Patent Publication Number: US-10326220-B1

Title: Magnetically attached electrical connection for a portable device

Description:
CROSS-REFERENCE 
     The current application is a continuation-in-part of U.S. patent application Ser. No. 14/959,976 filed on Dec. 4, 2015 and which claims the benefit of the filing date of U.S. Provisional Application No. 62/088,048 having a filing date of Dec. 5, 2014, the entire contents of both of which are incorporated herein by reference. 
    
    
     FIELD 
     The present disclosure relates generally to electrical interconnects. More specifically, the present disclosure relates to electrical interconnects for portable electronic devices that allow for recharging and or/directly powering the device. 
     BACKGROUND 
     Portable electronic devices which contain embedded batteries and which require large amounts of electrical energy typically require frequent recharging. This is especially evident in devices that are specifically designed to be compact, which reduces the size available for battery storage. 
     One example of high power compact portable electronic devices are vaporizers. Portable vaporizers are currently utilized to extract the active ingredients of herbs for inhalation. Users of such vaporizers often prefer the devices to be extremely compact. In this regard, users tend to prefer vaporizers having small form factors similar in size to pens or electronic cigarettes. However, due to the high temperatures required to vaporize herbs, significant amounts of electrical power are required. Along these lines, some prior art battery powered vaporizers are effective for only a small number of uses per charge. 
     To provide continued use, such devices sometimes feature external electrical connections to allow for battery charging and/or device operation from an external power source. 
     SUMMARY 
     The present inventors have recognized that electronic devices with narrow cylindrical form-factors have space and geometrical constraints that drastically limit design flexibility with regards to providing an electrical interface. The presented inventions solve this problem through use of a unique magnetic attachment mechanism. 
     The presented inventions are directed to electrical connection mechanisms for battery operated devices. In one non-limiting arrangement, the device is a portable herbal vaporizer that has the outward appearance of a common ink pen. However, the invention directly applies to any electronic device which is cylindrical, incorporates a pushbutton switch, and requires a means for attachment with an external electrical connection. 
     In one aspect, an electrical connection mechanism is provided that is a sleeve assembly having an aperture and at least two partially concentric terminals. The aperture of the assembly is configured for disposition about a depressible switch or actuator of the device and is maintained in contact with a surface of the device by means of a magnet. Such a magnet may be located in the sleeve assembly or in the device. In any arrangement, the magnet couples to a ferromagnetic surface. The sleeve assembly contains two electrically isolated terminals and, when attached about the actuator of the device, one of the terminals is electrically connected to the push button or actuator while the other terminal is electrically connected to a surface about the base of the push button or actuator. In this regard, two electrical connections may be provided through an end surface of a device having a narrow cylindrical form-factor with space and geometrical constraints. 
     In one arrangement, the assembly includes an inner sleeve and an outer sleeve. In such an arrangement, the inner sleeve generally defines the aperture that is configured to fit about the actuator. The inner sleeve is at least partially received within an interior of the outer sleeve such that these elements are at least partially concentric. In one arrangement, the aperture of the inner sleeve is oblong and/or non-aligned with a centerline axis of the actuator. Such an arrangement allows for tilting of the connection mechanism relative to the device thereby facilitating its removal. 
     Various electrical isolators may be disposed between the sleeves. Such electrical isolators may be individual components. In another arrangement, the electrical isolators may be a resin (e.g., thermoplastic, etc.) that is injected into the assembly during manufacture. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1A  is a perspective view of one embodiment of a vaporizer. 
         FIG. 1B  is an exploded perspective view of the vaporizer of  FIG. 1A . 
         FIG. 1C  is cross-sectional perspective view of a forward portion of the vaporizer of  FIG. 1A . 
         FIG. 1D  is cross-sectional perspective view of a rearward portion of the vaporizer of  FIG. 1A . 
         FIG. 2A  illustrates an electrical connection mechanism in a detached state. 
         FIG. 2B  illustrates the electrical connection mechanism connected to a portable electronic device. 
         FIG. 2C  is a cross-sectional view of the connection mechanism connected to the portable electronic device. 
         FIG. 3A-3D  illustrate another embodiment of a connection mechanism. 
         FIGS. 4A-4C  illustrate individual components of the connection mechanism of  FIGS. 3D-3D . 
         FIG. 5A  illustrates an electrical connection of an outer sleeve of the connection mechanism to an electrical conductor. 
         FIG. 5B  illustrates an electrical connection of an inner sleeve of the connection mechanism to an electrical conductor. 
         FIGS. 6A-6C  illustrates an injection molding process for connecting and electrically isolating components of the connection mechanism. 
     
    
    
     DETAILED DESCRIPTION 
     Reference will now be made to the accompanying drawings, which at least assist in illustrating the various pertinent features of the presented inventions. The following description is presented for purposes of illustration and description and is not intended to limit the inventions to the forms disclosed herein. Consequently, variations and modifications commensurate with the following teachings, and skill and knowledge of the relevant art, are within the scope of the presented inventions. The embodiments described herein are further intended to explain the best modes known of practicing the inventions and to enable others skilled in the art to utilize the inventions in such, or other embodiments and with various modifications required by the particular application(s) or use(s) of the presented inventions. 
     The present disclosure is directed to an electrical connection mechanism for a battery operated device. In one specific embodiment, the electrical connection mechanism is utilized with a portable herbal vaporizer that has the outward appearance of a common ink pen. However, the invention directly applies to any electronic device which is cylindrical, incorporates a pushbutton switch, and requires a means of attachment to an external electrical connection. Rechargeable flashlights, laser-pointers, or active styli are product examples to which this invention is well-suited. For purposes of the present disclosure, a portable electronic device is initially discussed followed by a discussion of the connection mechanism as configured for use with the portable electronic device. 
     Portable Electronic Device 
       FIG. 1A  illustrates a perspective of a portable vaporizer  10  for extracting active ingredients of herbs for inhalation. The vaporizer  10  is similar in size and form to a fountain pen. As shown, the vaporizer  10  includes a cylindrical body  20  and a mouthpiece  30 . The mouthpiece  30  tapers to an opening  36  that a user utilizes to draw air into the vaporizer via air inlet apertures  22  in the cylindrical body  10 . More specifically, the air is drawn through the interior of the vaporizer  10  where it passes through an internal heating element/heating exchanger, which heats the air to a desired temperature. The heated air passes through an internal herb chamber which holds a supply of herbs, which may be at least partially vaporized. The user draws the resulting vapor through the opening  36  in the mouthpiece. 
       FIG. 1B  illustrates an exploded perspective view of the vaporizer  10  and  FIG. 1C  illustrates a cross-sectional view of an assembled forward portion of the vaporizer  10 . As shown, the mouthpiece  30  is formed of a generally hollow cylindrical section  32  attached to a conical end section  34 . The mouthpiece  30  includes internal threads  33  located near the transition between the cylindrical section  32  and the conical end section  34  as best shown in  FIG. 1C . These internal threads  33  engage external threads  42  located on the forward end of a generally hollow herb chamber  40 . External threads  44  on a rearward end of the herb chamber attach to internal threads  24  on a forward end of the cylindrical body  20 . See  FIG. 1B . In the present embodiment, when the mouthpiece  30  is in threaded engagement with the herb chamber  40 , the cylindrical section  32  of the mouthpiece  30  extends over the herb chamber  40  and abuts with the forward end of the cylindrical body  10 . See  FIG. 1A . 
     Referring again to  FIGS. 1B and 1C , a rearward interior portion of the herb chamber  40  houses a heating element  100 , when the vaporizer  10  is assembled. A forward portion of the herb chamber  40  (i.e., in front of the heating element) provides an open internal space for placement of herbs. The heating element  100  is a convective heating element which heats air drawn into the herb chamber  40  from the air inlet apertures  22  in the cylindrical body. As illustrated, a screen  38  may be disposed within the mouthpiece  30  to prevent any particulate from passing through the device. In a further embodiment another screen (not shown) may be disposed within the herb chamber  40  proximate to the heating element  100 . 
     An air nozzle  50  is positioned against a rearward end of the heating element  100  as best shown in  FIG. 1C . The nozzle  50  extends from a small inlet aperture  51  (See  FIG. 1C ) to a larger exit aperture  52  (see  FIG. 1B ), juxtaposed against the rearward end of the heating element  100  to fluidly connect the inlet apertures  22  to the heating element  100 , when the herb chamber  40  is in threaded connection with the cylindrical body  20 . In the present embedment, external threads  54  on a rearward end of the air nozzle  52  connect with internal threads of a mount  60  having a flange  64  received within the rearward end of the herb chamber  40 . When assembled, the herb chamber  40  compresses a rim  66  of the mount  60  against the bottom of the internal threads  24  of the forward end of the cylindrical body  10 . A rearward surface of the mount  60  supports a forward electronics control circuit or forward circuit board  70 . Connecting wires  102  (e.g., power wires, sensor wires etc.) of the heating element  100  pass through the air nozzle  50  for connection with the forward circuit board  70 . Other connections are possible. 
     The cylindrical body  20  houses a battery  80  in its rearward portion behind the air inlet apertures  22 . See  FIG. 1B . An end cap assembly  90  having external threads  92  engages internal threads (not shown) on a rearward portion of the cylindrical body  20 . When the end cap assembly  90  is in threaded engagement with the cylindrical body  20 , a forward terminal of the battery  80  engages a first electrical contact  82  of the forward circuit board  70  and a second contact  94  of the end cap assembly  90  engages a rearward terminal of the battery  80 . The end cap assembly  90  includes a depressible power button  96  that allows for activating and deactivating the device  10  (i.e., completing an electrical circuit). Additionally, the end cap assembly  90  further includes a temperature adjustment dial  98 , which allows for adjusting the temperature of air passing through the device. In one embodiment, the end cap assembly  90  further includes a rearward circuit board  76  which cooperates with the forward circuit board  70  to control the operation of the vaporizer  10 . See  FIG. 1D . 
     In use, a user removes the mouthpiece  30  from the herb chamber  40 . Herbs are then placed within the forward portion of the herb chamber  40  in front of the heating element  100 . At this time, a user may select a temperature setting using the temperature adjustment dial  98  and to press the power button  96 . The control circuitry then supplies electrical power to the heating element  100 . Once the heating element achieves a desired temperature an indicator light (not shown) is illuminated to indicate that the vaporizer is ready for use. At this time, the user may draw air through the opening  36  in the mouthpiece, which draws air through the inlet apertures  22 , through the nozzle  50 , through the heating element  100  and through herbs within the herb chamber  40 . The user receives vapors through the opening  36 . 
     The high temperatures needed to vaporize active ingredients of the herbs within the herb chamber  40  require significant electrical power. Along these lines, the battery  80  requires periodic recharging. 
     Connection Mechanism 
       FIG. 2A  shows a perspective view of one embodiment of an electrical connection mechanism  110  in an unconnected state while  FIG. 2B  shows the connection mechanism in a connected state. Generally, the connection mechanism  110  is an annular sleeve assembly  120  which attaches to the device  10  by means of a magnet. In the current embodiment, the connection mechanism  110  contains a magnet, while the device  10  incorporates a ferromagnetic material/surface to which the magnet adheres. However, reversing the positions of the magnetic and ferromagnetic materials, replacing the ferromagnetic material with a second permanent magnet, or replacing the permanent magnets with electromagnets serve the same purpose and are within the scope of this invention. In the current embodiment, the sleeve assembly  120  of the mechanism  110  contains two electrically isolated terminals which are, at least partially, concentric. These two terminals electrically contact two mating terminals on the rearward end of the device  10 . The sleeve assembly  120  attaches to the device  10  by sliding the inside periphery of an internal aperture  122  around the push button  96  mounted on the rearward end of the device  10 . The inside periphery of the aperture  122  provides a clearance-fit around the push button  96  allowing normal operation of the push button  96  while the sleeve assembly  120  is attached to the device  10 . 
     In the illustrated embodiment, the sleeve assembly  120  includes an outer sleeve  130  and an inner sleeve  140 . The inner and outer sleeves are substantially concentric and define the electrical terminals of the connection mechanism  110 . See also  FIG. 2C . The space between the sleeves  120 ,  130  houses one or more magnets  170  as well as a multi-conductor electrical cable  160 , which in the present embodiment extends through the outer sleeve  130  at two locations. Conductors of the cable  160  provide power and/or data connection to the sleeve assembly  120 . First and second conductors of the electrical cable  160  electrically connect to the inner and outer sleeves of the sleeve assembly  120 . Any means of connection may be utilized. 
     In the illustrated embodiment, the inner sleeve  140  is formed of first and second annular elements  142   a  and  142   b  (hereafter  142  unless specifically referenced), which are threaded together. As shown, the annular elements  142  are identical except for their orientation. Each of the annular elements  142  has a smooth inside surface that is sized to provide the clearance fit around the push button  96 . In contrast, a portion of the outside surface of each annular element is threaded. The threads of two opposing annular elements are received within a threaded annulus  144 . Each of the annular elements  142  also include an outer rim  146  having a diameter that is greater than the diameter of the threads. 
     The inner sleeve  140  is mounted concentrically to and is electrically isolated from the outer sleeve  130  by means of an insulator  150 . In the present embodiment, the insulator  150  is formed of first and second annular insulators  150   a ,  150   b , which are disposed over the outside surface of the outer rims of the annular members  142 . In this regard, the annular insulators  150   a ,  150   a  each include a recessed surface that fits over a radially outward portion of the outer rim  146  and over a side portion of the outer rim  146 . That is, the annular insulators  150   a ,  150   b  are substantially L-shaped in cross-section. First and second annular magnets  170   a ,  170   b  (hereafter  170  unless specifically referenced) each have a recessed surface that extends over their respective insulator  150 . Like the annular insulators, the annular magnets  170  are substantially L-shaped in cross-section. The outer sleeve  130  is a substantially cylindrical member that is sized to receive the outward periphery of the annular magnets  170 . As shown, the outer rims of the annular elements  142  are operative to compress and maintain the insulators  150  and magnets  170  together and within the outer sleeve  130  when the opposing annular elements are threaded into the threaded annulus  144 . When disposed within the outer sleeve  130 , the peripheral end of the sleeve  130  is substantially planar with the magnet  170 . 
       FIGS. 2B and 2C  show perspective views of the electrical connection mechanism  110  in a connected state. When the inner sleeve/contact  140  is fit about the push button  96 , the magnet  170  magnetically attaches the sleeve assembly  120  to the ferromagnetic end surface  97  of the device  10 . This creates two electrical connections between the connector  110  and the device  10 . Specifically, the peripheral end surface of the outer sleeve  130  directly contacts the end surface  97  of the device housing to form a first electrical connection. The inner sleeve  140 , makes an electrical connection via contact with the push button  96 , which is electrically isolated from the end surface  97  via a bushing  99  as best shown in  FIG. 1D . 
     In the present embodiment, the magnetic attachment of the sleeve assembly  120  to the end surface  97  also slightly depresses the push button  98 . That is, to provide an electrical connection, the push button must be partially depressed to use the electrical connection mechanism  110  to recharge or power the device  10 . To provide such partial depression, the annular member  142  of the inner sleeve  140  includes an annular or partially annular contact  148  that protrudes above (i.e., raised contact) the planar surface of the magnet  170 , when the sleeve assembly  120  is assembled. When magnetically attached to the device  10 , the raised contact  148  contacts the bushing  99  (which in some embodiments may be a machined step of the push button) on the end of the device and slightly depresses the push button  96 , which is spring-loaded. The partial depression of the push button forms the second electrical connection. 
     In the illustrated embodiment, the sleeve assembly  120  is a two-terminal device where two isolated electrical terminals are the inner and outer sleeves  130 ,  140 . However, through the addition of more concentric insulators and circular conductors of differing diameters, it is straightforward to produce a device with an arbitrary number of terminals. 
       FIGS. 3A-3D  illustrate a further embodiment of the connection mechanism  210  in accordance with various aspects of the presented inventions. As shown, the connection mechanism  210  again includes a sleeve assembly having an outer sleeve  230  and inner sleeve  240 , which form first and second electrical connections with a portable electrical device  10 . As shown, this embodiment has a number of differences in relation to the previously described embodiment. For instance, the multi-conductor electrical cable  160  enters the outer sleeve  230  at single location. 
     One primary difference between this embodiment and the previous embodiment is that the aperture  222  of the inner sleeve  240  is not circular. Rather, the inner sleeve  140  has an oblong aperture  222  that allows the sleeve assembly  210  to pivot about the push button  96  as the sleeve assembly  210  is removed from the device  10 . This is best illustrated in  FIGS. 3C and 3D  which illustrate the aperture  222  of the inner sleeve  240  as having opposing angled surfaces  243   a  and  243   b . The inclusion of these angled surfaces prevents binding when removing the sleeve assembly from the device  10 . Stated otherwise, the aperture  222  has a centerline axis that is angled (i.e., non-perpendicular) relative to the planar surface of the magnet  270 . Stated otherwise, a centerline axis of the aperture  222  is nonaligned with a centerline axis of the push button  96 . 
     As will be appreciated, in the present embodiment, the inner sleeve  240  is not formed of first and second annular members, which thread together. Rather, the inner sleeve  240  may be integrally formed (e.g., milled, cast etc.) or may be formed of separate elements that are, for example, in a press fit engagement. Further, in the illustrated embodiment, a single magnet  270  may be utilized. As shown, the single magnet  270  is generally U-shaped. See  FIG. 4C . However, the function of the magnet remains the same. That is, the magnet is adapted to magnetically attach the sleeve assembly  210  to the ferromagnetic end surface  97  of the device  10  in order to make first and second electrical connections. 
     In the illustrated embodiment, the end surface of the outer sleeve  230  again couples to the ferromagnetic end surface  97  of the device  10  to form the first electrical connection. Likewise, the inner sleeve  240  again utilizes a protruding or raised contact  248 , which protrudes above the planar surface of the magnet  270 , to make a second electrical connection. When magnetically attached to the device  10 , the protruding contact  248  contacts the bushing  99  and slightly depresses the pushbutton  96 , which is spring-loaded to form a second electrical connection between the device and the sleeve assembly. As will be appreciated, the embodiment of  FIGS. 3A-3D  also incorporates various insulators to electrically isolate the outer sleeve from the inner sleeve. Accordingly, these insulators are appropriately shaped to provide isolation of the oblong inner sleeve from the outer sleeve. 
       FIGS. 4A, 4B and 4C  illustrate individual components of the second embodiment of the connection mechanism  210 . Specifically,  FIG. 4A  illustrates the outer sleeve  230 ,  FIG. 4B  illustrates the inner sleeve  240 , and  FIG. 4C  illustrates the magnet  270 . As shown in  FIG. 4A , the outer sleeve  230  is generally hollow cylindrical element having an end surface  232  that forms an electrical contact with the device  10  when magnetically coupled thereto. A sidewall of the outer sleeve  230  includes a cabling aperture  234  which provides access to the interior of the outer sleeve  230  for the cable  160 . Disposed within interior of the generally hollow cylindrical outer sleeve  230  is an electrical connection point  236 . In the illustrated embodiment, the electrical connection point  236  is formed as a piercing spike, which allows for creating a compression electrical contact with a conductor of the cable  160 . However, it will be appreciated that the electrical connection point may be differently configured for other connection methods including, for example, soldering. In this regard, the piercing spikes may be omitted. 
       FIG. 4B  illustrates the inner sleeve  240  which is sized for disposition within the outer sleeve  230  while being spaced from the outer sleeve to provide electrical isolation. As shown, the inner sleeve  240  includes the above described oblong aperture  222  as well as the protruding or raised contact  248 . In addition, the inner sleeve  240  includes a second electrical contact point  246 , which is configured for electrical connection with a second conductor of the cable  160 . 
       FIGS. 5A and 5B  illustrate the connection of the conductors  162  and  164  of the cable  162  with the connection points  236  and  246  of the inner and outer sleeves, respectively. As shown in  FIG. 5A , a portion of the cable  160  extends through the cabling aperture  234  of the outer sleeve  230  such that the first and second conductors  162  and  164  are disposed within the interior of the outer sleeve  230 . At such time, the first conductor  162  may be electrically attached to the connection point  236  of the inner sleeve. Likewise, the second conductor  164  may be attached to the connection point  246  of the inner sleeve  240  as shown in  FIG. 5B , which shows the inner sleeve removed from the outer sleeve for purposes of illustration. 
       FIGS. 6A and 6B  illustrate placement of the outer sleeve  230 , inner sleeve  240  and cable  160  within a mold  280  during assembly of the connection mechanism  110 . As shown, the inner and outer sleeves  230 ,  240  are disposed within a lower portion  282  of the mold  280 , which is shaped to receive and hold these sleeve members in a predetermined orientation. The cable  160  is then disposed through the cabling aperture  234  of the outer sleeve  230  such that the conductors  162 ,  164  may be attached to their appropriate connection points. See  FIG. 6A . At this time, the magnet  270  is disposed within the sidewall of the outer sleeve  230  and about an outer sidewall of the inner sleeve  240  (See  FIG. 6B ) such that an upper mold portion  284  may be fit to the lower mold portion  282  encapsulating the sleeves, cable and magnet therein. See  FIG. 6C . A resin (e.g., thermoplastic) is then injected into voids within the mold to form an isolator between the inner and outer sleeves  230 ,  240 . In addition, injection of the resin fixedly secures these elements in their final configuration. 
     In the embodiment illustrated in  FIGS. 6A-6C , upper and lower portions of the mold  280  are also configured to define a strain reliever  166  on an exterior of the cable  160 . See also  FIGS. 3A and 3B . That is, during the resin injection process, a strain reliever is molded about the cable  160  where it extends from the outer sleeve  240 . The inclusion of the strain reliever  166 , in conjunction with the oblong aperture  222  significantly reduces the stresses applied to the cable  160  and its connections with the sleeves when the connection assembly  210  is removed from the device. See  FIG. 3D . In this regard, a user may remove the assembly  210  by pulling on the cable  160  without concern of physically damaging the connection assembly. 
     The foregoing description has been presented for purposes of illustration and description. Furthermore, the description is not intended to limit the inventions and/or aspects of the inventions to the forms disclosed herein. Consequently, variations and modifications commensurate with the above teachings, and skill and knowledge of the relevant art, are within the scope of the presented inventions. The embodiments described hereinabove are further intended to explain best modes known of practicing the inventions and to enable others skilled in the art to utilize the inventions in such, or other embodiments and with various modifications required by the particular application(s) or use(s) of the presented inventions. It is intended that the appended claims be construed to include alternative embodiments to the extent permitted by the prior art.