BATTERY PACK ADAPTER ASSEMBLY FOR POWERED WEAPON ACCESSORY RAIL INTERFACE

A battery pack adapter and method for mounting battery pack to a weapon are provided. The battery pack adapter is detachable coupled to a powered rail system of a weapon such as a rifle or other firearm, the battery pack adapter for powering one or more weapon accessory devices on the powered rail system. In preferred embodiments, the battery pack adapter and method herein are advantageously configured for use with battery packs that comply with a Small Tactical Universal Battery (STUB) form factor.

BACKGROUND

The present disclosure relates generally to weapon mounted accessory devices and, in particular, to battery pack adapters and methods for mounting battery packs to a weapon, such as a rifle or other firearm, and methods of using same.

Advancements in weapons combat technologies has resulted in numerous specialized weapon accessory devices, such as laser sights, infrared and visible spectrum light sources, night vision and other optoelectronic devices, visible and thermal spectrum cameras, range finders, ballistic computers, fire control systems, among others. As the number of accessory devices has increased, so too has the power requirements for such systems. As such, an improved battery mounting system for powering such weapon accessory devices is contemplated.

SUMMARY

A battery pack adapter and method for mounting a battery pack to a weapon are provided. The battery pack adapter is detachably coupled to a powered rail system of a weapon, such as a rifle or other firearm, the battery pack adapter for coupling a power supply powering one or more weapon accessory devices on the powered rail system. In preferred embodiments, the battery pack adapter and method herein are advantageously configured for use with battery packs that comply with a Small Tactical Universal Battery (STUB) form factor.

In one aspect, a battery adapter comprises a housing having a first side and a second side transversely spaced apart from the first side. A first axially extending side wall is disposed on the first side and a second axially extending side wall is disposed on the second side. An axially extending channel is disposed intermediate the first and second side walls, the axially extending channel having a cross-sectional profile configured to physically and electrically mate with a portion of a weapon accessory mounting rail. A first battery pack interface member is hingedly coupled to the first side and a second battery pack interface member is hingedly coupled to the housing side. The first battery pack interface member is configured to physically and electrically mate with a first external battery pack and the second battery pack interface member is configured to physically and electrically mate with a second external battery pack. Each of the first battery pack interface member and the second battery pack interface member is pivotal between a deployed position configured for normal operation of the first external battery pack and the second external battery pack, respectively, and an accessible position configured for attachment and detachment of the first external battery pack and the second external battery pack, respectively.

The battery adaptor of claim1, further comprising electronic circuitry disposed within the housing electrically coupled to a first electrical connector disposed on the first battery pack interface member and a second electrical connector disposed on the second battery pack interface member, the first and second electrical connectors configured for electrical coupling to the first and second external battery packs, respectively.

In a more limited aspect, the battery adaptor further includes a third electrical connector disposed within the axially extending channel, wherein the electronic circuitry comprises power switching circuitry for coupling the third electrical connector to a selected one of the first electrical connector and the second electrical connector.

In another more limited aspect, the battery adaptor further includes a first manual actuator disposed on the first battery pack interface member for coupling the third electrical connector to the first electrical connector and a second manual actuator disposed on the second battery pack interface member for coupling the third electrical connector to the second electrical connector.

In another more limited aspect, the power switching circuitry is configured to automatically switch from one of the first and second external battery packs to the other one of the first and second external battery packs when a charge state of the one of the first and second external battery packs falls below a preselected threshold.

In another more limited aspect, the electronic circuitry comprises one or more capacitors configured to storing electrical energy and configured to act as one or both of a temporary power supply for preventing power interruption when the third electrical connector is switched from the first electrical connector to the second electrical connector or vice versa, and a temporary power supply for preventing power interruption when one or both of the first and second external battery packs are removed and/or replaced with a another like external battery pack.

In another more limited aspect, each of the first and second battery pack interface members comprises a plurality of electrical conductors extending between the plurality of electrical contacts and respective first and second electrical contact and the third electrical contact and a hollow pivot pin pivotally coupling the respective first and second battery pack interface members to the respective first and second side of the housing, wherein the hollow pivot pin defines a passageway for the plurality of electrical conductors.

In another more limited aspect, the hollow pivot pin includes an axial bore open at a distal end of the hollow pivot pin and a transverse aperture in communication with the axial bore disposed along a shaft of the hollow pivot pin.

In another more limited aspect, a distal end of the first external battery pack configured to pivot away from an axial centerline of the housing when the first battery pack interface member is pivoted from the deployed position to the accessible position when the first external battery pack is attached to the first battery pack interface member and a distal end of the second external battery pack is configured to pivot away from the axial centerline of the housing when the second battery pack interface member is pivoted from the deployed position to the accessible position when the second external battery pack is attached to the second battery pack interface member.

In another more limited aspect, each of the first and second battery pack interface members has an align-and-twist connector for detachably coupling the first and second external battery packs, respectively.

In another more limited aspect, the first and second battery pack interface members are configured to attach to first and second external battery packs having a Small Tactical Universal Battery (STUB) form factor.

In another more limited aspect, the first and second external battery packs mutually obstruct each other to prevent detachment when the first and second external battery packs are attached to the respective first and second battery pack interface members and the first and second external battery packs are in the deployed position.

In another more limited aspect, the battery adaptor further includes a spring element biasing the first and second first battery pack interface members to the accessible position.

In another more limited aspect, the battery adaptor further includes a first latch member configured to releasably engage a complementary catch member disposed on the first battery pack interface member to secure the first battery pack interface member in the deployed position. A second latch member is configured to engage a complementary catch member disposed on the second battery pack interface member to secure the second battery pack interface member in the deployed position.

In another more limited aspect, the battery adaptor further includes a locking plate configured to engage a distal end of the first external battery pack and a distal end of the second external battery pack and secure the first and second external battery packs in the respective deployed position.

In another more limited aspect, the battery adaptor further includes a tether cord securing the locking plate to the housing.

In another more limited aspect, the battery adaptor further includes one or more battery engagement features configured to retain the first and second external battery packs in the deployed position when the first and second external battery packs are attached to the respective first and second battery interface members.

In another more limited aspect, the one or more engagement features include one or both of first and second upstanding tabs disposed on opposing transverse sides of the locking plate and configured to engage a surface of the first and second external battery packs, respectively, when the first and second external battery packs are attached to the respective first and second battery interface members and in the deployed position; and one or more upstanding lugs having a dual dovetail cross-sectional shape and configured to simultaneously engage a pair of dovetail channels disposed on the first and second external battery packs when the first and second external battery packs are attached to the respective first and second battery interface members and in the deployed position.

In another more limited aspect, a battery adaptor in combination with first and second external battery packs is provided.

In a further aspect, a method of mounting first and second external battery packs to a weapon includes attaching a battery adapter to an accessory rail associated with the weapon, wherein the battery adapter includes a housing having a first side and a second side transversely spaced apart from the first side; a first axially extending side wall disposed on the first side, a second axially extending side wall disposed on the second side, and an axially extending channel disposed intermediate the first and second side walls, the axially extending channel having a cross-sectional profile configured to physically and electrically mate with a portion of a weapon accessory mounting rail; a first battery pack interface member hingedly coupled to the first side and a second battery pack interface member hingedly coupled to the housing side, the first battery pack interface member configured to physically and electrically mate with the first external battery pack and the second external battery pack interface member configured to physically and electrically mate with the second external battery pack; and each of the first battery pack interface member and the second battery pack interface member being pivotal between a first functional orientation configured to rotate the first external battery pack and the second external battery pack, respectively, between a deployed position configured for normal operation of the first external battery pack and the second external battery pack, respectively, and an accessible position configured for attachment and detachment of the first external battery pack and the second external battery pack, respectively. The first external battery pack is attached to the first battery pack interface member and the second external battery pack is attached to the second battery pack interface member.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Reference will now be made in detail to presently preferred embodiments of the invention, one or more examples of which are illustrated in the accompanying drawings. Each example is provided by way of explanation of the invention, not limitation of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present inventive concept in virtually any appropriately detailed structure. Further, the terms and phrases used herein are not intended to be limiting but rather to provide an understandable description of the present development. In fact, it will be apparent to those skilled in the art that modifications and variations can be made in the present invention without departing from the scope or spirit thereof. For instance, features illustrated or described as part of one embodiment may be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

The terms “a” or “an,” as used herein, are defined as one or more than one. The term “another,” as used herein, is defined as at least a second or more. The terms “including” and/or “having” as used herein, are defined as comprising (i.e., open transition). The term “coupled” or “operatively coupled,” as used herein, is defined as indirectly or directly connected.

As used in this application, the terms “front,” “rear,” “upper,” “lower,” “upwardly,” “downwardly,” “left,” “right,” and other orientation descriptors are intended to facilitate the description of the exemplary embodiment(s) of the present invention, and are not intended to limit the structure thereof to any particular position or orientation.

Referring now to the drawings,FIGS.1-4illustrate a weapon100having a battery pack adapter104removably attached thereto. The weapon100is illustrated with the upper receiver108, lower receiver112(partial view), a powered accessory rail mounting system120, and a barrel116, wherein the rearward portion of the lower receiver and the buttstock portion of the weapon100have been omitted for ease of illustration. Exemplary accessory devices124a(flashlight module) and124b(reflex sighting system) are coupled to the rail mounting system120and are in electrical communication with the adapter104via conductive circuit elements in the rail mounting system120.

In the illustrated embodiment, the adapter104is configured for attachment to a FUSION™ system available from Wilcox Industries Corp. of Newington, NH. In certain embodiments, the rail mounting system120may be as shown and described in commonly owned U.S. Pat. No. 10,969,202 issued Apr. 6, 2021, the entire contents of which are incorporated herein by reference in its entirety. In certain embodiments, the adapter104may be configured for coupling to other powered accessory rail systems as are known in the art, including powered Picatinny (MIL-STD-1913 or STANAG 2324) type rail systems, such as the powered rail system120aappearing inFIG.21or the powered rail system120bappearing inFIG.22. In certain embodiments, the powered rail system120amay be as shown and described in commonly owned U.S. Pat. No. 10,557,687 issued Feb. 11, 2020. In certain embodiments, the powered rail system120amay be as shown and described in commonly owned U.S. Pat. No. 10,557,687 issued Feb. 11, 2020, which is incorporated herein by reference in its entirety. In certain embodiments, the powered rail system120bmay be as shown and described in commonly owned U.S. Pat. No. 8,091,265 issued Jan. 10, 2012, which is incorporated herein by reference in its entirety.

Referring now toFIGS.5-9, and with continued reference toFIGS.1-4, the adapter104includes a center rail receiving module128having a housing which defines axially-extending side walls132on opposing sides of an axially-extending channel136, the channel136having a cross-sectional profile configured to receive a portion of the mounting rail120. Left and right side battery pack interface members138are hingedly attached to the center portion128. Each battery pack interface member138is configured to detachably receive a battery pack140. The center rail receiving portion128includes left and right center hinge knuckles144, where each knuckle144is disposed intermediate front and rear hinge knuckles148,152on the left and right battery pack interface members138, respectively. Each of the left and right hinges pivot about internal front and rear pivot pins156f,156rand pivot around a respective pivot axis160. In the preferred embodiments, the battery packs140are Small Tactical Universal Batteries (STUB). In embodiments, the battery pack140has a twist lock interface. To attach a battery, when the interface member138is in the accessible position, the battery pack140is aligned at a generally right angle with respect to the axial direction of the interface member138and rotated about 90 degrees as indicated by the arrow145appearing inFIG.7. To remove the battery pack140, the process is reversed, wherein once the battery pack is pivoted to the accessible or removal position, the user rotated the battery pack140about 90 degrees and pulls to remove.

Left and right torsion springs164bias the left and right side battery pack interface members138, respectively, toward the outwardly pivoted position (seeFIG.7), sometimes referred to herein as the accessible position or removal position. To secure the battery packs in the locked position, sometimes referred to herein as the deployed position, the user manually pivots the battery packs140to the inwardly pivoted position against the urging of the torsion springs164.

Referring now toFIGS.10and11, and with continued reference toFIGS.1-9, the battery pack interface members138are secured in the inwardly pivoted position via lock levers168. The lock levers168are slidable in the transverse direction in relation to the central member128as indicated by the arrows172(seeFIG.7). A spring or other resiliently compressible member176is disposed intermediate the lock levers168to urge the lock levers168outwardly, away from each other. In certain embodiments, the lock levers168may include indicia170(seeFIG.25), such as the letter “R” indicating the release function.

The lock levers168each include a latching portion180which is removably received within a recess or catch184on the respective battery pack interface member138. The battery pack interface members138likewise each include a latching portion188which is removably received within a recess or catch192on the lock levers168. In this manner, the lock levers168interlock with the battery pack interface member138to secure the battery pack interface member138in the downward pivoted position.

To move the battery pack interface member138to the outward pivoted position, e.g., to remove, attach, or exchange a battery pack140, the lock lever168is depressed inwardly, against the urging of the spring member176until the latch portion188disengages catch192and the latch180disengages the catch184, whereby the battery pack interface member138is pivoted outwardly by the torsion spring164. To move the battery pack interface member138to the locked, inward pivoted position from the outward pivoted position, e.g., after a battery pack140has been attached, the battery pack interface member138is manually pivoted to the inward pivoted position until the lock lever168reengages the battery pack interface member138. As the battery pack interface member138is manually pivoted to the inward pivoted position, a ramped or inclined surface196on the latch portion180slides past a ramped or inclined surface200on the latch member188to facilitate the latch members180,188moving past each other during pivoting movement between the outwardly and inwardly pivoted positions.

As best seen inFIG.12, and with continued reference toFIGS.1-11, the mechanical connection between the adapter104and the accessory rail120is via threaded fasteners (not shown) which engage openings204in the base of the channel136and engaging complementary threaded openings (not shown) on the rail120. The electrical connection between the adapter104and the accessory rail120is via a male multi-pin connector208which engages a complementary female multi-pin connector (not shown) on the rail120. In certain embodiments, the multi-pin connector208includes pins for power and ground. In certain embodiments, the multi-pin connector208additionally includes pins for data and control signals as well as ground, drain, and so forth.

Referring now toFIGS.13-16, and with continued reference toFIGS.1-12, battery pack interface member138includes a bayonet type mount212including a center post216extending from a surface218and opposing ears220. The ears220extend from the post216to define a retention groove224between each of the ears220and the surface218. A center terminal228on the bayonet mount assembly212is aligned with a center terminal232on the battery pack140, which includes terminals236that are electrically coupled to terminals on the multi-pin connector208. The terminals236are electrically coupled to terminals240on the battery pack140when the battery pack140is coupled to the battery pack interface member138.

Referring now toFIG.17, and with continued reference toFIGS.1-16, there is shown the center rail receiving portion128, with the hinge interface members138and center channel circuit board cover plate272removed for ease of exposition. Left and right manually actuatable battery selector buttons276L,276R are disposed on the center rail receiving portion. The battery selector buttons276L,276R are disposed over respective switches280on a circuit board282disposed within a circuit board cavity or receptacle278in the center module128. In embodiments, the switches280are normally open, momentary contact switches. When the right selector button276R is depressed, the battery pack center module128electrically couples the right battery pack140to the powered rail120. When the left selector button276L is depressed, the center module128electrically couples the left battery pack140to the powered rail120.

In embodiments, switching is performed via control logic implemented on the circuit board284. In embodiments, the control logic is implemented in a computer-based processing unit, such as a microprocessor or microcontroller having an associated memory and a program of instructions executable by the computer based processing unit. In embodiments, the processing unit is a programmable logic device (PLD), field programmable gate array (FPGA), field programmable object array (FPOA), or the like wherein configuration data for the logic functions is loaded from an external memory device such as a non-volatile memory device.

In operation, the user may use one of the battery packs140until it is depleted or nearly depleted and then use the selector switch276L,276R as appropriate to switch the electrical connection to the other one of the battery packs140. In certain embodiments, the selector buttons276L,276R may include indicia270such as “L” and “R,” respectively, to designate the left and right battery packs, or alternately “B1” and “B2” to designate first and second battery packs.

In embodiments, the selector buttons276L,276R allow switching between the left and right battery packs140without interruption to the power being supplied to the powered rail120. The circuitry on the circuit board282routing the power includes one or more capacitors286for storing electrical energy to act as a temporary power supply for brief periods to ensure that power to the connector208and thus to the rail system120is not interrupted when switching between battery packs, whether manually or automatically, or when a battery pack is removed and replaced.

This is particularly advantageous when an attached accessory device attached to the powered rail120is processor-based device which requires rebooting after power is lost or cycled and/or a networked device which requires reconnection to an associated network when power is lost or cycled, which processes can sometimes take several minutes to complete. In addition, in some processor-based devices, an abrupt loss of power may cause data loss, file corruption, or hardware failure. Each battery pack140is individually swappable such that when one battery pack140is depleted it can be changed without affecting operation of the devices being powered. In operation, when one of the battery packs140is depleted, the user then depresses the selector for the battery pack140that is fully charged. The depleted battery pack140can then be removed from the center module128.

In embodiments, control logic is provided on the circuit board284to switch automatically between the left and right battery packs140under preprogrammed control. For example, in certain embodiments, programmed control logic on the circuit board284is configured to automatically determine which battery140is operational, wherein the left and right selector buttons276L,276R are used to manually override the preprogrammed control logic. In certain embodiments, control logic is provided on the circuit board284to automatically switch from one battery to the other under preprogrammed control when the currently operational battery is depleted, or when the state of charge fall below some threshold value, without the need for the user to manually switch from one battery to the other using the buttons276L,276R. In certain embodiments, power switching from one battery source to the other is performed by an electromagnetic device such as a relay or a semiconductor device such as a transistor (e.g., a metal-oxide-semiconductor field-effect transistor (MOSFET) in combination with voltage detection circuits, such that when the voltage of one battery pack drops below a predetermined level, the semiconductor device automatically switch the power source to the other battery pack. In certain embodiments, the battery packs include so-called smart battery features such as built in circuitry that outputs information about their state of charge to the control logic within the battery pack adapter104. In embodiments, automatic switching of the battery packs is performed responsive to battery charge state or other parameter such as battery temperature communicated from the battery pack to the battery pack adapter104.

Referring now toFIGS.18-20, and with continued reference toFIGS.1-17, the battery packs140each comprise an interface including a center terminal232. The center terminal232includes an elastomeric sealing ring244for sealing between the terminal232and the housing of the battery pack140. The terminal232includes a USB-C charging port248, power and control signal terminals240, and state of charge indicia252.

Tabs256are disposed at opposing ends of the battery pack140on an interface surface258thereof, and are supported on respective posts or bosses260to define a peripheral retention channel264between the tabs256and the interface surface258. The tabs256include bayonet or align and twist type retention elements268for attachment of the battery pack140to the adapter surface218via twisting movement of the battery pack140relative to the STUB adapter interface surface218, as indicated by the rotation directional arrows inFIGS.7and9.

In the illustrated embodiment, the batteries140are secured together at their distal ends with a locking plate288. The locking plate288includes a base member292and opposing tabs296disposed on the left and right peripheral edges of the base292. The batteries140are supported on the bottom by the base292and the lateral sides by the tabs296. In certain embodiments, the opposing tabs296are configured to resiliently engage complementary recesses297disposed on the outward facing side of the battery packs140. In this manner, the tabs296and recesses297provide a detent mechanism resisting removal of the base plate292when it is secured to a pair of attached battery packs140. Alternately, the opposing tabs296are configured to secure the locking plate288to the battery packs140via a friction fit or press fit. The upstanding tabs296also resist pivoting movement from the deployed position to the accessible position. In operation, the locking plate288is removed prior to depressing the battery unlocking lever168.

In embodiments, locking lugs300extend upwardly from the base262and have a generally hourglass or dual dovetail shaped cross-sectional shape that is complementary with aligned and facing dovetail channels304(seeFIG.9) formed in the housing of the battery packs140. The dual dovetail shaped lugs300keep the two battery packs140aligned and also resist pivoting movement from the deployed position to the accessible position.

A first tether cord attachment member308is disposed on a front edge of the plate288and includes an opening312. A second tether cord attachment member320is disposed on a front edge of the center module128and includes an opening324(seeFIGS.14and15). A tether316forming a loop of flexible cord, wire, or the like passes through the openings316and324to tether the locking plate288to the center module128.

Referring now toFIGS.23-25and with continued reference toFIGS.1-21,FIG.23is an isometric view of the left side hinge assembly, with the right side being a mirror image thereof. The center hinge knuckle144on the center module128is disposed intermediate the spaced apart hinge knuckles148,152on the battery interface member138. The front hinge pin156fpasses through a bore328formed in the knuckle148along the pivot axis160and is received within an axial bore332fin the knuckle144. The hinge pin156fhas an enlarged diameter head336, which is received with a counterbore340on the knuckle148. A cross pin344passes through openings348in the knuckle148and an aligned opening352in the hinge pin156fto retain the pin156f. Elastomeric O-rings356a,356b, and356care received within annular grooves360a,360b, and360con the pin156fto seal against entry of moisture and contamination into the central module128via the bore328. In embodiments, the O-ring356calso provides increased friction to slow or control pivoting movement of the hinged interface member138, e.g., when the member138is unlocked and pivots outward at the urging of the torsion spring164.

The rear hinge pin156rpasses through a bore364formed in the knuckle152along the pivot axis160and is received within an axial bore332rin the knuckle144. The hinge pin156rhas an enlarged diameter head368, which is received with a counterbore372on the knuckle144. A cross pin344passes through openings376in the knuckle148and an aligned opening380in the hinge pin156rto retain the pin156r. An elastomeric O-ring384is received within an annular groove388on the pin156rto seal against entry of moisture and contamination into the central module128via the bore364. In embodiments, the O-ring384also provides increased friction to slow or control pivoting movement of the hinged interface member138, e.g., when the member138is unlocked and pivots outward at the urging of the torsion spring164.

As best seen inFIG.25, the hinge pin156fis hollow and defines an axial passageway392which is open at a distal end396of the pin156f. The shaft of the pin156falso includes an opening400which provides a passageway to electrical contacts236on the hinged battery pack interface member138. In this manner, circuitry may pass through the pin156fto electrically couple the circuit board284and switch280electronics in the center module128to the contacts236on the battery pack interface member138as indicated by the arrows.