Patent Publication Number: US-2023163540-A1

Title: Fast charging universal serial bus (usb type-c) connector and battery charging system for an auto battery charger

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a continuation of U.S. patent application Ser. No. 17/758,314, filed on Jul. 1, 2022, which is a national stage entry of International Patent Application No. PCT/US2020/067763, filed on Dec. 31, 2020, which claims priority from U.S. Provisional Application No. 62/956,892, filed on Jan. 3, 2020; International Patent Application No. PCT/US2020/067763 is also a continuation-in-part of U.S. Design patent application Ser. No. 29/719,409, filed on Jan. 3, 2020; International Patent Application No. PCT/US2020/067763 is also a continuation-in-part of U.S. Design patent application Ser. No. 29/719,413, filed on Jan. 3, 2020; each of which is incorporated by reference herein for all purposes. 
    
    
     FIELD 
     The present invention is directed to a fast charging universal serial bus (e.g. USB Type-C) connector, and battery charging system for an auto battery charger. 
     BACKGROUND 
     USB-C is a fast growing industry standard connector for transmitting both power and data on a single cable to combine both power with fast communications. 
     For full USB-C compatibility it is necessary to provide high function controller IC&#39;s as well as Driver IC&#39;s. Complex buck and boost converters are also required. The problem with this approach is it drives cost up. 
     There exists a need for a new approach that provides USB-C function and protection, but is cost effective. This approach can be applied to a new type of battery auto charger. 
     SUMMARY 
     The USB-C battery charger (e.g. auto charger) according to the present invention can be custom designed, both electrically and mechanically. The battery charger can include a new cable assembly with USB-C connector for connecting to a USB-C module. 
     The electrical design maximizes power delivery for jump starters (e.g. NOCO Boost Jumpstarters) while mechanically and electrically protecting standard USB-C devices such as smartphones. A block diagram is shown in the drawings and described below. 
     The electrical connector is a new version of a USB-C PD industry standard that delivers high power (e.g. 60-100 watts) allowing for fast charging of jump starters (e.g. NOCO Boost Jump-starters) at a low cost. 
     The presently described subject matter is directed to a universal serial bus (USB-C PD) connector, comprising or consisting of: an oval-shaped plug having an end face, the end face having an oval-shaped outer rim, an oval-shaped recess located within the oval-shaped outer rim, an oval-shaped inner protrusion located within the oval-shaped recess, and an oval-shaped inner recess disposed within the oval-shaped inner protrusion, wherein the oval-shaped inner recess is provided with one or more electrical conductors. 
     The presently described subject matter is directed to a universal serial bus (USB-C PD) connector, comprising or consisting of: an oval-shaped plug having an end face, the end face having an oval-shaped outer rim, an oval-shaped recess located within the oval-shaped outer rim, an oval-shaped inner protrusion located within the oval-shaped recess, and an oval-shaped inner recess disposed within the oval-shaped inner protrusion, wherein the oval-shaped inner recess is provided with one or more electrical conductors, wherein the one or more electrical conductors is multiple spaced apart electrical conductors. 
     The presently described subject matter is directed to a universal serial bus (USB-C PD) connector, comprising or consisting of: an oval-shaped plug having an end face, the end face having an oval-shaped outer rim, an oval-shaped recess located within the oval-shaped outer rim, an oval-shaped inner protrusion located within the oval-shaped recess, and an oval-shaped inner recess disposed within the oval-shaped inner protrusion, wherein the oval-shaped inner recess is provided with one or more electrical conductors, wherein the one or more electrical conductors is multiple spaced apart electrical conductors, and wherein the multiple spaced apart electrical conductors is multiple electrically conductive spaced apart contacts located within the oval-shaped inner recess. 
     The presently described subject matter is directed to a universal serial bus (USB-C PD) connector, comprising or consisting of: an oval-shaped plug having an end face, the end face having an oval-shaped outer rim, an oval-shaped recess located within the oval-shaped outer rim, an oval-shaped inner protrusion located within the oval-shaped recess, and an oval-shaped inner recess disposed within the oval-shaped inner protrusion, wherein the oval-shaped inner recess is provided with one or more electrical conductors, wherein the one or more electrical conductors is multiple spaced apart electrical conductors, wherein the multiple spaced apart electrical conductors is multiple electrically conductive spaced apart contacts located within the oval-shaped inner recess, and wherein the electrically conductive spaced apart contacts are affixed to an inner wall defining the oval-shaped inner recess. 
     The presently described subject matter is directed to a universal serial bus (USB-C PD) connector, comprising or consisting of: an oval-shaped plug having an end face, the end face having an oval-shaped outer rim, an oval-shaped recess located within the oval-shaped outer rim, an oval-shaped inner protrusion located within the oval-shaped recess, and an oval-shaped inner recess disposed within the oval-shaped inner protrusion, wherein the oval-shaped inner recess is provided with one or more electrical conductors, wherein the one or more electrical conductors is one or more conductive metal contacts. 
     The presently described subject matter is directed to a universal serial bus (USB-C PD) connector, comprising or consisting of: an oval-shaped plug having an end face, the end face having an oval-shaped outer rim, an oval-shaped recess located within the oval-shaped outer rim, an oval-shaped inner protrusion located within the oval-shaped recess, and an oval-shaped inner recess disposed within the oval-shaped inner protrusion, wherein the oval-shaped inner recess is provided with one or more electrical conductors, wherein the oval-shaped plug is made of a synthetic resin material or plastic and the one or more electrical conductors is insert molded into the oval-shaped plug. 
     The presently described subject matter is directed to a universal serial bus (USB-C PD) connector, comprising or consisting of: an oval-shaped plug having an end face, the end face having an oval-shaped outer rim, an oval-shaped recess located within the oval-shaped outer rim, an oval-shaped inner protrusion located within the oval-shaped recess, and an oval-shaped inner recess disposed within the oval-shaped inner protrusion, wherein the oval-shaped inner recess is provided with one or more electrical conductors, wherein the oval-shaped plug is provided with an upper flat surface and lower flat surface. 
     The presently described subject matter is directed to a universal serial bus (USB-C PD) connector, comprising or consisting of: an oval-shaped plug having an end face, the end face having an oval-shaped outer rim, an oval-shaped recess located within the oval-shaped outer rim, an oval-shaped inner protrusion located within the oval-shaped recess, and an oval-shaped inner recess disposed within the oval-shaped inner protrusion, wherein the oval-shaped inner recess is provided with one or more electrical conductors, wherein the oval-shaped plug is provided with an upper flat surface and lower flat surface, and wherein the oval-shaped plug is provided with a half cylinder-shaped outer left side surface and a half cylinder-shaped outer right side surface. 
     The presently described subject matter is directed to a universal serial bus (USB-C PD) port, comprising or consisting of: an oval-shaped outer rim, an oval-shaped recess located within the oval-shaped outer rim, an oval-shaped protrusion located within the oval-shaped recess, an oval-shaped inner recess disposed within the oval-shaped inner protrusion, wherein the oval-shaped inner recess is provided with one or more electrical conductors. 
     The presently described subject matter is directed to a universal serial bus (USB-C PD) port, comprising or consisting of: an oval-shaped outer rim, an oval-shaped recess located within the oval-shaped outer rim, an oval-shaped protrusion located within the oval-shaped recess, an oval-shaped inner recess disposed within the oval-shaped inner protrusion, wherein the oval-shaped inner recess is provided with one or more electrical conductors, and wherein the one or more electrical conductors is multiple spaced apart electrical conductors. 
     The presently described subject matter is directed to a universal serial bus (USB-C PD) port, comprising or consisting of: an oval-shaped outer rim, an oval-shaped recess located within the oval-shaped outer rim, an oval-shaped protrusion located within the oval-shaped recess, an oval-shaped inner recess disposed within the oval-shaped inner protrusion, wherein the oval-shaped inner recess is provided with one or more electrical conductors, wherein the one or more electrical conductors is multiple spaced apart electrical conductors, and wherein the multiple spaced apart electrical conductors is multiple electrically conductive spaced apart contacts located within the oval-shaped inner recess. 
     The presently described subject matter is directed to a universal serial bus (USB-C PD) port, comprising or consisting of: an oval-shaped outer rim, an oval-shaped recess located within the oval-shaped outer rim, an oval-shaped protrusion located within the oval-shaped recess, an oval-shaped inner recess disposed within the oval-shaped inner protrusion, wherein the oval-shaped inner recess is provided with one or more electrical conductors, wherein the one or more electrical conductors is multiple spaced apart electrical conductors, wherein the multiple spaced apart electrical conductors is multiple electrically conductive spaced apart contacts located within the oval-shaped inner recess, and wherein the electrically conductive spaced apart contacts are affixed to an inner wall defining the oval-shaped inner recess. 
     The presently described subject matter is directed to a universal serial bus (USB-C PD) port, comprising or consisting of: an oval-shaped outer rim, an oval-shaped recess located within the oval-shaped outer rim, an oval-shaped protrusion located within the oval-shaped recess, an oval-shaped inner recess disposed within the oval-shaped inner protrusion, wherein the oval-shaped inner recess is provided with one or more electrical conductors, and wherein the one or more electrical conductors is one or more conductive metal contacts. 
     The presently described subject matter is directed to a universal serial bus (USB-C PD) port, comprising or consisting of: an oval-shaped outer rim, an oval-shaped recess located within the oval-shaped outer rim, an oval-shaped protrusion located within the oval-shaped recess, an oval-shaped inner recess disposed within the oval-shaped inner protrusion, wherein the oval-shaped inner recess is provided with one or more electrical conductors, and wherein the oval-shaped port is made of a synthetic resin material or plastic and the one or more electrical conductors is insert molded into the oval-shaped port. 
     The presently described subject matter is directed to a universal serial bus (USB-C PD) port, comprising or consisting of: an oval-shaped outer rim, an oval-shaped recess located within the oval-shaped outer rim, an oval-shaped protrusion located within the oval-shaped recess, an oval-shaped inner recess disposed within the oval-shaped inner protrusion, wherein the oval-shaped inner recess is provided with one or more electrical conductors, and wherein the oval-shaped port is provided with an upper flat surface and lower flat surface. 
     The presently described subject matter is directed to a universal serial bus (USB-C PD) port, comprising or consisting of: an oval-shaped outer rim, an oval-shaped recess located within the oval-shaped outer rim, an oval-shaped protrusion located within the oval-shaped recess, an oval-shaped inner recess disposed within the oval-shaped inner protrusion, wherein the oval-shaped inner recess is provided with one or more electrical conductors, wherein the oval-shaped port is provided with an upper flat surface and lower flat surface, and wherein the oval-shaped port is provided with a half cylinder-shaped outer left side surface and a half cylinder-shaped outer right side surface. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         FIG.  1    is a block diagram of the fast charging system and device. 
         FIG.  2    is a perspective view of the electrical connector and electrical port according to the present invention shown separated apart. 
         FIG.  3    is a perspective view of the electrical connector and electrical port according to the present invention shown connected together. 
         FIG.  4    is an end view of the insertion end of the electrical connector shown in  FIG.  2   . 
         FIG.  5    is an opposite end of the electrical connector shown in  FIG.  4   . 
         FIG.  6    is a top planar view of the electrical connector shown in  FIG.  2   . 
         FIG.  7    is a bottom planar view of the electrical connector shown in  FIG.  2   . 
         FIG.  8    is a left side elevational view of the electrical connector shown in  FIG.  2   . 
         FIG.  9    is a right side elevational view of the electrical connector shown in  FIG.  2   . 
         FIG.  10    is an end elevational view of the electrical connector and electrical port shown in  FIGS.  3  and  4    connected together. 
         FIG.  11    is a longitudinal vertical cross-sectional view of the electrical connector and port shown in  FIGS.  3 ,  4 , and  10   . 
     
    
    
     DETAILED DESCRIPTION 
     The fast charging universal serial bus (e.g. USB Type-C) battery charging system  10  for use with a battery charger (e.g. auto charger) for handling higher power is shown in  FIGS.  1 ,  2 ,  10 , and  11   . 
     The battery charging system  10  comprises: 
     1) VBUS  12  (e.g. main power line); 
     2) AND gate  14 ; 
     3) switch  16 ; 
     4) over voltage and reverse polarity protection  18 ; 
     5) controller and undervoltage protection  20 ; 
     6) 10V-15V voltage source  22 ; 
     7) 5V voltage source  24 ; 
     8) safety switch  26 ; 
     9) switch  28 ; and 
     10) overtemperature protection. 
     VBUS 
     The VBUS  12  is a main power line. High power is provided on VBUS by delivering current directly from the Vehicle DC Power Port through a FET switch that is controlled by a customized USB-C Driver. The customized USB-C Driver communicates with our NOCO Boost Jump-starters, then when confirmed, enables the FET switch allowing power to be delivered for charging. 
     Overvoltage Protection 
     The battery charging system  10  can include overvoltage protection  18 , for example, in case a user accidentally connects to a 24V plug. 
     Undervoltage Protect 
     The battery charging system  10  can also include undervoltage protection  20  from car batteries that have a voltage that is too low. If the car battery  40  drops below 10V, the Auto Charger shuts off. 
     Reverse Voltage Protection 
     The battery charging system  10  can include reverse polarity protection  18  from Reverse Car Battery connections. 
     10-15V Source 
     The battery charging system  10  can include the ability to switch in a 10-15V Voltage source  22 . This is the main charging source for the NOCO Boost Jump-starters. The USB-C Driver will communicate with the Jump-starter to enable this 10-15V Voltage source  22 . 
     Safety Switch 
     The battery charging system  10  can include a safety switch  26  that will only allow the 10-15V Voltage source  22  to be passed through, if the USB-C driver determines that it is safe to do so. 
     5V Voltage Source 
     The battery charging system  10  can include a 5V Voltage Source  24  that is used for enabling and low power on the VBUS  12 . 
     Overtemperature Protection 
     The battery charging system  10  can include over temperature protection  30  that shuts down power on the VBUS  12 , if the temperature is ever detected too high. 
     Keyed Connector 
     The battery charging system includes a custom connector arrangement  50  comprising an electrical connector  52  and an electrical port  54 , as shown in  FIGS.  2 ,  3 ,  10 , and  11   , configured to allow this Auto charger to only plug into a particular type or brand of jump starter (e.g. NOCO Jump Starter). Specifically, the electrical connector  52  and electrical port  54  are compatible and configured to properly connect and operate in conjunction. 
     The electrical connector  52  is provided with an oval-shaped configuration, as shown in  FIGS.  4  and  5   . The electrical connector  52  comprises an oval-shaped outer rim  52 A, an oval-shaped recess  52 B, and an oval-shaped inner protrusion  52 F having an inner oval-shaped recess having electrical conductors, as shown in  FIG.  4   . 
     The electrical port  54  is provided with an oval-shaped configuration, as shown in  FIG.  2   . The electrical port  54  comprises an oval-shaped outer rim  54 A, an oval-shaped recess  54 B, an oval-shaped inner protrusion  54 C, an oval-shaped inner recess  54 D, and an oval-shaped protrusion  54 E having electrical conductors.