Battery connector

Abstract

The battery connector (7) for connecting a replaceable battery (6) to an airborne vehicle (1) includes a housing (10) configured to be secured to one of the replaceable battery (6) and the airborne vehicle (1) and a connector element (14) having a first connection portion (15) configured for detachable connection with an external connection element (4) of the other of the replaceable battery (6) and the airborne vehicle (1). The connector element (14) further includes a second connection portion (18) configured for fixed connection with one of the replaceable battery (6) and the airborne vehicle (1) to which the housing (10) is configured to be fixed. The connector element (14) is supported in the horizontal direction (XY) within the housing (10) by at least one flexible element (19) positioned between the connector element (14) and the housing (10) such that a gap exists between the connector element (14) and the housing (10) in the horizontal direction (XY). The connector element (14) is supported in the vertical direction (Z) within the housing (10) by an upper flexible element (21) positioned between an upper portion (23) of the connector element (14) and the housing (10) and a lower flexible element (22) positioned between a lower portion (24) of the connector element (14) and the housing (10) so that a gap exists between the connector element (14) and the housing (10) in the vertical direction (Z).

Description

[Technical Field]

[0001] The present disclosure relates to a battery connector. More specifically, the present disclosure relates to a battery connector for connecting a replaceable battery to an aerial vehicle, as defined in the introductory portion of claim 1. [Background technology]

[0002] An important aspect of aerial vehicles, especially drones, is weight. The lighter the aerial vehicle, the greater the lifting capacity it can have and the longer flight times it can achieve. Therefore, today's aerial vehicle designs are largely based on weight-efficient designs.

[0003] All components of an airborne vehicle can be optimized to reduce weight while maintaining safety and reliability. To maximize flight time, airborne vehicles are generally equipped with replaceable batteries so that when a battery runs out of charge, it can be easily and quickly replaced with a fully charged battery. The battery connector for connecting the replaceable battery to the airborne vehicle should also be as light as possible and easy to handle so that battery replacement can be performed without difficulty or malfunction.

[0004] The battery connector generally includes a first connection portion for removable connection to an external connection element of one of the replaceable battery and the airborne vehicle, and a second connection portion for fixed connection to the other of the replaceable battery and the airborne vehicle. If the connection is fixed, the first connection portion may be subjected to stress each time the replaceable battery is replaced, or the airborne vehicle may not even be optimally designed to allow the replaceable battery to be connected and disconnected to a fixed or rigid connection.

[0005] Wear and tear on fixed connections can also cause battery connectors to fail over time. To reduce weight or keep weight as low as possible, it is desirable to utilize as few and light components as possible. Known battery connectors are bulky and complex, or do not allow for sufficient movement of the connections.

[0006] Therefore, there is a need for an improved connector to reduce or eliminate the above-mentioned drawbacks of known technology. It is an object of the present invention to achieve this and to provide further advantages over the state of the art.

[0007] Literature useful for understanding the technical field includes Patent Documents 1, 2, and 3. Patent Document 1 describes a UAV battery positioning and locking device, the positioning and locking device comprising a battery and a UAV, a charging male connector and a plurality of positioning protrusions arranged on the periphery of the charging male connector being arranged on the battery, and a charging female connector, a plurality of connectors, and a plurality of elastic blocks being arranged on the UAV, the charging female connector being combined with the charging male connector, the plurality of connectors being connected to the positioning protrusions in a one-to-one correspondence, and the plurality of elastic blocks being arranged on the periphery of the charging male connector.

[0008] The prior art also includes U.S. Patent No. 5,623,669, which describes a three-phase undervoltage tripping device that can automatically trip a circuit breaker based on an undervoltage in a three-phase line voltage, including a line to which three-phase power is applied. The undervoltage tripping device is connected to the line to which three-phase power is applied and is configured to operate to automatically trip a circuit breaker when an open-phase condition occurs in any of the three phases of the power.

[0009] The prior art also includes U.S. Patent No. 5,629,999, which describes a battery system for an electric vehicle comprising a battery bay for receiving a battery pack disposed under the electric vehicle. The battery bay comprises a first latch on the underside of the electric vehicle, the first latch comprising a first hook configured to mechanically engage a first striker at a first end of the battery pack, and a second latch on the underside of the electric vehicle, the second latch comprising a second hook configured to mechanically engage a second striker at a second end of the battery pack, the first and second latches configured to mechanically couple the battery pack to the underside of the electric vehicle by substantially simultaneously engaging, vertically lifting, and locking the first and second strikers of the battery pack into the electric vehicle. [Prior art documents] [Patent documents]

[0010] [Patent Document 1] Chinese Patent Application Publication No. 108394309 [Patent Document 2] International Publication No. 2019 / 095275 [Patent Document 3] Chinese Utility Model No. 205327435 [Patent Document 4] European Patent Application Publication No. 3346566 [Patent Document 5] European Patent Application Publication No. 2340951 Summary of the Invention [Problem to be solved by the invention]

[0011] It is an object of the present invention to mitigate, alleviate or eliminate one or more of the above-mentioned deficiencies and disadvantages in the prior art or at least solve the problems mentioned above. [Means for solving the problem]

[0012] According to a first aspect, a battery connector for connecting a replaceable battery to an airborne vehicle is provided. The battery connector includes a housing configured to be secured to one of the replaceable battery and the airborne vehicle. The battery connector further includes a connector element including a first connection portion configured for detachable connection with an external connection element of the other of the replaceable battery and the airborne vehicle. The connector element further includes a second connection portion configured for fixed connection with one of the replaceable battery and the airborne vehicle to which the housing is configured to be fixed. The connector element is supported horizontally within the housing by at least one flexible element positioned at least in part between the connector element and the housing, such that a gap exists between the connector element and the housing in the horizontal direction. The connector element is supported vertically within the housing by an upper flexible element positioned between an upper portion of the connector element and the housing and a lower flexible element positioned between a lower portion of the connector element and the housing, such that a gap exists between the connector element and the housing in the vertical direction.

[0013] According to one embodiment of the present invention, the first mating portion of the connector element is supported horizontally within the housing by at least one flexible element, an upper flexible element and a lower flexible element.

[0014] According to one embodiment of the present invention, the first connecting part has a substantially cylindrical outer shape for abutment with at least one flexible element.

[0015] According to one embodiment of the present invention, the housing comprises an upper housing portion and a separate lower housing portion.

[0016] According to one embodiment of the present invention, the at least one flexible element is fixedly secured to the housing between the upper and lower housing portions.

[0017] According to one embodiment of the present invention, the at least one flexible element comprises at least three separate flexible elements.

[0018] According to one embodiment of the present invention, the at least three flexible elements are evenly spaced around the connector element.

[0019] According to one embodiment of the present invention, the at least one flexible element is four separate flexible elements.

[0020] According to one embodiment of the present invention, the first connector is a female connector.

[0021] According to one embodiment of the present invention, the first connection portion comprises a connector liner.

[0022] The present invention will become apparent from the detailed description given below. The detailed description and specific examples disclose preferred embodiments of the present invention by way of example only. Those skilled in the art will understand that, from the guidance of the detailed description, changes and modifications can be made within the scope of the present invention.

[0023] Accordingly, it is understood that the invention disclosed herein is not limited to the specific components of such apparatus or steps of such methods, as the apparatus and methods described may vary. It is also understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting. It should be noted that, as used in the specification and the appended claims, the articles "a," "an," and "the" are intended to mean that there is one or more elements, unless the context clearly dictates otherwise. Thus, for example, reference to a "unit" or "the unit" may include several apparatuses, etc. Furthermore, the words "comprising," "including," "including," and similar words do not exclude other elements or steps.

[0024] The above objects and additional objects, features and advantages of the present invention will be more fully understood by reference to the following illustrative and non-limiting detailed description of one embodiment of the invention when considered in conjunction with the accompanying drawings. [Brief explanation of the drawings]

[0025] [Figure 1] 1 shows a perspective view of the airborne vehicle excluding the battery, exposing the external connection elements. [Figure 2] 1 shows a detailed perspective view of one embodiment of an external connection element in the form of a male connector. [Figure 3] 1 illustrates a perspective view of one embodiment of a replaceable battery with a battery connector. [Figure 4] 1 illustrates an exploded view of one embodiment of a battery connector. [Figure 5] 1 illustrates a detailed perspective view of one embodiment of a battery connector. [Figure 6] 1 depicts a top view of one embodiment of a battery connector with an upper housing portion removed for purposes of illustration. DETAILED DESCRIPTION OF THE INVENTION

[0026] The present invention will now be described with reference to the accompanying drawings, in which a preferred example embodiment of the invention is shown. However, the present invention may be embodied in other forms and should not be construed as limited to the embodiment disclosed herein. The disclosed embodiment is provided so that the scope of the invention will be fully conveyed to those skilled in the art.

[0027] The following description may use terms such as "horizontal," "vertical," "upper," "lower," "inner," "outer," "front," and "rear." These terms generally refer to perspectives and orientations depicted in the figures and associated with normal use of the invention. Such terms are used solely for the convenience of the reader and are not limiting. Thus, a horizontal plane need not be an actual horizontal plane, and a vertical direction need not be an actual vertical direction, but rather is oriented approximately perpendicular to a horizontal plane, as will be understood by those skilled in the art.

[0028] Referring initially to Figures 1, 2, and 3, an aerial vehicle 1 is illustrated in Figure 1. The aerial vehicle 1 may be a drone, also known as a multicopter, and in the illustrated embodiment, the aerial vehicle 1 includes four motors and rotors 2 connected to a body 3. The body 3 of the aerial vehicle 1 includes an external connection element 4. The aerial vehicle 1 may include two external connection elements 4 on each side, although only one external connection 4 is visible in Figure 1. The external connection element 4 is illustrated in more detail in Figure 2. In the illustrated embodiment, the external connection element 4 is a male connector including pins 5, although in alternative embodiments, it may be a female connector. The external connection element 4 may be a rigid element that is fixed to the aerial vehicle 1 and therefore does not allow for significant movement.

[0029] A replaceable battery 6 (shown in FIG. 3 ) may be connected to the body 3 and the external connection element 4, thereby powering the airborne vehicle 1. In the illustrated embodiment, two replaceable batteries 6 may be connected to the airborne vehicle 1, one battery 6 on each side of the body 3. Battery connectors 7 are configured for connection with the external connection element 4, thus connecting the replaceable batteries 6 to the airborne vehicle 1 and transferring power from the replaceable batteries 6 to the airborne vehicle 1. As shown in FIG. 3 , each replaceable battery 6 may include two battery connectors 7. In the illustrated embodiment, the battery connectors 7 are female connectors, but in alternative embodiments, they may be male connectors.

[0030] In the illustrated embodiment, the battery connector 7 is fixed to the replaceable battery 6, but in an alternative embodiment, the battery connector 7 may be fixed to the airborne vehicle 1. In this alternative embodiment, an external connection element, which may be male or female, may be fixed to the replaceable battery.

[0031] Additionally, the replaceable battery 6 may be securely fastened to the airborne vehicle 1 by means known in the art, such as screws, snap locks, clips, etc., so that the replaceable battery 6 is securely attached to the airborne vehicle 1 when mounted on the airborne vehicle 1.

[0032] 4, one embodiment of the battery connector 7 is illustrated in an exploded view. The battery connector 7 includes a housing 10 configured for securing with one of the replaceable battery 6 and the airborne vehicle 1. The housing 10 may include an upper housing portion 11 and a lower housing portion 12. The lower housing portion 12 may have an opening and be configured for resting against a surface, with the upper housing portion 11 configured for installation on top of the lower housing portion 12.

[0033] The housing 10 may include a fastening means receptacle 13 so that the housing 10 can be secured to a replaceable battery or an airborne vehicle. The fastening means receptacle 13 may simply be a hole through the housing 10 so that the battery connector 7 can be screwed or otherwise secured to the replaceable battery or airborne vehicle, or the fastening means receptacle 13 may be other means known in the art for attaching a housing to a surface. The fastening means receptacle 13 may also include a fastening means, such as a buckle, clip, or the like. In the illustrated embodiment, the fastening means receptacle 13 extends through both the upper and lower housing portions 11 and 12 such that when a screw is inserted through the fastening means receptacle 13, the upper housing portion 11 is secured to the lower housing portion 12.

[0034] The battery connector 7 includes a connector element 14. The connector element 14 is made from a conductive material, such as a metal, and is configured to transfer power from the replaceable battery to the airborne vehicle.

[0035] The connector element 14 includes a first connecting portion 15. The first connecting portion 15 is configured for removable connection with an external connection element, as described with reference to FIGS. 1 and 2. In the illustrated embodiment, if the external connection element is a male connection, the first connecting portion 15 includes an inner cylindrical portion 16 configured to receive a pin of the external connection element. The first connecting portion 15 may also include an outer cylindrical shape. The first connecting portion 15 may additionally include a connector liner 17. The connector liner 17 may ensure a tight fit with the male external connection element, and the connector liner 17 may be a standard product manufactured by a third-party supplier and may be inserted into the first connecting portion 15.

[0036] The connector element 14 includes a second connection portion 18. As described with reference to FIG. 3, the second connection portion 18 is configured for fixed connection with either the replaceable battery or the airborne vehicle. The second connection portion 18 in the illustrated embodiment is fixed to the replaceable battery. Thus, the second connection portion 18 is configured for fixed connection with a battery cell of the replaceable battery. The second connection portion 18 may be fixedly connected to the replaceable battery, for example, by a wire welded to the second connection portion 18.

[0037] The connector element 14 is supported horizontally within the housing 10 by a flexible element 19. The horizontal plane XY is indicated by two arrows in Figure 4, and the vertical direction is indicated by arrow Z. The horizontal plane XY is therefore defined as the plane perpendicular to the direction in which the external connection element is inserted into the battery connector 7. The external connection element is connected to the battery connector by pushing it up in the vertical direction indicated by arrow Z in Figure 4, and is disconnected from the battery connector by pulling it down vertically.

[0038] At least a portion of the flexible element 19 is positioned between the connector element 14 and the housing 10 such that a gap exists between the connector element 14 and the housing 10. Thus, the connector element 14 does not contact the housing 10 in the horizontal plane XY. More specifically, at least a portion of the flexible element 19 is positioned between the first connecting portion 15 of the connector element 14 and the housing 10. The flexible elements 19 may be evenly spaced around the first connecting portion 15, and the battery connector 7 may include any number of flexible elements 19. The illustrated embodiment includes four separate flexible elements 19. At least three flexible elements may be provided in the battery connector to bias the connector element 14 toward a neutral center. However, one or two flexible elements may be provided, provided that the flexible elements extend sufficiently around the circumference of the first connecting portion 15.

[0039] The flexible element 19 in the illustrated embodiment is an O-ring, but may itself be any resilient or flexible element. The housing 10 includes a cavity 20 in which the connector element 14 is positioned, and the flexible element 19 is positioned within the housing 10 such that a portion of the flexible element 19 is positioned in the space between the housing 10 and the connector element 14. The connector element 14 abuts the flexible element 19 such that the connector element 14 is biased to a neutral, aligned position. The flexible element 19 may be held in place between the upper and lower housing portions 11, 12 and securely fastened to the housing 10. This allows for easy and inexpensive assembly and installation of the connector 7, as the upper housing portion 11 is secured to the lower housing portion 12 and the flexible element 19 is simultaneously secured to the housing 10.

[0040] The connector element 14 is supported vertically within the housing 10 by an upper flexible element 21 and a lower flexible element 22. The upper flexible element 21 is positioned between an upper portion 23 of the first connecting portion 15 and the housing 10. In the illustrated embodiment, the upper flexible element 21 is positioned between the upper portion 23 and the upper housing portion 11. The upper flexible element 21 may be an O-ring. The lower flexible element 22 is positioned between a lower portion 24 of the first connecting portion 15 and the housing 10. In the illustrated embodiment, the lower flexible element 22 is positioned between the lower portion 24 and the lower housing portion 12. The lower flexible element 22 may be an O-ring. As a result, a gap exists between the connector element 14 and the housing 10, and the connector element 14 does not contact the housing 10 in the vertical direction Z. In the illustrated embodiment, the upper flexible element 21 , the connector element 14 and the lower flexible element 22 are sandwiched between the upper housing portion 11 and the lower housing portion 12 .

[0041] During entry, the pins of the external connection element may not be inserted straight or centered into the battery connector 7 due to insufficient spacing, a tight entry angle, etc. The flexible characteristics of the flexible element 19, upper flexible element 21, and lower flexible element 22 allow the connector element 14 to move somewhat relative to the housing 10. If the housing 10 is secured to the surface of a rechargeable battery or the like, the connector element 14 may move and tilt within the housing 10. When the external connection element 4 (not shown in FIG. 4 , see FIG. 2 ) is fully inserted or fully withdrawn, the connector element 14 is centered within the housing by the flexible element 19, upper flexible element 21, and lower flexible element 22. This permitted movement of the connector element 14 provides for smooth entry and extraction of the corresponding external connection element 4 with minimal wear and tear on the parts. The battery connector 7 as described is of very simple and lightweight construction and is capable of carrying up to 500A continuously.

[0042] Referring now to FIG. 5 , the assembled battery connector 7 is illustrated. The flexible element 19 is maintained between the upper housing portion 11 and the lower housing portion 12. The flexible element 19 may be ring-shaped, which may result in a portion of the flexible element 19 being exposed outside the housing 10. The second connection portion 18 of the connector element 14 may extend outside the housing 10 through the opening 25. As previously described, the second connection portion 18 may be connected to, for example, a battery cell by a wire. The opening 25 is larger than the connector element 14 that extends through the opening 25 such that a gap exists between the opening 25 and the connector element 14. Thus, the opening 25 does not contact the connector element 14, and therefore the connector element 14 is allowed to move within the opening 25 without the housing 10 restricting the movement of the connector element 14.

[0043] Referring now to Figure 6, the figure shows a top view (looking down the XY plane along the Z axis described with reference to Figure 4) of the battery connector 7. The upper housing portion has been removed for purposes of illustration. As can be seen, four flexible elements 19 bias and support the connector element 14 in the horizontal plane. More specifically, the flexible elements 19 bias and support the first connection portion 15 in the horizontal plane.

[0044] Those skilled in the art will understand that the present invention is not limited to the preferred embodiments described above. Those skilled in the art will further understand that modifications and variations are possible within the scope of the appended claims. Additionally, variations to the disclosed embodiments can be understood and effected by those skilled in the art in practicing the claimed invention, from a study of the drawings, the specification, and the appended claims. [Explanation of symbols]

[0045] 1...airborne vehicle, 4...external connection element, 6...replaceable battery, 7...battery connector, 11...upper housing part, 12...lower housing part, 14...connector element, 15...first connection part, 17...connector liner, 18...second connection part, 19...flexible element, 21...upper flexible element, 22...lower flexible element, 23...upper part of connector element, 24...lower part of connector element, XY...horizontal direction, Z...vertical direction

Claims

1. A battery connector (7) for connecting a replaceable battery (6) to an airborne vehicle (1), a housing (10) configured to be secured to one of the replaceable battery (6) and the airborne vehicle (1); a connector element (14) having a first connection portion (15) configured for detachable connection in a vertical direction (Z) with an external connection element (4) of the other of the replaceable battery (6) and the airborne vehicle (1); the connector element (14) further comprises a second connection portion (18) configured for fixed connection with one of the replaceable battery (6) and the airborne vehicle (1) to which the housing (10) is configured to be fixed; the connector element (14) is supported in the housing (10) in the horizontal direction (XY) by at least one flexible element (19) positioned at least partially between the connector element (14) and the housing (10) so that a gap exists between the connector element (14) and the housing (10) in the horizontal direction (XY); The battery connector (7) is supported in the housing (10) in the vertical direction (Z) by an upper flexible element (21) positioned between an upper portion (23) of the connector element (14) and the housing (10) and a lower flexible element (22) positioned between a lower portion (24) of the connector element (14) and the housing (10), such that a gap exists between the connector element (14) and the housing (10) in the vertical direction (Z).

2. 2. The battery connector (7) of claim 1, wherein the first connection portion (15) of the connector element (14) is supported horizontally within the housing (10) by at least one of the flexible element (19), the upper flexible element (21), and the lower flexible element (22).

3. 3. The battery connector (7) according to claim 1 or 2, wherein the first connection part (15) has a substantially cylindrical outer shape for abutment with the at least one flexible element (19).

4. The battery connector (7) according to any one of claims 1 to 3, wherein the housing (10) comprises an upper housing portion (11) and a separate lower housing portion (12).

5. 5. The battery connector (7) according to claim 4, wherein at least one said flexible element (19) is fixedly secured to said housing (10) between said upper housing part (11) and said lower housing part (12).

6. The battery connector (7) according to any one of claims 1 to 5, wherein the at least one flexible element (19) comprises at least three separate flexible elements (19).

7. 7. The battery connector (7) of claim 6, wherein at least three of the flexible elements (19) are evenly spaced around the connector element (14).

8. The battery connector (7) according to any one of claims 1 to 5, wherein the at least one flexible element (19) is four separate flexible elements (19).

9. The battery connector (7) according to any one of claims 1 to 8, wherein the first connection portion (15) is a female connection portion.

10. 10. The battery connector (7) according to claim 9, wherein the first connection portion (15) comprises a connector liner (17).

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