Abstract: An inductive charging coupler for use in an inductive charging apparatus used to charge a battery. The charging coupler is insertable into a charge port that is coupled to the battery. The charge port comprises a housing, an opening into which the charging coupler is inserted, and a ferrite core surrounded by secondary windings. The charging coupler comprises a housing having a hollow disk-shaped section with substantially flat opposed surfaces and a tapered handle extending therefrom. An opening is disposed through each of the flat opposed surfaces. A center magnetic core is disposed in the opening and has opposed flat surfaces that are substantially coplanar with the substantially flat opposed surfaces of the housing. A primary winding is disposed in the hollow disk-shaped section around the center magnetic core. The coupler has the shape of a paddle and is designed to give a vehicle operator a sense of safety when transferring electric power to the battery of an electric vehicle, for example.

Abstract: An inductive battery charging system comprising a charge probe and a charge port that employs multi-turn spiral and helical windings in the charge probe to provide improved thermal management of the power produced by the charging system. The thermal management provided by the multi-turn windings of the present invention improves the power handling capacity of the system and reduces AC proximity losses. Numerous flat helical coil and spiral transformer windings are disclosed that provide for differing thermal management schemes. The present invention may be used to increase the inductive charging capacity of electric vehicle propulsion batteries to on the order of 120 KW. The present invention may be used with almost any transformer or inductor that uses foil windings.

Abstract: An inductive battery charging system that uses heat conducting heat exchangers that shape electromagnetic fields produced by the windings of the charging system. The field shaping provided by the heat exchangers of the present invention improves the power handling capacity of the system. The charging system includes a charge probe that includes a primary winding of a transformer and a charge port that includes secondary windings of the transformer. The heat exchangers are heat sinks that are inserted between or are disposed adjacent turns of the windings and are used to remove heat from windings. In the present invention, the heat exchangers are also used to shape the leakage flux near the edges of the windings in such a manner that AC losses in the windings are considerably reduced. The present invention may be used to increase the inductive charging capacity of an electric vehicle battery pack to on the order of 120 KW and beyond.

Abstract: A transmission cable system that incorporates cooling channels that encircles electrical conductors with coolant. The transmission cable system also provides for breach or leak detection. More specifically, the transmission cable system maybe used with an inductive charging system that transfers electric power from a power source to batteries of an electric vehicle. The cable system includes a cooling system for storing, cooling, and pumping coolant, and a pressure sensitive switch for determining the pressure in the cooling system and for providing an output signal indicative of a drop in sensed pressure. A controller is coupled to the pressure sensitive switch that is responsive to the output signal from the switch for shutting down the inductive charging system in the event of a drop in sensed pressure. The transmission cable is electrically coupled between the power source and the electric vehicle for coupling electrical power to the batteries.

Abstract: A high voltage cable system for use with a contactless battery charging system that charge propulsion batteries of an electric vehicle, and the like. The contactless battery charging system includes a primary power converter coupled to a power source and a secondary power converter located on the electric vehicle that is coupled propulsion batteries of the electric vehicle. The primary and secondary power converters are connected by way of a coaxial power cable. An isolation transformer is coupled between the output of the primary power converter and the coaxial power cable. This transformer allows one of the two outputs of the primary power converter to be connected to ground potential. The isolation transformer improves the safety and reduces electromagnetic interference (EMI) when coupling power to the secondary power converter.

Abstract: An inductive charging apparatus for use in charging a battery of an electric vehicle, for example, that provides for a tactile feel. The inductive charging apparatus comprises an inductive charging coupler and a charge port disposed in the electric vehicle and coupled to the battery of the electric vehicle. The charging coupler comprises a center magnetic core, and a primary winding disposed around the center magnetic core. A charger cable is coupled between the primary winding and an external power source for coupling energy to the charging coupler. A coupler housing is provided that has two mating coupler halves that are configured to provide a handle, and the mating coupler halves enclose the primary winding and the center magnetic core, and secures the charger cable in the handle. A plurality of indentations are formed in the side of the housing. The charge port has an opening into which the inductive charging coupler is inserted.

Abstract: An inductive charging coupler for use in an inductive charging system comprising a charge port into which the coupler is inserted that minimizes damage to its magnetic core. The charging coupler comprises a housing, and a magnetic core disposed in the housing. A primary winding is disposed around the magnetic core. A current conductor is coupled to the primary winding for coupling current thereto. The magnetic core has plastic-ferrite covers disposed on opposite sides thereof. The plastic-ferrite covers are typically bonded to exterior flat surfaces of the magnetic core. The plastic-ferrite covers protect the ferrite core while preserving the magnetic properties of the coupler when it is inserted in the charge port. The plastic-ferrite material exhibits both plastic and ferrite properties and covers and protects the magnetic core in the coupler.

Abstract: An electromagnetically shielded inductive charging apparatus for use in charging a battery of an electric vehicle, for example. The inductive charging apparatus comprises an inductive charging coupler and a charge port disposed in the electric vehicle and coupled to the battery of the electric vehicle. The charging coupler comprises a center magnetic core, and a primary winding disposed around the center magnetic core. A charger cable is coupled between the primary winding and an external power source for coupling energy to the charging coupler. A plastic coupler housing is provided that has two mating coupler halves that are configured to provide a handle, and the mating coupler halves enclose the primary winding and the center magnetic core, and secures the charger cable in the handle. A plurality of metallized ribs are disposed in the handle that engage outer shielding braid of the charger cable.

Abstract: An inductively-coupled transformer charging apparatus comprising a charging port having a nonmoving secondary core and a charging coupler that is insertable therein. The charging coupler comprises a primary winding disposed around a primary core. The charging port comprises a fixed secondary core comprising two secondary core halves and two secondary windings, and includes an opening into which the charging coupler is inserted. Heat transfer media in the charging port remove heat during charging. The opening and coupler are sized such that a gap is provided between the secondary core halves and the coupler to provide for a slip fit therebetween. The close fitting relationship between the coupler and the charge port acts to remove dirt build-up present on the coupler as it is inserted into the charging port.

Abstract: A four bar linkage (46) supports a head-up-display (HUD) combiner (12) for movement between an upper storage position and a lower operating position. A stop and overcenter mechanism (28a,58;28b,52a;48,52) securely locks the combiner (12) in the operating position. A switch (60) is actuated by the linkage (46) when the combiner (12) is in the operating position.