Abstract:
A wireless charging system for power tools and other devices includes a charging module, docking frame, and tool holder. When a device is placed on a charging surface of the charging module, the charging module is configured to wirelessly charge the device. The charging module can be mounted within the docking frame or the tool holder via a mounting interface, and the tool holder can be affixed to a rigid surface. The docking frame can also be attached to a rigid surface, or can be mounted within the tool holder as an intermediate piece. The tool holder is configured to support the charging module such that the charging surface is at an angle. This configuration optimally locates the device relative to the charging module and allows the charging surface to act as a resting surface for the device between operations.

Description:
RELATED APPLICATION 
     This Application claims priority to U.S. Provisional Application No. 62/049,458 filed on Sep. 12, 2014, entitled “Interface and Mounting Structure for a Wireless Charger or Intermediate Piece,” the disclosure of which is incorporated by reference herein in its entirety. Where a definition or use of a term in a reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply. 
    
    
     TECHNICAL FIELD 
     This disclosure relates generally to wireless chargers, and, more particularly, to interfaces between wireless chargers and structures. 
     BACKGROUND 
     A common problem associated with the use of electronic devices and tools is the necessity of powering such electronic devices. Power cords connected to an external power source provide sufficient power, but are an obtrusive and problematic interference, especially with regard to power tools which are desirably easily manipulated in and around workspaces that are often crowded and obstructed, or which are desirably transported between different job sites. 
     Rechargeable cordless tools are a common alternative. Such systems typically include a removable rechargeable battery and a charging station. When depleted, a rechargeable battery can be removed from the tool and inserted into the charging station for charging. U.S. Pat. No. 5,144, 217 describes a cordless tool battery housing and charging system that accommodates a variety of sizes and power charges of different batteries via a controlled wired charging process. Such technologies typically require not only removal of the battery from the tool in order to initiate charging, but also require a wired contact connection between the battery and charging station, which may be susceptible to damage due to, for example, moisture, dirt, or physical damage that prevents the battery from optimally coupling with the charging station. 
     Technology has been developed in an effort to alleviate these concerns via inductive or wireless charging. U.S. Pat. No. 8,482,160 describes a system whereby a plurality of wireless charging modules are placed underneath a workspace in order to inductively charge a secondary tool placed on the workspace in a region of one of the modules. However, such a system is expensive and complex to install, only enables wireless charging at the fixed regions of the modules, does not ensure that a tool is optimally located within a charging region for optimal charging, and is inapplicable to mobile applications. Further, such a system does not provide protection against a tool being unintentionally jostled and relocated during charging. For instance, a user might place a tool near a charging module with the expectation that the tool will charge. The user might then continue work with another device or tool, and in so doing, unintentionally move the tool away from the module, such that when the user again wishes to use the tool, it has not been charged as desired. Other conventional wireless chargers resemble pads, and are similarly unsecured. 
     Other types of wireless charging devices have also been developed for charging tools and other devices, and typically resemble a pad on which a device is rested to initiate charging. However, such chargers present undesirable use cases when used as a tool resting surface since they are not secured to a supporting surface, nor do they secure the tool itself from unintended motion or vibration. 
     In one such undesirable use case, a user is operating a power drill powered by a rechargeable battery. When the battery becomes depleted, the drill becomes inoperable. In order to resume work, the user can, for example, replace the depleted battery with a charged replacement battery, or place the battery and/or tool onto a charging station and wait for the battery to recharge. Replacing the battery requires the user to obtain, store, and maintain charging for multiple batteries, which increases the expense and complexity of operating the drill, and waiting for the battery to recharge can necessitate delays in workflow before the user can resume drilling. 
     Additionally, conventional wireless charging stations do not guide an optimal location of the battery/tool for optimized charging, and do not secure the battery/tool in place. As a result, the battery/tool that is not optimally placed on a wireless charging station may charge slower or may fail to completely charge. Even if optimally placed, the battery/tool may become dislodged or moved due to inadvertent contact from the user, another tool or object, or other external forces such as vibrations from machinery. In another example, a charging station is positioned in a vehicle, and a battery/tool is placed thereon for charging. During transport, motion from the vehicle can jostle the battery/tool out of position and hinder or prevent charging. These types of impacts, jostling, and vibrations can also result in damage to the battery/tool when the battery/tool is unsecured. 
     Therefore, what is needed is a way of charging a battery of a tool without interrupting its use or obstructing a workspace with cords or a charging station in such a way that optimally positions the tool for charging and protects against unintentional interruption of charging of the tool. 
     SUMMARY 
     The following is a brief summary of subject matter described in greater detail herein. This summary is not intended to be limiting as to the scope of this disclosure or to the claims. 
     A wireless charging module for a wireless charging system includes a charging surface. When a device is placed on the charging surface, the charging module is configured to wirelessly charge the device. 
     A docking frame can be used to support the charging module and/or the device. The charging module further includes a mounting interface that can be received by a receiving interface of the docking frame in order to mount the charging module within the docking frame. The docking frame can also include a guiding structure to guide the device into an optimal location on the charging surface for wireless charging. A bottom surface of the docking frame can be affixed to a rigid surface in order to provide a fixed support for the device. The docking frame can also be mounted within a tool holder, whereby a further mounting interface of the docking frame is configured to be received by a further receiving interface of the tool holder. The charging module can also be directly mounted within the tool holder. 
     The tool holder has a base surface, a receiving portion that includes the further receiving interface, and a tool holding portion. In addition to being configured to receive the docking frame, the further receiving interface can also be configured to directly receive the charging module. The further receiving interface is oriented at an angle relative to the base surface. This configuration allows the docking frame and/or charging module to by urged by gravity into the receiving portion of the tool holder, and causes the charging surface of the charging module to be oriented at said angle relative to the base surface. The base surface can be affixed to a rigid and substantially horizontal surface, and a side of the tool holder can be affixed to a rigid and substantially vertical surface. The tool holding portion is configured to at least partially support a device disposed on the charging surface, and is positioned to allow the device to be urged by gravity into the tool holder portion due to the angled orientation of the charging surface of the charging module. 
     The above presents a simplified summary of this disclosure in order to provide a basic understanding of some aspects of the technologies disclosed herein, and is not an extensive or complete overview of such topics. As such, the summary above does not delineate the scope of this disclosure, and is not intended to identify key or critical aspects of the disclosure. Further details are provided by the detailed description, the claims, and the drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a side view of a wireless charging module according to this disclosure. 
         FIG. 2  is a perspective view of the wireless charging module of  FIG. 1 . 
         FIG. 3  is a side view of a docking frame according to this disclosure. 
         FIG. 4  is a perspective view of the docking frame of  FIG. 3 . 
         FIG. 5  is a perspective image of a tool with a removable battery resting on a charging surface of a charging module docked in a docking frame according to this disclosure. 
         FIG. 6  is a side cross section view of an exemplary embodiment of a tool holder according to this disclosure. 
         FIG. 7  is a side view of an exemplary embodiment of a wireless charging system according to this disclosure that includes the tool holder of  FIG. 6 . 
         FIG. 8  is a perspective view of a docking frame of  FIG. 7 . 
         FIG. 9  is a side view of another exemplary embodiment of a wireless charging system according to this disclosure that includes the tool holder of  FIG. 6 . 
         FIG. 10  is a perspective view of an exemplary embodiment of a docking frame with a couple roller interface according to this disclosure. 
         FIG. 11  is a side view of an exemplary embodiment of a couple roller-type interface for a tool holder according to this disclosure. 
         FIG. 12  is a perspective view of a snap-type interface according to this disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     For the purposes of promoting an understanding of the principles of the embodiments described herein, reference is now made to the drawings and descriptions in the following written specification. No limitation to the scope of the subject matter is intended by the references. This disclosure also includes any alterations and modifications to the illustrated embodiments and includes further applications of the principles of the described embodiments as would normally occur to one of ordinary skill in the art to which this document pertains. 
       FIG. 1  depicts a side view and  FIG. 2  illustrates a perspective view of a wireless charging module  100  according to this disclosure. The wireless charging module  100  defines a charging surface  102 , and includes an induction charging coil  103 , a mounting interface  104 , and a plurality of feet  108 . 
     The charging surface  102  is formed by a top surface of the charging module. The induction charging coil  103  is disposed within the charging module  100 , and is configured to inductively charge a rechargeable battery placed on or near a charging surface  102 . Acceptable wireless inductive battery charging devices are described in U.S. Pat. No. 5,959,433, WO2014/096052, WO2014/096037, and WO2014/096048. Other types of conventional inductive charging systems are also contemplated. For example, the wireless charging module  100  supports Q 1  inductive charging, or the like. 
     The mounting interface  104  is disposed on the lateral sides of the charging module  100 , and is configured to removably mount the charging module  100  within another structure, such as a docking frame or tool holder as discussed below, to enable rigid support of the charging module  100  on a surface, wall, tool box, vehicle, cart, work surface, or the like. As illustrated in  FIG. 2 , in this embodiment the mounting interface  104  includes a rail  106  configured to removably mate with a receiving interface of the other structure. In other embodiments, the mounting interface  104  can include one or more of, for example, a rail, a snap structure, a roller, or other removable mounting structures. 
     The plurality of feet  108  are disposed on a bottom of the charging module  100  opposite the charging surface  102 , and are configured to provide at least partial damping and/or restraint against motion. For example, the plurality of feet  108  can provide at least partial damping relative to the other structure housing the charging module  100 , or can provide at least partial damping when the charging module  100  is not mounted in another structure and is resting directly on an unsecured surface. The feet  108  can include rubber footing, grips, or other structure configured to arrest motion or provide damping. In another embodiment, the mounting interface  104  includes a damping material configured to provide at least partial damping between the charging module  100  and the other structure. 
     The charging module  100  can be used to charge a removable battery that is not connected to a tool and is placed on the charging surface  102 , or can be used to charge a battery configured to remain within a tool during charging. In some cases, a battery within a tool may be spaced apart from a bottom surface of the tool. Thus, the optimal position for a battery for wireless charging via the induction charging coil  103  may be on or near the charging surface  102 , or at a distance spaced apart from the charging surface  102 . In an embodiment, the charging module  100  is configured to adjust the optimal charging location based on the tool or device placed on the charging surface  102 . 
     The charging module  100  is usable to charge a variety of sizes and powers of batteries. For example, the battery can include a Lithium ion battery, a Lithium air battery, a Lithium metal battery, a Lithium sulfur battery, or a metal-air battery. The charging module  100  can also be used to charge multiple batteries or multiple tools at once 
     In an embodiment, the charging module  100 , in addition to being configured to transfer energy to charge the tool and/or battery, is further configured to transfer energy to charge at least one non-power tool device such as, for example, a battery tester, a vehicle diagnostic system, a wireless device, a wearable device, a mobile device, or a device for a vehicle. 
     Because the induction charging coil  103  enables wireless charging, the charging module  100  does not need a physical contact point for electrically connecting the battery/tool to the charging module. In conventional chargers, contact points can become obstructed by debris, or can be damaged such as by wear or impact, which can negatively impact the performance of the charger. Many types of contact points also require that the battery or tool is removably coupled to the charger, which necessitates a decoupling action before the battery/tool can be removed. By eliminating contact points, the charging module  100  not only removes the risk of debris or impact affecting the performance of charging a battery, but also enables maintaining a tool in an always-ready condition where the tool is easily removable from the charging module  100  without requiring any detachment or decoupling. 
     The charging surface  102  of the charging module  100  can be used as a resting surface on which the tool may be placed when not in active use. In an exemplary use case, a user performing a repetitive drilling operation iterates between operating a power drill with a rechargeable battery, and inserting a member into a hole resulting from the drilling operation. When using a conventional rechargeable drill, the battery is continually drained during operation, and continues to drain or at best holds steady when not in use. According to this disclosure, when inserting the member into the hole, the user can place the drill on the charging surface  102  of the charging module  100 , and then the user can retrieve the drill for the subsequent drilling operation. In this way, the battery of the drill is at least partially recharged each time it is set aside while the user inserts a member. Because placing and removing the drill on the charging surface  102  does not require a coupling or uncoupling action, the drill can be placed and recovered without interruption to the user&#39;s workflow. Additionally, because the drill is charged whenever it is resting on the charging surface  102 , the time over which the drill can be operated without stopping to recharge or replace the battery is extended relative to conventional charging systems. 
     In one embodiment, the charging module  100  further includes an electric plug (not shown) configured to connect the charging module  100  to an electrical power source, such as a wall socket, car power outlet, power converter, etc. In an embodiment, the charging module also includes a charging control unit (not shown) that is configured to operate the induction charging coil  103  to control a charging operation. Such a charging control unit can include a wireless communication device for communicating with, for example, a battery, a tool, a mobile device, or the like such as an RF antenna, near field communication (NFC), WiFi, Bluetooth, or the like. For example, the charging control unit can be configured to communicate with the battery and/or the tool to charge the battery based at least in part upon a charge level and/or state of the battery. 
     As discussed above, mounting the charging module  100  on another structure can be beneficial for securing the battery/tool during charging or between periods of use.  FIG. 3  illustrates a cross section view and  FIG. 4  illustrates a perspective view of an exemplary docking frame  200  for mounting the charging module  100  according to this disclosure. The docking frame  200  includes a receiving interface  202 , an attachment surface  204 , and a guiding structure  206 , and also defines a receiving region  208  for receiving the charging module  100  and a stop surface  210  that together with the attachment surface  204  and the receiving interface  202  delimits the receiving region  208 . 
     The attachment surface  204  forms a base of the docking frame  200 . The receiving interface  202  extends away from the attachment surface  204  from the lateral sides thereof, whereby the receiving region  208  is the region between the lateral sides of the receiving interface  202 . The receiving interface  202  is configured to removably receive the mounting interface  104  of the charging module  100  when the charging module  100  is received in the receiving region  208 . 
     In this embodiment, the geometry of the mounting interface  104  and the receiving interface  202  are configured to engage with each other. As illustrated in  FIG. 4 , the receiving interface  202  includes a plurality of nubs  202 a that fit into the sliding slot  106  ( FIG. 1 ) of the mounting interface  104 , although in other embodiments, the mounting interface  104  includes nubs and the receiving interface  202  includes a slot. 
     In another embodiment, the receiving interface  202  has a geometry that is at least partially complementary to geometry of the mounting interface  104  of the charging module  100 . For example, one of the receiving interface  202  and the mounting interface  104  can include a protruding rib, and the other can include a rib-shaped recession configured to slidingly receive the rib. Other types of interfaces are also contemplated, including roller interfaces, and snap interfaces, as described in further detail below. 
     The receiving interface  202  can also include a stop member (not shown) configured to limit an extent to which the charging module  100  can be inserted into the docking frame  200 . The stop member can include, for example, a ridge protrusion, a back-wall, a cross-member, and a ridge located the receiving interface  202  configured to delimit motion of the charging module  100  along the direction of the rail  106 . In this embodiment, the stop surface  210  extends perpendicularly to the receiving interface  202  and delimits a front side of the receiving region  208  along the direction of the rail  106 . 
     The attachment surface  204  is configured to be affixed to a rigid support, such as surface of a cart, a vehicle, a workbench, a table, a floor, a scaffold, or the like. The attachment surface  204  defines a plurality of holes  204 a configured to receive a bolt, screw, clip, clamp, or other acceptable attachment member in order enable such attachment. When the docking frame  200  is affixed to a surface via the attachment surface  204 , the docking frame  200  thus provides a secured mounting point for the charging module  100  that resists unintended motion. 
       FIG. 5  is a perspective image of a tool  500  resting on a chagrining surface  102  of a charging module  100  mounted in a docking frame  200 . The guiding structure  206  is configured to guide the tool  500  onto a charging module  100  that is received by docking frame  200 . The guiding structure  206  ensures that the devise is properly located for optimal charging of the battery by the charging module  100 , and can also be configured to at least partially restrain the tool in the docking frame  200  in order to counteract unintended motion or vibration. In an embodiment, the guiding structure  206  has a geometry that is at least partially complementary to a geometry of the tool  500  such that, as the tool  500  is placed on the charging surface, the geometry of the guiding structure  206  engages the geometry of the tool to guide an optimal placement of the tool  500  on the charging surface  102 . 
     Additional restraint of the tool may be desirable. For example, as illustrated in  FIG. 5 , while the guiding structure  206  ensures that a base of tool  500  is properly located, a remainder of the tool  500  may be susceptible to impacts or motion that can damage the tool  500  or tip the tool  500  out of position.  FIG. 6  illustrates a side cross section view of an exemplary embodiment of a tool holder  602  that can be used to mount a charging module and/or a docking frame housing a charging module in order to provide additional support of a tool, as discussed below. The tool holder  602  includes a second receiving interface  606 , a further stop member  610 , and a tool holder portion  611 , and defines an attachment surface  614  that forms a base of the tool holder  602 . 
     The attachment surface  614  is configured to affix the tool holder  602  to a surface such as a desk, table, or the like, similarly to operation of the attachment surface  204  for affixing the docking frame  200  to such a surface. In this embodiment, the tool holder  602  further defines side attachment holes  616  on a surface perpendicular to the base  614  that are configured to mount the tool holder on a wall or side of a structure. 
     In one embodiment, illustrated in  FIG. 7 , the receiving interface  606  is configured to receive a docking frame  600 , whereby the docking frame is configured to house the charging module  100 .  FIG. 8  illustrates a perspective view of the docking frame  600 . 
     In addition to a receiving interface configured to receive a charging module (not shown), the docking frame  600  includes a second mounting interface  604 , and an additional stop member  608 . The second mounting interface  604  of the docking frame  600  is configured to engage with the second receiving interface  606  of the tool holder  602  in a manner similar to the engagement between the mounting interface  104  and receiving interface  202  of the charging module  100  and docking frame  200  ( FIGS. 1 and 3 ). In this embodiment, the second mounting interface  604  includes a protruding rail  618  ( FIG. 8 ) that is configured to be slidingly received in a slot  613  of the second receiving interface  606  ( FIG. 6 ), but other types of mounting interfaces are also contemplated. 
     The second receiving interface  606  is oriented at an angle  612  relative to the base  614  of the tool holder  602  such that the side of the second receiving interface  606  facing away from the further stop member  610  is elevated compared to the opposite side of the second receiving interface  606 . Due to the angle  612 , the docking frame  600 , when mounted via the second receiving interface  606 , is urged by gravity to slide down along the second receiving interface  606  toward the tool holding portion  611 . The further stop member  610  is configured to engage with the additional stop member  608  of the docking frame to delimit a range of motion of the docking frame  600  along the slot  613  into the tool holder  602 . 
     Since the docking frame  600  is oriented at the angle  612 , the charging surface  102  of the charging module  100  is also oriented at the angle  612  when the charging module  100  is mounted in the docking frame  600 . In other words, the charging module  100  is oriented such that the charging surface  102  slopes downward toward the tool holding portion  611 . 
     The tool holder portion  611  extends upwards from a region of the second receiving interface  606  proximate to the further stop member  610 , and is configured to at least partially support the body of a tool disposed on the charging surface  102 . Because the charging surface  102  is oriented at the angle  612 , the tool is urged by gravity into the tool holder portion  611 . The magnitude of the angle  612  is selected to enable a user to insert and remove the tool from the tool holder portion  602  via a swiping motion that results in a bottom surface of the tool sliding against the charging surface  102  so as to clear any debris disposed thereon. The tool holder  611  thus acts as a transverse support for a device resting on the sloped charging surface  102 . 
     In another embodiment, illustrated in  FIG. 9 , the charging module  100  is mounted directly in the tool holder  602 , whereby the second receiving interface  606  is configured to engage directly with the mounting interface  104  of the charging module  100 , and the docking frame  600  can be dispensed with. In this embodiment, the further stop element  610  of the tool holder  602  engages with an end surface of the charging module  100 . By incorporating or dispensing with the docking frame  600 , the tool holder can be selectively configured to accommodate a variety of different charging modules and tools with different dimensions and other attributes. 
     In a further embodiment, the docking frame  600  and/or the tool holder  602  includes a cord guide (not shown) configured to guide a power cord out from the charging module, through the docking frame  600  and/or tool holder  602 , such that the power cord to be connected to a power source is unobstructed by the docking frame  600  and/or tool holder  602 . 
     In addition to the nubs-and-slot and rib-and-slot interfaces discussed above, other types of interfaces between charging modules, docking frames, and tool holders are also contemplated.  FIG. 10  illustrates a perspective view of an exemplary docking frame  900  having a second mounting interface  904  that includes couple rollers  902 , and  FIG. 11  is a side view of an exemplary receiving interface  906  of a tool holder that includes couple rollers  908  configured to engage the couple rollers  902  of the docking frame. The couple rollers  902  and  908  are configured to operate in a similar fashion to drawer slides with rollers. 
     The receiving interface  906  further includes stop members  910  configured such that the docking frame  900  can be slid and dropped into the receiving interface  906  with a single motion, but that removing the docking frame  900  from the tool holder requires both a lifting and pulling motion. An acceptable draw slider assembly is described in U.S. Pat. No. 2,860,929, the disclosure of which is incorporated in its entirety. Other conventional drawer slider assemblies are also contemplated. While  FIGS. 10 and 11  illustrate a drawer slider assembly as applied to the second mounting interface  904  and the second receiving interface  906 , it should be understood that a similar drawer slider interface can also be applied to the mounting interface of the charging module and the receiving interface of a docking frame. 
       FIG. 12  illustrates a perspective view of an exemplary snap fit interface  1100  that can be used between a charging module, docking frame, and/or tool holder according to this disclosure. As illustrated in  FIG. 12 , the interface is formed between a mounting surface  1102  and a receiving surface  1104  configured to receive the mounting surface  1102 . The receiving surface  1104  defines at least one snap receptacle  1106 . The mounting surface  1102  has a complementary geometry to the geometry of the receiving surface  1104 , and defines at least one a snap member  1108  configured to have a snap fit with the at least one snap receptacle  1106  when the mounting surface  1102  is mounted onto the receiving surface  1104 . 
     In one embodiment according to this disclosure, a snap interface  1100  is incorporated into the docking frame  600  and tool holder  602  ( FIG. 7 ). The additional stop member  608  and further stop member  610  are each configured to include one of the mounting surface  1102  and receiving surface  1104 . When the docking frame  600  is inserted into the tool holder  602 , the docking frame  600  may be removably snap coupled to the tool holder  602  via a snap-fitting the additional stop member  608  and further stop member  610  together. 
     In another embodiment, a snap interface  1100  is incorporated into the charging module  100  and docking frame  200  ( FIGS. 1 and 3 ). Each of the bottom surface of the charging module and the attachment surface  204  facing the receiving region  208  is configured to include one of the mounting surface  1102  and the receiving surface  1104 . When the charging module  100  is inserted into the receiving region, the charging module  100  may be removable snap-fitted to the attachment surface  204  by snap-fitting the bottom of the charging module  100  with the attachment surface  204 . Similarly, a bottom surface of the docking frame  600  and an inside surface of the tool holder  602  can each be configured to include one of the mounting surface  1102  and receiving surface  1104 . 
     The snap fit interface  1100  can replace the engagement between the mounting and receiving interfaces of the charging module, docking frame, and tool holder, or can be used to along with such mountings. 
     It is contemplated that different tool holders and docking frames may be configured to be used with different tools, and so to may different charging modules be configured to be used with different batteries and with different docking stations. Thus, in a further embodiment, a plurality of different tool holders are configured to be used with different docking frames and charging modules of different sizes and powers via common interfaces. 
     In an example, a first docking frame is mounted within a tool holder, and houses a first charging module. The first tool holder and the first charging module are configured to work with a first tool. When a second tool is desirably charged, the first docking frame is removed from the tool holder, and a second docking frame housing a second charging module is inserted therein, wherein the second charging module is configured to charge the second tool, and wherein the second docking frame has a mounting interface configured to engage with the receiving interface of the tool holder. In other words, tool holders, docking frames, and charging modules may be mixed and matched as desired due to common mounting and receiving interfaces. 
     It will be appreciated that variants of the above-described and other features and functions, or alternatives thereof, may be desirably combined into many other different systems, applications or methods. Various presently unforeseen or unanticipated alternatives, modifications, variations or improvements may be subsequently made by those skilled in the art that are also intended to be encompassed by the disclosure.