Electric vehicle charging connector

Abstract

An electrical connector (10) includes: a plurality of cylindrical electrical terminals (12) connected to ends of a plurality of first cables (14); a housing (18) defining a plurality of housing terminal cavities (16), wherein the plurality of cylindrical electrical terminals (12) are disposed; and a cover (20) attached to the housing (18), having a plurality of cover cavities (22) axially aligned with the plurality of housing terminal cavities (16). The plurality of cover cavities (22) are configured to receive the plurality of cylindrical electrical terminals (12) when the plurality of cylindrical electrical terminals (12) are inserted into the plurality of housing terminal cavities (16).

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of priority to U.S. patent application Ser. No. 16 / 999,776, filed on Aug. 21, 2020, which is incorporated herein by reference in its entirety. Technical Field

[0003] The present invention relates generally to electrical connectors, and more particularly to electrical connectors for electric vehicle charging applications. Background Art

[0004] Electric vehicle charging connectors, such as those compliant with the Society of Automotive Engineers (SAE) J1772, International Electrotechnical Commission (IEC) 62196, Japan Automobile Research Institute CHAdeMO, or Goubiao / T (GBT) 20234.1 standards, are typically bulky and difficult to assemble. Figure 1 The example shown involves machining many separate wiring leads, terminals, seals, retainers, and fasteners, resulting in a complex assembly. Additionally, this electric vehicle charging connector is designed and constructed to be repairable. Summary of the Invention

[0005] Given that an electric vehicle charging connector undergoes a large number of mating / unmating cycles during its service life, the inventors have recognized a need to create an electric vehicle charging connector that is repairable and / or has replaceable contacts and terminals.

[0006] According to one or more aspects of the present disclosure, an electrical connector includes: a plurality of cylindrical electrical terminals connected to the ends of a plurality of first cables; a housing defining a plurality of shell terminal cavities in which the plurality of cylindrical electrical terminals are placed; and a cover attached to the housing, the cover having a plurality of cover cavities axially aligned with the plurality of shell terminal cavities, the plurality of cover cavities being configured to receive the plurality of cylindrical electrical terminals when the plurality of cylindrical electrical terminals are inserted into the plurality of shell terminal cavities.

[0007] In one or more embodiments of the electrical connector according to the previous paragraph, the electrical connector may further include a plurality of terminal retainers surrounding the plurality of first cables, the terminal retainers being configured to cooperate with the plurality of cover cavities to retain the plurality of cylindrical electrical terminals within the plurality of housing terminal cavities.

[0008] In one or more embodiments of the electrical connector according to any of the preceding paragraphs, the electrical connector may further include a plurality of first cable seals surrounding the plurality of first cables, the first cable seals being configured to provide an environmental seal between the plurality of first cables, the plurality of terminal retainers, and the inner walls of the plurality of cover cavities.

[0009] In one or more embodiments of the electrical connector according to any of the preceding paragraphs, the electrical connector may further include a yoke configured to separate the plurality of first cables and configured to secure the plurality of terminal retainers within the plurality of cover cavities.

[0010] In one or more embodiments of the electrical connector according to any of the preceding paragraphs, the cover can define a plurality of cover terminal cavities configured to receive a plurality of planar electrical terminals attached to the plurality of second electrical cables. The plurality of planar electrical terminals can be attached to a plurality of conductive members disposed within the cover via a plurality of threaded fasteners.

[0011] In one or more embodiments of the electrical connector according to any of the preceding paragraphs, one of the plurality of planar electrical terminals may be laterally and longitudinally offset from another of the plurality of planar electrical terminals.

[0012] In one or more embodiments of the electrical connector according to any of the preceding paragraphs, the cover can define an access port (access portal) positioned, sized, and arranged to allow tool access to the plurality of threaded fasteners.

[0013] In one or more embodiments of the electrical connector according to any of the preceding paragraphs, the electrical connector may further include a plurality of second cable seals surrounding the plurality of second cables, the second cable seals being configured to provide an environmental seal between the plurality of second cables and inner walls of the plurality of cover terminal cavities.

[0014] In one or more embodiments of the electrical connector according to any of the preceding paragraphs, the electrical connector may further include a plurality of second cable retainers configured to retain the plurality of second cable seals within the plurality of cover terminal cavities.

[0015] In one or more embodiments of the electrical connector according to any of the preceding paragraphs, the electrical connector may further include a removable access plug configured to seal the access port.

[0016] In one or more embodiments of the electrical connector according to any of the preceding paragraphs, the cover can be configured to route the plurality of first cables and the plurality of second cables in a rightward direction, a leftward direction, or a downward direction.

[0017] In one or more embodiments of the electrical connector according to any of the preceding paragraphs, the housing may include a printed circuit board assembly defining a plurality of circuit board apertures through which the plurality of cylindrical electrical terminals extend.

[0018] In one or more embodiments of the electrical connector according to any of the preceding paragraphs, the printed circuit board assembly may include a connector header, and wherein the connector header is sealed to the cover.

[0019] According to one or more aspects of the present disclosure, a method for assembling an electrical connector includes inserting a plurality of cylindrical electrical terminals connected to ends of a plurality of first cables into a plurality of shell terminal cavities of a connector device, the connector device having a shell defining the plurality of shell terminal cavities and a cover attached to the shell, the cover having a plurality of cover cavities axially aligned with the plurality of shell terminal cavities, wherein the plurality of cover cavities receive the plurality of cylindrical electrical terminals when inserted into the plurality of shell terminal cavities.

[0020] In one or more embodiments of the method according to the preceding paragraph, the method may further include attaching a plurality of terminal retainers to a plurality of first cables, wherein the plurality of first cables cooperate with the plurality of cover cavities to retain the plurality of cylindrical electrical terminals within the plurality of housing terminal cavities.

[0021] In one or more embodiments of the method according to any of the preceding paragraphs, the method may further include inserting a plurality of planar electrical terminals attached to a plurality of second cables into a plurality of cover terminal cavities defined by the cover, and attaching the plurality of planar electrical terminals to a plurality of conductive members disposed within the cover via a plurality of threaded fasteners.

[0022] In one or more embodiments of the method according to any of the preceding paragraphs, the method may further include laterally and longitudinally offsetting one of the plurality of planar electrical terminals from another of the plurality of planar electrical terminals.

[0023] In one or more embodiments of the method according to any of the preceding paragraphs, the method may further include inserting a removable passage plug into an access port positioned, sized, and arranged to allow tool access to the plurality of threaded fasteners.

[0024] In one or more embodiments of the method according to any of the preceding paragraphs, the method may further include inserting a plurality of cylindrical electrical terminals through a plurality of circuit board holes defined by a printed circuit board assembly disposed within the housing. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 is an exploded perspective view of an electric vehicle charging connector according to the prior art;

[0026] Figure 2 is a perspective view of an electric vehicle charging connector according to some embodiments;

[0027] Figure 3 According to some embodiments Figure 1 An exploded perspective view of an electric vehicle charging connector;

[0028] Figure 4 According to some embodiments Figure 1A partially exploded perspective view of an electric vehicle charging connector;

[0029] Figure 5A According to some embodiments Figure 1 A perspective view of a cable retainer of an electric vehicle charging connector;

[0030] Figure 5B According to some embodiments Figure 5B A perspective view of the cable holder partially mounted on the cable; and

[0031] Figure 6 According to some embodiments Figure 1 An exploded cross-sectional view of an electric vehicle charging connector;

[0032] Figure 7 According to some embodiments Figure 6 A cross-sectional view of an electric vehicle charging connector;

[0033] Figure 8 According to some embodiments Figure 1 Another exploded view of the electric vehicle charging connector;

[0034] Figure 9 According to some embodiments Figure 1 A partial front view of an electric vehicle charging connector;

[0035] Figure 10 According to some embodiments Figure 1 Another exploded view of the electric vehicle charging connector;

[0036] Figure 11 According to some embodiments Figure 10 X-ray exploded view of the electric vehicle charging connector;

[0037] Figure 12 According to some embodiments Figure 10 X-ray assembly view of an electric vehicle charging connector;

[0038] Figure 13 According to some embodiments Figure 12 A front view of an electric vehicle charging connector;

[0039] Figure 14 According to some embodiments Figure 1 X-ray view of an electric vehicle charging connector;

[0040] Figure 15 According to some embodiments Figure 1 A partially assembled view of an electric vehicle charging connector;

[0041] Figure 16 According to some embodiments Figure 1 A cross-sectional view of an electric vehicle charging connector;

[0042] Figure 17 According to some embodiments Figure 1 A cross-sectional view of a connector head of an electric vehicle charging connector;

[0043] Figure 18 is a perspective view of an electric vehicle charging connector according to some embodiments, wherein the cables are laid in a rightward direction;

[0044] Figure 19 is a perspective view of an electric vehicle charging connector according to some embodiments, wherein the cable is laid in a leftward direction;

[0045] Figure 20 is a perspective view of an electric vehicle charging connector according to some embodiments, wherein the cable is laid in a downward direction;

[0046] Figure 21 According to some embodiments Figure 18 A front view of an electric vehicle charging connector; and

[0047] Figure 22 is a flow chart of a method of assembling an electrical connector according to some embodiments. DETAILED DESCRIPTION

[0048] An example of an electrical connector, such as an electric vehicle charging connector, is shown in Figures 2 to 21 This electrical connector is used to interconnect three alternating current (AC) cables and two high-power direct current (DC) cables, such as those used in the SAE J1772 Combined Charging System (CCS).

[0049] The electrical connector 10 includes a plurality of cylindrical AC electrical terminals 12 that connect to the ends of an AC cable 14. When assembled, the AC terminals 12 are disposed within an AC terminal cavity 16 defined by a dielectric housing 18 of the electrical connector 10. A dielectric cover 20 is attached to the housing 18. The cover 20 has a plurality of cover cavities 22 that are axially aligned with the AC terminal cavities 16 and extend through the cover 20. Figure 6 and Figure 7 As shown, the cover cavity 22 is configured to receive the AC terminal 12 when the AC terminal 12 is inserted into the AC terminal cavity 16. The electrical connector 10 further includes a printed circuit board (PCB) assembly 24, such as Figure 15 As best shown, a PCB assembly 24 is within the housing 18. The PCB assembly 24 defines a circuit board aperture through which the AC terminals 12 extend. The PCB assembly 24 includes a connector header (plug / receptacle) 26 that is sealed to the cover 20.

[0050] The electrical connector 10 also includes a compliant terminal seal 28 that provides an environmental seal between the AC terminal 12 and the cover 20. The terminal seal 28 is located between the housing 18 and the cover 20. The terminal seal 28 is described in more detail in U.S. Patent Application No. TBD, the entire disclosure of which is incorporated by reference. A dielectric terminal retainer 30 surrounding the AC cable 14 cooperates with the cover cavity 22 to secure the AC terminal 12 within the AC terminal cavity 16. An AC cable seal 32 surrounding the AC cable 14 is configured to provide an environmental seal between the AC cable 14, the terminal retainer 30, and the inner wall of the cover cavity 22. A dielectric yoke 36 is fastened to the cover 20 by screws or other fasteners and is configured to separate the AC cable 14 and secure the terminal retainer 30 within the cover cavity 22.

[0051] The cover 20 also defines a plurality of cover terminal cavities 38, see Figure 10 These cover terminal cavities are configured to receive pairs of planar DC electrical terminals 40 or busbars attached to DC cables 42 that are sized to carry more power than the AC cables 14. The planar DC terminals 40 are attached to pairs of conductive members that form cylindrical DC electrical terminals 44, as shown in FIG. Figure 15 As best shown in FIG, these conductive components are disposed within housing 18. Planar DC terminal 40 is attached to cylindrical DC terminal 4 by threaded fasteners, such as hexagonal or socket head bolts. Figure 10 As shown, the hole on the planar DC electrical terminal 40 can be keyed with the cylindrical DC terminal 44 to ensure proper alignment between the planar DC electrical terminal 40 and the cylindrical DC terminal 44. Figure 12 As best shown, the cylindrical DC terminals 44 are positioned, sized, and arranged so that one of the planar DC terminals 40 is laterally and longitudinally offset relative to the other planar DC electrical terminal 40. The electrical connector 10 includes a pair of DC cable seals 46, such as Figure 10 As shown, surrounding the DC cable 42, the DC cable seal 46 is configured to provide an environmental seal between the DC cable 42 and the inner wall of the cover terminal cavity 38. The cover 20 has a pair of DC cable retainers 48 configured to retain the DC cable seal 46 within the cover terminal cavity 38.

[0052] The cover 20 defines an access port (access portal) 50 , which is positioned, sized, and arranged to allow a tool, such as a screwdriver, to access the threaded fasteners. A removable access plug 52 having an access seal 54 is used to cover and seal the access port 50 .

[0053] like Figure 18-20As shown in FIG, the cover may be configured to route the plurality of first cables and the plurality of second cables in a rightward direction (cover 20), a leftward direction (cover 20'), or a downward direction (cover 20").

[0054] The electrical connector 10 is designed as a "device" that allows the user to directly insert the plug terminals 12, 40 and the connector into it, and is manufactured Figure 1 Compared to the construction steps required for the electric vehicle charging connector shown, the construction steps of the wiring harness assembly are simplified. This makes the electrical connector 10 a "pluggable" solution. The AC terminal 12 is directly inserted through the pre-assembled device, namely the housing 18, the PCB assembly 24 and the terminal seal 28. All low-voltage signals, such as thermistor and / or vehicle control signals, are routed through the connector end 26 on the PCB assembly 24, which allows the low-voltage connector to be directly plugged into the PCB assembly 24. The flat DC terminal 40 has a bolt connection with the cylindrical DC terminal 44. The AC terminal 12 and the flat DC terminal 40 can be easily removed from the electrical connector 10, allowing the electrical connector 10 to be replaced without having to replace the wiring harness attached to the electrical connector 10, thereby reducing repair and warranty costs. The design is also "modular", allowing the product to accommodate a variety of cable routing orientations by simply changing the cover 20, which has a minimal impact on the overall design cost of the electrical connector 10.

[0055] The electrical connector 10 described herein provides the following benefits:

[0056] The construction process for manufacturing a wiring harness including the electrical connector 10 is significantly simplified by reducing assembly operations by more than 50%.

[0057] Makes the electrical connector 10 repairable; the AC terminals 12 and DC terminals 40 can be removed from the electrical connector 10 and replaced.

[0058] Make the housing subassembly a “pluggable device”, allowing terminals / connectors to be inserted and passed through.

[0059] Providing modular electrical connectors 10, 10', 10", which can adapt to various cable laying orientations simply by changing the covers 20, 20', 20".

[0060] Eliminates the need to manage complex low voltage wire routing within the electrical connector 10.

[0061] Eliminates the need for frosted seals, which add complexity and labor costs to the assembly process.

[0062] Meets ingress protection code ratings of IP6K9K according to International Electrotechnical Commission standard 60529.

[0063] Figure 22An example of a method 100 for assembling an electrical connector, such as an electric vehicle charging connector, is shown in FIG. The method 100 includes the following steps:

[0064] Step 102: Inserting a plurality of cylindrical electrical terminals connected to the ends of a plurality of first cables into a plurality of housing terminal cavities of a connector device, the connector device having a housing defining a plurality of housing terminal cavities and a cover attached to the housing and having a plurality of cover cavities, the cover cavities being axially aligned with the plurality of housing terminal cavities. Step 102 includes inserting a plurality of cylindrical electrical terminals 12 connected to the ends of a plurality of first cables 14 into a plurality of housing terminal cavities of a connector device 10, the connector device 10 having a housing 18 defining a plurality of housing terminal cavities 16 and a cover attached to the housing 18 and having a plurality of cover cavities 22, the plurality of cover cavities 22 being axially aligned with the plurality of housing terminal cavities 16. Figure 6 As shown, the plurality of cover cavities 22 receive the plurality of cylindrical electrical terminals 12 when the plurality of cover cavities 22 are inserted into the plurality of housing terminal cavities 16 .

[0065] Step 104, "Insert a plurality of cylindrical electrical terminals through a plurality of circuit board holes defined by a printed circuit board assembly 24 disposed within the housing," includes inserting a plurality of cylindrical electrical terminals 12 through a plurality of circuit board holes defined by a printed circuit board assembly 24 disposed within the housing 18, such as Figure 6 As shown in .

[0066] Step 106, "Attaching a plurality of terminal retainers to a plurality of first cables," includes attaching a plurality of terminal retainers 30 to a plurality of first cables 14, such as Figure 5B As shown. Figure 7 As shown, a plurality of first electrical cables cooperate with a plurality of cover cavities to retain a plurality of cylindrical electrical terminals within a plurality of housing terminal cavities.

[0067] Step 108, "Inserting a plurality of planar electrical terminals attached to a plurality of second electrical cables within a plurality of cover terminal cavities defined by the cover," includes inserting a plurality of planar electrical terminals 40 attached to a plurality of second electrical cables 42 within a plurality of cover terminal cavities 38 defined by the cover 20, as shown. Figure 10-12 As shown;

[0068] Step 110, "Attaching a plurality of planar electrical terminals to a plurality of conductive members disposed within the cover via a plurality of threaded fasteners," includes attaching a plurality of planar electrical terminals 40 to a plurality of conductive members 44 disposed within the cover 20 via a plurality of threaded fasteners, such as Figure 11 and 12 As shown;

[0069] Step 112, "laterally and longitudinally offsetting another planar electrical terminal in the plurality of planar electrical terminals from one planar electrical terminal in the plurality of planar electrical terminals," includes laterally and longitudinally offsetting another planar electrical terminal 40 in the plurality of planar electrical terminals from one planar electrical terminal 40 in the plurality of planar electrical terminals, such as Figure 12 shown; and

[0070] Step 114, "Insert a removable access plug into an access port positioned, sized, and arranged to allow tool access to a plurality of threaded fasteners," includes inserting a removable access plug 52 into the access port 50 defined by the cover 20. Figure 10 As shown, the access port 50 is positioned, sized, and arranged to allow tool access to a plurality of threaded fasteners.

[0071] While the embodiments described herein are used as electric vehicle charging connectors, alternative embodiments of the electrical connector are contemplated for use in other connection applications.

[0072] Although the present invention has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present invention. In addition, various modifications may be made to adapt circumstances or materials to the teachings of the present invention without departing from its broad scope. Therefore, the present invention is not intended to be limited to the disclosed embodiments, but is intended to include all embodiments falling within the scope of the appended claims.

Claims

1. An electrical connector (10), comprising: a plurality of cylindrical electrical terminals (12) connected to ends of a plurality of first electrical cables (14); a housing (18) defining a plurality of housing terminal cavities (16) in which the plurality of cylindrical electrical terminals (12) are disposed; and a cover (20) attached to the housing (18), the cover having a plurality of cover cavities (22) axially aligned with the plurality of housing terminal cavities (16), the plurality of cover cavities (22) being configured to receive the plurality of cylindrical electrical terminals (12) when the plurality of cylindrical electrical terminals (12) are inserted into the plurality of housing terminal cavities (16), A plurality of cover terminal cavities (38), the cover terminal cavities (38) being configured to receive a plurality of planar electrical terminals (40) attached to a plurality of second cables (42), and wherein the plurality of planar electrical terminals (40) are attached to a plurality of conductive members (44) disposed within the cover (20) via a plurality of threaded fasteners, wherein one planar electrical terminal (40) of the plurality of planar electrical terminals (40) is laterally and longitudinally offset relative to another planar electrical terminal (40) of the plurality of planar electrical terminals (40), and wherein holes in the planar electrical terminals (40) are keyed to the conductive members (44) to ensure alignment between the planar electrical terminals (40) and the conductive members (44).

2. The electrical connector (10) according to claim 1, characterized in that: Further included is a terminal seal (28) configured to provide an environmental seal between the plurality of cylindrical electrical terminals (12) and the cover (20), the terminal seal (28) being disposed between the housing (18) and the cover (20).

3. The electrical connector (10) according to claim 1, characterized in that Further comprising a plurality of terminal retainers (30) surrounding the plurality of first cables (14), the terminal retainers (30) being configured to cooperate with the plurality of cover cavities (22) to retain the plurality of cylindrical electrical terminals (12) within the plurality of housing terminal cavities (16).

4. The electrical connector (10) according to claim 3, characterized in that: Further comprising a plurality of first cable seals (32) surrounding the plurality of first cables (14), the first cable seals (32) being configured to provide an environmental seal between the plurality of first cables (14), the plurality of terminal retainers (30), and inner walls of the plurality of cover cavities (22).

5. The electrical connector (10) according to claim 3, further comprising a yoke (36), wherein the yoke (36) is configured to separate the plurality of first cables (14) and to secure the plurality of terminal retainers (30) within the plurality of cover cavities (22).

6. The electrical connector (10) according to claim 1, characterized in that The cover (20) defines access ports positioned, sized, and arranged to allow tool access to the plurality of threaded fasteners.

7. The electrical connector (10) according to claim 6, characterized in that: Further included are a plurality of second cable seals (46) surrounding the plurality of second cables (42), the plurality of second cable seals (46) being configured to provide an environmental seal between the plurality of second cables (42) and inner walls of the plurality of cover terminal cavities (38).

8. The electrical connector (10) according to claim 7, characterized in that: Further included are a plurality of second cable retainers (48) configured to retain the plurality of second cable seals (46) within the plurality of cover terminal cavities (38).

9. The electrical connector (10) according to claim 7, characterized in that: Further included is a removable access plug (52) configured to seal the access port.

10. The electrical connector (10, 10', 10") according to claim 1, characterized in that The cover (20, 20', 20") can be configured to lay the plurality of first cables (14) and the plurality of second cables (42) in a rightward direction, a leftward direction, or a downward direction.

11. The electrical connector (10) according to claim 1, characterized in that The housing (18) includes a printed circuit board assembly (24) defining a plurality of circuit board apertures through which the plurality of cylindrical electrical terminals (12) extend.

12. The electrical connector (10) according to claim 11, characterized in that The printed circuit board assembly (24) includes a connector header (26), and wherein the connector header (26) is sealed to the cover (20).

13. The electrical connector (10) according to claim 1, characterized in that The electrical connector is an electric vehicle charging connector, which is used to interconnect three AC cables and two high-power DC cables. The plurality of cylindrical electrical terminals are three AC electrical terminals, and the plurality of conductive members (44) are DC terminals.

14. A method (100) of assembling an electrical connector (10), comprising: inserting (102) a plurality of cylindrical electrical terminals (12) connected to ends of a plurality of first electrical cables (14) into a plurality of housing terminal cavities (16) of a connector device, the connector device having a housing (18) defining the plurality of housing terminal cavities (16) and a cover (20) attached to the housing (18), the cover having a plurality of cover cavities (22) axially aligned with the plurality of housing terminal cavities (16), wherein the plurality of cover cavities (22) receive the plurality of cylindrical electrical terminals (12) when the plurality of cylindrical electrical terminals (12) are inserted into the plurality of housing terminal cavities (16), inserting (104) the plurality of cylindrical electrical terminals (12) through a plurality of circuit board holes defined by a printed circuit board assembly (24) disposed within the housing (18), inserting (108) a plurality of planar electrical terminals (40) attached to a plurality of second electrical cables (42) within a plurality of cover terminal cavities (38) defined by the cover (20); and The plurality of planar electrical terminals (40) are attached (110) to a plurality of conductive members (44) disposed within the cover (20) via a plurality of threaded fasteners, wherein one planar electrical terminal (40) of the plurality of planar electrical terminals (40) is offset laterally and longitudinally relative to another planar electrical terminal (40) of the plurality of planar electrical terminals (40), and wherein holes in the planar electrical terminals (40) are keyed to the conductive members (44) to ensure alignment between the planar electrical terminals (40) and the conductive members (44).

15. The method (100) according to claim 14, characterized in that Further including: A plurality of terminal retainers (30) are attached (106) to the plurality of first electrical cables (14), wherein the plurality of first electrical cables (14) cooperate with the plurality of cover cavities (22) to retain the plurality of cylindrical electrical terminals (12) within the plurality of housing terminal cavities (16).

16. The method (100) according to claim 14, characterized in that Further including: A removable access plug (52) is inserted (114) into an access port positioned, sized, and arranged to allow tool access to the plurality of threaded fasteners.

17. The method (100) according to claim 14, characterized in that The electrical connector is an electric vehicle charging connector, which is used to interconnect three AC cables and two high-power DC cables. The plurality of cylindrical electrical terminals are three AC electrical terminals, and the plurality of conductive members are DC terminals.

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