DEVICES AND SYSTEMS FOR INDUCTIVE TRANSFER OF ELECTRICAL ENERGY

Abstract

Devices and systems are described for inductively charging a portable electronic device, such as a tracking device, and for communicatively coupling the portable electronic device to a computer monitoring station or other computing device.

Description

RELATED APPLICATIONS

This application is a continuation of, claims priority to, and hereby incorporates by reference in its entirety U.S. patent application Ser. No. 11/933,024 filed on Oct. 31, 2007, entitled “Apparatus and Method for Manufacturing an Electronic Package.” This application also incorporates by reference in its entirety U.S. patent application Ser. No. 11/753,979 filed on May 25, 2007, entitled “Apparatus and Method for Providing Location Information on Individuals and Objects Using Tracking Devices.”

BACKGROUND

An electronic tracking device is often defined in part by its ability to replenish its battery level and as well as provide a means of efficient data transfer, e.g., when a device battery is charging and may be electrically connected to a remote terminal, such as a location coordinate monitoring station. Many conventional electronic tracking devices' power replenish and recharge capabilities are limited to physically plugging a port of the electronic tracking device into a standard electrical wall outlet or computer device port. In some instances, physical replacement of a device battery is required. Furthermore, many conventional electronic tracking devices provide signal transfer capability that is limited to direct connection of the electronic tracking device to a sub-station or central location coordinate monitoring station.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates an electrical block diagram of a tracking device in accordance with an embodiment of the present invention.

FIG. 2A illustrates a perspective top view of a mold tool to produce an electronic package for an electrical component in accordance with an embodiment of the present invention.

FIG. 2B illustrates a side view of a mold tool to inject a thermoplastic resin into a first fill area in accordance with an embodiment of the present invention.

FIG. 2C illustrates a side view of a mold tool to inject a thermoplastic resin into a second fill area in accordance with an embodiment of the present invention.

FIG. 2D illustrates a perspective view of a PCB illustrated in FIGS. 2A-2C for electronic packaging in accordance with an embodiment of the present invention.

FIG. 2E illustrates a side view of an electronic package produced by molding tools shown in FIGS. 2A-2C in accordance with an embodiment of the present invention.

FIG. 2F illustrates a two-piece mating electronic package produced using the processing steps described with reference to FIGS. 2A-2E in accordance with an embodiment of the present invention.

FIG. 3A illustrates a diversity antenna located on a first side of a tracking device to support message communication in accordance with an embodiment of the present invention.

FIG. 3B illustrates a diversity antenna located on a second side of a tracking device to support message communication in accordance with an embodiment of the present invention.

FIG. 4A illustrates wireless battery charging circuitry of a tracking device and an inductive charging pad in accordance with an embodiment of the present invention.

FIG. 4B illustrates wireless battery charging circuitry of a tracking device and a dual-sided inductive charging unit in accordance with an embodiment of the present invention.

FIG. 4C illustrates wireless battery charging circuitry of a tracking device and a first conformal-shaped inductive charger in accordance with an embodiment of the present invention.

FIG. 4D illustrates wireless battery charging circuitry of a tracking device and a second conformal-shaped inductive charger in accordance with an embodiment of the present invention.

FIG. 4E illustrates wired battery charging connection of a tracking device in accordance with an embodiment of the present invention.

FIG. 5 illustrates a flow chart of the injection molding process in accordance with one embodiment of the present invention.

FIG. 6 illustrates a flow chart to manage battery power usage of a tracking device in accordance with one embodiment of the present invention.

DETAILED DESCRIPTION

Reference is now made to the drawings wherein like numerals refer to like parts throughout.

As used herein, the terms “location coordinates” refer without limitation to any set or partial set of integer, real and/or complex location data or information such as longitudinal, latitudinal, and elevational positional coordinates.

As used herein, the terms “tracking device” refers to without limitation to any hybrid electronic circuit, integrated circuit (IC), chip, chip set, system-on-a-chip, microwave integrated circuit (MIC), Monolithic Microwave Integrated Circuit (MMIC), 10 low noise amplifier, power amplifier, transceiver, receiver, transmitter and Application Specific Integrated Circuit (ASIC) that may be constructed and/or fabricated. The chip or IC may be constructed (“fabricated”) on a small rectangle (a “die”) cut from, for example, a Silicon (or special applications, Sapphire), Gallium Arsenide, or Indium Phosphide wafer. The IC may be classified, for example, into analogue, digital, or hybrid (both analogue and digital on the same chip and/or analog-to-digital converter). Digital integrated circuits may contain anything from one to millions of logic gates, invertors, and, or, nand, and nor gates, flipflops, multiplexors, etc. on a few square millimeters. The small size of these circuits allows high speed, low power dissipation, and reduced manufacturing cost compared with board-level integration.

As used herein, the terms “wireless data transfer”, “wireless tracking and location system”, “positioning system,” and “wireless positioning system” refer without limitation to any wireless system that transfers and/or determines location coordinates using one or more devices, such as Global Positioning System (GPS). The terms “Global Positioning System” refer to without limitation to any services, methods or devices that utilize GPS technology that determine a position of a GPS receiver based on measuring signal transfer times between satellites having known positions and the GPS receiver. The signal transfer time of a signal is proportional to a distance of a respective satellite from the GPS receiver. The distance between a satellite and a GPS receiver may be converted, utilizing signal propagation velocity, into a respective signal transfer time. The positional information of the GPS receiver is calculated based on distance calculations from at least four satellites to determine positional information of the GPS receiver.

As used herein, the terms “wireless network” refers to, without limitation, any digital, analog, microwave, and millimeter wave communication networks that transfer signals from one location to another location, such as IEEE 802.11g, Bluetooth, WiMax, GSM, IS-95, CGM, CDMA, wCDMA, PDC, UMTS, TDMA, FDMA, two-way satellite communications or any combinations thereof.

Major Features

In one aspect, the present invention discloses an apparatus and method of providing an electronic packaging apparatus using an injection molding process to manufacture a substantially shockproof, waterproof unit for a tracking device. In one embodiment, the unit provides a diversity antenna capable of improving receiver sensitivity. In one embodiment, the unit prevents unauthorized reverse engineering of electronic components contained therein. In other embodiment, inductive circuitry enables near-field wireless charging and data communication between a tracking device and a battery charger and/or a remote monitoring station to potentially improve user ease of use and decrease a user's communication costs. As described though out the following specification, the present invention generally provides packaging of tracking devices for locating and tracking an individual or an object. More specifically, the package of the present invention is substantially durable in nature to withstand harsh environmental conditions and/or hard surface impacts that may occur before location is determined of a missing, lost, or abducted person, Alzheimer's syndrome patient, mentally ill person, or a criminal by a guardian or law enforcement authority.

The present invention may be used to provide a package for a tracking device concealed on an individual in one (or more) form factor(s). Form factors may include a pen carried in a pocket or backpack, an inner surface of a shoe, a button, a necklace, a toy, a shirt collar, and decoration, fabric of a jacket or sweater, or the like. Various device skins are available to camouflage a tracking device. A device skin, such as a plastic sticker or housing, attaches to a tracking device to blend a tracking device appearance with that of an object or individual to prevent discovery by an abductor (as compared to being incorporated as part of a conspicuous device, e.g., a mobile phone, pager, personal data assistant). In one exemplary embodiment, the tracking device may be a personal locator device implanted under an individual's skin. The personal locating device may, in one example, have capability of inductively charging its battery, for instance, utilizing an inductive charging technology, methodology or apparatus described supra in FIGS. 4A-4D. In one variant, a battery of a personal locator tracking device may be trickle-charged in response to an individual movement's (e.g. using technology similar to a flashlight that charges its battery level in response to user providing a shaking or back and forth motion to the flashlight).

The present invention discloses, in one embodiment, a substantially waterproof and shockproof device and, in one instance, substantially sealed and having no exposed metal contacts. Consequently, if the tracking device is submerged in water (such as when the tracking device is inadvertently washed in a washing machine as part of laundry) or exposed to cold temperature conditions, e.g., snow, the device remains functional. The tracking device may also find use monitoring and locating lost or stolen animals and objects, such as vehicles, goods and merchandise. Please note that the following discussions of manufacturing a tracking device to monitor and locate individuals is nonlimiting and the present invention may be useful in other electronic packaging applications, such as watches, calculators, clocks, computer keyboards, computer mice, mobile phones and the like.

Exemplary Apparatus

Referring now to FIGS. 1-5, exemplary embodiments of the electronic packaging system of the invention are described in detail. It will be appreciated that while described primarily in the context of tracking individuals or objects, at least portions of the apparatus and methods described herein may be used in other applications, such as, utilized, without limitation, for control systems that monitor components such as transducers, sensors, and electrical and/or optical components that are part of an assembly line process. Moreover, it will be recognized that the present invention may find utility beyond purely tracking and monitoring concerns. Myriad of other functions will be recognized by those of ordinary skill in the art given the present disclosure.

Electronic Packaging

Referring to FIG. 1, the electronic components 141 insert into the mold tooling 240 (depicted in FIG. 2A). The electronic components 141 include a signal receiver 144, a signal transmitter 146, and a microprocessor/logic circuit 148. In one embodiment, the electronic components 141 are disposed, deposited, or mounted on a substrate (such as a circuit board (PCB) 143). The PCB 143, for example, may be manufactured from: polyacryclic (P A), polycarbonate, (PC) composite and arylonitrilebutadiene-styrene (ABS) substrates, blends or combinations thereof, or the like. The microprocessor/logic circuit 148 is configured to store a first identification code (of the tracking device 142), produce a second identification code, determine location coordinates of the tracking device 142 and generate a positioning signal that contains location data (as described in U.S. patent application Ser. No. 11/753,979 filed on May 25, 2007, previously incorporated herein by reference). For instance, the location data includes longitudinal, latitudinal, and elevational position of a tracking device, current address or recent address of the tracking device, a nearby landmark to the tracking device, and the like.

In one embodiment, a positioning system logic circuit, e.g., wireless location and tracking logic circuit 150, calculates location data sent to the microprocessor/logic circuit 148 from a monitoring station 151. Memory1 153a and memory2 153b store operating software and data, for instance, communicated to and from the microprocessor/logic circuit 148 and/or the wireless location and tracking logic circuit 150. A power level sensor 149 detects a receive signal power level. Signal detecting circuitry 155 detects a battery level of battery 154, which may contain one or more individual units or be grouped as a single unit. One or more antennas 152a, 152b connect, in this example, to the signal transmitter 146 and the signal receiver 144. In one variant, the signal transmitter 146 and the signal receiver 144 may be replaced by a transceiver circuit, chip, or integrated circuit. The signal transmitter 146 transmits a signal including location data from a tracking device 142 to the monitoring station 151. The signal receiver 144 receives a signal from the monitoring station 151, for example, by wireless data transfer, e.g., wireless telephone communication or via an Internet electronic message. A demodulator circuit 159 extracts baseband signals, for instance at 100 KHz, including tracking device configuration and software updates, as well as converts a low-frequency AC signal to a DC voltage level. The DC voltage level, in one example, is supplied to battery charging circuitry 157 to recharge a battery level of the battery 154. The blocks 131a-d, in this example, represents battery charging components (such as inductors 408a-d described supra with reference to FIGS. 4A-4D).

In one embodiment, a user of a monitoring station 151 by listening (or downloading) one or more advertisements may reduce and/or shift phone usage charges to another user, account, or database (as disclosed in U.S. patent application Ser. No. 11/784,400 entitled “Communication System and Method Including Dual Mode Capability” and 111784,318 entitled “Communication System and Method Including Communication Billing Options” each filed on Apr. 5, 2007, herein incorporated by reference).

Referring to FIG. 2A, a mold tool 240 supports the PCB board 143 (including the electronic components 141 shown in FIG. 1) in accordance with an embodiment of the present invention. Retractable pins 256a-d support the PCB 143 within the mold tooling 240. The mold tooling 240, in this non-limiting example, produces a tracking device 142 to conform to a desired electronic package shape, for example, a shape of a button. Furthermore, the molding tool 240, in another example, forms the tracking devices 402, 410 (from the application Ser. No. 11/753,979 incorporated previously by reference). In other embodiments, dimensionality of a mold tool conforms to a desired tracking device dimensionality, e.g., a lapel pin, button, shirt collar, shoe insert, pen, belt buckle and the like.

The following is a non-limiting example of the present invention. The mold tool 240 includes one or more molds (e.g., first mold 237a, second mold 237b, third mold 238a, fourth mold 238b) forming one or more internal cavity areas, such as molding areas 239a, 239b shown in FIG. 2B, 2C, respectively. A plastic composite material is flowed into the molding areas 239a, 239b to encapsulate, e.g., substantially seal, the tracking device 142. In one embodiment, the plastic composite material flows through at least one of the openings 258a, 258b to fill, for instance, the molding area 239a and/or the molding area 239b. If a printed circuit board was utilized, e.g., PCB 143, the PCB may be formed by any of the following: a polycarbonate acrylic-styrene (PCI ABS), polycarbonate (PC), acrylic-styrene (ABS) chemical composition, polymer, polyurethane, polycarbonateurethane (PCU), thermoplastic, or blends thereof. For encapsulating the tracking device 142 using one or more molds, the plastic composite material, for example, may be a thermoset plastic, thermoplastic resin, polymer, polycarbonate, elastomer, urethane, urethane elastomer, polyurethane, copolymers, thermoplastic vulcanizates, thermoplastic urethanes, olefinics, copolyamides, arylonitrile-butadiene-styrene (ABS), or blends thereof.

Processing properties of the plastic composite material include melt temperature, mold temperature, mold dimensionality and injection pressure. The processing properties, for instance, depend on a manufacturing lot and material composition as well as whether electronic components 141 to encapsulate are one or more integrated circuits or a PCB 143. In this non-limiting example, manufacturer specifications conform to those by Bayer Polymers, the Polymer Technology Group and the Teknor Apex Company. More specifically, urethane elastomer processing parameters include a melt temperature between 150 to 250 degrees C., a mold temperature between 30 to 45 degrees C., and an injection pressure between 30 to 50 MPa. A drying process may follow opening of first mold 237a, 237b and/or second mold 238a, 238b and removal of the tracking device 142. Afterwards, the tracking device 142 substantially replicates a combined form factor of first mold 237a, a second mold 237b, a third mold 238a, and fourth mold 238b. Consequently, the tracking device 142 conforms to physical features (e.g., belt buckles, button on a shirt, inner surface of a shoe, or the like) of the mold tooling.

Referring to FIG. 2B, one or more electronic components 141, such as packaged integrated circuits, resistors and capacitors, disposed on a PCB (such as PCB 143) are encapsulated in the first molding process. In particular, during the first molding process, a first mold 237a and a second mold 237b form a cavity, e.g., a first fill area 239a, to fill a first region on the PCB 143 using a plastic composite material, e.g., selected from the materials described above. In this example, the first region includes an active region of the electronic components 141. Referring to FIG. 2C, in a second molding process, a third mold 238a and fourth mold 238b form a second region. The second region, for instance, is a second fill area 239b. The second fill area 239b, for example, is an area about an outer region of the first filling area 339a for filing with a plastic composite material, to further process the PCB 143 coated with a first fill area 239a.

Following one or more of the molding processes, for instance the first and the second molding process, an injection step may be required to intermediately cure the plastic composite material. This curing step may include having the composite plastic material remain in a mold until sufficient hardening occurs, or it may include a sequence of steps of actively heating or cooling the plastic composite material within or outside of the mold to achieve a desired uniformity and consistency. For instance, if the composite plastic material is a thermoset plastic material, the curing step may be automatic due to its inherent chemical properties. For thermoset plastic material, however, it may be generally advantageous to cool to hasten its solidification.

In one embodiment, retractable pins 256a-d, shown in FIG. 2A, are capable of providing PCB 143 support during injection mold processing. In one embodiment, injection mold may involve a sequential or parallel arrangement of injections of one or more plastic composite materials, (e.g., chemical compositions and/or varieties of a heated thermoplastic resin) to fill areas (e.g., fill area 239a, fill area 239b) on the PCB 143. In one embodiment, an integrated circuit, such as circuits 146, 150 depicted in FIG. 1, are sealed in a first fill area 239a during a first molding process. The first molding process may include a plastic composite material of a first type. Thus, advantageously, subsequent molding processes, such as a second molding process, having a second fill area 239b, may, in one embodiment, utilize a plastic composite material of the first type or, in the alternative, a second type, e.g., optimized for a property different than the first type.

For instance, the second fill area 239b may be optimized for moisture and chemical resistance properties and the first fill area 239a may be optimized for high resistance to breakage and stress. Consequently, this invention, in one embodiment, by using multiple types, multiple level polymers, injection processing may provide custom injection tailoring on per unit area basis on the PCB 143 to achieve one or more desired electronic packaging properties. The electronic packaging properties may include tensile strength, hardness, and flexural modulus, tear strength, coefficient of temperature expansion, flammability, brittleness, linear mold shrinkage, specific gravity and melt flow. Thus, this embodiment of custom tailored layering as opposed to conventional single application polymer processing provides a tracking device having a non-uniform profile wireless communication conducting packages.

Furthermore, the present process eliminates a need for first sealing an integrated circuit, e.g., before beginning an injection processing, such as requiring an integrated circuit to be packaged in a ferrite, ceramic lead package, or the like to prevent circuitry degradation. Thus, multiple level sealing process of an electronic circuit (such as electronic components 141) using the present invention provides for improved electronic package throughput and improved package performance, e.g., improved electrostatic discharge (ESD) protection for active devices, disposed in a first fill area 239a. Still other advantages of the present processing include improved communication properties for electronic components, such as electronic components 141. In one embodiment, a system designer places signal communicating apparatus, e.g., antennas 152a, 152b proximate to the electrical components 141 in a first fill area. In yet another embodiment, the signal communication apparatus, e.g., antennas 152a, 152b may be disposed (external to the first fill area) within a second fill area 239b. Thus, a user may selectively choose a plastic composite material in the first fill area 239a to improve wireless communication (e.g., provide increased signal isolation) for signal sensitive components. Furthermore, a user may choose a second fill area 239b for improve signal reception (for instance if the signal communication apparatus (e.g., antennas 152a, 152b are present in this area) or to enhance other electronic properties such as filtering, tensile strength, or density modulus in a second fill area 239b.

In one embodiment, the second fill area 239b may be disposed with a metallic 25 material forming a multiple surface patch antenna, e.g., dual patch antennas 152a, 152b, to improve receiver sensitivity and/or improve signal reception (see FIG. 3 for a more detailed discussion of the dual patch antenna 152a, 152b). In one variant, multiple filling areas, such as the first fill area 239a, near the electronic components 141 may be processed at a lower temperature and pressure, cooled, and impurities and air bubbles removed from the electronic components 141. Continuing with this same variant, processing of a second fill area 239b proximate to (e.g., surrounding the first fill area 239b) may proceed at a higher temperature with minimal degradation to the integrated circuit because the first fill area 239a forms a protective heat barrier for heat sensitive integrated circuits, e.g., circuits 146, 150 shown in FIG. 1. In one variant, the first fill area 239a has a higher temperature resistance than a temperature capability of the integrated circuit mounted on the PCB 143 (but a lower temperature resistance than the second fill area 239b); therefore, the integrated circuits, e.g., circuits 146, 150, as shown in FIG. 1, are protected from a higher temperature injection material, for instance, utilized to fill the second fill area 239b, e.g., including antennas 152a, 152b.

In another embodiment, if more than one injector applies the molding material, a plastic composite material mass flow rate distribution may be realized having a more uniform distribution; thus, board materials and electrical components may be subjected to reduced tensile pressure per unit area, e.g., preventing damage, for instance, of a PCB 143 and the integrated circuits, e.g., circuits 146, 150. As such, the present invention advantageously provides a lower pressure resin mass flow rate and more uniform plastic composite material application than a conventional mold tool utilizing a single injector entry, single application molding, and a single injector exit port.

In another non-limiting example, the plastic composite material, in one example, includes a filler material or weighing material, that bundles with, for example, a binder disposed in or with the plastic composite material. In one variant, a filler material, such as a glass fiber, glass ball or carbon fiber being chopped and applied to the plastic composite material, e.g., such as polycarbonate and acrylonitrile-butadiene-styrene (ABS) copolymer or others listed above. In one embodiment, the glass fiber or glass balls have a low dielectric constant, e.g., approximately 2.2. Continuing with this variant, the filler material provides have a low-loss tangent at signal transmission frequencies (such as at CDMA and GSM frequency ranges) to enhance electrical signal conductivity, such as for antennas 152a, 152b. Furthermore, the filler material should maintain a high tensile strength to prevent electronic package breakage if inadvertently struck against a hard or sharp surface.

One advantage of the present invention packaging approach is the plastic composite material bonds directly to the electronics components 141 to form a tracking device 142 having an enclosed package that is substantially hermetically sealed. In one embodiment, if the tracking device 142 is discovered by an assailant, it would be difficult to view its internal components, because attempted removal of the plastic composite material (e.g., flowed over the PCB 143) would substantially destroy electronic circuits 141. Thus, it would be difficult to inspect the electronic components 141, as compared to conventional electronic packages having a lid or an encapsulated package where removal of the package causes minimal damage to any electronic components disposed therein.

Furthermore, the disclosed packaging approach is resistant to failure of electronic components 141 being dropped as compared to conventional electronic packages having poor resistance to shock, vibration, moisture, and other environmental factors (e.g., snow). Because of this durability, the tracking device 142, for instance, may be incorporated on child's person, such as part of a shoe or in a collar of a child's shirt, that may strike an object, be accidentally placed in a clothes washing machine, or be exposed to water.

Another advantage is the thermoplastic resin color and/or texture may be selected to match a particular design or pattern. The resin color and texture, in one instance, blends or camouflages the tracking device 142 in its surroundings. In one embodiment, in contrast to many conventional tracking devices having a highly distinguishable and noticeable (e.g., by would be assailant), the size, style and color of the tracking device (such as tracking device 142) blends as part of a room decoration or room ornament, so if discarded by an individual (to prevent detection) its design is disguised to prevent destruction by an assailant (and to provide last know location to a monitoring device terminal). In another embodiment, as compared to many conventional tracking devices, the tracking device 142 is substantially water impermeable and resistant to environmental conditions, such as rain, snow, wind and vibration.

Referring to FIG. 2D, electronic packaging process described above in FIGS. 2A-2C, may be modified to provide packaging for temperature sensitive electronic components. Temperature sensitive electronic components may include a Low Noise Amplifier (LNA), RF Transceiver unit (RF transceiver), or Central Processing Unit (CPU) produced from a heat sensitive or temperature sensitive material. The electronic packaging process described above is modified to form an electronic tracking package in two mating sections, e.g., sections 264, 266. Each mating section 264, 266 is formed utilizing one plastic perform unit having a substantially identical footprint (e.g., backside, front side, thickness, and the like) of the electrical circuit board, such as PCB 143, to insert therein except that the perform unit includes additionally dimensionality conforming to a desired shape of a mating lip 260, or a seam 262. After producing both mating sections 264, 266, the perform unit is removed. Electronics components 141 populate the mating sections 264, 266 (including the antennas 152a, 152b) as well as other components. The mating sections 264, 266 are snapped or glued together, e.g., using a commercially available epoxy composition, along the mating lip 260 or seam 262, to form a substantially sealed, polycarbonate electronic package.

Antenna Design

Referring to FIG. 3, a multi-patch antenna, e.g., microstrip patch antennas 152a, 152b, in one example, disposed proximately to electronic package surfaces 105, 107. In one embodiment, the microstrip patch antennas 152a, 152b are positioned parallel on opposing faces of the tracking device 142. In one embodiment, the microstrip patch antennas 152a, 152b are quarter-wave length microstrip patches deposited on an alumina substrate. In one example, the operating frequency range of the microstrip patch antenna is 3 GHz, but may be selected to support an operating frequency range of a skyward satellite or an RF base station. In one example, a separation distance between parallel microstrip patch antennas 152a, 152b may be approximately 0.1 Lambda (wavelength); however, the separation distance may be any distance that supports signal spatial separation between the antennas. In one variant, deposited between the microstrip patch antennas 152a, 152b, a fill material, for example, of a dielectric constant (Er) between 3 to 9 allows a decreased separation distance, e.g., to provide smaller electrical packagesize and provide communication signal spatial differentiation, between the microstrip patch antennas 152a, 152b.

Electrically coupled to the antennas 152a, 152b, are low noise amplifiers 120a, 120b (shown in FIG. 1) to increase received signal power level. During a tracking device startup procedure, e.g., satellite communication signal acquisition phase, a receiver 144 receives location coordinates, such as GPS coordinates, from one or more base stations or satellites, such as satellites 302, 304, and 306. The receiver 144 mounted on the tracking device 142 to measures a snapshot of a receive signal strength on patches 152a, 152b. Referring to FIG. 1, after measuring a snapshot of signal strength, the low noise amplifiers (LNAs) 120a, 120b and the receiver 144 and transmitter 146 shifts to a low power state, e.g., substantially sleep state with a nominal quiescent current, to reduce current drain; therefore, tracking device battery charge is conserved. In a low power state, a Global Positioning System (GPS)/Global Positioning Radio System (GPRS) based processor, e.g., an NXP semiconductor GPS processor 150 (see FIG. 1) processes a snapshot, e.g., 10 ms to 100 ms, of raw location coordinates received from each of the patches 152a, 152b.

In one embodiment, the resulting analysis of the snapshot of raw location coordinates determines which of the antennas, e.g., patches 152a, 152b, predict (based on previous snapshot measurements) better receiver sensitivity for future signal acquisition. In another embodiment, the resulting analysis from each of the patches 152a, 152b provides information on a percentage of battery power to direct to a tracking device's electrical components, e.g., LNAs 120a, 120b, patches 152a, 152b, to maximize signal directivity of the tracking device. Consequently, the invention provides for shifting and/or supplying power to one or multiple antennas, e.g., first patch 152a or the second patch 152b, in response to a location orientation of the tracking device 142 to a monitoring tower or station, e.g., a base station or a satellite. Thus, this approach extends battery life of a tracking device 142 and provides capability to achieve as close as possible 360 degree view of the sky.

In contrast, many conventional tracking systems (during startup procedure) obtain their positional coordinates signal over several minutes; thus, tracking device battery power is depleted (due to an extended startup procedure). Still other conventional mobile tracking device's have one fixed antenna, which may or may not be oriented skyward to a satellite; thus, these systems cause low receiver sensitivity and may not provide adequate antenna directivity to receive location coordinates of a tracking device. More importantly, other conventional mobile tracking device's having one or more fixed antennas oriented in one direction deplete available battery level when out of orientation with a skyward satellite or base station than the present invention multiple antenna approach that responsively transmits power (e.g., to components (LNA, transceiver, or the like) to an appropriate antenna, e.g., patch 152a, 152b, to maximize battery charge.)

In one variant of this embodiment, one or more microstrip patch antennas may be attached to additional sides of a tracking device (for instance if the tracking device is square or rectangular shaped) to realize further improved tracking device directivity and control and increase a receiver sensitivity to weak signals received skyward from a satellite or from a base station monitoring tower. In another variant, the LNAs and the transceivers may be replaced by multiple voltages or current adjustable gain or output power controlled LNAs and/or multiple voltage or current adjustable gain controlled transceiver(s). Continuing with this variant, the adjustable gain or output power LNAs and/or transceivers may be electrically coupled and switched into and out of a signal path of one or more of the antennas, e.g., patches 152a, 152b, to realize a multi-path, multigrain tracking unit with more options to increase receiver sensitivity, including attenuation of high power or adjusting a signal level communicated. In still another variant, each of the patches 152a, 152b may be replaced by one or more antenna patches on the same side, e.g., a patch array antenna, to achieve additional signal acquisition control.

Battery Charging

Referring to FIGS. 4A-4D, various embodiments of battery chargers are disclosed. Referring to FIG. 4A, the battery charger 420 requires no external metal contact points, e.g., DC, RF, and AC inputs. In this embodiment, the inductive charging pad of the charger 420 provides a surface, e.g., horizontal surface that electrically couples to a voltage/current transformer 424. Wire-wound ferrite inductive cores 408a-d (depicted in FIG. 1 as blocks 131a-d) are, for instance, mounted on the circuit board 143 of the tracking device 142 and are electrically coupled (e.g., using wires) to a switching circuit, e.g., demodulator 159, and afterwards to one or rechargeable batteries, e.g., battery 154. About the antenna patches 152a, 152b, inductive charging flux paths through the plastic package 142 couple electromagnetic energy from one or more wire-wound inductive cores, such as ferrite cores 410a-d, (e.g., located within an inductive charging pad 420) receiving electrical energy from a computer connection, e.g., USB port 426 to inductive cores 408a-d. In one embodiment, the inductive charging pad 420 provides near field communication between the tracking device 142 and a computer monitoring station, such as computer 428. Signal demodulator 159 demodulates a low frequency signal received from magnetic flux from the inductive charging pad 420 (e.g., the low frequency signal originated from a computer connection, e.g., USB port 426.) The near field communication communicates periodic tracking device software updates, data downloading/uploading, and other tracking device firmware updates.

In one embodiment, a voltage/current transformer, e.g., voltage/current transformer 421, couples energy, for instance, from a standard AC wall outlet 418 converting a 220V output voltage level, for example, to a 15 volt voltage level. In this example, magnetic flux transfer ac flux from the inductors 410a-d to the inductors 408ad. On the tracking device 142, a demodulator circuit 159 and a battery charging circuitry 157 provide a dc voltage level to the battery 154 (as shown in FIG. 1).

Referring to FIG. 4B, a dual-sided inductive charging unit 430 (with transformer 425) charges the tracking device 142 using multiple tracking device sides 105, 107 to provide increased battery charging capability. Increased battery charging capability is achieved by an increased inductive flux contact between inductive components, e.g., 408a-d, between the tracking device 142 and inductive components, e.g., 410a-h, within the inductive charging unit 430. In one example, the inductive charging unit 430 includes a transformer 425 to obtain AC/DC power and/or low frequency wireless communication from a computer connection, e.g., USB ports 427, 429, of the computer 428. In one variant, inductive components 408e-h (a second circle of inductors to the tracking device 142) may be added to further increase magnetic flux between a tracking device and inductive components, e.g., 410a-h).

Referring to FIGS. 4C, 4D, conformal inductive chargers 432, 434 (including one conformal, ferrite core inductor 450), e.g., side inductive coupled units, are realized with the tracking device 142. In one example, the inductive chargers 432, 434 connect through a transformer 424 to obtain AC/DC power and/or low frequency wireless communication signals. Referring to FIG. 4E, a tracking device 435 is illustrated having an electrical connector, e.g. USB connector 438, to charge the battery 154 when electrically coupled between a transformer 424, e.g. through a USB connector 426, to a computer 428.

Referring to FIG. 5, a flow chart 500 illustrates one example of an injection molding process (as described above in FIGS. 2A-2D) in accordance with one embodiment of the present invention. In step 510, electronic components 141 are placed in the mold tooling 240 (see FIG. 2A). In step 520, a thermoplastic resin is injected into the mold (as shown in FIGS. 2B and 2C). In step 264, the electronic components 141 are enclosed by the thermoplastic resin as shown in FIGS. 2B and 2C). In step 530, the mold tooling 240 is removed and the tracking device 142 is formed. In step 540, the tracking device 142 is tested.

Referring to FIG. 6, a flow chart 600 illustrates a signal acquisition procedure (as described above in FIG. 3) in accordance with one embodiment of the present invention. In step 610, a first patch 152a and a second patch 153b acquire a snapshot of receive signals. In step 620, a processing unit, e.g., 148, 150, processes the snapshot of the receive signals. In step 640, the processing unit communicates battery power management instructions to electrical components associated with the first patch 152a and the second patch 152a to increase receiver sensitivity, antenna directivity, and maximize battery power usage.

It is noted that many variations of the methods described above may be utilized consistent with the present invention. Specifically, certain steps are optional and may be performed or deleted as desired. Similarly, other steps (such as additional data sampling, processing, filtration, calibration, or mathematical analysis for example) may be added to the foregoing embodiments. Additionally, the order of performance of certain steps may be permuted, or performed in parallel (or series) if desired. Hence, the foregoing embodiments are merely illustrative of the broader methods of the invention disclosed herein.

While the above detailed description has shown, described, and pointed out novel features of the invention as applied to various embodiments, it will be understood that various omissions, substitutions and changes in the form and details of the device or process illustrated may be made by those skilled in the art without departing from the spirit of the invention. The foregoing description is of the best mode presently contemplated of carrying out the invention. This description is in no way meant to be limiting, but rather should be taken as illustrative of the general principles of the invention. The scope of the invention should be determined with reference to the claims.

Claims

1. A charging device comprising:

a receiving component configured to receive electrical energy from an electrical energy source; and

an electrical energy transfer component configured to inductively provide storable electrical energy to a portable electronic device and to transfer data between the portable electronic device and a computer monitoring station.

2. The charging device of claim 1, wherein the electrical energy transfer component comprises an inductive charging pad that provides near-field communication between the portable electronic device and the computer monitoring station.

3. The charging device of claim 2, wherein the inductive charging pad is configured to communicate software and firmware updates to the portable electronic device.

4. The charging device of claim 1, wherein the receiving component is configured to receive electrical energy from an AC electrical power source, the charging device comprises a transformer to convert the AC electrical energy to DC electrical energy, and the electrical energy transfer component is configured to inductively provide the DC electrical energy to the portable electronic device.

5. The charging device of claim 1, wherein the receiving component is configured to receive electrical energy from a DC electrical power source.

6. The charging device of claim 1, wherein the receiving component is configured to receive electrical energy from the computer monitoring station.

7. The charging device of claim 1, wherein the electrical energy transfer component comprises a plurality of inductive charging pads that provide near-field communication between a plurality of portable electronic devices and one or more computer monitoring stations.

8. The charging device of claim 2, wherein the inductive charging pad is configured to have a shaped opening such that the portable device fits at least partially inside the shaped opening of the inductive charging pad.

9. A tracking device comprising:

an inductive component configured to inductively receive electrical energy from a charging device;

an energy storage component configured to store the electrical energy received from the charging device; and

a processor configured for two way communications between the tracking device and a communications satellite and configured to transfer data between the tracking device and a computer monitoring station via the charging device.

10. The tracking device of claim 9, wherein the inductive component is configured to communicate with at least one of the charging device and the computer monitoring station through near-field communication.

11. The tracking device of claim 9, wherein the inductive component is configured to receive software and firmware updates from at least one of the charging device and the computer monitoring station.

12. The tracking device of claim 9, wherein a housing of the tracking device is configured to at least partially fit inside a shaped space formed by a shaped inductive charging pad of the charging device.

13. A system comprising:

a tracking device comprising: an inductive component configured to inductively receive electrical energy, an energy storage component configured to store the electrical energy, and a processor configured for two way communications between the tracking device and a communications satellite and configured to transfer data between the tracking device and a computer monitoring station; and

a charging device comprising: a receiving component configured to receive an electrical energy from a electrical energy source, and an electrical energy transfer component configured to inductively provide storable electrical energy to the inductive component of the tracking device and to communicatively couple the tracking device to the computer monitoring station when the tracking device is in close proximity to the charging device.

14. The system of claim 13, wherein the electrical energy transfer component comprises an inductive charging pad that provides near-field communication between the tracking device and the computer monitoring station.

15. The system of claim 14, wherein the inductive charging pad is configured to communicate software and firmware updates to the tracking device.

16. The system of claim 13, wherein the receiving component is configured to receive electrical energy from an AC electrical power source, the charging device comprises a transformer to convert the AC electrical energy to DC electrical energy, and the electrical energy transfer component is configured to inductively provide the DC electrical energy to the tracking device.

17. The system of claim 13, wherein the receiving component is configured to receive electrical energy from a DC electrical power source.

18. The system of claim 13, wherein the receiving component is configured to receive electrical energy from the computer monitoring station.

19. The system of claim 13, wherein the electrical energy transfer component comprises a plurality of inductive charging pads that provide near-field communication between a plurality of portable electronic devices and one or more computer monitoring stations, and wherein at least one of the plurality of portable electronic devices is the tracking device.

20. The system of claim 14, wherein the inductive charging pad is configured to have a shaped opening such that the portable device fits at least partially inside the shaped opening.