Patent Publication Number: US-2023155415-A1

Title: Storage container for in-vehicle wireless tool charging

Description:
BACKGROUND 
     The present disclosure relates to wireless charging of battery-powered devices. More particularly, the present disclosure relates to in-vehicle chargers for battery-powered tools. 
     SUMMARY 
     According to the present disclosure, a tool container for wirelessly charging tools comprises a wireless charging transmitter, a tool tray coupled to the wireless charging transmitter, and a tool tray liner removably coupled to the tool tray. The tool tray liner comprises a flexible brush pad. 
     In illustrative embodiments, the tool container comprises a tool cover coupled to the tool tray. The tool cover is moveable between a closed position and an open position. When the tool cover is in the closed position the tool tray liner and the tool cover define a charging volume configured to retain a device comprising a wireless charging receiver for charging by the wireless charging transmitter. 
     In illustrative embodiments, the tool container further comprises thermal conductive foam coupled to the tool cover. When the tool cover is in the closed position the thermal conductive foam and the tool tray liner define the charging volume. 
     In illustrative embodiments, the thermal conductive foam comprises a silicone material. 
     In illustrative embodiments, the tool tray liner comprises a silicone material. 
     In illustrative embodiments, the tool tray liner comprises a plurality of flexible fingers that extend from the tool tray toward the charging volume. 
     In illustrative embodiments, the tool tray liner comprises a first area positioned at a central part of the tool tray and a second area surrounding the first area. The central part of the tool tray is positioned opposite a central part of the wireless charging transmitter. The flexible fingers of the first area extend a first height from the tool tray, and the flexible fingers of the second area extend a second height from the tool tray. The second height is larger than the first height. 
     In illustrative embodiments, the tool tray liner comprises a third area surrounding the second area, the flexible fingers of the third area extending a third eight from the tool tray, the third height larger than the first height. 
     In illustrative embodiments, the wireless charging transmitter is configured to receive electrical power from a vehicle power supply. 
     In illustrative embodiments, the tool container is configured to be mounted to a vehicle. 
     In illustrative embodiments, the device comprises a wireless power tool or a rechargeable battery. 
     In illustrative embodiments, the wireless charging transmitter comprises a resonant charging transmitter. 
     In illustrative embodiments, the wireless charging transmitter comprises a first resonator having a first resonant frequency, and the wireless charging receiver comprises a second resonator having the first resonant frequency. 
     Additional features of the present disclosure will become apparent to those skilled in the art upon consideration of illustrative embodiments exemplifying the best mode of carrying out the disclosure as presently perceived. 
    
    
     
       BRIEF DESCRIPTIONS OF THE DRAWINGS 
       The detailed description particularly refers to the accompanying figures in which: 
         FIG.  1    is a perspective and diagrammatic view of a vehicle including an integrated tool storage container for wireless tool charging in accordance with the present disclosure; 
         FIG.  2    is a perspective view of the tool storage container of  FIG.  1   ; 
         FIG.  3    is an elevation view of the tool storage container of  FIGS.  1  and  2   ; and 
         FIGS.  4 - 5    are cross-sectional elevation views of the tool storage container of  FIGS.  1 - 3   . 
     
    
    
     DETAILED DESCRIPTION 
     A tool storage container  102  in accordance with the present disclosure is adapted for use with a vehicle  100  such as, for example, a vehicle  100  as shown in  FIG.  1   . The vehicle  100  is illustratively a light truck; however, in other embodiments the vehicle  100  may be a passenger car, a van, a sport utility vehicle, a heavy truck, or any other suitable vehicle. Similarly, the tool storage container  102  is illustratively a tool box mounted in a truck bed of the vehicle  100 ; however, in other embodiments the tool storage container  102  may be embodied as or included in a glove box, a trunk, a vehicle seat, an under-seat storage compartment, a map pocket, or any other compartment or other part of the vehicle  100 . 
     As shown in  FIGS.  1 - 2   , the illustrative tool storage container  102  includes multiple side walls  104  surrounding a floor  106  and a hinged cover  108  attached to one of the side walls  104 . The side walls  104 , the floor  106 , and the cover  108  define an interior  110 , which includes one or more tool trays  112 . As described further below, the tool tray  112  provides a location for storing and wirelessly charging tools, batteries, or other chargeable devices. 
     As shown in  FIGS.  1 - 5   , the tool tray  112  is coupled to a wireless charging transmitter  114 . The wireless charging transmitter  114  is a resonant charger that may transmit energy wirelessly to one or more wireless charging receivers  116  that are positioned in the tool tray  112 . In particular, the illustrative transmitter  114  includes a resonator (e.g., an inductor-capacitor circuit) tuned for a particular resonant frequency. Similarly, each receiver  116  includes a resonator tuned for that same resonant frequency. Each receiver  116  is in turn coupled to a device  118  that may be wirelessly charged or otherwise powered by energy received from the transmitter  114 . For example, the device  118  may be embodied as a portable power tool  120  such as a drill, saw, hammer, flashlight, torch, or other electrically powered tool. As another example, the device  118  may be embodied as a removable battery  122 , a battery charger, or any other energy storage device that may be wirelessly charged or otherwise powered. 
     The transmitter  114  is coupled to an electrical power system of the vehicle  100 . For example, the transmitter  114  may receive electrical power from a DC power supply, an alternator, an inverter, a DC-DC converter, or other electrical power supply of the vehicle  100 . When the transmitter  114  is energized, the transmitter  114  generates a magnetic field that oscillates at the resonant frequency of the transmitter  114 . This oscillating magnetic field couples with each receiver  116  placed in the tool tray  112  and transfers energy that may be used to charge or otherwise power the coupled device  118 . As a resonant charger, the transmitter  114  is capable of relatively high-powered charging of devices  118  as compared to typical inductive chargers. For example, in an embodiment the transmitter  114  may be capable of charging devices  118  at a rate of about 150 watts. Additionally, the transmitter  114  may be capable of providing energy to multiple receivers  116  simultaneously, such as between one to three receivers  116  simultaneously. As described further below, the tool tray  112  is adapted to receive and retain multiple devices  118  while they are being charged by the transmitter  114 . 
     As discussed above, the storage container  102  includes a tool tray  112  positioned inside the storage container  102 . The tool tray  112  includes multiple inner walls  124  that surround a floor  126 . The transmitter  114  is coupled to the underside of the floor  126  of the tool tray  112  such that, when a device  118  including a receiver  116  is positioned in the tool tray  112  in any position and/or orientation, the receiver  116  may be charged by the transmitter  114 . Although illustrated in  FIGS.  1 - 2    as occupying part of the interior  110  of the tool storage container  102 , it should be understood that in some embodiments, the tool tray  112  may extend through the entire interior  110  of the storage container  102 . Additionally or alternatively, although illustrated as including a separate tool tray  112  positioned within the tool storage container  102 , in some embodiments the tool storage container  102  and the tool tray  112  may be integrated. For example, in some embodiments, the transmitter  114  may be coupled to the floor  106  of the storage container  102 , and one or more receivers  116  may be located in any position and/or orientation within the tool storage container  102 . 
     The tool tray  112  further includes a removable tray liner  128 . The tray liner  128  may be embodied as a brush pad that includes multiple, flexible fingers extending upward from the floor  126  of the tool tray  112 . The tray liner  128  may be formed from silicone or another flexible and/or elastomeric material. When a device  118  including a receiver  116 , such as a tool  120  or a battery  122 , is placed on the tray liner  128 , the flexible fingers of the brush pad conform to the shape of the device  118  and thus retain or otherwise secure the device  118  while the vehicle  100  is in motion. The tray liner  128  may also cushion road vibrations or otherwise retain the device  118 . Additionally, when the device  118  is placed on the tray liner  128 , the device  118  is positioned at a distance above the floor  126  of the tool tray  112 . Thus, the device  118  may be positioned above any water, dirt, or other debris that may collect at the bottom of the tool tray  112 . Additionally, and as described above, the tray liner  128  may be removed for cleaning or replacement. 
     As described above, the storage container  102  further includes a cover  108 , and a cover liner  130  is coupled to the underside of the cover  108 . The cover  108  is moveable from an open position, in which the interior  110  of the storage container  102  (including the tool tray  112 ) is accessible, to a closed position, in which the interior  110  of the storage container  102  (including the tool tray  112 ) is not accessible. Additionally, when the tool cover  114  is in the closed position, the storage container  102  may be water and/or dust resistant. Additionally or alternatively to the cover  108 , in some embodiments the tool tray  112  may itself include a separate tool cover that is coupled to a cover liner  130 . 
     The cover liner  130  may be embodied as a thermal conductive foam, such as a silicone foam. Such thermal conductive foam may be operable to assist in removing excess heat from one or more devices  118  as they are being charged within the tool tray  112 . Additionally, in some embodiments, the cover liner  130  may include multiple, flexible fingers that, when in the closed position, extend inward from the cover  108  toward the tray liner  128 . When the cover  108  is in the closed position, the fingers of the cover liner  130  may contact each device  118  stored in the tool tray  112  and thereby secure each device  118  while the vehicle  100  is in motion. As shown in  FIGS.  1 - 2   , in the illustrative embodiment, the flexible fingers of the cover liner  130  may be larger (e.g., larger in diameter and/or length) as compared to the flexible fingers of the tray liner  128 . 
     In the closed position, the cover  108  and the tool tray  112  cooperate to define a charging volume  132 . As described above, the tray liner  128  and the cover liner  130  surround the charging volume  132 . When the cover  108  is in the closed position, the tray liner  128  and the cover liner  130  may contact any tools  120 , batteries  122 , or other devices  118  positioned within the charging volume  132  and retain those devices  118  in position. Thus, the charging volume  132  is configured to receive and retain one or more tools  120 , batteries  122 , or other devices  118 . When such devices  118  are positioned within the charging volume  132 , they may be wirelessly charged by the transmitter  114 . 
     As described above, the transmitter  114  is a resonant transmitter. 
     Accordingly, and as opposed to inductive wireless charging systems, each receiver  116  coupled to a device  118  may not be required to be in any particular, predetermined position and/or alignment relative to the transmitter  114  during charging. Thus, the storage container  102  and tool tray  112  may allow for convenient “throw and go” high-power charging of wireless devices  118 , without requiring that the devices  118  be stored in any particular arrangement within the tool tray  112 . For example, a tool  120  may be positioned horizontally within the tool tray  112  as shown in  FIGS.  3 - 5   , or vertically, or in any other orientation within the tool tray  112   
     Although no particular alignment is required to perform wireless charging, in some embodiments charging power and/or charging efficiency may be improved if each receiver  116  is positioned closer to a central part of the transmitter  114 . As shown in  FIGS.  3 - 5   , the tray liner  128  may include a central area  134  positioned toward the center of the tool tray  112 , as well as a middle area  136  surrounding the central area  134  and an outer area  138  surrounding the middle area  136 . The central area  134  may thus also be positioned over the central part of the transmitter  114 . As shown in  FIGS.  4  and  5   , the flexible fingers of the tray liner  128  within the central area  134  extend a height  140  above the floor  126  of the tool tray  112 . The flexible fingers within the middle area  136  extend a height  142  above the floor  126  of the tool tray  112  that is larger than the height  140 , and the flexible fingers within the outer area  138  extend a height  144  above the floor  126  of the tool tray  112  that is larger than the height  142 . Thus, when a device  118  is positioned on the tray liner  128 , the increasing heights  140 ,  142 ,  144  may tend to position the device  118  toward the central area  134  (having the lowest height  140 ) and thus toward the center of the transmitter  114 . Therefore, charging power and/or charging efficiency may be improved as compared to when the device  118  is positioned toward the middle area  136  and/or the outer area  138 . Additionally or alternatively, although illustrated as including a central area  134 , a middle area  136 , and an outer area  138 , it should be understood that in other embodiments the tray liner  128  may include a different number and/or arrangement of areas having different heights. In each embodiment, the flexible fingers of the tray liner  128  may have a smaller height closer to the center of the tray liner  112 . 
     As shown in  FIG.  4   , the tool tray  112  may further include a pair of tabs  146  that extend outward from the inner walls  124  of the tool tray  112 . When the tool tray  112  is inserted in the interior  110  of the storage container  102 , the tabs  146  may be attached to the side walls  104 . Thus, the tool tray  112  may be secured within the storage container  102 . 
     In the illustrative embodiment, the tray liner  128  is removably coupled to the tool tray  112  and the cover liner  130  is coupled to the cover  108 . However, it should be understood that in some embodiments those components and/or the features of those components may be reversed. For example, in some embodiments, the tray liner  128  may be embodied as thermal conductive foam and the cover liner  130  may be embodied as a silicone brush pad. 
     The following numbered clauses include embodiments that are contemplated and non-limiting: 
     Clause 1. A tool container for wirelessly charging tools, the tool container comprising 
     a wireless charging transmitter; 
     a tool tray coupled to the wireless charging transmitter; and 
     a tool tray liner removably coupled to the tool tray, wherein the tool tray liner comprises a flexible brush pad. 
     Clause 2. The tool container of clause 1, any other clause, or combination of clauses, further comprising a tool cover coupled to the tool tray, wherein the tool cover is moveable between a closed position and an open position, and wherein when the tool cover is in the closed position the tool tray liner and the tool cover define a charging volume configured to retain a device comprising a wireless charging receiver for charging by the wireless charging transmitter. 
     Clause 3. The tool container of clause 2, any other clause, or combination of clauses, further comprising thermal conductive foam coupled to the tool cover, wherein when the tool cover is in the closed position the thermal conductive foam and the tool tray liner define the charging volume. 
     Clause 4. The tool container of clause 3, any other clause, or combination of clauses, wherein the thermal conductive foam comprises a silicone material. 
     Clause 5. The tool container of clause 4, any other clause, or combination of clauses, wherein the tool tray liner comprises a silicone material. 
     Clause 6. The tool container of clause 5, any other clause, or combination of clauses, wherein the tool tray liner comprises a plurality of flexible fingers that extend from the tool tray toward the charging volume. 
     Clause 7. The tool container of clause 6, any other clause, or combination of clauses, wherein 
     the tool tray liner comprises a first area positioned at a central part of the tool tray and a second area surrounding the first area, wherein the central part of the tool tray is positioned opposite a central part of the wireless charging transmitter; and 
     the flexible fingers of the first area extend a first height from the tool tray, and the flexible fingers of the second area extend a second height from the tool tray, wherein the second height is larger than the first height. 
     Clause 8. The tool container of clause 7, any other clause, or combination of clauses, wherein the tool tray liner comprises a third area surrounding the second area, the flexible fingers of the third area extending a third eight from the tool tray, the third height larger than the first height. 
     Clause 9. The tool container of clause 8, any other clause, or combination of clauses, wherein the wireless charging transmitter is configured to receive electrical power from a vehicle power supply. 
     Clause 10. The tool container of clause 9, wherein the tool container is configured to be mounted to a vehicle. 
     Clause 11. The tool container of clause 10, wherein the device comprises a wireless power tool or a rechargeable battery. 
     Clause 12. The tool container of clause 11, wherein the wireless charging transmitter comprises a resonant charging transmitter. 
     Clause 13. The tool container of clause 12, wherein: 
     the wireless charging transmitter comprises a first resonator having a first resonant frequency; and 
     the wireless charging receiver comprises a second resonator having the first resonant frequency.