Cable device for a portable battery charging system

Abstract

A cable device for a portable battery charging system that includes a power supply. The cable device has a multi-section cable having a round first cable, a flattened second cable, and a round third cable. The second cable has a thin, non-circular outer profile and contains laterally arranged, flattened or oval conductors that maintain substantially the same conductive area as the round conductors in the first and third cables. This configuration allows the second cable to pass between a vehicle trunk lid and vehicle body while the trunk is closed, without interrupting electrical performance. The flattened geometry distributes compressive forces, preserves current flow, and supports high-current charging. The system enables charging of a vehicle battery while the power supply remains secured inside an enclosed space, reducing exposure and risk of theft.

Description

Attorney Docket No. 3146.001WOCABLE DEVICE FOR A PORTABLE BATTERY CHARGING SYSTEMCROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to US 63 / 764,876 filed on February 28, 2025, the entirety of which is hereby incorporated by reference herein for all purposes.FIELD

[0002] The present disclosure relates to a portable battery charging system, and more particularly to a cable device for a portable battery charging system for use in an enclosed space such as a vehicle trunk.BACKGROUND

[0003] Electric vehicles (EVs) have gained widespread adoption due to their environmental benefits and advancements in battery technology. However, one of the primary challenges facing EV owners is ensuring reliable access to charging infrastructure, particularly during long-distance travel or in areas with limited charging stations. The availability and accessibility of charging solutions remain key factors in the broader adoption of EVs.

[0004] Existing EV charging options primarily include fixed charging stations installed at homes, workplaces, and public locations. While these stations offer convenient charging solutions, they lack portability and are often inaccessible in remote or emergency situations. Portable EV chargers have been developed to address this issue; however, many known portable chargers require a dedicated external power source, which may not always be available when needed. Moreover, use of many known charging systems requires exposing the charging system to the environment and problems (e g., theft, weather, etc.) associated therewith.

[0005] Accordingly, there is a need for an improved portable charger for electric vehicles that offers enhanced portability and security, efficient energy delivery, and increased reliability in various use cases, including roadside emergencies, remote charging, and extended travel scenarios.

[0006] The background description provided here is for the purpose of generally presenting the context of the disclosure. Work of the presently named inventors, to the extent it is described in this background section, as well as aspects of the description that may not otherwise qualify asAttorney Docket No. 3146.001WOprior art at the time of filing, are neither expressly nor impliedly admitted as prior art against the present disclosure.SUMMARY

[0007] One aspect of the disclosure provides a cable device for a portable battery charging system. The cable device includes a first cable and a second cable. The first cable defines a first thickness. The second cable is coupled to the first cable and defines a second thickness that is less than the first thickness.

[0008] Further areas of applicability of the present disclosure will become apparent from the detailed description, the claims, and the drawings. The detailed description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the disclosure.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The present disclosure will become more fully understood from the detailed description and the accompanying drawings.

[0010] FIG. 1 is a schematic view of an example portable battery charging system in accordance with the principles of the present disclosure.

[0011] FIG. 2 is a transverse cross-sectional view of the first cable of the portable battery charging system of FIG. 1, taken along line 2-2.

[0012] FIG. 3 is a transverse cross-sectional view of the second cable of the portable battery charging system of FIG. 1, taken along line 3-3.

[0013] FIG. 4 is an enlarged detail view of a portion of the first cable and the second cable, taken at detail 4 of FIG. 1

[0014] FIG. 5 is a schematic view of a portable battery charging system in use in an enclosure in accordance with the principles of the present disclosure.

[0015] FIG. 6 is a schematic view of a portable battery charging system in use in an enclosure in accordance with the principles of the present disclosure.

[0016] FIG. 7A illustrates a portable battery charging system in use in a vehicle.

[0017] FIG. 7B illustrates a portable battery charging system in use in a vehicle.Attorney Docket No. 3146.001WO

[0018] In the drawings, reference numbers may be reused to identify similar and / or identical elements.DETAILED DESCRIPTION

[0019] With reference to FIG. 1, an example portable battery charging system 10 is illustrated.

[0020] As will be explained in more detail below, in use, the portable battery charging system 10 may be stored within an enclosed space (e.g., a vehicle trunk). Electric power can be delivered from the system 10 inside of the enclosed space to a primary power supply or to an electrically powered device located outside of the enclosed space. Electric power can also be delivered from a power supply located outside of the enclosed space to the portable battery charging system 10 located inside of the enclosed space.

[0021] The battery charging system 10 may include a power supply 12. The power supply 12 may be or may include one or more batteries. For example, the power supply 12 may include one or more lithium phosphate, lithium ion, solid state batteries. The power supply 12 may be rechargeable. The power supply 12 may comprise a first connector 14.

[0022] The battery charging system 10 may comprise a cable device 15. The cable device 15 may comprise one or more cables. The one or more cables of the cable device 15 may include a first cable 16, a second cable 18, and a third cable 20. The cable device 15 may also include one or more second connectors 22.

[0023] The first cable 16 may be coupled (e.g., directly coupled) to, and in electrical communication with, the second cable 18. The connection between the first and second cables 16, 18 may be permanent, such that the cables 16, 18 are not intended to be separated without destroying or materially damaging one or both of the cables 16, 18 and / or the conductors of the cables. In other configurations, the connection between the first and second cables 16, 18 may be configured to be separable, such that the cables 16, 18 can be repeatedly connected and disconnected without adversely affecting the performance or functionality of the cables 16, 18.

[0024] The second cable 18 may be coupled (e.g., directly coupled) to, and in electrical communication with, the third cable 20. The connection between the second and third cables 18, 20 may be permanent, such that the cables 18, 20 are not intended to be separated without destroying or materially damaging one or both of the cables 18, 20 and / or the conductors of the cables. In other configurations, the connection between the second and third cables 18, 20 may beAttorney Docket No. 3146.001WOconfigured to be separable, such that the cables 18, 20 can be repeatedly connected and disconnected without adversely affecting the performance or functionality of the cables 18, 20.

[0025] The first cable 16 may be removably coupled to, and in electrical communication with, the first connector 14 and the power supply 12.

[0026] In some implementations, the first connector 14 may be or may include, for example, a National Electrical Manufacturers Association (NEMA) 14-50 connector. It will be appreciated, however, that the first connector 14 may include other types of connectors within the scope of the present disclosure. For example, the first connector 14 may include other forms of connectors suitable for electric vehicle (EV) charging, recreational vehicles (RVs), and various household or heavy-duty appliances. By way of example, the first connector 14 may be configured for connection to a standard 110-120-volt electrical outlet (e.g., single-phase AC) or a 220-240-volt electrical outlet (e.g., single-phase or split-phase AC), and may be rated for any suitable current level, such as 15 amps, 20 amps, 30 amps, 40 amps, or 50 amps.

[0027] The second connector 22 may include any of a variety of connectors configured to be selectively coupled to a power source and / or a power-receiving device. In some implementations, the second connector 22 may be configured for connection to a charging port of an electric vehicle (EV), such as a SAE J1772 connector. In other implementations, the second connector 22 may be configured for connection to a charging station, wall outlet interface, battery pack, energy storage device, inverter, generator, or other power-supplying or power-consuming device. Accordingly, the second connector 22 may facilitate bidirectional or unidirectional transfer of electrical power, including delivering electrical power to charge a battery or drawing electrical power from a battery or other energy source.

[0028] In some implementations, the second connector 22 may be configured to electrically couple the power supply 12 to a vehicle, such that electrical power is delivered from the power supply 12 through the cable device 15 to charge a vehicle battery. The second connector 22 may interface with a vehicle charging port and may be configured to transmit controlled electrical current and voltage from the power supply 12 to the vehicle battery in accordance with a predetermined charging protocol and applicable safety standards.

[0029] The battery charging system 10, the power supply 12, and / or the cable device 15 may comprise one or more control devices 24. The control system 24 may comprise one or more electronic controllers and / or electronic processors, such as a programmable microprocessor,Attorney Docket No. 3146.001WOmicrocontroller, and / or application-specific integrated circuit (ASIC). The control system 24 may include a central processing unit (CPU), memory (e.g., a non-transitory computer-readable storage medium), and an input / output (I / O) interface. The memory may store executable instructions that, when executed by the processor, cause the control system 24 to perform one or more control, monitoring, and protection functions.

[0030] For example, the control system 24 may be programmed to monitor voltage, current, temperature, and / or state-of-charge conditions, and to regulate operation of the power supply 12 to prevent overcurrent conditions, current-limit failures, overcharging, excessive discharge, and / or depletion of a primary power supply 26 (FIG. 4). The control system 24 may comprise a single controller or a plurality of distributed controllers in communication with one another. In some implementations, the control system 24 may be operatively connected to a user interface, such as a display and / or touch screen, to provide status information and / or receive user inputs.

[0031] With reference to FIG. 2, the first cable 16 may include one or a plurality of conductors 26 enclosed within an outer cover or sheath insulation material 28. The conductors 26 may be referred to herein as first conductors 26. In certain embodiments, the first cable 16 comprises at least two conductors, and may include three, four, five, six, seven, or more conductors. The conductors 26 may include one or more power conductors, ground conductors, communication or signal conductors, neutral conductors, or any combination thereof. The conductors 26 may be formed as solid conductors and / or multi-stranded or braided conductors.

[0032] The outer cover or sheath insulation material 28 may comprise a polymeric, thermoplastic polyurethane (TPU), cross-linked polyethylene (XLPE), polyvinyl chloride (PVC), or another suitable insulating material surrounding the one or more conductors 26.

[0033] The outer cover or sheath insulation material of the first cable may be the same material as the outer cover or sheath material of the third cable.

[0034] If the first cable 16 comprises a plurality of conductors 26. The conductors 26 may be arranged in a predetermined pattern when viewed in transverse cross-section. For example, the conductors 26 may be arranged in a generally circular configuration, such as three, four, five, etc. conductors positioned circumferentially within the sheath 28 and spaced apart from one another. The plurality of first conductors 26 may be arranged radially around a central longitudinal axis of the first cable within the first outer sheath. The plurality of conductors 26 may be arranged around a central axis of the sheath 28. In some implementations, the conductors 26 may be radially offsetAttorney Docket No. 3146.001WOfrom a central longitudinal axis of the sheath 28 such that each conductor 26 is spaced from the central longitudinal axis and from an inner circumferential surface of the sheath 28. The conductors may be positioned or arranged equidistant from the central longitudinal axis of the cable 16. In some configurations, the centers of the conductors may lie on a common imaginary circle concentric with the sheath. In some configurations, the conductors are angularly spaced approximately 72 degrees apart relative to the central longitudinal axis. In some configurations, the conductors may be arranged in a symmetric radial pattern about the central longitudinal axis. In other implementations, the conductors 26 may be vertically stacked, including arrangements in which a center of one conductor is positioned vertically above, below, and / or laterally offset from a center of one or more other conductors 26.

[0035] A transverse cross-section of one or more of the conductors 26 of the first cable 16 may be substantially round or circular. Similarly, a transverse cross-section of the first cable 16 and / or the outer sheath 28 may be substantially round or circular, with the plurality of conductors 26 disposed therein and surrounded by insulating material. In contrast, the second cable 18 may define a non-circular transverse cross-section, such as a generally flattened, oval, or rectangular profile, thereby distinguishing the geometry of the first cable 16 from that of the second cable 18.

[0036] With reference to FIG. 3, in some implementations, the second cable 18 may include one or a plurality of conductors 26’ . The conductors 26’ may be referred to herein as second conductors 26’. The number of second conductors 26’ may be the same as or correspond to the number of first conductors 26 in the first cable 16. One or more of the conductors 26’ may correspond to, and in certain implementations may be continuous with, the first conductors 26 that extend through the first cable 16 as illustrated and described with respect to FIG. 2. For example, where the connection between the first and second cables 16, 18 is permanent, the conductors 26, 26’ may comprise the same continuous conductors extending through both cables. In embodiments where the first and second cables 16, 18 are physically separable, the conductors 26, 26’ may comprise discrete wires that are electrically connected together in a connection region between the first and second cables 16, 18.

[0037] The conductors 26’ of the second cable 18 may be enclosed within an outer sheath insulation material 30. In some implementations, the outer sheath insulation material 30 may comprise a heat-shrinkable braided sleeving formed as a fabric tubing. The braided sleeving 30 may comprise a tight woven or braided construction including a combination of polyesterAttorney Docket No. 3146.001WOmultifilament fibers and modified polyolefin filaments. Upon the application of heat (e g., via a heat gun or other suitable source, for example), the braided sleeve 30 may shrink radially and shorten longitudinally to form a tightened, conforming outer sheath around the conductors 26’. After shrinkage, the woven structure may increase in thickness and define a dense, abrasionresistant protective layer.

[0038] The heat-shrinkable braided sleeving 30 may provide enhanced abrasion resistance, durability, and flexibility relative to conventional polyolefin heat-shrink tubing. The woven construction may facilitate heat dissipation and reduce moisture accumulation, thereby making the second cable 18 suitable for elevated-temperature operating environments. In addition, the braided structure may conform to irregular shapes while maintaining bundle integrity, suppressing friction-induced noise, reducing coil rattling, and retaining the conductors 26’ in a compact, tightly bundled configuration.

[0039] In some implementations, each of the conductors 26’ disposed within the sheath material 30 may be individually insulated. For example, each conductor 26’ may include an electrically conductive core surrounded by a respective insulating layer formed from a dielectric material suitable for the intended voltage and temperature rating. The individual insulation layers may electrically isolate the conductors 26’ from one another within the outer sheath 30 and may provide additional mechanical protection.

[0040] Prior to heat application and radial shrinkage of the sheath material 30, one or more positioning devices 31 may be used to maintain the conductors 26’ in a predetermined arrangement. For example, a high-temperature-resistant tape, such as an aluminum tape or other heat-stable adhesive tape, may be a positioning device 31 that is applied around or between the conductors 26’ to maintain the conductors 26’ in a laterally spaced, side-by-side configuration and to prevent overlap during assembly. The tape 31 may remain in place after shrinkage of the sheath material 30, or may be partially or fully encapsulated by the sheath material 30 following heat application.

[0041] In the illustrated embodiment, the second cable 18 comprises a plurality of conductors 26’ arranged in a generally side-by-side, laterally spaced configuration within the sheath 30. The conductors 26’ may be horizontally aligned along a common plane and may extend generally parallel to one another along a longitudinal axis of the second cable 18. In transverse cross-section, each of the conductors 26’ may define a generally non-circular shape, such as an oval or ellipticalAttorney Docket No. 3146.001WOprofile. The major axes of the conductors 26’ may extend generally parallel to one another and parallel to a major axis of the sheath 30.

[0042] In some implementations, one or more of the conductors 26’ may be formed from an initially round conductor that is subsequently flattened by applying compressive force in a transverse direction. For example, vertical pressure may be applied to the conductor using a press, vise, roller assembly, or other compression device to deform the conductor into an oval, flattened, or generally rectangular cross-sectional shape. Such deformation may reduce an overall thickness of the second cable 18 while maintaining the desired electrical conductivity.

[0043] In some implementations, a cross-sectional conductive area of each of the conductors 26’ of the second cable 18 may be substantially equal to a cross-sectional conductive area of the corresponding conductors 26 of the first cable 16 (and / or conductors of the third cable 20). Although the conductors 26’ of the second cable 18 may define a non-circular, flattened, oval, or generally rectangular transverse cross-section, the total conductive cross-sectional area may be maintained so as to be substantially equivalent to that of the round conductors 26 of the first cable 16. Maintaining substantially equivalent conductive cross-sectional areas may reduce or prevent current restriction, resistive bottlenecks, localized heating, and voltage drop as electrical power flows from the first cable 16 through the second cable 18 and to the third cable 20.

[0044] The outer sheath 30 of the second cable 18 may define a substantially non-circular transverse cross-section, such as a generally rectangular or flattened profile. In this regard, the second cable 18 may be substantially flat, defining a thickness T and a width W, where the width W is greater than the thickness T. In some implementations, the thickness T of the second cable 18 may be less than a diameter of the first cable 16, thereby facilitating routing in constrained spaces while maintaining the desired current-carrying capacity.

[0045] In some implementations, the second cable 18 may define a maximum thickness T of 0.3125 inches + / - 10%. In some implementations, the maximum thickness T of the second cable 18 may be between 5% and 50% of a minimum thickness (e.g., diameter) of the first cable 16 and / or the third cable 20, and a minimum W of the second cable 18 may be between 100% and 300% of the maximum thickness (e.g., diameter) of the first cable 16. As will be explained in more detail below, during use of the battery charging system 10, the thickness T and / or width W of the second cable 18 may allow a user to enclose a portion of the battery charging system 10 (e.g., the power supply 12 and / or the first cable 16) within an enclosure, while at least part of theAttorney Docket No. 3146.001WOsecond cable 18 is located outside of the enclosure, while ensuring the integrity of, and the flow of electrical current (e.g., level 2 or level 3 charging) through, the second cable 18 and the connector 22 is not inhibited or restricted.

[0046] The third cable 20 may be substantially similar to the first cable 16. In this regard, the third cable 20 may be coupled to (e.g., directly coupled to), and in electrical communication with, the second cable 18 and may include an insulation material (e.g., thermoplastic polyurethane, cross-linked polyethylene, polyvinyl chloride, etc.) surrounding a plurality of conductors. The third cable 20 may define a substantially circular cross section. In some implementations, the third cable 20 is integrally formed with the second cable 18. The conductors in the third cable 20 may have a round cross section like the first conductors 26 or they may have a flat or oval cross section like the second conductors 26’. The number of conductors in the third cable 20 may be the same as or correspond to the number of conductors in the first cable 16 and / or second cable 18.

[0047] Referring now to FIG. 4, the cable device 15 may comprise one or more cable connection devices 36. A cable connection device 36 may be configured to mechanically and electrically connect the first cable 16 (or outer sheath of the first cable 16) to the second cable 18 (or outer sheath of the second cable 18). In a similar manner, a corresponding cable connection device 36 may be configured to connect the second cable 18 to the third cable 20.

[0048] In some implementations, the cable connection device 36 may comprise a dual-wall adhesive-lined heat-shrink tubing. The heat-shrink tubing may be formed from a polyolefin material and may include an inner adhesive layer configured to soften upon the application of heat and to bond to adjacent cable sheath materials of the first and second outer sheaths. A connection device 31 may also or may instead be provided between the second and third cables to bond to adjacent cable sheath materials of the second and third outer sheaths to maintain a connection between the cables.

[0049] The tubing may define a heat-shrink ratio of approximately 3:1, such that upon application of heat, the tubing radially contracts to approximately one-third of its expanded diameter.

[0050] During installation, heat (e.g., from a heat gun) may be applied substantially uniformly around the tubing, causing the tubing to shrink tightly around the outer sheath of the first cable 16 and the outer sheath 30 of the second cable 18 (and / or between the second cable 18 and the third cable 20). As the tubing shrinks, the inner adhesive layer may soften and flow to seal the interfaceAttorney Docket No. 3146.001WObetween the respective cable sheaths, thereby forming a sealed, insulated, and substantially permanent connection. After cooling, the tubing may define a thickened, mechanically secure outer sleeve that provides electrical insulation, environmental sealing, strain relief, and improved durability at the cable junction.

[0051] With reference to FIG. 5, a user may position at least a portion of the battery charging system 10 (e.g., the power supply 12 and / or the first cable 16) within an enclosure 38. In some implementations, the enclosure 38 may comprise a vehicle trunk or cargo compartment having a decklid 32 movable relative to a body portion 34 between open and closed positions. When the decklid 32 is closed and / or latched, the second cable 18 may extend from the enclosure 30 and be disposed between the decklid 32 and the body portion 34.

[0052] The second cable 18 may define a reduced thickness T relative to the first cable 16 and / or the third cable 20, such that the second cable 18 can be positioned between the decklid 32 and the body portion 34 without materially impairing structural integrity or electrical performance. For example, the thickness T may be selected relative to a diameter or maximum thickness of the first and / or third cables 16, 20 to permit closure of the decklid 32 while maintaining electrical continuity and current flow through the second cable 18 and connector 22.

[0053] Positioning the power supply 12 within the enclosure 30 may reduce the likelihood of theft, tampering, or unauthorized removal while maintaining electrical communication between the battery charging system 10 and an external device.

[0054] With reference to FIG. 6, in one implementation the connector 22 at a distal end of the second cable 18 may be coupled to a vehicle charging port while the power supply 12 remains positioned within the enclosure 38. In this configuration, electrical power may be delivered from the battery charging system 10 to a vehicle battery while the enclosure 38 remains closed, thereby permitting charging while the power supply 12 is secured within the vehicle.

[0055] FIGS. 7A and 7B illustrate the portable battery charging system 10 positioned within a vehicle 40. The power supply 12 may be disposed within a trunk or other vehicle enclosure 38. The first cable 16 may extend from the power supply 12 and be coupled to the second cable 18, which extends outwardly from the enclosure 38.

[0056] The second cable 18 may be configured to permit a decklid or trunk lid 32 to close against the second cable 18 without materially distorting the cable or impairing electrical power transmission through the conductors therein. This capability may be achieved, at least in part, byAttorney Docket No. 3146.001WOthe second cable 18 defining a flattened outer sheath and / or including conductors arranged in a lateral, side-by-side relationship, thereby reducing an overall thickness T of the second cable 18.

[0057] As a result, the decklid 32 may close and latch with the second cable 18 positioned between the decklid 32 and an adjacent vehicle body structure without triggering pinch sensors or other obstruction-detection systems that might otherwise prevent closure. Positioning the power supply 12 within the enclosure 38 may reduce the likelihood of theft, tampering, or unauthorized removal while maintaining electrical communication between the battery charging system 10 and an external device.

[0058] In some implementations, the second cable 18 is configured to withstand compressive loading when positioned between a movable closure member (e.g., a decklid 32) and an adjacent body structure without loss of electrical continuity. The second cable 18 may be capable of being compressed by at least 10%, 20%, 30%, or more of its maximum thickness T while maintaining electrical conductivity through the second conductors 26’. In some implementations, the second cable 18 may withstand repeated compression cycles associated with opening and closing of a vehicle trunk without measurable degradation in voltage delivery, ampacity, insulation integrity, or conductor continuity. The flattened configuration may distribute compressive forces across the width W of the second cable 18 to reduce localized stress concentrations.

[0059] In some implementations, the maximum thickness T of the second cable 18 may be selected relative to a closure clearance dimension associated with an automotive decklid or trunk interface. For example, the thickness T may be less than a typical decklid seal compression gap, weatherstrip compression allowance, and / or trunk seal deflection depth. In certain embodiments, the maximum thickness T of the second cable 18 may be less than approximately 0.375 inches, and in other embodiments may be less than approximately 0.3125 inches, or within a tolerance of ±10% thereof.

[0060] In some implementations, the thickness T may be less than a compressible range of a vehicle weatherstrip such that, when the decklid 32 is closed, the weatherstrip compresses around the second cable 18 while maintaining latch engagement and sealing performance. The flattened geometry of the second cable 18 may therefore permit positioning between the decklid 32 and the vehicle body without exceeding seal deflection limits, interfering with closure sensors, or preventing full latching. By sizing the thickness T relative to the available seal compression depth,Attorney Docket No. 3146.001WOthe second cable 18 may cooperate with existing vehicle closure architecture without requiring modification to the vehicle.

[0061] In some implementations, a transition region may be provided between the first cable 16 and the second cable 18 and / or between the second cable 18 and the third cable 20. The transition region may include a gradual geometric transformation from a substantially circular cross-section to a flattened or non-circular cross-section. In certain embodiments, one or more conductors may gradually deform from a round profile to an oval or flattened profile along a longitudinal transition length. The transition region may further include strain-relief features, over molding, adhesive-lined heat shrink material, or reinforcing structures to reduce stress concentrations and maintain mechanical and electrical integrity.

[0062] In some implementations, the non-circular second conductors 26’ may maintain a conductive cross-sectional area substantially equal to that of the round first conductors 26, even though the geometric profile differs. Maintaining substantially equivalent conductive area may preserve current-carrying capacity and reduce resistive heating, voltage drop, and bottleneck effects between the first cable 16, the second cable 18, and the third cable 20. In certain embodiments, deformation of the second conductors 26’ may increase surface area relative to a round conductor of equivalent cross-sectional area, thereby facilitating heat dissipation.

[0063] In some implementations, the thickness T of the second cable 18 may be selected relative to a clearance dimension associated with a vehicle trunk seal or decklid interface such that the second cable 18 may be positioned between the closure member and the vehicle body without interfering with latch engagement, weather sealing, or closure sensor operation. The flattened geometry may cooperate with compressible vehicle seals to reduce intrusion risk while maintaining enclosure security.

[0064] In some implementations, the second cable 18 may include one or more internal reinforcement members disposed within or adjacent to the outer sheath 30. Such reinforcement members may include high-strength fibers, aramid fibers (e.g., Kevlar® strands), tensile load members, woven strengthening filaments, or other elongate reinforcement structures configured to increase tensile strength and resistance to mechanical fatigue. The reinforcement members may extend longitudinally along the second cable 18 and may be positioned between the conductorsAttorney Docket No. 3146.001WO26’ and the outer sheath 30, embedded within the sheath 30, or disposed along lateral edges of the flattened profile.

[0065] In some implementations, the second cable 18 may further comprise one or more electromagnetic shielding structures. For example, the second cable 18 may include a metallic shield layer, an aluminum or copper foil layer, a braided copper shield, and / or a ground conductor configured to reduce electromagnetic interference (EMI). The shielding structure may surround the plurality of second conductors 26’ or may be positioned between the conductors and the outer sheath 30. In certain embodiments, the shielding layer may also function as a ground path.

[0066] Inclusion of reinforcement and / or shielding structures may enable the second cable 18 to support high-current electric vehicle charging (including Level 2 and Level 3 charging), improve strain resistance under repeated compression, and facilitate compliance with electromagnetic compatibility (EMC) requirements while maintaining the reduced thickness T and flattened profile described herein.

[0067] In some implementations, the plurality of second conductors 26’ disposed within the second cable 18 may be oriented in a controlled and fixed rotational position relative to the outer sheath 30. For example, where the second conductors 26’ define oval or flattened transverse crosssections, the major axes of the conductors 26’ may be aligned substantially parallel to the width W of the second cable 18. The sheath material 30, internal positioning members, adhesive layers, or compression forming process may cooperate to resist rotational movement of the second conductors 26’ within the sheath 30. By maintaining the major axes of the second conductors 26’ in a predetermined orientation, the reduced thickness T of the second cable 18 may be preserved and unintended twisting or thickening of the cable profile may be reduced during installation or use.

[0068] In some implementations, the lateral side-by-side arrangement of the second conductors 26’ may define a neutral bending axis extending longitudinally along the second cable 18. The flattened geometry of the second cable 18 may result in anisotropic mechanical behavior, such that the second cable 18 exhibits greater flexibility in a width-wise bending direction and increased stiffness in a thickness-wise compression direction. This directional stiffness may assist in resisting vertical compressive forces applied by a decklid 32 while permitting lateral conformity to vehicle seal structures. In certain embodiments, the second conductors 26’ may be positionedAttorney Docket No. 3146.001WOsymmetrically about the neutral axis to distribute compressive loads and reduce localized stress concentrations.

[0069] In some implementations, only a defined longitudinal portion of the second cable 18 may define the flattened, non-circular transverse cross-section. For example, a central section of the second cable 18 may be flattened to define the reduced thickness T, while one or both end regions of the second cable 18 may transition to a substantially circular cross-section. A transition region may gradually transform the conductor geometry and outer sheath shape between the circular and flattened sections. The flattened portion may have a predetermined length selected to correspond to a closure interface region of a vehicle trunk or enclosure, thereby allowing only the portion positioned between the decklid 32 and the vehicle body to define the reduced thickness profile while maintaining conventional round geometry in other regions.

[0070] The foregoing description is merely illustrative in nature and is in no way intended to limit the disclosure, its application, or uses. The broad teachings of the disclosure can be implemented in a variety of forms. Therefore, while this disclosure includes particular examples, the true scope of the disclosure should not be so limited since other modifications will become apparent upon a study of the drawings, the specification, and the following claims. In the written description and claims, one or more steps within a method may be executed in a different order (or concurrently) without altering the principles of the present disclosure. Similarly, one or more instructions stored in a non-transitory computer-readable medium may be executed in a different order (or concurrently) without altering the principles of the present disclosure. Unless indicated otherwise, numbering or other labeling of instructions or method steps is done for convenient reference, not to indicate a fixed order.

[0071] Further, although each of the embodiments is described above as having certain features, any one or more of those features described with respect to any embodiment of the disclosure can be implemented in and / or combined with features of any of the other embodiments, even if that combination is not explicitly described. In other words, the embodiments described are not mutually exclusive, and permutations of one or more embodiments with one another remain within the scope of this disclosure.

[0072] Spatial and functional relationships between elements (for example, between modules, circuit elements, semiconductor layers, etc.) are described using various terms, including “connected,” “engaged,” “coupled,” “adjacent,” “next to,” “on top of,” “above,” “below,” andAttorney Docket No. 3146.001WO“disposed.” Unless explicitly described as being “direct,” when a relationship between first and second elements is described in the above disclosure, that relationship encompasses a direct relationship where no other intervening elements are present between the first and second elements as well as an indirect relationship where one or more intervening elements are present between the first and second elements.

[0073] As noted below, the term “set” generally means a grouping of one or more elements. However, in various implementations a “set” may, in certain circumstances, be the empty set (in other words, the set has zero elements in those circumstances). As an example, a set of search results resulting from a query may, depending on the query, be the empty set. In contexts where it is not otherwise clear, the term “non-empty set” can be used to explicitly denote exclusion of the empty set — that is, a non-empty set will always have one or more elements.

[0074] A “subset” of a first set generally includes some of the elements of the first set. In various implementations, a subset of the first set is not necessarily a proper subset: in certain circumstances, the subset may be coextensive with (equal to) the first set (in other words, the subset may include the same elements as the first set). In contexts where it is not otherwise clear, the term “proper subset” can be used to explicitly denote that a subset of the first set must exclude at least one of the elements of the first set. Further, in various implementations, the term “subset” does not necessarily exclude the empty set. As an example, consider a set of candidates that was selected based on first criteria and a subset of the set of candidates that was selected based on second criteria; if no elements of the set of candidates met the second criteria, the subset may be the empty set. In contexts where it is not otherwise clear, the term “non-empty subset” can be used to explicitly denote exclusion of the empty set.

[0075] In the figures, the direction of an arrow, as indicated by the arrowhead, generally demonstrates the flow of information (such as data or instructions) that is of interest to the illustration. For example, when element A and element B exchange a variety of information, but information transmitted from element A to element B is relevant to the illustration, the arrow may point from element A to element B. This unidirectional arrow does not imply that no other information is transmitted from element B to element A. Further, for information sent from element A to element B, element B may send requests for, or receipt acknowledgements of, the information to element A.Attorney Docket No. 3146.001WO

[0076] In this application, including the definitions below, the term “module” can be replaced with the term “controller” or the term “circuit.” In this application, the term “controller” can be replaced with the term “module.” The term “module” may refer to, be part of, or include: an Application Specific Integrated Circuit (ASIC); a digital, analog, or mixed analog / digital discrete circuit; a digital, analog, or mixed analog / digital integrated circuit; a combinational logic circuit; a field programmable gate array (FPGA); processor hardware (shared, dedicated, or group) that executes code; memory hardware (shared, dedicated, or group) that is coupled with the processor hardware and stores code executed by the processor hardware; other suitable hardware components that provide the described functionality; or a combination of some or all of the above, such as in a system-on-chip.

[0077] The module may include one or more interface circuits. In some examples, the interface circuit(s) may implement wired or wireless interfaces that connect to a local area network (LAN) or a wireless personal area network (WPAN). Examples of a LAN are Institute of Electrical and Electronics Engineers (IEEE) Standard 802.11-2020 (also known as the WIFI wireless networking standard) and IEEE Standard 802.3-2018 (also known as the ETHERNET wired networking standard). Examples of a WPAN are IEEE Standard 802.15.4 (including the ZIGBEE standard from the ZigBee Alliance) and, from the Bluetooth Special Interest Group (SIG), the BLUETOOTH wireless networking standard (including Core Specification versions 3.0, 4.0, 4.1, 4.2, 5.0, and 5.1 from the Bluetooth SIG).

[0078] The module may communicate with other modules using the interface circuit(s). Although the module may be depicted in the present disclosure as logically communicating directly with other modules, in various implementations the module may actually communicate via a communications system. The communications system includes physical and / or virtual networking equipment such as hubs, switches, routers, and gateways. In some implementations, the communications system connects to or traverses a wide area network (WAN) such as the Internet. For example, the communications system may include multiple LANs connected to each other over the Internet or point-to-point leased lines using technologies including Multiprotocol Label Switching (MPLS) and virtual private networks (VPNs).

[0079] In various implementations, the functionality of the module may be distributed among multiple modules that are connected via the communications system. For example, multiple modules may implement the same functionality distributed by a load balancing system. In a furtherAttorney Docket No. 3146.001WOexample, the functionality of the module may be split between a server (also known as remote, or cloud) module and a client (or, user) module. For example, the client module may include a native or web application executing on a client device and in network communication with the server module.

[0080] Some or all hardware features of a module may be defined using a language for hardware description, such as IEEE Standard 1364-2005 (commonly called “Verilog”) and IEEE Standard 1076-2008 (commonly called “VHDL”). The hardware description language may be used to manufacture and / or program a hardware circuit. In some implementations, some or all features of a module may be defined by a language, such as IEEE 1666-2005 (commonly called “SystemC”), that encompasses both code, as described below, and hardware description.

[0081] The term code, as used above, may include software, firmware, and / or microcode, and may refer to programs, routines, functions, classes, data structures, and / or objects. Shared processor hardware encompasses a single microprocessor that executes some or all code from multiple modules. Group processor hardware encompasses a microprocessor that, in combination with additional microprocessors, executes some or all code from one or more modules. References to multiple microprocessors encompass multiple microprocessors on discrete dies, multiple microprocessors on a single die, multiple cores of a single microprocessor, multiple threads of a single microprocessor, or a combination of the above.

[0082] The memory hardware may also store data together with or separate from the code. Shared memory hardware encompasses a single memory device that stores some or all code from multiple modules. One example of shared memory hardware may be level 1 cache on or near a microprocessor die, which may store code from multiple modules. Another example of shared memory hardware may be persistent storage, such as a solid state drive (SSD) or magnetic hard disk drive (HDD), which may store code from multiple modules. Group memory hardware encompasses a memory device that, in combination with other memory devices, stores some or all code from one or more modules. One example of group memory hardware is a storage area network (SAN), which may store code of a particular module across multiple physical devices. Another example of group memory hardware is random access memory of each of a set of servers that, in combination, store code of a particular module. The term memory hardware is a subset of the term computer-readable medium.Attorney Docket No. 3146.001WO

[0083] The apparatuses and methods described in this application may be partially or fully implemented by a special-purpose computer created by configuring a general-purpose computer to execute one or more particular functions embodied in computer programs. Such apparatuses and methods may be described as computerized or computer-implemented apparatuses and methods. The functional blocks and flowchart elements described above serve as software specifications, which can be translated into the computer programs by the routine work of a skilled technician or programmer.

[0084] The computer programs include processor-executable instructions that are stored on at least one non-transitory computer-readable medium. The computer programs may also include or rely on stored data. The computer programs may encompass a basic input / output system (BIOS) that interacts with hardware of the special-purpose computer, device drivers that interact with particular devices of the special-purpose computer, one or more operating systems, user applications, background services, background applications, etc.

[0085] The computer programs may include: (i) descriptive text to be parsed, such as HTML (hypertext markup language), XML (extensible markup language), or JSON (JavaScript Object Notation), (ii) assembly code, (iii) object code generated from source code by a compiler, (iv) source code for execution by an interpreter, (v) source code for compilation and execution by a just-in-time compiler, etc. As examples only, source code may be written using syntax from languages including C, C++, C#, Objective-C, Swift, Haskell, Go, SQL, R, Lisp, Java®, Fortran, Perl, Pascal, Curl, OCaml, JavaScript®, HTML5 (Hypertext Markup Language 5th revision), Ada, ASP (Active Server Pages), PHP (PHP: Hypertext Preprocessor), Scala, Eiffel, Smalltalk, Erlang, Ruby, Flash®, Visual Basic®, Lua, MATLAB, SIMULINK, and Python®.

[0086] The term non-transitory computer-readable medium does not encompass transitory electrical or electromagnetic signals propagating through a medium (such as on a carrier wave). Non-limiting examples of a non-transitory computer-readable medium are nonvolatile memory circuits (such as a flash memory circuit, an erasable programmable read-only memory circuit, or a mask read-only memory circuit), volatile memory circuits (such as a static random access memory circuit or a dynamic random access memory circuit), magnetic storage media (such as an analog or digital magnetic tape or a hard disk drive), and optical storage media (such as a CD, a DVD, or a Blu-ray Disc).Attorney Docket No. 3146.001WO

[0087] The term “set” generally means a grouping of one or more elements. The elements of a set do not necessarily need to have any characteristics in common or otherwise belong together. The phrase “at least one of A, B, and C” should be construed to mean a logical (A OR B OR C), using a non-exclusive logical OR, and should not be construed to mean “at least one of A, at least one of B, and at least one of C.” The phrase “at least one of A, B, or C” should be construed to mean a logical (A OR B OR C), using a non-exclusive logical OR.

[0088] The following Clauses provide an exemplary configuration for A portable battery charging system, as described above.

[0089] Clause 1: A portable battery charging system comprising: a first cable defining a first thickness; a second cable coupled to the first cable and defining a second thickness that is less than the first thickness.

[0090] Clause 2: The portable battery charging system of clause 1, further comprising a power supply coupled to the first cable.

[0091] Clause 3: The portable battery charging system of any of clauses 1 or 2, further comprising a connector coupled to the second cable.

[0092] Clause 4: The portable battery charging system of any of clauses 1 through 3, wherein the second cable defines a maximum second thickness less than or equal to 0.3125 inch.

[0093] Clause 5: The portable battery charging system of any of clauses 1 through 4, wherein a ratio of the maximum of the second thickness to a minimum of the first thickness is between 10% and 50%.

Claims

Attorney Docket No. 3146.001WOCLAIMSClaim 1. A cable device for a portable battery charging system, the cable device comprising:a first cable having a plurality of first conductors disposed within a first outer sheath, the first cable defining a substantially circular transverse cross-section;a second cable electrically coupled to the first cable, the second cable comprising a plurality of second conductors disposed within a second outer sheath; anda third cable electrically coupled to the second cable;wherein the second cable defines a non-circular transverse cross-section including a flattened profile having a thickness and a width, the width being greater than the thickness; the plurality of second conductors each define a non-circular transverse cross-section; and the thickness of the second cable is less than a maximum diameter of the first cable.Claim 2. The cable device of claim 1, wherein the plurality of second conductors are arranged in a side-by-side and laterally spaced configuration along a common plane within the second outer sheath.Claim 3. The cable device of claim 1 or 2, wherein each of the plurality of second conductors define an oval, elliptical, or flattened transverse cross-section.Claim 4. The cable device of claim 1 or any one of the previous claims, wherein each of the plurality of second conductors has a conductive cross-sectional area substantially equal to a conductive cross-sectional area of a corresponding one of the first conductors.Claim 5. The cable device of claim 1, wherein the second outer sheath comprises a heat-shrinkable braided sleeve having a woven or braided construction.Attorney Docket No. 3146.001WOClaim 6. The cable device of claim 5, wherein the braided sleeving comprises polyester multifdament fibers and modified polyolefin filaments, and the first outer sheath comprises polyurethane (TPU), cross-linked polyethylene (XLPE), or polyvinyl chloride (PVC.Claim 7 The cable device of claim 1 or to any one of the previous claims, wherein the plurality of second conductors are formed by compressing initially round conductors to define the non-circular transverse cross-sections, and the second cable comprises a positioning device that is applied around or between the second conductors to attach the second conductors to the second outer sheath and maintain the second conductors in a laterally spaced, side-by-side configuration.Claim 8. The cable device of claim 1, wherein the thickness of the second cable is between 5% and 50% of a diameter of the first cable.Claim 9. The cable device of claim 1 or to any one of the previous claims, wherein the second cable is configured to be positioned between a movable decklid and a vehicle body structure while permitting closure of the decklid without impairing electrical continuity through the second cable.Claim 10. The cable device of claim 9 or to any one of the previous claims, wherein the flattened profile of the second cable reduces activation of a pinch-detection sensor of the vehicle during closure of the decklid.Claim 11. The cable device of claim 1 or to any one of the previous claims, wherein the plurality of first conductors are arranged radially around a central longitudinal axis of the first cable within the first outer sheath and define substantially circular transverse cross-sections.Claim 12. The cable device of claim 6 or to any one of the previous claims, further comprising a connection device disposed between the first cable and the second cable, the connection deviceAttorney Docket No. 3146.001WOcomprising an adhesive-lined heat-shrink tubing configured to mechanically and electrically secure the first and second cables together.Claim 13. The cable device of claim 1 or to any one of the previous claims, wherein each of the second conductors is individually insulated within the second outer sheath.Claim 14. The cable device of claim 1 or to any one of the previous claims, wherein the second cable is integrally formed with at least one of the first cable or the third cable.Claim 15. The cable device of claim 1, wherein the flattened profile of the second cable is configured to permit routing through a closure interface of an enclosure while maintaining current flow suitable for Level 2 or Level 3 electric vehicle charging.Claim 16. A cable device comprising:a first cable having a substantially circular outer sheath and five round conductors disposed within the first cable;a second cable directly coupled to the first cable, the second cable having a flattened outer sheath defining a non-circular transverse cross-section and having five oval conductors disposed within the second cable; anda third cable directly coupled to the second cable and having a substantially circular outer sheath and five conductors disposed within the third cable;wherein the five oval conductors of the second cable are arranged in a laterally spaced, side-by-side configuration along a common plane; a conductive cross-sectional area of each oval conductor of the second cable is substantially equal to a conductive cross-sectional area of a corresponding round conductor of the first cable; the flattened outer sheath of the second cable defines a maximum thickness that is less than a diameter of the first cable; and the second cable is configured to be positioned between a vehicle decklid and a vehicle body structure while permitting the decklid to close without impairing electrical continuity through the second cable.Attorney Docket No. 3146.001WOClaim 17. The cable device of claim 16, wherein a major axis of each oval conductor of the second cable extends substantially parallel to a width of the flattened outer sheath.Claim 18. The cable device of claim 17, wherein the five oval conductors are rotationally fixed relative to the flattened outer sheath to maintain alignment of their respective major axes during bending and compression.Claim 19. The cable device of claim 18, wherein the five oval conductors are symmetrically arranged about a longitudinal neutral axis of the second cable.Claim 20. The cable device of claim 19, wherein the flattened profile of the second cable is configured to permit routing through a closure interface of an enclosure while maintaining current flow suitable for Level 2 or Level 3 electric vehicle charging.

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