary embodiment, the mating end 202 is at the front 240 of the supply housing 212, and the cable end 204 of the supply power connector 210 is at the bottom 246 of the supply housing 212. The cable 230 enters / exits the supply housing 212 at the bottom 246.

[0038] In an exemplary embodiment, the supply housing 212 includes a supply contact chamber 206 for receiving the supply power contact 220 and a supply cable chamber 208 for receiving the supply power cable 230. The supply contact chamber 206 extends through the body 214 of the supply housing 212 between the front 240 and the rear 242. The supply power contact 230 can be loaded into the supply contact chamber 206 through the rear 242. Optionally, a portion of the supply power contact 230 can be located in 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 is open at the bottom 246 to receive the cable 230. In the illustrated embodiment, the supply contact chamber 206 extends generally horizontally and the supply cable chamber 208 extends generally vertically. In this way, the cable 230 can extend from the bottom 246 (e.g., generally perpendicular to the supply power contact 220). In the exemplary embodiment, supply power contact 220 is a right angle contact that extends into supply cable chamber 208, which allows supply power cable 230 to extend along a linear path through supply cable chamber 208 to bottom 246 of supply housing 212. Supply power cable 230 does not include a bend within supply housing 212.

[0039] Each 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 is stamped and formed. The mating end 226 is configured to mate with a receiving power connector 310 (such as Figure 2 ) as shown. In the illustrated embodiment, the mating end 226 is a sheet contact. The body 224 is flat at the mating end 226. Other types of contacts, such as pins, sockets, spring beams, etc., may be provided at the mating end 226. In an exemplary embodiment, the body 224 includes a 90° bend between the mating end 226 and the termination end 228. In this way, the termination end 228 is oriented perpendicular to the mating end 226. The termination end 228 extends into the supply cable chamber 208 for connection to the supply power cable 230. The termination end 228 may be oriented at other non-parallel angles relative to the mating end 226, such as at an angle between 30° and 60°.

[0040] Additional references Figure 7 and Figure 8 , Figure 7 is an exploded partial cross-sectional view of a rear portion of a supply charging device 200 according to an exemplary embodiment, and Figure 8 is a bottom perspective partial cut-away view of a supply charging device 200 according to an exemplary embodiment. Figure 7 and Figure 8 The terminating end 228 of the supply power contact 220 is shown. In an exemplary embodiment, the terminating end 228 includes a separable termination interface for terminating to a supply power cable 230. The supply power cable 230 can be mated and unmated with the separable termination interface, such as for repair or replacement of the supply power connector 210 or the supply power cable 230.

[0041] In an exemplary embodiment, the supply power contact 220 includes a cable clamp 250 at the terminating end 228. The cable clamp 250 has a cable space 252 between a base 254 and a clamping member 256. The clamping member 256 can be in a clamping position ( Figure 8 ) and release position ( Figure 7 ) between the base 254 and the clamping member 256. The size of the cable space 252 is smaller in the clamping position and larger in the release position. In the release position, the end 234 of the supply power cable 230 can be loaded into the cable clamp 250 and can be removed from the cable clamp 250. When in the clamping position, the supply power cable 230 is mechanically and electrically connected to the cable clamp 250 between the base 254 and the clamping member 256. In an exemplary embodiment, the cable clamp 250 includes a set screw 258 operably coupled between the base 254 and the clamping member 256. The set screw 258 is tightened to move the clamping member 256 from the release position to the clamping position to clamp to the end 234 of the supply power cable 230. The set screw 258 is loosened to move the clamping member 256 from the clamping position to the release position to allow the end 234 of the supply power cable 230 to be removed from the cable clamp 250. Other types of clamps may be used in alternative embodiments. In other embodiments, other types of detachable connections may be used at the terminating end 228. In alternative embodiments, the terminating end 228 may be permanently connected to the supply power cable 230, such as using a crimp connection or a weld connection.

[0042] When the cover 216 is opened ( Figure 7), the termination end 228 of the supply power contact 220 is accessible, such as access to the set screw 258 to tighten or loosen the cable clamp 250. After the supply power cable 230 is loaded into the cable clamp 250 and the cable clamp 250 is tightened into the clamped position, the cover 216 is closed and coupled to the body 214 to enclose the termination. The cover 216 can be secured using fasteners, clamps, latches, or other securing features. The cover 216 can clamp the supply power cable 230 when closed to provide strain relief for the supply power cable 230. In various embodiments, the cover 216 is rotatably coupled to the body 214 at the cover shaft 218.

[0043] Fig. 9 is a rear perspective view of a data communication module 280 according to an exemplary embodiment. Fig.10 2 is a front perspective view of a data communication module 280 according to an exemplary embodiment. 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. The data communication module 280 includes a data communication module shield 288 surrounding the data communication module housing 282. The data communication module shield 288 provides electrical shielding for the data communication module contacts 284. The data communication module shield 288 is electrically connected to the wire shield of the data communication module wires 286.

[0044] In an exemplary embodiment, the data communication module contacts 284 include pin contacts 284a and socket contacts 284b. For example, the data communication module contacts 284 include a pair of pin contacts 284a and a pair of socket contacts 284b. In alternative embodiments, other types and / or different numbers of data communication module contacts 284 may be provided. In the illustrated embodiment, the socket contacts 284b are located in the extension 292 of the data communication module housing 282. The pin contacts 284a are located in the recess 294 of the data communication module housing 282.

[0045] In an exemplary embodiment, the data communication module housing 282 and the data communication module contacts 284 form a hermaphroditic mating interface at the mating end 281 of the data communication module 280. The mating end 281 is configured to mate with the data communication module 380 receiving the power connector 310 (e.g., Figure 2). In an exemplary embodiment, the data communications module shield 288 includes a mating beam 296 and a mating pad 298 at opposite sides of the data communications module housing 282. The mating beam 296 is configured to interface with the mating pad of the receiving data communications module 380 to electrically connect the data communications module shield 288 to the receiving data communications module 380. The mating pad 298 is configured to receive the mating beam of the receiving data communications module 380 to electrically connect the data communications module shield 288 to the receiving data communications module 380.

[0046] Fig.11 is a cross-sectional view of a supply charging device 200 showing a supply data communication module 280 according to an exemplary embodiment. Fig.11 A data communications module 280 is shown in the supply housing 212 .

[0047] In an exemplary embodiment, the data communication module 280 is received in the supply contact chamber 206. The data communication module 280 is disposed at the mating end 202 for mating with a data communication module receiving the power connector 310 (eg, Figure 2 214). The data communication module wire 286 extends from the rear end of the main body 214 into the cover space 217 formed by the cover 216. The data communication module wire 286 is bent 90° in the cover space 217 to extend to the bottom 246 of the supply housing 212. The data communication module wire 286 can be captured between the cover 216 and the main body 214.

[0048] Fig.12 is a front perspective view of a receiving charging device 300 according to an exemplary embodiment. Fig.13 is a rear perspective exploded view of a receiving charging device 300 according to an exemplary embodiment.

[0049] The receiving 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. In an exemplary embodiment, the receiving power connector 310 is a straight connector having a receiving power cable 330 that exits the receiving housing 312 parallel to the mating end of the receiving contact 320. For example, the receiving power cable 330 can extend along a cable axis 331 that is parallel to the mating axis 110. The receiving power cable 330 can be routed from the receiving power connector 310 to a battery or other component of the mobile device.

[0050] The receiving housing 312 includes a body 314 and a cover 316 coupled to the body 314. In various embodiments, the cover 316 is a multi-piece cover including an upper cover 317 and a lower cover 318. The upper cover 317 and the lower cover 318 are coupled together using fasteners 319. The upper cover 317 and the lower cover 318 are fixed to the body 314, for example, using a keyway 313 in the body and a key 315 in the cover 316. Other fixing features, such as fasteners, clips, latches, etc., can be used in alternative embodiments. The upper cover 317 and the lower cover 318 include a recess or channel for receiving a receiving power cable 330. The receiving power cable 330 is configured to be sandwiched between the upper cover 317 and the lower cover 318.

[0051] 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 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 rear portion 342. However, in alternative embodiments, the cable end 304 can be at the bottom portion 346. For example, the receiving power connector 310 can be a right angle connector.

[0052] 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 receiving power cable 330. The receiving contact chamber 306 extends through the body 314 of the receiving housing 312 between the front portion 340 and the rear portion 342. The receiving power contact 330 can be loaded into the receiving contact chamber 306 through the rear portion 342. Optionally, a portion of the receiving power contact 330 can be located within the receiving cable chamber 308 to connect with the receiving power cable 330. The receiving cable chamber 308 is located at the rear portion 342, such as behind the receiving contact chamber 306. The receiving cable chamber 308 is open at the rear portion 342 to receive the cable 330.

[0053] Each receiving power contact 320 includes a body 324 extending between a mating end 326 and a terminating end 328. In an exemplary embodiment, the body 324 is stamped and formed. The mating end 326 is configured to mate with the supply power connector 210 ( Figure 2 In the embodiment shown, the mating end 326 is a socket contact. Other types of contacts, such as pins, sheets, spring beams, etc., can be provided at the mating end 326.

[0054] Additional references Figure 14-16 , Fig.14 is a rear perspective partial cross-sectional view of a receiving charging device 300 according to an exemplary embodiment, Fig.15 is a side cross-sectional view of a receiving charging device 300 according to an exemplary embodiment, and Fig.16 is an end cross-sectional view of a receiving charging device 300 according to an exemplary embodiment. Figure 14-16 The terminating ends 328 of the receiving power contacts 320 are shown. In an exemplary embodiment, each terminating end 328 includes a separable termination interface for terminating to a receiving power cable 330. The receiving power cable 330 can be mated and unmated with the separable termination interface, such as for repairing or replacing the receiving power connector 310 or the receiving power cable 330.

[0055] In an exemplary embodiment, the body 324 of the supply power contact 320 includes an upper wall 336 and a lower wall 338 at the mating end 326, with a socket 337 between the upper wall 336 and the lower wall 338. The upper wall 336 includes a spring plate 335 along the upper wall 336 in the socket 337. The lower wall 338 includes a spring plate 339 along the lower wall 338 in the socket 337. The spring plates 335, 339 are compressible. The spring plates 335, 339 have a contact with the supply power contact 220 ( Figure 4 The spring plates 335, 339 may include separate spring beams.

[0056] In an exemplary embodiment, the receiving power contact 320 includes a cable clamp 350 at the terminating end 328. The cable clamp 350 has a cable space 352 between a base 354 and a clamping member 356. The clamping member 356 can be in a clamping position ( Figure 15-16 ) and release position ( Fig.14 ) between the base 354 and the clamping member 356. The size of the cable space 352 is smaller in the clamping position and larger in the release position. In the release position, the end 334 of the receiving power cable 330 can be loaded into the cable clamp 350 and can be removed from the cable clamp 350. When in the clamping position, the receiving power cable 330 is mechanically and electrically connected to the cable clamp 350 between the base 354 and the clamping member 356. In an exemplary embodiment, the cable clamp 350 includes a set screw 358 operably coupled between the base 354 and the clamping member 356. Tightening the set screw 358 moves the clamping member 356 from the release position to the clamping position to clamp to the end 334 of the receiving power cable 330. Loosening the set screw 358 moves the clamping member 356 from the clamping position to the release position to allow the end 334 of the receiving power cable 330 to be removed from the cable clamp 350. Other types of clamps may be used in alternative embodiments. In other embodiments, other types of detachable connections may be used at the terminating end 328. In alternative embodiments, the terminating end 328 may be permanently connected to the receiving power cable 330, such as using a crimp connection or a solder connection.

[0057] When the cover 316 is opened ( Figure 7 ), the terminal end 328 of the receiving power contact 320 is accessible, such as accessing the set screw 358 to tighten or loosen the cable clamp 350. After the receiving power cable 330 is loaded into the cable clamp 350 and the cable clamp 350 is tightened to the clamped position, the cover 316 is coupled to the body 314 to close the termination. The cover 316 clamps the receiving power cable 330 when closed to provide strain relief for the receiving power cable 330.

[0058] Fig.17 is a cross-sectional view of a receiving charging device 300 showing a receiving data communication module 380 according to an exemplary embodiment. Fig.17 312. The data communication module 380 is shown in the receiving housing 312. The data communication module 380 may be similar to the data communication module 280 (in Figure 9-10 ). In various embodiments, data communication module 380 can be identical to data communication module 280. For example, data communication module 380 and data communication module 280 can have hermaphroditic mating interfaces.

[0059] 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. The data communication module 380 includes a data communication module shield 388 surrounding the data communication module housing 382. The data communication module shield 388 provides electrical shielding for the data communication module contacts 384. The data communication module shield 388 is electrically connected to the wire shields of the data communication module wires 386.

[0060] In an exemplary embodiment, a data communication module 380 is received in the receiving contact chamber 306. The data communication module 380 is disposed at the mating end 302 for mating with the data communication module 280 of the supply power connector 210. The data communication module wires 386 extend from the rear end of the body 314 into a channel or groove of the cover 316. The cover 316 can provide strain relief for the data communication module wires 386. For example, the data communication module wires 386 can be captured between the upper cover 317 and the lower cover 318.

[0061] Fig.18 is a perspective view of a portion of the charging system 100 showing the supply data communications module 280 and the receiving data communications module 280 ready to mate with each other. Fig.19 2 is a cross-sectional view of the supply data communication module 280 and the reception data communication module 280 cooperating with each other. Fig. 20 2 is a cross-sectional view of the supply data communication module 280 and the reception data communication module 280 cooperating with each other.

[0062] In an exemplary embodiment, the data communication module housing 282, 382 and the data communication module contacts 284, 384 form a hermaphroditic mating interface. The pin contacts 284a, 384a are configured to mate with the socket contacts 284b, 384b. The extensions 292, 392 of the data communication module housings 282, 382 are configured to be received in the recesses 294, 394 of the data communication module housings 282, 382. The data communication module shields 288, 388 are configured to be electrically connected when mated. For example, the mating beams 296, 396 mate with the mating pads 298, 398.

[0063] Fig.21 is a cross-sectional view of a portion of the charging system 100 showing the supply charging device 200 coupled to the mobile charging device 300. The mating end 202 of the supply charging device 200 plugs into the mating end 302 of the mobile charging device 300. The supply power contact 220 is coupled to the receiving power contact 320. For example, a blade is inserted into a socket.

[0064] In an exemplary embodiment, the cable clamps 250, 350 at the termination ends 228, 328 of the contacts 220, 320 are electrically connected to the power cables 230, 330 at a detachable termination interface. In the illustrated embodiment, the supply power cable 230 is oriented perpendicular to the receiving power cable 330. For example, the supply power cable 230 is oriented vertically and the receiving power cable 330 is oriented horizontally. In alternative embodiments, the supply power cable 230 and / or the receiving power cable 330 may leave the respective housings at other angles and may be oriented in other non-parallel or non-perpendicular orientations. In an exemplary embodiment, the supply power contact 220 is a right-angle contact so that the cable clamp 250 at the termination end 228 is oriented perpendicular to the cable clamp 350 at the termination end 328. The cable clamps 250, 350 clamp in a vertical direction. The cable 230 can be suspended straight down from the supply power connector 210 when inserted into the receiving power connector 310. In this way, the stress and strain on the cable 230 is reduced compared to a connector having a cable extending parallel to the mating axis and then bending 90° downward and back from the connector. This bend in the cable causes strain between the cable and the contacts, which may cause failure over time. The cover 216 clamps the supply power cable 230 when closed to provide strain relief for the supply power cable 230.

Claims

1. A supply charging device (200) for a mobile device (102), the supply charging device comprising: A supply power connector (210) having a supply housing (212) extending between a front portion (240) and a rear portion (242), the supply housing having a top portion (244) and a bottom portion (246), the supply power connector having a mating end (202) at the front portion, the mating end being configured to mate with a receiving power connector (310) of the mobile device along a mating axis (110), the supply power connector having a cable end (204) at the bottom portion, the supply housing including a supply contact chamber (206) at the mating end and a supply cable chamber (208) at the cable end, the supply power connector including a supply power contact (220) in the supply contact chamber, the supply power contact (220) being used to mate with the receiving power connector along the mating axis, the supply power connector including a data communication module (380) at the mating end for electrically connecting to the receiving power connector; and A cable assembly (232) coupled to the supply power connector and extending from the cable end at the bottom of the supply housing, the cable assembly comprising a supply power cable (230) terminated to corresponding supply power contacts, the supply power cable extending along a cable axis (231) oriented non-parallel to the mating axis.

2. The supply charging device (200) according to claim 1, wherein: The supply power cable (230) is terminated to the supply power contact (220) at a separable termination interface.

3. The supply charging device (200) according to claim 1, wherein: A supply power cable (230) extends along a linear path from the supply power cable through the supply cable (208) chamber to a bottom (246) of the supply housing (212).

4. The power supply and charging device (200) according to claim 1, wherein: The cable axis (231) of the power supply cable (230) is oriented substantially perpendicular to the mating axis (110).

5. The supply charging device (200) according to claim 1, wherein: The supply power cable (230) exits the supply housing (212) at an angle between 30° and 60° relative to the mating axis (110).

6. The power supply and charging device (200) according to claim 1, wherein: Each supply power contact (220) includes a body (18) extending between a mating end (202) and a terminating end (228) extending into the supply cable chamber (208) to terminate to the supply power cable (230), the mating end being oriented perpendicular to the terminating end.

7. The power supply and charging device (200) according to claim 6, wherein: The terminating end (228) includes a cable clamp (250) configured to clamp to the supply power cable (230).

8. The power supply and charging device (200) according to claim 1, wherein: Each supply power contact (220) includes a clamping contact having a cable space (252) between a base (254) and a clamping member (256), the clamping member being movable relative to the base between a clamping position and a release position, wherein the cable space is smaller in size in the clamping position, an end (234) of the supply power cable (230) being received in the cable space and mechanically and electrically connected to the cable clamp (250) between the base and the clamping member when in the clamping position.

9. The power supply and charging device (200) according to claim 8, wherein: The cable clamp (250) includes a set screw (258) operably coupled between the base (254) and the clamping member (256), the set screw being tightened to move the clamping member from the release position to the clamping position to clamp to the end (234) of the supply power cable (230).

10. The supply charging device (200) according to claim 1, wherein: The data communication module (380) includes a data communication module housing (382), the data communication module housing retaining data communication module contacts (384) and data communication module wires (386) extending from the data communication module contacts, the data communication module housing and the data communication module contacts forming a hermaphroditic mating interface at a mating end (202) of the data communication module, the mating end being configured to mate with the data communication module of the receiving power connector (310).

11. The supply charging device (200) according to claim 10, wherein: The data communications module includes a data communications module shield surrounding the data communications module housing, the data communications module shield being electrically connected to wire shields of the data communications module wires.

12. The supply charging device (200) according to claim 1, wherein: The supply housing includes a main body and a cover coupled to the main body, the cover being opened to expose the supply cable chamber to terminate the supply power contact to the supply power cable.

13. The supply charging device (200) according to claim 12, wherein: The cover is rotatably coupled to the body at a cover axis.

14. The supply charging device (200) according to claim 12, wherein: The cover forms a cover space, and the data communication module includes data communication module wires extending from the body through the cover space to the cable end to exit the supply housing at the bottom of the supply housing.

15. The supply charging device (200) according to claim 12, wherein: The cover is coupled to the body at a rear portion.

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