Patent Description:
Wireless charging systems use an electromagnetic field to transfer energy between two objects through induction. For example, a portable device may include an inductive coil, and a charging system may include a corresponding inductive coil. The coils of the portable device and the charging system need to be within a minimum distance to interact and allow for effective wireless charging of the portable device. However, many protective cases used to protect the charging system and the portable device, respectively, can be thick and bulky in order to provide sufficient protection from impacts or other exterior forces that may be applied to either the charging system or the portable device. As such, the distance between the coil of the portable device and the coil of the charging system may be too far apart to permit effective or efficient operative interaction between the two coils during wireless charging.

It is with these observations in mind, among others, that various aspects of the present disclosure were conceived and developed.

<CIT> relates to a holder for a mobile telephone which includes at least one charging coil that is movable between at least two different positions. When a mobile telephone is positioned within an accommodation device of the holder, the position of the charging coil in the accommodation device can be changed to make charging of the mobile telephone battery as efficient as possible. The mobile telephone holder allows for charging of telephones of different configurations and for orienting telephones in different orientations.

Corresponding reference characters indicate corresponding elements among the view of the drawings. The headings used in the figures do not limit the scope of the claims.

The present disclosure relates to a charging system configured to couple with a portable device and/or a protective case that encases a portable device. In some embodiments, the charging system includes a charging mount to couple with the portable device and/or the protective case of the portable device and a charging module which includes a coil configured to interact with a device coil in the portable device for wireless charging of the portable device. In some embodiments, the charging module may be removably coupled with the charging mount. The construction of the charging mount and the protective case of the portable device are configured such that the coil and the device coil can efficiently interact during a wireless charging. In some embodiments, the charging mount includes a coil receiver which may define a recess or an aperture. In one embodiment, the coil of the charging module may be received within the coil receiver such that the reduced material thickness of the charging module between the coil and the device coil allows for efficient interaction being established between the coil and the device coil for wireless charging. In another embodiment, the coil of the charging module may be received within the coil receiver adjacent an aperture defined by the charging mount for allowing the efficient interaction between the coil and the device coil for wireless charging. Referring to the drawings, embodiments of a charging system are illustrated and generally indicated as <NUM> in <FIG>.

Referring to <FIG>, an embodiment of a charging system, designated <NUM>, includes a charging mount <NUM> configured to be removably coupled with a protective case <NUM> for a portable device <NUM>. While the present disclosure discusses the charging system <NUM> being coupled with the protective case <NUM>, in some embodiments, the charging system <NUM> can also couple directly with the portable device <NUM>. The portable device <NUM> includes a device coil <NUM> which is disposed within a device housing <NUM>. In some embodiments, the portable device <NUM> may be a phone such as a smartphone or a tablet. In some embodiments, the portable device <NUM> may be encased in a protective case <NUM>. The protective case <NUM> at least partially surrounds the device housing <NUM> of the portable device <NUM>. In one aspect, the protective case <NUM> may prevent wear of the device housing <NUM> and/or decrease any force that may be applied to the portable device <NUM>, for example when the portable device <NUM> is dropped to the ground or receives other types of impacts from an external source. Exemplary protective cases <NUM> are the JUGGERNAUT CASE, the JUGGERNAUT SLEEV, the JUGGERNAUT BUMPR, and the JUGGERNAUT IMPCT; however, the types of protective cases <NUM> are not limited to these specific examples.

Referring to <FIG>, the charging mount <NUM> of charging system <NUM> has a mount body <NUM> defining a front surface <NUM> and an opposite rear surface <NUM>. In some embodiments, the charging mount <NUM> includes a first device coupler <NUM> and a second device coupler <NUM> which extend from opposite respective first and second sides <NUM>, <NUM> of the mount body <NUM>. In particular, as shown in <FIG>, the first device coupler <NUM> is configured to abut a first side <NUM> of the protective case <NUM> and the second coupler <NUM> is configured to abut the second side <NUM> of the protective case <NUM> such that the protective case <NUM> is securely engaged to the charging mount <NUM>. In some embodiments, the first device coupler <NUM> and the second device coupler <NUM> collectively engage with the protective case <NUM> by a snap fit connection. For example, when the protective case <NUM> is coupled with the charging mount <NUM>, the first device coupler <NUM> and the second device coupler <NUM> initially engages and deflects away from the first and second sides <NUM>, <NUM> of the protective case <NUM> and then the first and second device couplers <NUM> and <NUM> revert to their original shape such that the protective case <NUM> becomes fully engaged with the charging mount <NUM>. As such, unlike conventional magnetic coupling, the charging mount <NUM> is physically coupled with the protective case <NUM> and/or the portable device <NUM> even if the protective case <NUM> and/or the portable device <NUM> is moved or experiences an external force. Other suitable methods for coupling the charging mount <NUM> with the protective case <NUM> may be utilized. When the charging mount <NUM> is coupled with the protective case <NUM>, the front surface <NUM> of the mount body <NUM> is positioned directly adjacent to the protective case <NUM>. In some embodiments, the mount body <NUM> may be made of a plastic. In some embodiments, the mount body <NUM> may be made of acrylonitrile butadiene styrene and/or polycarbonate.

Referring specifically to <FIG>, the charging system <NUM> may also include a coil <NUM> of the charging module <NUM> that is configured to interact with the device coil <NUM> of the portable device <NUM> for allowing wireless charging of the portable device <NUM>. In some embodiments, the operative interaction between the coil <NUM> and the device coil <NUM> is electromagnetic induction. In some embodiments, the coil <NUM> of the charging module <NUM> functions as a transmitting coil. In addition, the coil <NUM> generates an oscillating magnetic field such that the magnetic field induces an alternating current in a receiving coil, for example the device coil <NUM>. As such, the coil <NUM> and the device coil <NUM> collectively provide inductive charging of the portable device <NUM>. For example, the coil <NUM> and the device coil <NUM> may provide a voltage up to <NUM> volts and a current up to <NUM> amperes during charging of the portable device <NUM>. In some embodiments, the inductive charging of the portable device <NUM> operates under the QI standard. The coil <NUM> and the device coil <NUM> must be within a predetermined distance to properly interact and allow for wireless charging. In some instances, the protective case <NUM> may be large and add bulk or size that surrounds the encased portable device <NUM>, which can necessarily increase the distance between the coil <NUM> and the device coil <NUM> and thereby prevent the wireless charging system from properly interacting with portable devices <NUM> engaged to the charging mount <NUM>. As such, the charging system <NUM> as discussed herein minimizes the distance between the coil <NUM> and the device coil <NUM> to allow for the efficient wireless charging of portable devices <NUM> encased in protective cases <NUM>.

Referring to <FIG> and <FIG>, the rear surface <NUM> of the mount body <NUM> is configured to receive a charging module <NUM>. In some embodiments, the charging module <NUM> includes the coil <NUM> for wireless charging the portable device <NUM>. As shown, the charging module <NUM> also includes a connector <NUM> which can transfer data and/or power to and from the charging module <NUM>. In some embodiments, the connector <NUM> may be a USB A cable. In other embodiments, the connector <NUM> may be a USB C cable, a lightning cable, a mini-USB cable, or any other suitable connector to transfer data and/or power. In some embodiments, the connector <NUM> may be removably coupled with the charging module <NUM>. When the connector <NUM> is coupled with the charging module <NUM>, fluid is prevented from communicating across the connection of the connector <NUM> and the charging module <NUM> such that the connection is substantially waterproof. In other embodiments, the connector <NUM> may be fixedly coupled with the charging module <NUM> by soldering or any other suitable method of attachment. The connector <NUM> may be overmolded such that fluid is prevented from communicating across the connection of the connector <NUM> and the charging module <NUM>. As such, the connection is substantially waterproof.

A plurality of external fasteners <NUM> extend from the rear surface <NUM> of the mount body <NUM> with each external fastener <NUM> being configured to correspond with and engage an external mount <NUM> as illustrated in <FIG> when coupling the charging mount <NUM> to the external mount <NUM>. As shown in <FIG> and <FIG>, in some embodiments the charging mount <NUM> includes four external fasteners <NUM>; however, in other embodiments, one, two, three, five, or more external fasteners <NUM> may be included as desired.

Referring to <FIG>, in some embodiments the charging module <NUM> includes a circuit board <NUM>, a coil <NUM> coupled with the circuit board <NUM>, and a connector <NUM> which is also coupled with the circuit board <NUM>. The coil <NUM> as illustrated is substantially circular. In other embodiments, the coil <NUM> may be substantially rectangular, ovoid, triangular, or any other suitable shape. <FIG> illustrates the charging module <NUM> omitting a module casing, and <FIG> illustrates the charging module <NUM> with a module casing <NUM>.

In some embodiments, the module casing <NUM> includes an overmolded polymer surrounding the coil <NUM>, the circuit board <NUM>, and at least a portion of the connector <NUM>. In some embodiments, the overmolded polymer of the module casing <NUM> is a thermoplastic material, for example a thermoplastic elastomer. In some embodiments, the overmolded polymer of the module casing <NUM> may be potted with an epoxy. In some embodiments, the module casing <NUM> is waterproof such that fluid communication across the module casing <NUM> with the coil <NUM> and/or the circuit board <NUM> is prevented. The coil <NUM> and/or the circuit board <NUM> can be encapsulated with the overmolded module casing <NUM>. An epoxy may then be used to pot any holes caused by the overmolding tool to achieve a waterproof module casing <NUM>. In some embodiments, the module casing <NUM> of the charging module <NUM> may be rated at IP58 or better, where an IP58 rating means that the charging module <NUM> is dust resistant and can be immersed in <NUM> meters of freshwater for up to <NUM> minutes. In some embodiments, the module casing <NUM> of the charging module <NUM> may be rated at IP67 or better, where an IP67 rating means that the charging module <NUM> is dust tight such that there is no ingress of dust and can be immersed in up to <NUM> meter of freshwater for up to <NUM> minutes.

In some embodiments, the module casing <NUM> is rugged such that the charging module <NUM> can function under high environmental stresses. In some embodiments, environmental stresses may be, for example, extreme temperatures, vibrations, shock, high altitude, and/or humidity. For example, the charging module <NUM> may function in temperatures ranging from about -<NUM> to <NUM>, vibration of up to about <NUM>, altitude up to about <NUM>,000feet, and/or humidity up to about <NUM>%.

Referring to <FIG>, the charging module <NUM> is removably coupled with the charging mount <NUM>. In some embodiments, the charging mount <NUM> includes a module receiver <NUM> configured to receive the charging module <NUM>. In some embodiments, the module casing <NUM> of the charging module <NUM> defines a front side <NUM> which is sized and shaped, when the charging module <NUM> is received within the module receiver <NUM>, is positioned directly adjacent to the charging mount <NUM>. In some embodiments, the module casing <NUM> defines a rear side <NUM> which is formed opposite the front side <NUM>. The charging mount <NUM> may include extending walls <NUM> which extend outwardly from the rear surface <NUM> of the mount body <NUM>. When the charging module <NUM> is received within the module receiver <NUM>, the walls <NUM> surround at least a portion of the charging module <NUM> to limit the movement of the charging module <NUM>.

The charging mount <NUM> may also include one or more mount couplers <NUM> having a respective tang <NUM> formed at the free end thereof which is sized and shaped to correspond with module couplers <NUM> that define recesses <NUM> configured to receive and engage a respective tang <NUM> to couple the charging module <NUM> with the charging mount <NUM>. In some embodiments, the module couplers <NUM> may be positioned along the rear side <NUM> of the module casing <NUM>. In one aspect, the charging mount <NUM> and the charging module <NUM> may be removably coupled. When installing the charging module <NUM>, the tang <NUM> of each mount coupler <NUM> may initially deflect when abutting the module casing <NUM> and then engage a respective recess <NUM> for establishing a snap fit connection between the charging module <NUM> and the charging unit <NUM>. Other suitable methods for coupling the charging mount <NUM> with the charging module <NUM> may be utilized as desired, such as a threaded engagement or a hook and fastener engagement.

Referring to <FIG>, the module receiver <NUM> includes a coil receiver <NUM>. The coil <NUM>, when the charging module <NUM> is installed within the module receiver <NUM>, is positioned within the coil receiver <NUM>. In some embodiments, the shape of the coil receiver <NUM> may correspond to the shape of the portion of the charging module <NUM> which contains the coil <NUM>. In some embodiments, the charging module <NUM> may not include a separate portion or shape for the coil <NUM>, and the coil receiver <NUM> and the module receiver <NUM> may be the same feature.

Referring to <FIG>, in some embodiments the coil receiver <NUM> can define a recess <NUM>. The mount body <NUM> defines a thickness T1 which is greater than a thickness T2 of the mount body <NUM> which corresponds with the coil receiver <NUM>. As further shown in <FIG>, the recess <NUM> is defined as the mount body <NUM> and defines a thickness T2 which is greater than zero. When the thickness T2 is zero, the coil receiver <NUM> defines an aperture <NUM>, as shown in <FIG>.

As shown in <FIG>, the coil receiver <NUM> extends toward the front surface <NUM> of the charging mount <NUM> so that a distance D1 defined between the front surface <NUM> of the charging mount <NUM> and the coil receiver <NUM> is less than a distance D2 defined between the front surface <NUM> of the charging mount <NUM> and the rear surface <NUM> of the charging mount <NUM>. As such, when the coil <NUM> is positioned in the coil receiver <NUM>, a distance D3 defined between coil <NUM> and the front surface <NUM> of the charging mount <NUM> and subsequently a distance D4 defined between the coil <NUM> and the device coil <NUM>, are minimized to allow for improved interaction between the coil <NUM> and the device coil <NUM> during a wireless charging operation. In some embodiments, the distance D4 defined between the coil <NUM> and the device coil <NUM> to allow for greater operative interaction between the coil <NUM> and the device coil <NUM> may be equal to or less than about <NUM>. In some embodiments, a thickness of at least a portion of the front side <NUM> of the module casing <NUM> may be reduced in relation to the rear side <NUM> of the module casing <NUM> to further minimize the distance D4 between the coil <NUM> and the device coil <NUM>.

Referring to <FIG>, in one aspect the charging system <NUM> may be coupled with an external mount <NUM> to mount the charging system <NUM> and the portable device <NUM> (such as the portable device <NUM> illustrated in <FIG>), for example on a vehicle. As such, the portable device <NUM> may be used in a hands-free mode. In some embodiments, the external mount <NUM> may have one or more arms <NUM>. The arm, as illustrated in <FIG>, includes a plate <NUM>. The plate <NUM>, as illustrated, is substantially rectangular, but in other embodiments can be any other suitable shape such as circular, triangular, or ovoid. The plate <NUM> includes one or more holes <NUM>. The holes <NUM> are aligned with the external fasteners <NUM> positioned on the rear surface <NUM> of the mount body <NUM>. The external mount <NUM>, as illustrated in <FIG>, includes fasteners <NUM> which are configured to correspond with the external fasteners <NUM> of the mount body <NUM>. The fasteners <NUM> are inserted into and extend through the holes <NUM> to engage with the external fasteners <NUM>. The fasteners <NUM> can be removed from the external mount <NUM>. In some embodiments, the external mount <NUM> can include a plurality of arms <NUM>, and each arm <NUM> includes one or more holes <NUM> and/or fasteners <NUM>. In some embodiments, the external mount <NUM> may not include a plate <NUM>. In some embodiments, the external mount <NUM> may have not have holes <NUM>, and the fasteners <NUM> may be non-removable portions of the external mount <NUM>.

As illustrated in <FIG>, the external mount <NUM> includes <NUM> holes <NUM> formed on the plate <NUM> and <NUM> corresponding fasteners <NUM>. In some embodiments, the fasteners <NUM> and external fasteners <NUM> may have threaded engagements. In other embodiments, the fasteners <NUM> and external fasteners <NUM> may have snap fit connections. The fasteners <NUM> and external fasteners <NUM> may also be magnetic. Other suitable methods to couple the charging mount <NUM> with the external mount <NUM> may be utilized as desired, such as a hook and fastener engagement or an adhesive connection.

Referring to <FIG>, a flowchart is presented in accordance with an example embodiment. The method <NUM> is provided by way of example, as there are a variety of ways to carry out the method. The method <NUM> described below can be carried out using the configurations illustrated in <FIG>, for example, and various elements of these figures are referenced in explaining example method <NUM>. Each step shown in <FIG> represents one or more processes, methods or subroutines, carried out in the example method <NUM>. Furthermore, the illustrated order of blocks is illustrative only and the order of the blocks can change according to the present disclosure. Additional steps may be added or fewer blocks may be utilized, without departing from this disclosure. The example method <NUM> can begin at step <NUM>.

At step <NUM>, a charging mount <NUM> is provided. The charging mount <NUM> may include a mount body <NUM> which defines a rear surface <NUM> and a front surface <NUM> defined in opposite relation to the rear surface <NUM>. The rear surface <NUM> and the front surface <NUM> of the mount body <NUM> define a first thickness T1. The rear surface <NUM> of the mount body <NUM> includes a module receiver <NUM> with a coil receiver <NUM>. The mount body <NUM> corresponds with the coil receiver <NUM> and defines a second thickness T2 which is less than the first thickness T1. In some embodiments, as illustrated in <FIG>, the second thickness T2 may be greater than zero, and the coil receiver <NUM> may define a recess <NUM>. In other embodiments, as illustrated in <FIG>, the second thickness T2 may be zero, and the coil receiver <NUM> may define an aperture <NUM>.

At step <NUM>, the charging mount <NUM> is engaged with a portable device <NUM>. In some embodiments, portable device <NUM> may be encased in a protective case <NUM>, and the charging mount <NUM> may be engaged with the protective case <NUM>. The portable device <NUM> includes a device coil <NUM>. When engaged, the front surface <NUM> of the mount body <NUM> is engaged with the portable device <NUM> such that the front surface <NUM> of the mount body <NUM> is positioned adjacent to the portable device <NUM>.

At step <NUM>, a charging module <NUM> is positioned within the module receiver <NUM> provided on the rear surface <NUM> of the mount body <NUM>. The charging module <NUM> includes a coil <NUM> which is configured to interact with the device coil <NUM> to wireless charge the portable device <NUM>.

To minimize the distance D4 between the coil <NUM> and the device coil <NUM>, at step <NUM>, the coil <NUM> is positioned within the coil receiver <NUM>.

At step <NUM>, the charging module <NUM> is coupled with the charging mount <NUM>. In some embodiments, the charging module <NUM> may be coupled with the charging mount <NUM> by a snap fit connection or other suitable methods as discussed above.

At step <NUM>, the portable device <NUM> is wirelessly charged with the charging module <NUM> by the interaction of the coil <NUM> and the device coil <NUM>. The smaller the distance D4 between the coil <NUM> and the device coil <NUM>, the more efficiently and/or effectively the portable device <NUM> is charged.

In some embodiments, the charging mount <NUM> can also be coupled with an external mount <NUM> by one or more external fasteners <NUM> positioned on the rear surface <NUM> of the mount body <NUM> as discussed above.

Claim 1:
A charging apparatus (<NUM>) configured to couple to and wirelessly charge a portable device (<NUM>) having a device coil (<NUM>), the charging apparatus (<NUM>) comprising:
a charging mount (<NUM>) with a mount body (<NUM>) defining a rear surface (<NUM>) and a front surface (<NUM>) defined in opposite relation to the rear surface (<NUM>), the rear surface (<NUM>) and the front surface (<NUM>) of the mount body (<NUM>) defining a first thickness (T1), the front surface (<NUM>) of the mount body (<NUM>) configured to be engaged with the portable device (<NUM>) such that the front surface (<NUM>) of the mount body (<NUM>) is positioned adjacent to the portable device (<NUM>); and
a charging module (<NUM>) including a coil (<NUM>) operable to interact with the device coil (<NUM>) of the portable device (<NUM>) to wirelessly charge the portable device, the coil (<NUM>) being positioned within a coil receiver (<NUM>),
characterized by:
the rear surface (<NUM>) of the mount body (<NUM>) including a module receiver (<NUM>) with the coil receiver (<NUM>) that extends toward the front surface of the charging mount (<NUM>) so that the mount body (<NUM>) corresponding with the coil receiver (<NUM>) defines a second thickness (T2) between the front surface (<NUM>) of the mount body (<NUM>) and the coil receiver (<NUM>), wherein the second thickness (T2) is less than the first thickness (T1) such that the coil receiver (<NUM>) defines a recess (<NUM>), and
the charging module (<NUM>) being removably coupled with the charging mount (<NUM>) and positioned within the module receiver (<NUM>) on the rear surface (<NUM>) of the mount body (<NUM>).