Patent Publication Number: US-2023134050-A1

Title: Receptacle inductive charging devices

Description:
RELATED APPLICATION(S) 
     This application is a continuation of and claims priority to U.S. patent application Ser. No. 15/944,130, filed Apr. 3, 2018, which claims priority to U.S. Provisional Patent Application No. 62/481,382, filed Apr. 4, 2017. The entire contents of the aforementioned applications are hereby incorporated by reference. 
    
    
     FIELD 
     Various exemplary embodiments relate to indoor outlets for inductive charging electronic devices. 
     BACKGROUND 
     Electrical outlet boxes that house power and/or data receptacles are well-known in the industry. Such boxes can stand alone or be recessed within any of a wall, the floor or the ceiling of a room. Conventional electrical outlets have a housing that is connected to a recessed junction box. The housing can include a separate front and back covers that are connected by screws. A mounting strap with flanges at opposite ends generally extends between the front and back covers and allows the housing to be attached to a suitable structure, such as a building wall or a junction box. In some electrical receptacle designs, the mounting strap has a generally U-shape so as to wrap around portions of the front and back covers of the housing. In other electrical receptacle designs, the mounting strap is a relatively flat shape and is disposed between the front and back covers of the housing. 
     Typical wall outlets provide power to electronic devices using a power socket connected to a main power supply. In the United States, standard wall outlets generally provide power via a two or three pronged socket or other alternative socket such as a universal serial bus (USB) port. Portable devices, such as cell phones, tablets, music players, and other personal electronic devices are being configured to be charged not only by typical male/female connectors, but through wireless inductive charging. 
     SUMMARY 
     According to an exemplary embodiment, a wall outlet inductive charger includes a base connected to a set of terminals for receiving power supply conductors. A faceplate is connected to the base. The faceplate includes a charging portion. A device support extends from the faceplate. A charger housing is connected to the base and positioned between the base and the faceplate. A charging pad including an inductive coil is positioned in the charger housing. 
     According to an exemplary embodiment, a wall outlet inductive charger includes a mounting bracket configured to connect to an outlet housing. A base is connected to the mounting bracket and to a set of terminals for receiving power supply conductors. A faceplate is connected to the base. The faceplate includes a charging portion. A device support is connected to the faceplate. A charger housing is connected to the base and positioned between the base and the faceplate. A charging pad includes an inductive coil positioned in the charger housing. 
     According to an exemplary embodiment, a wall outlet inductive charger includes a base configured to connect to an outlet housing and a set of terminals for receiving power supply conductors. The base includes a receptacle receiving portion and an inductive charger portion. A faceplate is connected to the base. The faceplate includes a charging portion and a receptacle opening. A device support is connected to the faceplate. A charger housing is connected to the base and positioned between the base and the faceplate. A charging pad includes an inductive coil and is positioned in the charger housing. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The aspects and features of various exemplary embodiments will be more apparent from the description of those exemplary embodiments taken with reference to the accompanying drawings, in which: 
         FIG.  1    is a perspective view of an exemplary receptacle inductive charger; 
         FIG.  2    is a front view of  FIG.  1   ; 
         FIG.  3    is side view of  FIG.  1   ; 
         FIG.  4    is a top view of  FIG.  1   ; 
         FIG.  5    is a bottom view of  FIG.  1   ; 
         FIG.  6    is a front view of an exemplary combination outlet and inductive charger; 
         FIG.  7    is a side view of  FIG.  6   ; 
         FIG.  8    is a top view of  FIG.  6   ; 
         FIG.  9    is a bottom view of  FIG.  6   ; 
         FIG.  10    is a rear perspective view of  FIG.  6   ; 
         FIG.  11    is a rear view of  FIG.  6   ; 
         FIG.  12    is a perspective view of an exemplary receptacle inductive charger; 
         FIG.  13    is a front view of  FIG.  12   ; 
         FIG.  14    is a side view of  FIG.  12   ; 
         FIG.  15    is a rear view of  FIG.  12   ; 
         FIG.  16    is a front perspective view of an exemplary faceplate; 
         FIG.  17    is a rear perspective view of  FIG.  17   ; 
         FIG.  18    is a rear perspective view of an exemplary device support; 
         FIG.  19    is an exploded view of an exemplary charger assembly; 
         FIG.  20    is a side, sectional view of the assembled charger assembly of  FIG.  19   ; 
         FIG.  21    is a rear perspective view of  FIG.  20   ; 
         FIG.  22    is a front perspective view of an exemplary base and a set of electrical components received therein; 
         FIG.  23    is a side view of  FIG.  22   ; 
         FIG.  24    is a rear perspective view of an exemplary set of electrical components; 
         FIG.  25    is a front perspective view of an exemplary mounting bracket; 
         FIG.  26    is front perspective view of an exemplary 2-gang charger and outlet; 
         FIG.  27    is a front view of  FIG.  26   ; 
         FIG.  28    is a rear view of  FIG.  26   ; 
         FIG.  29    is a partially exploded, front perspective view of the base and the charger assembly; 
         FIG.  30    is a front perspective view of the base of  FIG.  26   . 
     
    
    
     DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS 
     Various exemplary embodiments are directed to inductive charging devices that can be connected to or incorporated with typical power receptacles.  FIGS.  1 - 5    show an exemplary embodiment of an inductive charger that is configured to connect to a standard receptacle opening. The charger includes a wall plate  10  having an outer flange  12  surrounding a charging portion  14 . The charger is sized to fit a standard single-gang outlet opening, however it can be modified to be incorporated with a larger outlet configurations, such as a two, four, or six-gang configuration. 
     The outer flange  12  has a front surface  16  facing a room or other interior environment and an interior surface (not shown) facing a structural component such as a wall. A rear edge  18  of the outer flange  12  is configured to engage the structural component, and the interior portions of the outer flange  12  can be raised or otherwise spaced from the rear edge  18  to provide additional room behind the wall plate  10  for components and electrical connections. The outer flange  12  can include curved surface features to provide a low-profile look, although other shapes and configurations can be used. Top and bottom openings  20  extend through the outer flange  12 . Fasteners can be inserted into the openings  20  to connect the wall plate  10  to a receptacle opening or junction box. Other connection features can be used, include snap-fit features. 
     The charging portion  14  is positioned substantially in the center of the wall plate  10  and includes a pad  22  having a charging surface. The pad  22  is spaced from the outer flange  12  by an outer wall having a top portion  24 , a bottom portion  26 , and a pair of side portions  28 . The corners of the outer wall can be curved. According to an exemplary embodiment, the bottom wall  26  has a height that is greater than the height of the top wall  24  and the side walls  28  have a variable height between the top wall  24  and the bottom wall  26  as best shown in  FIGS.  3 - 5   . This results in a lower portion of the pad  22  extending from the outer flange  12  a greater distance than the upper portion of the pad  22 , giving the charging portion  14  an angled configuration. 
     According to various exemplary embodiments, the charging portion  14  is configured to be collapsible or otherwise moveable so that it has a lower profile when not in use. The charging pad  22  and one or more portions of the outer wall can include telescopic or accordion features that allow the charging portion  14  to be moved toward and away from the outer flange  12 . The charging portion  14  can be pivoted about the upper wall  24  or a point substantially near the upper wall  24  to pivot the bottom portion of the charging pad  22  relative to the outer flange. 
     The charging portion  14  also includes at least one retaining member. In the illustrated embodiment, the retaining member includes a pair of hooks  30  extending from the bottom of the charging portion. The first and second hook members  30  are spaced form one another and also spaced from the outer side edges of the charging pad  22  as best shown in  FIG.  2   . Each of the hooks  30  includes a bottom section  32  extending away from the charging pad  22  and a front section  34  extending up from the bottom section as best shown in  FIG.  3   . In this embodiment the bottom section  32  and the front section  34  of the hook  30  are substantially perpendicular to one another and also include a curved transition. Other sizes, shapes, and configurations can also be used. Although this embodiment depicts two discreet retaining members, a single retaining member can be used extending along any length of the charging pad  22 . Additional retaining members can also be incorporated into the inductive charger. 
     The charging portion  14  is configured to receive a portable electronic device, for example a smart phone. The electronic device can be positioned on the charging pad  22  and the retaining members and angled pad surface help secure the electronic device to the charger. The charging pad  22  can also have one or more surface features that helps retain or secure an electronic device to the charger. For example, the charging pad  22  can include a semi-adhesive or tacky surface material, such as a polyethylene film with an acrylic adhesive. Other suitable materials can also be used. Other surface features, for example friction enhancing surface features can also be used. 
     The charging portion  14  is configured to provide wireless, inductive charging to an electronic device. One or more inductive coils (not shown) can be positioned inside of the charging portion  14 , for example positioned behind the charging surface. The coils can be positioned inside a wall of the charging pad  22  or connected to the rear of the charging pad  22 . One or more electrical connectors are operatively connected to the coils to provide power from a mains power supply to the coils. 
       FIGS.  6 - 11    show an exemplary embodiment of a combination outlet and inductive charger. The combination device includes a wall plate  110  having an outer flange  112  surrounding a receptacle portion  114  and an inductive charging member  116  extending from the outer flange  112 . The combination device is sized to fit a standard single-gang outlet opening, however it can be modified to be incorporated with a larger outlet configurations, such as a two, four, or six-gang configuration. 
     The outer flange  112  has a front surface facing a room and an interior surface facing a structural component such as a wall. A rear edge  118  of the outer flange  112  is configured to engage the structural component, and the interior portions of the outer flange  112  can be raised or otherwise spaced from the rear edge  118  to provide additional room behind the wall plate for components and electrical connections. The outer flange  112  can include curved surface features to provide a low-profile look, although other shapes and configurations can be used. Top and bottom openings  120  extend through the outer flange  112 . Fasteners can be inserted into the openings to connect the wall plate to a receptacle opening or junction box. Other connection features can be used, include snap-fit features. 
     The receptacle portion  114  is positioned substantially in the center of the outer flange  112  and includes a top three-prong outlet  120 , a bottom three prong outlet  122 , and a pair of USB outlets  124 . Different outlet configurations can also be used, including two prong outlets or only USB outlets. 
     The charging portion  116  extends from the bottom of the outer flange  112  and includes a support  126  connected to the outer flange  112 , a charging pad  128  extending from the front of the support  126  and a charger housing  130  extending from the rear of the support  126 . The support  126  has a first portion  132  extending below the outer flange  112  and a second portion  134  that extends at an angle below and away from the first portion  132  at an oblique angle away from the wall or other support surface. This results in a lower portion of the pad  128  extending from the outer flange  112  a greater distance than the upper portion of the pad  128 , giving the charging portion  116  an angled configuration as best shown in  FIG.  7   . In alternative embodiments, the charging portion  116  can also be configured to extend from the top or sides of the outer flange  112 . 
     According to various exemplary embodiments, the charging portion  116  is configured to be moveable so that it has a lower profile when not in use. For example the support member can be pivotable from the position shown in  FIG.  7    to a collapsed position where the second portion  134  of the support member  126  is substantially vertically aligned with the first portion  132  or further toward the support surface. The support member  126  can include a hinge, for example a living hinge, to allow for pivotal movement. The support member  126  can also be configured to rotate in the opposite direction further than what is shown in  FIG.  7   . 
     The charging portion  116  also includes at least one retaining member. In the illustrated embodiment, the retaining member includes a single hook  136  extending from, and along the length of, the bottom of the charging portion  116 . The hook  136  includes a bottom section  138  extending away from the charging pad  128  and a front section  140  extending up from the bottom section  138  as best shown in  FIG.  7   . In this embodiment the bottom section  138  and the front section  140  of the hook are substantially perpendicular to one another and also include a curved transition. Multiple retaining members and other sizes, shapes, and configurations can also be used. Additional retaining members can also be incorporated into the inductive charger. 
     The charging portion  116  is configured to receive a portable electronic device, for example a smart phone. The electronic device can be positioned on the charging pad  128  and the retaining member and angled pad help secure the electronic device to the charger. The charging pad  128  can also have one or more surface features that helps retain or secure an electronic device to the charger. For example, the charging pad  128  can have a semi-adhesive or tacky surface material. For example the charging pad  128  can include a polyethylene film with an acrylic adhesive. Other suitable material can also be used. Other surface features, for example friction enhancing surface features can also be used. 
     The charging portion  128  is configured to provide wireless, inductive charging to an electronic device. One or more inductive coils (not shown) can be positioned inside of the charging housing  130 . The inductive coils are electrically connected to a mains power supply to provide charging to an electronic device. For example, the inductive coils can be powered by one or more conductors that extend through the support member and to a contact or other electrical connection in the receptacle portion  114 . In this way, the combination outlet and inductive charger can be easily retrofit to an existing outlet housing.  FIGS.  10  and  11    best show the back of the receptacle portion which can include snap-fit connections  142  for attaching the combination outlet and inductive charger to a rear outlet housing. 
       FIGS.  12 - 15    show another exemplary embodiment of an inductive charger  200  that is configured to connect to a standard one-gang receptacle opening. The charger  200  includes a faceplate  202  that is connected to a base  204 . A device support  206  extends from the faceplate  202  to receive an electronic device for charging. The device support  206  can include a pad  208  to provide increased friction and/or a cushioned surface for the electronic device. The base  204  includes a pair of side terminal connections  210  for receiving power supply conductors. The base  204  is connected to a mounting bracket  212  that can be connected to an outlet housing or junction box. A charger assembly  214  and a set of electrical components  216  are positioned between the faceplate  202  and the base  204  to provide inductive charging to an electronic device. 
       FIGS.  16  and  17    show an exemplary embodiment of the faceplate  202  that includes a front wall  218  and an outer edge  220  that define an interior. The front wall  218  includes an upper section having a charging region with a first charging portion  222  and a second charging portion  224 . The first and second charging portions  222 ,  224  can accommodate different devices and devices in different orientations. For example, the first charging portion  222  can charge a phone in a vertical, or portrait, orientation and the second charging portion  224  can charge a phone in a horizontal, or landscape, orientation. 
     The lower section of the faceplate includes a ledge  226  extending outwardly from the charging region. The ledge  226  includes an aperture for receiving an indicator light  228 , for example and LED. The bottom of the ledge  226  includes a snap-fit connection feature, for example first and second protrusions  230  having a ramped surface. A side pocket  232  is positioned on both sides of the ledge  226 . The side pockets  232  include an outer flange  234  extending around a depression. An inverted T-shaped protrusion  236  extends through the side pockets  232 . The T-shaped protrusion  236  defines a first channel and a second channel on respective sides of the protrusion  236 . 
       FIG.  17    shows the interior compartment of the faceplate  202  which includes a depression  238  for receiving the charger assembly  214 . A set of upper ribs  240  and a set of lower ribs  242  extend from the outer edge  220  on each side of the faceplate  292  into the interior compartment. Grooves are defined between each of the ribs  240 ,  242 . The ribs  240 ,  242  are used to adjustably connect the faceplate  202  to the base  204 . 
       FIG.  18    shows an exemplary embodiment of the device support  206  having an outer ledge  244  for supporting an electronic device. One or more prongs  246 , for example first and second prongs  246  extend up from the sides of the outer ledge  244 . Although shown as split prongs  246 , a single prong or more than two prongs can be used. The prongs  246  curve toward the faceplate  202  and can be resilient to accommodate devices of different thicknesses. The device support  206  includes a central region  248  having an opening receiving the indicator light  228 . A bottom wall  250  of the central region includes a snap fit connector for connecting the device support  206  to the faceplate  202 . For example, a set of flexible tabs  252  are provide to mate with the ramped projections  230  on the faceplate  202 . When making the connection, the tabs  252  will deflect as they slide over the ramped projections  230  which are received in openings in front of the tabs  252 . A side track is positioned on both sides of the central region  248 . The side tracks include an outer rim  254  and a pair of rails  256 . A groove is defined between the rails  256  for receiving the T-shaped protrusion  236  of the faceplate  202 . 
       FIGS.  19 - 21    show an exemplary embodiment of the charger assembly  214  that includes a rear cover  258 , a charging pad  260 , an upper circuit board  262 , a lower circuit board  264 , and a front cover  266 . The upper and lower circuit boards  262 ,  264  are configured to control the power through the charging pad  260 . The front cover  266  and rear cover  258  are connected together and define a chamber for receiving the charging pad  260  and the upper and lower circuit boards  262 ,  264 . When assembled together, the charger assembly  214  is received in the base  204 . 
     The rear cover  258  includes a rear wall  268  and an outer wall  270  that define an interior. A depression  272  is provided in an upper section of the rear wall  268  for receiving the upper board  262 . A pair of bosses  274  extend from the rear wall  268  and the upper board  262  is provided with openings corresponding to the bosses  274 . The bosses  274  include an upper knub  276 . A support  278  extends from the interior of the outer wall  270  on each side of the rear cover  258  to hold the charging pad  260 . A hook  280  extends from the interior of the outer wall  270  on each side of the rear cover  258  to support the lower board  264 . 
     The exterior of the outer wall  270  includes a first snap-fit connector for connecting to the front cover  266  and a second snap-fit connector for connecting to the base  204 . The first snap-fit connector includes an upper and lower ramped protrusion  282 . The second snap-fit connector includes a deflectable arm with a hooked protrusion  284 . As best shown in  FIG.  21   , the exterior of the rear wall  268  includes snap-fit connectors including an upper hook  286  and a pair of lower hooks  288 . 
     The charging pad  260  includes a first charging coil  290  and a second charging coil  292 . The first and second charging coils  290 ,  292  correspond to the first and second charging portions  222 ,  224  of the faceplate  202  to accommodate different devices and devices in different orientations. A pair of opening  294  are provided in the upper portion of the charging pad  260  that receive the knubs  276  from the rear cover  258 . 
     The front cover  266  includes a front wall  294  and an outer edge  296  extending from the front wall  294 . Indentions  298  are provided in the front wall  294  that align with the centers of the charging coils  290 ,  292 . A snap-fit connector is provided on the outer edge  296  for connecting the front cover  266  to the rear cover  258 . The connector includes upper and lower slots  300  that receive the ramped protrusions  282  from the rear cover  258 . 
       FIGS.  22  and  23    show an exemplary embodiment of the base  204  that includes a raised outer edge  302  surrounding a rear wall  304 . The outer edge  302  includes corner openings  306  that are configured to receive fasteners to connect the base  304  to the mounting bracket  212 . The rear wall  304  is configured to receive the charger assembly  214 . A pair of slots  308  are provided in the rear wall  304  to receive the deflectable arm  284  of the rear cover  258 . A chamber  310  is provided in the rear wall  304  for receiving the component assembly  216 , including a component board  312  and a number of electrical components connected to the board  312  ( FIG.  24   ). The components are configured to convert the power supply received by the terminals  210 . 
     The base  204  is configured to mate with the faceplate  202 . As best shown in  FIG.  23   , a lower portion  314  extends from the rear wall  304  to engage the ledge  226  of the faceplate  202 . The sides of the base  304  include an upper protrusion  316  and a lower protrusion  318 . In an exemplary embodiment the protrusions  316 ,  318  are tapered as they extend outwardly from the side edge, having a base and a point that gives them a substantially triangular cross-section, although other shapes can be used. When the faceplate  202  is connected to the base  204 , the ribs  240 ,  242  on the interior of the faceplate  202  will slide over the respective protrusion  316 ,  318  so that the protrusions  316 ,  318  will mate with the grooves defined between the ribs  240 ,  242 . In this way, the position of the faceplate  202  is adjustable relative to the base  204  so that the faceplate  202  can be positioned flush to a wall. 
       FIG.  25    shows an exemplary embodiment of the mounting bracket  212 . The mounting bracket  212  includes corner flanges  320  that receive fasteners connected to the base  204 . The mounting bracket  212  includes a first set of openings  322  and a second set of openings  324  to connect to a junction box or outlet housing. A ground tab  326  allows the mounting bracket  212  to be connected to a ground wire. 
       FIGS.  26 - 28    show an exemplary embodiment of a two-gang charger  400  configuration with a receptacle portion and an inductive charger portion. The two-gang charger  400  includes a faceplate  402  that is connected to a base  404 . A first side of the faceplate  402  includes a receptacle opening  406  providing access to an electrical outlet  408 . The base  404  is configured to receive the outlet  408  and a set of electrical components  410 , and is configured to connect to an outlet housing or junction box. Although the charger  400  is a two-gang assembly, it is configured to connect to a standard one-gang outlet housing. The outlet  408  includes a pair of three-prong outlets  412  and a pair of USB outlets  414 . Different outlet configurations can also be used, including two prong outlets or only USB outlets. 
     A second side of the faceplate  402  includes an inductive charging portion  416 , and a charger assembly  418  is positioned between the faceplate  402  and the base  404  to provide inductive charging to an electronic device. One or more conductors  420  extend from the outlet portion to the charger assembly  418  to provide power to the inductive charger. A device support  422  extends from the faceplate  402  to receive an electronic device for charging. The device support  422  can include a pad  424  to provide increased friction and/or a cushioned surface for the electronic device. 
     The features of the two-gang charger  400  are substantially the same as those described above for the one-gang charger  200 . As shown in  FIGS.  29  and  30   , the charger assembly  418  does not include a rear cover and instead the charging pad  426 , circuit boards, and front cover  432  are received directly by the base  404 . The base  404  includes a set of snap-fit projections, for example deflectable hooks  434  that are configured to connect to the slots  436  in the front cover  432 . A pair of bosses  438  extend from the base  404  and the upper circuit board is provided with openings corresponding to the bosses  438 . The bosses  438  include an upper knub  440 . The knubs  440  are used to engage openings  442  on the charging pad  426 . Side projections  444  are used to center the charging pad  426  and the lower circuit board and various internal projections  446  are used to space the charger assembly  418  components above the rear wall of the base  404 . 
     As best shown in  FIG.  30   , the outlet portion of the base  404  includes an upper depression  450  and a lower depression  452  for receiving a standard outlet mounting strap. An upper boss  454  and a lower boss  456  engage openings in the mounting strap and upper apertures  458  and lower apertures  460  receive fasteners to secure the outlet to the base  404 . The outlet portion includes one or more cable management components to position the conductor extending between the outlet portion and the charging portion. The cable management components can include an arm  462  and a first hook  464  positioned in the outlet portion and a second hook  466  positioned between the outlet portion and the charging portion. 
     The foregoing detailed description of the certain exemplary embodiments has been provided for the purpose of explaining the general principles and practical application, thereby enabling others skilled in the art to understand the disclosure for various embodiments and with various modifications as are suited to the particular use contemplated. This description is not necessarily intended to be exhaustive or to limit the disclosure to the exemplary embodiments disclosed. Any of the embodiments and/or elements disclosed herein may be combined with one another to form various additional embodiments not specifically disclosed. Accordingly, additional embodiments are possible and are intended to be encompassed within this specification and the scope of the appended claims. The specification describes specific examples to accomplish a more general goal that may be accomplished in another way. 
     As used in this application, the terms “front,” “rear,” “upper,” “lower,” “upwardly,” “downwardly,” and other orientational descriptors are intended to facilitate the description of the exemplary embodiments of the present disclosure, and are not intended to limit the structure of the exemplary embodiments of the present disclosure to any particular position or orientation. Terms of degree, such as “substantially” or “approximately” are understood by those of ordinary skill to refer to reasonable ranges outside of the given value, for example, general tolerances associated with manufacturing, assembly, and use of the described embodiments.