Battery cell container and interface assembly for same

Abstract

To provide battery pack attachments systems for helmet mounting apparatuses and, in particular, a new and improved battery cell container and interface assembly for the same.SOLUTION: A battery pack receiver assembly 112 for detachably securing a battery pack 104 to a helmet mounted device comprises a first battery pack engaging feature for engaging the battery pack. An interface plate comprises a second battery pack engaging feature. A frame is slidably coupled to the interface plate and movable between battery pack retaining and releasing positions. The frame is manually movable to the battery pack releasing position by a user grasping the battery pack. The second battery pack engaging feature is configured to positively retain the battery pack when the frame is in the battery pack retaining position and disengage with the battery pack when the frame is in the battery pack releasing position.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of priority to U.S. Provisional Patent Application No. 63 / 647,911, filed May 15, 2024. The foregoing application is incorporated herein by reference in its entirety. [Background technology]

[0002] The present disclosure relates generally to a battery pack mounting system for a helmet-mounted device, and more particularly to a new and improved battery cell container and coupling assembly therefor. Summary of the Invention

[0003] In one aspect, a battery pack receiving assembly for removably securing a battery pack to a helmet-mounted device includes a frame including a first battery pack engagement mechanism configured to engage with the battery pack and a connection plate including a second battery pack engagement mechanism configured to engage with the battery pack. The frame is slidably coupled to the connection plate and is movable between a battery pack retaining position and a battery pack release position. A biasing member is coupled to the frame and configured to bias the frame toward the battery pack retaining position. The frame is manually movable from the battery pack retaining position to the battery pack release position by a user grasping the battery pack when the battery pack is engaged with the first battery pack engagement mechanism. The second battery pack engagement mechanism is configured to hold the battery pack facing forward when the frame is in the battery pack retaining position and to disengage the battery pack when the frame is in the battery pack release position.

[0004] In a more limited aspect, the second battery pack engagement mechanism can be engaged with the battery pack by a user grasping the battery pack with one hand, and the frame can be manually moved to a battery pack release position by a user grasping the battery pack with one hand.

[0005] In another more narrow aspect, the frame includes first and second opposing, axially extending rails extending between a first end and a second end of the frame and first and second cross members, the first cross member extending between the first and second rails at the first end and the second cross member extending between the first and second rails at the second end, the first battery pack engagement mechanism including a movable retention hook disposed on the first cross member, and the second battery pack engagement mechanism including a fixed retention hook disposed on the connecting plate.

[0006] In another more limited aspect, the biasing member includes one or more spring members disposed intermediate the second cross member and the connecting plate and configured to urge the frame toward the battery pack retaining position.

[0007] In another more narrow aspect, the battery pack receiving assembly further includes a plurality of electrical contacts disposed on the connecting plate and configured to operably mate with the plurality of contacts on the battery pack when the battery pack is coupled to the battery pack receiving assembly.

[0008] In another more narrow aspect, the connection plate is configured to removably couple to a battery pack that conforms to established battery connection standards.

[0009] In another more limited aspect, the established battery interlocking standard is the Small Tactical Universal Battery (STUB) standard.

[0010] In a further aspect, a battery pack coupling assembly for removably coupling to a battery pack receiving assembly includes a first surface configured to removably engage with the battery pack receiving assembly, the first surface having a first plurality of electrical contacts configured to engage respective second plurality of electrical contacts on the battery pack receiving assembly, a second surface configured to engage with a battery container, the second surface configured to electrically couple the first plurality of electrical contacts to one or more batteries disposed within the battery container.

[0011] In a more limited embodiment, the first surface conforms to established battery connection standards.

[0012] In another more limited aspect, the established battery interlocking standard is the Small Tactical Universal Battery (STUB) standard.

[0013] In a further aspect, a battery pack includes a battery pack coupling assembly for removably coupling to the battery pack receiving assembly and includes a battery cell container coupled to the battery pack coupling assembly. The battery pack coupling assembly includes a first surface configured to removably engage with the battery pack receiving assembly, the first surface having a first plurality of electrical contacts configured to engage with respective second plurality of electrical contacts on the battery pack receiving assembly. The battery pack coupling assembly further includes a second surface configured to engage with the battery cell container, the second surface having one or more electrical connectors configured to electrically couple the first plurality of electrical contacts to one or more batteries disposed within the battery cell container.

[0014] In a more limited aspect, the battery cell container is configured to receive one or more battery cells selected from the group consisting of an L92 battery cell, an 18650 battery cell, and a CR123A battery cell.

[0015] In another more limited aspect, the first surface conforms to established battery connection standards.

[0016] In another more limited aspect, the established battery interlocking standard is the Small Tactical Universal Battery (STUB) standard.

[0017] In a further aspect, the modular system of components includes two or more battery packs as disclosed herein, each of the two or more battery packs interchangeably mountable in the battery pack receiving assembly, and each of the two or more battery packs configured to receive a different type of battery cell.

[0018] One advantage of the invention of the present development is found in that it enables a user to remove and replace the battery pack on a helmet-mounted device with one hand and without having to remove the device. In this way, the present development facilitates quick and efficient battery replacement and ease of use in constrained or high-stress environments.

[0019] The various benefits and advantages of the present invention will become apparent to those skilled in the art upon reading and understanding the following detailed description of the preferred embodiments.

[0020] The invention may take form in various components and arrangements of components, and in various steps and arrangements of steps. The drawings are only for purposes of illustrating preferred embodiments and are not to be construed as limiting the invention. [Brief explanation of the drawings]

[0021] [Figure 1] FIG. 1 is an isometric view of a battery mounting and bridge assembly configured for attachment to a battery mounting fixture on a helmet. [Figure 2]FIG. 2 is an isometric view of the battery mounting and bridge assembly shown in FIG. 1 illustrating the manner in which the battery pack is attached and detached. [Figure 3] FIG. 2 is an isometric view of the battery mounting and bridge assembly appearing in FIG. 1 with both battery packs removed. [Figure 4] FIG. 2 is a front view of the battery pack receiving assembly. [Figure 5A] FIG. 10 is a side view of the battery pack receiving assembly in a fixed position. [Figure 5B] FIG. 10 is a side view of the battery pack receiving assembly in the unlocked position. [Figure 6] FIG. 2 is an enlarged view of the battery pack receiving assembly. [Figure 7] FIG. 2 is a first partially exploded isometric view of the battery pack of the first embodiment. [Figure 8] FIG. 8 is a second partially exploded isometric view of the battery pack appearing in FIG. 7. [Figure 9] FIG. 10 is a partially exploded isometric view of a battery pack of a second embodiment. [Figure 10] FIG. 10 is a partially exploded isometric view of a battery pack of a third embodiment. [Figure 11] 10A and 10B are side views illustrating a manner in which a battery pack is attached to a battery pack receiving assembly. [Figure 12] FIG. 10 is a side view illustrating a battery pack mounted in a battery pack receiving assembly. [Figure 13] FIG. 1 is a schematic diagram of an exemplary battery pack. [Figure 14] FIG. 1 is a functional block diagram of an exemplary helmet system operable to embody the present developments. DETAILED DESCRIPTION OF THE INVENTION

[0022] Reference will now be made in detail to presently preferred embodiments of the invention, one or more examples of which are illustrated in the accompanying drawings. Each embodiment is provided by way of explanation of the invention, and not as a limitation of the invention, which may be embodied in various forms. Accordingly, the specific structural and functional details disclosed herein should not be construed as limiting, but merely as a basis for the claims and as a representative basis for teaching those skilled in the art to variously utilize the principles of the invention in any effectively detailed structure. Moreover, the terms and phrases used herein are not intended to be limiting, but rather to provide an understandable description of the present development. Indeed, it will be apparent to those skilled in the art that modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For example, features illustrated or described as part of one embodiment may be used in another embodiment to yield still further embodiments. Accordingly, it is intended that the present invention cover such modifications and variations as come within the scope of the appended claims and their equivalents.

[0023] The terms "a" or "an," as used herein, are defined as one or more. The term "another," as used herein, is defined as at least a second or more. The terms "including" and / or "having," as used herein, are defined as comprising (i.e., open transitions). The terms "coupled" or "operatively coupled," as used herein, are defined as indirectly or directly connected.

[0024] As used in this application, the terms "front," "rear," "top," "bottom," "upper," "lower," "left," "right," and other directional descriptors are intended to facilitate the description of the exemplary embodiment(s) of the invention and are not intended to limit the structure to any particular position or orientation.

[0025] All numbers herein are assumed to be modified by the term "about" unless otherwise indicated. The recitation of numerical ranges by endpoints includes all numbers subsumed within that range (e.g., 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, and 5).

[0026] Referring now to the drawings, FIGS. 1 and 2 illustrate an exemplary battery mounting assembly 100 having an exemplary battery pack 104 removably coupled thereto. FIG. 3 illustrates the battery mounting assembly 100 with the battery pack 104 removed. The battery mounting assembly 100 includes a housing 108 having first and second battery pack receiving assemblies 112 for mounting two (left and right) battery packs 104. In the illustrated embodiment, the battery mounting assembly 100 includes a mounting receptacle 116 configured to mount to a mounting fixture 118 (see FIG. 14 ) on a helmet 122 (see FIG. 14 ), which may be a component of a helmet mounting system such as the Universal Helmet Mount Assembly (Wilcox Industries Corp., Newington, NH).

[0027] As best seen in FIG. 14 , an exemplary helmet mounting system is shown including a helmet 122, such as a military or tactical helmet, having a rear mounting fixture 118 and a front mounting fixture 130. A battery mounting assembly 100 is coupled to the rear mounting fixture 118, which in turn may be removably coupled to first and second battery packs 104. In an embodiment, the battery mounting assembly 100 is operably coupled to first and second side helmet mounting fixtures 134, with the battery mounting assembly 100 acting as a bridge between the first and second side helmet mounting fixtures 134.

[0028] 1 and 2, in certain embodiments, the battery mounting assembly 100 is configured to be coupled to a rear helmet mounting fixture 118, which is further configured to transmit data and / or control signals 126 along with power to a front helmet mounting fixture 130. It will be appreciated that the present development may be adapted for other mounted helmet or head-mounted power supply systems.

[0029] In the illustrated embodiment, the battery mounting assembly 100 further includes left and right power, data, and control connectors 120 configured to couple with side accessory mounting fixtures or shrouds (not shown) located on opposite sides of an associated helmet. The housing 108 encloses circuitry configured to operably power accessories on either the front or side mounting fixtures using either the left or right battery pack and to act as a bridge or link for transmitting data and / or control signals between accessories coupled to the forward helmet mounting fixture 130 and one or more, for example, left and right side mounting fixtures 134, of an associated helmet mounting system.

[0030] 4, 5A, 5B, and 6 illustrate a battery pack receiving assembly 112, which includes a sliding frame 124 and a connecting plate 128. The sliding frame 124 includes a pair of opposing, axially extending rails 132. A first upright wall 136 extends laterally between the first and second rails 132 at a first end of the sliding frame 124, and a second upright wall 140 extends laterally between the first and second rails 132 at a second end of the sliding frame 124.

[0031] A connecting plate 128 is disposed on the first and second rails 132 intermediate the first and second upright walls 136 and 140, such that the frame 124 is axially slidable in the direction indicated by arrow 144. A movable retention hook 148 is disposed on the first upright wall 136 and defines a channel 152. A ramp or chamfer 156 is disposed on the outward-facing edge of the hook 148. A fixed retention hook 160 is disposed on the connecting plate 128 and defines a channel 164. The connecting plate 128 is rigidly attached to the body of the battery mounting assembly 100 by a threaded fastener 158 (see FIG. 3 ), which passes through a clearance opening 162 in the connecting plate 128 and threadably engages the battery mounting assembly 100 such that the frame 124 is slidable in the direction 144 relative thereto.

[0032] The sliding frame 124 includes a central opening or aperture 166. A guide rail 168 disposed on the underside of the link plate 128 is received within the central opening 166, which is sized to allow a range of sliding movement in the axial direction 144. A bearing or guide pin 172 is received within a complementary notch 176 in the guide rail 168 and functions to reduce wear and friction between the link plate 128 and the sliding frame 124 and helps maintain alignment therebetween.

[0033] One or more spring members 180 are disposed in receptacles 184 on the connection plate 128 and weight the second upright wall 140 to apply a compressive force between the connection plate 128 and the sliding frame 124. A plurality of power contacts 188 and a control signal contact 190 are provided on the connection plate and configured to operably couple with a plurality of contacts 192, 194 (see FIG. 7 ) on the battery pack 104. In the illustrated embodiment, the pins 188 are spring-loaded (e.g., pogo) type pins. In the illustrated embodiment, the insulator 196 includes a central boss 200 and opposing end bosses 204. The central boss 200 is received in aligned openings 208 in the connection plate 128. The central boss 200 includes a plurality of openings 212 that receive one of the pins 188. The end bosses 204 are received in aligned openings 216 in the connection plate 128. The end bosses 204 each include an opening 220 that each receives one of the pins 188 .

[0034] 7 and 8, a first embodiment battery pack 104a appears, including a container portion 224a and a coupling assembly 228. In an embodiment, the coupling portion is compatible with an established standard. As used herein, the term "established standard" refers to a specification, protocol, or set of requirements established by a recognized authority, such as a military or government agency, a standards development organization, or through the publication of an Interface Control Document (ICD). In an embodiment, the coupling assembly 228 is compatible with the Small Tactical Universal Battery (STUB) coupling standard.

[0035] The coupling assembly 228 includes a center terminal 232. The center terminal 232 includes a resilient sealing ring 236 for sealing between the terminal 232 and the coupling plate 128. The terminal 232 includes a USB-C charging port 240, a power terminal 192, a control signal terminal 194, and a charging status indicator 244.

[0036] The tabs 248 are disposed on opposite ends of the linkage assembly 228 and are supported on respective ports or bosses 252 (see FIG. 11) to define a peripheral retention channel 256 (see FIG. 11) between the tabs 248 and the linkage assembly 228.

[0037] The container portion 224a includes a housing 260 having a plurality of battery cell receptacles 264a for receiving a plurality of battery cells 268a. A hinged lid 272 is secured to the housing 260. A resilient sealing ring 276 is provided to prevent the ingress of moisture or other contaminants. A latch member 280 releasably engages a groove or catch 284 on the lid 272. A latch lever 288 is provided for latching and unlatching the lid 272. A circuit board 292, such as a flex circuit on a flexible film substrate, is disposed within the housing 260 and includes circuitry for electrically coupling the battery cells 268a to electrical contacts 296. The electrical contacts 296 are in turn in electrical communication with electrical contacts 298 (see FIG. 14 ) on the coupling assembly 228.

[0038] Container portion 224a, shown in Figures 7 and 8, includes three receptacles 264a configured to receive three L92 or AA battery cells 268a. Referring now to Figure 9, second embodiment battery pack 104b appears as described above with reference to first embodiment battery pack 104a, except that container portion 224b includes two receptacles 264b configured to receive two 18650 battery cells. Referring now to Figure 10, third embodiment battery pack 104c appears as described above with reference to first embodiment battery pack 104a, except that container portion 224c includes two receptacles 264c configured to receive a total of four CR123A battery cells. It will be appreciated that further embodiments are contemplated in which the container portion is configured to receive other materials and types of battery cells, including rechargeable and non-rechargeable battery cells, including, but not limited to, alkaline, lithium, lithium ion, lithium polymer, lithium manganese (IMR), CR123, 14500, 18350, 26650, and others.

[0039] 11 and 12 , to couple the battery pack 104 to the battery pack receiving assembly 112, one edge of the connecting assembly 228 is manually placed into engagement with the fixed hook 160 so that the tab 248 is received in the channel 164 and the distal end of the hook 160 is received in the channel 256. The opposing edge of the battery pack 104 is pivoted downward until the opposing tab 248 engages the angled edge 156 of the movable hook 148. Pressure against the angled edge 156 creates a wedging action that slides the sliding frame 124 against the connecting plate 128 such that the first upright wall 136 moves away from the connecting plate 128, thereby compressing the one or more spring members 180. The movement of the first upright wall 136 provides clearance for the tab 248 to move past. After tab 248 moves past hook 148, the compressive force of one or more spring members 180 causes sliding frame 124 to slide relative to connecting plate 128 such that first upright wall 136 moves back toward connecting plate 128, with hook 148 received in channel 256 and tab 248 received in channel 152, as shown in FIG. 12 . To remove battery pack 104, second upright wall 140 is manually pushed forward (upward in the orientation shown in FIG. 1 ) against the bias of one or more spring members 180, and the process is reversed. In an embodiment, the outward-facing surface of second upright wall 140 may be textured, for example, by providing ridges or bumps to enhance manipulation.

[0040] 13, a schematic diagram of an exemplary battery pack 104 is shown that includes a circuit 300 configured to sense an input DC voltage from a battery cell 268 and convert it to a predetermined output DC voltage. In a particular embodiment, the circuit 300 includes a voltage sensing circuit 304 for sensing the input voltage from the battery cell 268 and a voltage regulation and conversion circuit 308 for converting the input voltage to a desired output voltage. In a preferred embodiment, the sensed input voltage is converted to a power delivery (PD) contract defined and negotiated between the battery pack and the host device. In a particular embodiment, the PD contract may conform to a known standard, such as the USB Power Delivery (USB PD) specification. In a particular embodiment, the battery pack 244 includes an integrated coulomb counter configured to provide an accurate measurement of the battery pack's state of charge. In an embodiment, a visual indication of the state of charge can be displayed on the charge status indicator 244.

[0041] In certain embodiments, the basic design of battery pack 104 is such that the battery pack is configured to accommodate a variety of different cell types, chemistries, or voltages, and circuit 300 is adaptable based on the characteristics of the connected cells 268. In this manner, the battery pack basic architecture is modular and enables use with different battery cell types through the selection of appropriate electrical and mechanical couplings. In embodiments, circuit 300 is configured to determine which type of cell(s) 268 are connected by measuring electrical parameters of the cell(s) 268, such as voltage measurements, and identifying the type or configuration of the cell(s) 268 based at least in part on the measured electrical parameters. Circuit 300 then provides an appropriate output voltage to the host device. The appropriate output voltage may be determined based on a PD contract defined and negotiated between the battery pack and the host device, as described above.

[0042] The present invention has been described with reference to preferred embodiments. Modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the invention be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.

Claims

1. 1. A battery pack receiving assembly for removably securing a battery pack to a helmet-mounted device, the battery pack receiving assembly comprising: a frame including a first battery pack engagement mechanism configured to engage the battery pack; a connection plate including a second battery pack engagement mechanism configured to engage the battery pack, the frame being slidably coupled to the connection plate, the frame being movable between a battery pack retaining position and a battery pack releasing position; and a biasing member coupled to the frame and configured to bias the frame toward the battery pack holding position; the frame is manually movable from the battery pack holding position to the battery pack releasing position by a user gripping the battery pack when the battery pack is engaged with the first battery pack engagement mechanism; the second battery pack engagement mechanism is configured to hold the battery pack facing forward when the frame is in the battery pack holding position; the second battery pack engagement mechanism is configured to disengage the battery pack when the frame is in the battery pack release position; The battery pack receiving assembly.

2. 2. The battery pack receiving assembly of claim 1, wherein the second battery pack engagement mechanism is capable of engaging with the battery pack by a user gripping the battery pack with one hand, and the frame is manually movable to the battery pack release position by a user gripping the battery pack with one hand.

3. The frame is first and second opposing, axially extending rails extending between the first and second ends of the first and second cross members; a first cross member extending between the first and second rails at the first end, and a second cross member extending between the first and second rails at the second end; the first battery pack engagement mechanism includes a movable retention hook disposed on the first cross member; the second battery pack engagement mechanism includes a fixed retention hook disposed on the connecting plate; The battery pack receiving assembly of claim 1 .

4. 4. The battery pack receiving assembly of claim 3, wherein the biasing member includes one or more spring members disposed intermediate the second cross member and the connecting plate and configured to urge the frame toward the battery pack retaining position.

5. 10. The battery pack receiving assembly of claim 1, further comprising a plurality of electrical contacts provided on the connecting plate and configured to operably couple with a plurality of contacts on the battery pack when the battery pack is coupled to the battery pack receiving assembly.

6. The battery pack receiving assembly of claim 1 , wherein the connection plate is configured to removably couple to a battery pack that conforms to established battery connection standards.

7. 7. The battery pack receiving assembly of claim 6, wherein the established battery connection standard is the Small Tactical Universal Battery (STUB) standard.

8. 1. A battery pack coupling assembly for removably coupling to a battery pack receiving assembly, said battery pack coupling assembly comprising: a first surface configured to removably engage the battery pack receiving assembly, the first surface having a first plurality of electrical contacts configured to engage respective second plurality of electrical contacts on the battery pack receiving assembly; a second surface configured to engage a battery container, the second surface having one or more electrical connectors configured to electrically couple the first plurality of electrical contacts to one or more batteries disposed within the battery container; and The battery pack connection assembly.

9. 10. The battery pack coupling assembly of claim 8, wherein the first surface conforms to established battery coupling standards.

10. 10. The battery pack coupling assembly of claim 9, wherein the established battery coupling standard is the Small Tactical Universal Battery (STUB) standard.

11. 1. A battery pack comprising: a battery pack coupling assembly for removably coupling to the battery pack receiving assembly; a battery cell container coupled to the battery pack connecting assembly; the battery pack coupling assembly includes a first surface configured to removably engage the battery pack receiving assembly, the first surface having a first plurality of electrical contacts configured to engage respective second plurality of electrical contacts on the battery pack receiving assembly; the battery pack connecting assembly further includes a second surface configured to engage a battery cell container, the second surface having one or more electrical connectors configured to electrically couple the first plurality of electrical contacts to one or more batteries disposed within the battery cell container. The battery pack.

12. 12. The battery pack of claim 11, wherein the battery cell container is configured to receive one or more battery cells selected from the group consisting of an L92 battery cell, an 18650 battery cell, and a CR123A battery cell.

13. 12. The battery pack of claim 11, wherein the first surface conforms to established battery coupling standards.

14. 14. The battery pack of claim 13, wherein the established battery coupling standard is the Small Tactical Universal Battery (STUB) standard.

15. 12. The modular system of components including two or more battery packs of claim 11, wherein each of the two or more battery packs is interchangeably mountable in a battery pack receiving assembly, and wherein each of the two or more battery packs is configured to receive a different type of battery cell.

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