Charging connector

Abstract

A charging connector includes a lock lever having a latch, a cooperative portion, a switch mechanism, and a temporary holding mechanism. The latch is movable between an engagement position and a release position via a predetermined position. When the latch is positioned at the engagement position, the switch mechanism is positioned at an initial position. The switch mechanism includes a pressing portion. When the latch is positioned between the engagement position and the predetermined position, the temporary holding mechanism temporarily holds the switch mechanism at the initial position. When the latch is positioned between the predetermined position and the release position, the cooperative portion presses the pressing portion of the switch mechanism to move the switch mechanism from the initial position to abut against the temporary holding mechanism, thereby changing a state of the switch body from an initial state to a release state.

Description

TECHNICAL FIELD

[0001] The present application relates to a charging connector. BACKGROUND

[0002] For example, a connector of this type is disclosed in JP 2012-099254 A (Patent Document 1), the contents of which are incorporated herein by reference.

[0003] REFERENCE FIG. 16 Patent Document 1 discloses a connector 90 that can be mated with a mating connector 98. In a mating state in which the connector 90 is mated with the mating connector 98, the connector 90 supplies electric power to the mating connector 98. Therefore, the connector 90 is a charging connector.

[0004] The connector 90 includes a lock lever 91, a switch 93, and a pressable portion (operation portion) 95. The lock lever 91 has an engaging portion (latch) 92. The switch 93 has a driving portion 94. The operation portion 95 can operate a release portion 96. The lock lever 91 is supported by a shaft so that the latch 92 is vertically movable.

[0005] The latch 92 is moved downward in an intermediate state shown in FIG. 1, in which the connector 90 is in a process of being mated with the mating connector 98. The latch 92 is moved upward in a mating state (not shown). When the latch 92 is moved upward, the latch 92 engages with an engaging portion (mating latch) 99 of the mating connector 98 to be locked. In this state, electric power is supplied to the mating connector 98. When the operation portion 95 is operated after charging, the release portion 96 pushes the lock lever 91 from below so that the latch 92 is moved downward. As a result, the latch 92 is unlocked. FIG. 16 When the latch 92 is moved downward, the lock lever 91 pushes the driving portion 94 of the switch 93 downward so that the switch 93 is in a released state in which the switch 93 is unlocked. When the latch 92 is moved upward, the driving portion 94 is not pressed so that the switch 93 is in a state different from the released state.

[0006] As described above, according to Patent Document 1, the state of the switch is changed depending on the operation of the operation portion. However, two requirements described below are required for a charging connector. The first requirement is that the state of the switch is not changed to the released state even if the operation portion is operated in a locked state in which the latch is locked. The second requirement is that the released state of the switch is maintained until mating of the connector is completed.

[0007] SUMMARY

[0008] Therefore, an object of the present application is to provide a charging connector including a switch, the state of which is not changed to a released state even if an operation portion is operated in a locked state, and the switch is maintained in the released state until mating of the connector is completed. ​

[0009] Generally, when the latch is engaged, the locking portion regulates the movement of the locking lever to lock the latch. However, the locking lever has a play in the locked state. According to the first requirement, the state of the switch does not change as long as the locking lever moves within a range defined by the play. Therefore, in order to satisfy the first requirement, the switch should be disposed near a portion of the locking lever that moves only slightly according to the operation of the operation portion. More specifically, the switch should be disposed near the rotational axis of the locking lever.

[0010] In order to satisfy the second requirement, the switch should continuously maintain the released state unless the latch is engaged with the counterpart latch. In other words, the switch should continuously maintain the released state even when the latch moves vertically only slightly. Therefore, in order to satisfy the second requirement, the switch should be disposed near a portion of the locking lever that moves to a large extent according to the operation of the operation portion. More specifically, the switch should be disposed away from the rotational axis of the locking lever.

[0011] As can be seen from the above description, when the charging connector includes a small switch that is commonly used, the charging connector cannot satisfy both the first and second requirements.

[0012] The inventor of the present invention conceived a novel structure of a charging connector that satisfies both the first and second requirements. According to the novel structure, the charging connector is provided with a switch mechanism, a temporary holding mechanism, and a cooperative portion. The temporary holding mechanism temporarily holds the switch mechanism at an initial position. The cooperative portion controls the position of the switch mechanism in cooperation with the movement of the locking lever. In detail, the temporary holding mechanism positions the switch mechanism at the initial position unless the latch moves beyond a range defined by the play of the locking lever. In addition, when the latch moves beyond the range defined by the play of the locking lever, the cooperative portion moves the switch mechanism to abut against the temporary holding mechanism. The first and second requirements can be satisfied by the functions of the above-described switch mechanism, temporary holding mechanism, and cooperative portion. More specifically, an aspect of the present invention provides a charging connector as described below.

[0013] An aspect of the present application provides a charging connector including a connector main body, a lock lever, an operation portion, a cooperative portion, a switch mechanism, and a temporary holding mechanism. The lock lever is incorporated into the connector main body. The lock lever has a latch. The latch is moved in a vertical direction between an engagement position and a release position via a predetermined position according to operation of the operation portion. The cooperative portion is moved in the vertical direction in cooperation with movement of the latch in the vertical direction. The switch mechanism is incorporated into the connector main body so as to be movable in the vertical direction. The switch mechanism is located in an initial position when the latch is located in the engagement position. The switch mechanism includes a switch main body and a pressing portion. The switch main body assumes an initial state when the switch mechanism is located in the initial position. The temporary holding mechanism temporarily holds the switch mechanism in the initial position when the latch is located between the engagement position and the predetermined position. The cooperative portion presses the pressing portion of the switch mechanism to move the switch mechanism from the initial position to abut against the temporary holding mechanism when the latch is located between the predetermined position and the release position, thereby changing a state of the switch main body from the initial state to a release state.

[0014] The temporary holding mechanism of the aspect of the present application temporarily holds the switch mechanism in the initial position, in which the switch mechanism assumes the initial state when the latch is located between the engagement position and the predetermined position or close to the engagement position. Therefore, in a state where the latch is locked, the switch mechanism is held in the initial position as long as the lock lever is moved within a range defined by a play according to operation of the operation portion. Thus, the first requirement is satisfied. Further, the cooperative portion moves the switch mechanism from the initial position to change the state of the switch main body to the release state when the latch is located between the predetermined position and the release position or away from the engagement position beyond the predetermined position. Therefore, the release state of the switch mechanism is maintained until mating of the charging connector is completed so that the latch is located between the engagement position and the predetermined position. Thus, the second requirement is satisfied.

[0015] As described above, the aspect of the present application provides a charging connector including a switch, which does not change a state to a release state even when an operation portion is operated in a locked state, and which is maintained in the release state until mating of the charging connector is completed.

[0016] The object of the present application will be understood and its structure will be more fully appreciated by studying the following description of the preferred embodiments, when taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF DRAWINGS

[0017] FIG. 1 is a perspective view showing a connector according to an embodiment of the present application.

[0018] FIG. 2 is a side view showing FIG. 1 the connector of

[0019] FIG. 3 is an exploded perspective view showing the connector of FIG. 1 .

[0020] FIG. 4 is an exploded perspective view showing the internal components of the connector of FIG. 3 .

[0021] FIG. 5 is a perspective view showing a sub-assembly of the internal components of FIG. 4 .

[0022] FIG. 6 is an exploded perspective view showing a sub-assembly of FIG. 5 .

[0023] FIG. 7 is another perspective view showing a sub-assembly of FIG. 5 .

[0024] FIG. 8 is an exploded perspective view showing a sub-assembly of FIG. 7 .

[0025] FIG. 9 is a side view showing the switching mechanism of a sub-assembly of FIG. 8 .

[0026] FIG. 10 is an exploded perspective view showing the switching mechanism of FIG. 9 .

[0027] FIG. 11 is a side view showing the reinforcing member of a sub-assembly of FIG. 8 .

[0028] FIG. 12 is a cross-sectional view showing the internal components of the connector of FIG. 3 , wherein the connector is in a disengaged state, the connector is disengaged from the portal, the latches are in an engaged position, the overall charging unit is not shown but only the upper end of the charging unit is shown, a portion of the outline of the portal is shown in dashed lines, and the outline of the latches in the released position is shown in dot-dash lines.

[0029] FIG. 13 is a cross-sectional view showing the internal components of the connector of FIG. 12 , wherein the connector is in an intermediate state, here the connector is in the process of being docked with the portal, and the latches are in a released position.

[0030] FIG. 14 is a cross-sectional view showing the internal components of FIG. 12 , wherein the connector is in a docked state, here the connector is docked with the portal, and the latches are in an engaged position.

[0031] FIG. 15 is aFIG. 12 A cross-sectional view of the internal components, wherein the connector is in a fully mated state, where the connector is fully mated with the inlet, and the operating part is operated so that the latch is in a predetermined position.

[0032] FIG. 16 This is a partial side view showing the charging connector and mating connector of Patent Document 1 together.

[0033] While the invention is open to various modifications and alternatives, specific embodiments thereof are illustrated by way of example in the accompanying drawings and will be described in detail herein. However, it should be understood that the drawings and their detailed description are not intended to limit the invention to the specific forms disclosed; rather, the invention is intended to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims. Detailed Implementation

[0034] Reference FIG. 1 According to an embodiment of the present invention, the charging connector 10 is a connector configured to supply power from an electrical system (not shown) such as an electric vehicle (EV) station to a mating device (not shown) such as a charging device incorporated in an electric vehicle.

[0035] Reference FIG. 2 The charging connector 10 is connected to the power system (not shown) via a cable 70. A mating device (not shown) has an inlet 80. The charging connector 10 mates with the inlet 80 in the forward-backward direction. In this embodiment, the forward-backward direction is the X direction. In this embodiment, "forward" represents the positive X direction, and "backward" represents the negative X direction. (The last sentence appears to be incomplete and possibly refers to a different embodiment.) FIG. 2 When the charging connector 10 and the inlet 80 are connected to each other, the power of the power system is supplied to the mating device through the cable 70, the charging connector 10 and the inlet 80.

[0036] The charging connector 10 of this embodiment will then be described.

[0037] refer to FIG. 1 and FIG. 3 The charging connector 10 of this embodiment includes a front cover 12 made primarily of an insulator, two side covers 13 each made primarily of an insulator, a charging unit 15, a sub-assembly 19, and a rotating shaft 68 made of metal. The front cover 12, the side covers 13, and the charging unit 15 are combined to form a connector body 11. Therefore, the charging connector 10 includes a connector body 11, a sub-assembly 19, and a rotating shaft 68. The connector body 11 includes the front cover 12, the side covers 13, and the charging unit 15.

[0038] The charging unit 15 is a member that provides a charging function to the charging connector 10 and is connected to the cable 70. The sub-assembly 19 is a member for controlling charging. The rotation shaft 68 is a member for attaching the sub-assembly 19 to the charging unit 15. The rotation shaft 68 is a pin having a cylindrical shape and extending linearly in the lateral direction. The sub-assembly 19 and the charging unit 15 are combined with each other into the inner assembly 14 by using the rotation shaft 68. The front cover 12 and the side covers 13 cover and protect the inner assembly 14.

[0039] The inner assembly 14 is housed in the charging connector 10 and attached to the side covers 13 so as to be located between the two side covers 13 in the lateral direction perpendicular to the front-rear direction. The lateral direction of the present embodiment is the Y direction. The inner assembly 14 attached to the side covers 13 is covered from the front by the front cover 12.

[0040] The charging unit 15 of the present embodiment includes two terminals 16, each of which is made of a conductor. Each terminal 16 is connected to a core wire (not shown) of the cable 70 and can receive electric power of a power system (not shown). See FIG. 4 The charging unit 15 has two side walls 17. Each side wall 17 is located at an upper end of the charging unit 15 in the up-down direction perpendicular to the front-rear direction and the lateral direction. The up-down direction of the present embodiment is the Z direction. In the present embodiment, "upward" means the positive Z direction and "downward" means the negative Z direction. The two side walls 17 are separated from each other in the lateral direction and extend parallel to each other along a vertical plane (XZ plane) perpendicular to the lateral direction.

[0041] Each side wall 17 is formed with a press-fit hole 178. Each press-fit hole 178 is a circular hole and passes laterally through the side wall 17. Each press-fit hole 178 has a size that allows the rotation shaft 68 to be press-fitted thereto. The two press-fit holes 178 are located at the same position as each other in the XZ plane.

[0042] The charging unit 15 has a locking portion 18. Therefore, the connector main body 11 includes the locking portion 18. The locking portion 18 is located at a lower end of the side wall 17 in the up-down direction and between the two side walls 17 in the lateral direction. The locking portion 18 is used to lock a portion of the lower end of the sub-assembly 19, as described below. See FIG. 4 and FIG. 12 The locking portion 18 of the present embodiment is a plane extending along a horizontal plane (XY plane) perpendicular to the up-down direction. However, the present application is not limited thereto. For example, the shape of the locking portion 18 is not particularly limited. In addition, the locking portion 18 can also be a portion of a member other than the charging unit 15.

[0043] Referring to FIG. 4 The sub-assembly 19 is formed with a center hole 66. The center hole 66 is a circular hole and passes laterally through the sub-assembly 19. The center hole 66 has a size that allows the rotation shaft 68 to be inserted therein with substantially no friction. SeeFIG. 3 Along with FIG. 4 The sub-assembly 19 is attached to the charging unit 15 and arranged such that the center hole 66 is located between two press-fit holes 178 of the charging unit 15 in the lateral direction. The rotation shaft 68 is press-fit into the two press-fit holes 178 while a portion thereof passes through the center hole 66. The sub-assembly 19 thus attached is movable relative to the charging unit 15. More specifically, the sub-assembly 19 is movable in a reciprocating manner about the rotation shaft 68. For example, when the rear end of the sub-assembly 19 is pushed downward, the front end of the sub-assembly 19 moves upward.

[0044] Referring to FIG. 3 The internal assembly 14 assembled as described above is covered by the front cover 12 and the side cover 13 of the connector body 11 as described previously. The charging unit 15 of the internal assembly 14 is fixed not to move relative to the front cover 12 and the side cover 13. In contrast, the sub-assembly 19 of the internal assembly 14 is coupled to move in a reciprocating manner relative to the connector body 11 including the charging unit 15.

[0045] Referring to FIG. 1 The terminals 16 of the charging unit 15 extend through the front cover 12 in the front-rear direction. With FIG. 1 Referring to FIG. 2 Each of the terminals 16 is connected to a mating device (not shown) of the inlet 80 in the mating state, so that power can be supplied to the mating device.

[0046] Referring to FIG. 3 The charging connector 10 of the present embodiment has the above-described structure. However, the present application is not limited thereto, and the structure of the charging connector 10 can be variously modified as needed. For example, the charging connector 10 can include other members in addition to the connector body 11, the sub-assembly 19, and the rotation shaft 68. The connector body 11 can include other members in addition to the front cover 12, the side cover 13, and the charging unit 15. The structure of the charging unit 15 is not particularly limited.

[0047] The sub-assembly 19 can be attached to the charging unit 15 by means other than the rotation shaft 68, as long as the front end thereof is vertically movable. The sub-assembly 19 can be attached directly to the side cover 13. The sub-assembly 19 can be supported by a member such as a spring (not shown) such that the front end thereof is not vertically movable unless an external force is applied to the sub-assembly 19.

[0048] Hereinafter, the sub-assembly 19 of the present embodiment will be described more specifically. The structure of the sub-assembly 19 is not limited to the present embodiment and modified structure described below, but can be further modified as described later.

[0049] Referring to FIG. 5 to FIG. 8In this embodiment, sub-assembly 19 includes a locking lever 20, a switching mechanism 40, a temporary holding mechanism (coil spring) 50, a screw 62 made of metal, and a shaft 64 made of metal. Therefore, the charging connector 10 in this embodiment includes the locking lever 20, the switching mechanism 40, the temporary holding mechanism 50, the screw 62, and the shaft 64. Sub-assembly 19 in this embodiment only includes the above-described components. However, the invention is not limited thereto, and sub-assembly 19 may further include other components besides those described above.

[0050] Together FIG. 3 Let's refer to each other. FIG. 5 Sub-assembly 19 is attached to the charging unit 15 of connector body 11 as previously described and is thus integrated into connector body 11. Therefore, each of the locking lever 20, switching mechanism 40, temporary holding mechanism 50, screw 62, and shaft 64 is integrated into connector body 11.

[0051] Reference FIG. 5 to FIG. 8 The locking lever 20 of this embodiment includes a lever body 22 made of an insulator such as resin and a reinforcing member 30 made of metal. The lever body 22 extends in a front-rear direction. A press-fit groove 23 is formed on the lever body 22. The press-fit groove 23 is formed at the lower part of the lever body 22 and extends in the front-rear direction between the front and rear ends of the lever body 22. The reinforcing member 30 is a single metal plate with a fixed dimension in the lateral direction. The dimension of the reinforcing member 30 in the front-rear direction is substantially the same as the dimension of the press-fit groove 23. The reinforcing member 30 is press-fitted into the press-fit groove 23 from below. According to this embodiment, the lever body 22 can be reinforced by the reinforcing member 30.

[0052] The locking lever 20 in this embodiment has an operating portion 24, a latch 26, and a mating portion 32. Therefore, the sub-assembly 19 includes the operating portion 24, the latch 26, and the mating portion 32. The charging connector 10 includes the operating portion 24, the latch 26, and the mating portion 32.

[0053] The operating portion 24 is located at the rear end of the lever 22 and extends upward. In this embodiment, the operating portion 24 is part of the lever 22 of the locking lever 20. However, the invention is not limited thereto. For example, the operating portion 24 may be a component formed separately from the locking lever 20.

[0054] The latch 26 is located at the front end of the locking lever 20. In this embodiment, the latch 26 protrudes downward. In other words, the latch is downward-facing. The latch 26 has an arc-shaped front end. The latch 26 has a rear end, which is a rearwardly inclined surface. In this embodiment, the latch 26 is formed by the front end of the lever 22 and the front end of the reinforcing member 30 and has high strength. However, the invention is not limited thereto. For example, the latch 26 may be formed only by the front end of the lever 22. Furthermore, the latch 26 may face upward, as described below.

[0055] Referring to FIG. 7 and FIG. 11 , the cooperating portion 32 of the present embodiment is a part of the reinforcing member 30. Thus, the reinforcing member 30 has the cooperating portion 32. In detail, the reinforcing member 30 has a lower end which projects downwardly and then extends forwardly. The cooperating portion 32 of the present embodiment is an upper edge surface of the forwardly extending portion.

[0056] Referring to FIG. 9 and FIG. 10 , the switch mechanism 40 of the present embodiment includes a switch body 42 made of metal and a switch plate 46. The switch body 42 has a flat plate shape parallel to the XZ plane. The switch plate 46 is a single metal plate which has a fixed size in the lateral direction and is formed with a bent portion.

[0057] Referring to FIG. 6 together with FIG. 10 , the switch body 42 is formed with a screw hole 422. The screw hole 422 passes through the switch body 42 in the lateral direction. The switch body 42 has a positioning protrusion 44. The positioning protrusion 44 is provided on one of the opposite surfaces of the switch body 42 in the lateral direction and projects outwardly therefrom. The switch plate 46 is formed with a screw hole 462 and a positioning hole 464. Each of the screw hole 462 and the positioning hole 464 passes through the switch plate 46 in the lateral direction. The screw hole 462 and the positioning hole 464 are respectively located in the XZ plane at positions coinciding with the positions of the screw hole 422 and the positioning protrusion 44 in the XZ plane.

[0058] As described below, the switch body 42 and the switch plate 46 are combined with each other. First, the positioning protrusion 44 is inserted into the positioning hole 464 so that the switch body 42 and the switch plate 46 are positioned to each other. Then, a screw 62 is screwed into the screw hole 422 through the screw hole 462. As a result, the switch body 42 and the switch plate 46 are combined with and fixed to each other. As described above, the switch body 42 of the present embodiment is fixed to and supported by the switch plate 46.

[0059] Referring to FIG. 7 and FIG. 9 , the switch body 42 of the present embodiment has a pressing portion 45 and a button 43. Thus, the switch mechanism 40 includes the pressing portion 45 and the button 43. The charging connector 10 includes the pressing portion 45 and the button 43.

[0060] The pressing portion 45 is proved on one of the opposite surfaces of the switch body 42 in the lateral direction and projects outwardly therefrom in the lateral direction, the one of the opposite surfaces of the switch body 42 being provided with the positioning protrusion 44 (see FIG. 6The pressing portion 45 is located in the XZ plane at the same position as the position of the positioning protrusion 44 in the XZ plane. It can be seen from this configuration that the switch board 46 of the present embodiment can be attached to either of the opposite surfaces of the switch main body 42 in the lateral direction.

[0061] The button 43 of the present embodiment is a push-down button. The switch main body 42 assumes one of two states different from each other depending on whether the button 43 is pressed or not. The switch mechanism 40 of the present embodiment includes two signal lines 49 in addition to the switch main body 42 and the switch board 46. For each of the signal lines 49, one of the opposite ends is connected to the switch main body 42, and the remaining one of the opposite ends (not shown) is connected to a power system (not shown). The signal lines 49 transmit the state of the switch main body 42 to the power system.

[0062] Next, a method of assembling the subassembly 19 of the present embodiment and a method of incorporating the subassembly 19 into the connector main body 11 will be described.

[0063] Referring to FIG. 6 , the lever body 22 of the present embodiment is formed with two shaft holes 28. Each of the shaft holes 28 is a circular hole and laterally passes through a portion of the lever body 22. The two shaft holes 28 are located at positions identical to each other in the XZ plane and separated from each other in the lateral direction. The reinforcing member 30 of the present embodiment is formed with a shaft hole 38. The shaft hole 38 is a circular hole and laterally passes through the reinforcing member 30. Referring to FIG. 5 and FIG. 6 , the shaft hole 38 is located between the two shaft holes 28 in the lateral direction when the reinforcing member 30 is attached to the lever body 22. Each of the shaft holes 28 and the shaft hole 38 arranged as described above has a size that allows the shaft 64 to be press-fitted therein.

[0064] Referring to FIG. 6 , the switch board 46 of the present embodiment is formed with a shaft hole 48. The shaft hole 48 is a circular hole and laterally passes through the switch board 46. The shaft hole 48 has a size that allows the shaft 64 to be inserted therein substantially without friction. Referring to FIG. 5 and FIG. 6 , the shaft 64 passes through the shaft hole 48 and is press-fitted into the shaft holes 28 of the lever body 22 and the shaft hole 38 of the reinforcing member 30. Thus, the shaft 64 is fixed to the lock lever 20. The shaft 64 thus fixed is formed with the central hole 66 described above. Referring to FIG. 4 , the rotation shaft 68 is inserted into the central hole 66 as described above. Referring to FIG. 12 , as described above, when the switch board 46 (see FIG. 6 ) is attached to the lock lever 20 (see FIG. 6 ), the switch mechanism 40 is located just above the latching portion 18.

[0065] Referring to FIG. 3According to the above-described structure, the lock lever 20 is rotatable about the rotation axis 68. Referring to FIG. 5 and FIG. 3 , the shaft 64 is not fixed to the switch plate 46 of the switch mechanism 40. Therefore, the switch mechanism 40 is rotatable about the shaft 64 or about the rotation axis 68 with respect to the lock lever 20. Thus, the lock lever 20 and the switch mechanism 40 of the present embodiment are rotatable independently of each other about the shaft they share.

[0066] As described above, the switch plate 46 of the present embodiment is attached to the lock lever 20 for rotation. The subassembly 19 of the present embodiment can be easily assembled by using the shaft 64, while the switch body 42 is reinforced by the switch plate 46. However, the present application is not limited thereto. For example, the switch body 42 can be formed without the switch plate 46, and can be formed with a shaft hole (not shown). Alternatively, the switch mechanism 40 can be connected to be rotatable with respect to the lock lever 20 by a member other than the shaft 64. The rotation center of the lock lever 20 and the rotation center of the switch mechanism 40 can be different from each other.

[0067] Referring to FIG. 6 and FIG. 11 , the reinforcing member 30 of the present embodiment has an attachment portion 34. The attachment portion 34 is a part of the reinforcing member 30. The attachment portion 34 protrudes downward from the lower edge surface of the reinforcing member 30. Referring to FIG. 6 and FIG. 9 , the switch plate 46 of the present embodiment has an attachment portion 47. The attachment portion 47 is a part of the switch plate 46. The attachment portion 47 extends laterally from the lower edge surface of the switch plate 46, and then protrudes upward.

[0068] Referring to FIG. 6 , the temporary holding mechanism 50 of the present embodiment is a coil spring having opposite end portions 52 and 54. The end portion 52 is located at the upper end of the coil spring 50. The end portion 54 is located at the lower end of the coil spring 50. One of the opposite end portions 52 and 54 of the coil spring 50 or the end portion 54 is attached to the switch mechanism 40. The remaining one of the opposite end portions 52 and 54 of the coil spring 50 or the end portion 52 is attached to the lock lever 20. In detail, in the present embodiment, the end portion 52 is attached to the attachment portion 34 of the reinforcing member 30, and the end portion 54 is attached to the attachment portion 47 of the switch plate 46. The coil spring 50 thus attached can apply a downward force to the switch plate 46.

[0069] Referring to FIG. 5 , by using only one shaft 64 and only one coil spring 50 as described above, the lock lever 20 and the switch mechanism 40 of the present embodiment are combined with each other into a subassembly 19. Referring to FIG. 4 , the subassembly 19 and the charging unit 15 are combined into the inner assembly 14 by using only one rotation axis 68.

[0070] Referring to FIG. 3 and FIG. 4 , the charging connector 10 of the present embodiment can be easily manufactured by attaching only the inner assembly 14, which is one of the assemblies of a large number of components, to the side cover 13. However, the present application is not limited to this. For example, the sub assembly 19 can be supported by the side cover 13 with the rotation shaft 68 without being combined with the charging unit 15.

[0071] Referring to FIG. 6 , if a force is applied in a direction perpendicular to the axial direction of the button 43 or FIG. 6 , the button 43 of the switch mechanism 40 of the present embodiment is easily damaged. According to the assembly method of the present embodiment, the force that can damage the button 43 can be prevented from being applied to the button 43 during assembly. Further, since the position of the switch mechanism 40 is fixed when the inner assembly 14 is assembled, the position of the switch mechanism 40 can be accurately adjusted during the assembly of the inner assembly 14.

[0072] As described above, according to the assembly method of the present embodiment, the charging connector 10 is easily assembled while reducing tolerances. In particular, the lock lever 20 and the switch mechanism 40 of the present embodiment are combined with each other by using the coil spring 50 except for the shaft 64. The lock lever 20 and the switch mechanism 40 combined with each other are incorporated in the connector main body 11 (see FIG. 3 ) while the switch mechanism 40 is pressed against the locking portion 18 by compressing the coil spring 50 (see FIG. 12 ).

[0073] During the process in which the lock lever 20 and the switch mechanism 40 are combined one after another in the connector main body 11 (see FIG. 3 ), it is difficult to attach the coil spring 50. According to the present embodiment, even if the charging connector 10 includes a component such as the coil spring 50 that is not easy to attach, the charging connector 10 can be easily assembled. However, the present application is not limited to this. For example, the components included in the sub assembly 19 can be combined one after another in the connector main body 11. In this case, the upper end portion 52 of the coil spring 50 can be attached to the connector main body 11.

[0074] Referring to FIG. 6 , the switch main body 42 of the present embodiment is attached to the lock lever 20 by the switch plate 46. Since the switch plate 46 is formed of a metal plate, the switch plate 46 can be shaped in various shapes and can be easily attached to the lock lever 20. For example, the switch plate 46 can be easily formed with the attachment portion 47. According to the present embodiment, the sub assembly 19 can be more easily assembled without increasing parts. However, the present application is not limited to this. For example, the attachment portion 47 can be a component formed separately from the switch plate 46. The switch plate 46 can be provided as necessary.

[0075] As described above, the rod body 22 of the present embodiment is reinforced by the reinforcing member 30. Since the reinforcing member 30 is formed of a metal plate, the reinforcing member 30 is easily shaped into various shapes. For example, the reinforcing member 30 can be easily formed with the cooperating portion 32 and the attachment portion 34. According to the present embodiment, when the rod body 22 is reinforced, various portions can be provided without increasing the components. In particular, the latch 26, which is susceptible to receiving a force, is reinforced. However, the present application is not limited thereto. For example, each of the cooperating portion 32 and the attachment portion 34 can be a member formed separately from the reinforcing member 30. The reinforcing member 30 is provided as needed.

[0076] The charging connector 10 assembled as described above can cooperate with the portal 80 (see FIG. 12 ) as described below.

[0077] Referring to FIG. 1 and FIG. 2 , when the inner assembly 14 is housed in the charging connector 10, the latch 26 of the locking lever 20 protrudes forward from the front cover 12, and the operating portion 24 protrudes upward from the side cover 13. The latch 26 thus arranged can be inserted into the portal 80. The operating portion 24 thus arranged can be operated by an operator.

[0078] Referring to FIG. 12 , when the charging connector 10 is in a separation state in which the charging connector 10 is separated from the portal 80 as shown in FIG. 12 , the latch 26 of the locking lever 20 is located in the engaged position (see solid line in FIG. 12 ). The latch 26 is temporarily held in the engaged position due to its own weight or by a mechanism such as a spring (not shown), for example. When the operating portion 24 is pushed downward, the locking lever 20 rotates about the rotation axis 68, so that the latch 26 moves upward (see dotted line in FIG. 12 ).

[0079] Referring to FIG. 13 , in an attempt to dock the charging connector 10 with the portal 80, the charging connector 10 is moved forward and toward the portal 80. When the charging connector 10 is moved forward, the arc-shaped front end of the latch 26 abuts the portal 80 and receives an upward force from the portal 80. As a result, the latch 26 is inserted into the portal 80 while moving upward. The state of the charging connector 10 at this time is referred to as an intermediate state or a half-docking state in which the charging connector 10 is not completely docked with the portal 80. When the charging connector 10 is in the intermediate state, the latch 26 is located in the released position as illustrated.

[0080] Referring to FIG. 14, the entrance 80 is formed with a recessed portion which is concave downward. The recessed portion is provided with a mating latch 82. The mating latch 82 is a plane which is parallel to the predetermined plane (YZ plane). When the charging connector 10 is moved forward, the latch 26 moves to the recessed portion of the entrance 80, and then moves downward. The latch 26 which moves downward is located at an engagement position which engages with the mating latch 82. At this time, the charging connector 10 becomes a mating state.

[0081] When the charging connector 10 in the mating state is pulled backward, the inclined surface of the rear end of the latch 26 is pressed against the mating latch 82. Therefore, when the charging connector 10 is pulled backward only, the engagement between the latch 26 and the mating latch 82 is not released. As described below, the charging connector 10 in the mating state can be disengaged from the entrance 80.

[0082] Reference is made to FIG. 14 and FIG. 13 , first, the operation portion 24 is pushed downward so that the latch 26 moves upward. Then, when the charging connector 10 is pulled backward, the charging connector 10 becomes the same state as the intermediate state. Reference is made to FIG. 13 and FIG. 12 , when the charging connector 10 is pulled further backward, the charging connector 10 is in a separation state.

[0083] Hereinafter, the switch mechanism 40 of the present embodiment will be described.

[0084] Reference is made to FIG. 12 and FIG. 13 , as described above, according to the operation of the charging connector 10, the latch 26 moves between an engagement position shown in FIG. 12 and a release position shown in FIG. 13 . Reference is made to FIG. 12 and FIG. 14 , when the latch 26 is located at the engagement position, the temporary holding mechanism 50 pushes the switch mechanism 40 downward. As a result, the switch mechanism 40 is partially pressed against the stop portion 18. This position of the switch mechanism 40 is referred to as an initial position. When the switch mechanism 40 is located at the initial position, the pressing portion 45 of the switch mechanism 40 is away from the cooperative portion 32 of the lock lever 20, and is located above the cooperative portion 32.

[0085] As can be seen from FIG. 12 , FIG. 13 and FIG. 15 , in the course of the latch 26 moving from the engagement position toward the release position, the cooperative portion 32 of the lock lever 20 moves upward and abuts against the pressing portion 45 of the switch mechanism 40. The position of the latch 26 at this time is referred to as a predetermined position. The predetermined position is FIG. 15The position shown, and is a position between the engaged position and the released position. Thus, the latch 26 is movable in the up-and-down direction between the engaged position and the released position via the predetermined position in accordance with the operation of the operation portion 24.

[0086] The cooperation portion 32 moves in the up-and-down direction in cooperation with the up-and-down movement of the latch 26. When the latch 26 moves upward, the cooperation portion 32 of the present embodiment moves upward, and when the latch 26 moves downward, the cooperation portion 32 of the present embodiment moves downward. However, the present application is not limited to this. As described below, when the latch 26 moves upward, the cooperation portion 32 can move downward, and when the latch 26 moves downward, the cooperation portion 32 can move upward.

[0087] When the latch 26 moves upward beyond the predetermined position, the cooperation portion 32 pushes the press portion 45 upward. As a result, the switch mechanism 40 moves upward from the initial position. As described above, the switch mechanism 40 is incorporated in the connector body 11 (see FIG. 3 ) so as to be movable in the up-and-down direction. When the latch 26 is located in the engaged position, the switch mechanism 40 is located in the initial position. When the latch 26 is located in the released position, the switch mechanism 40 is located in FIG. 13 the position shown, which is called the intermediate position. Thus, when the latch 26 is located in the released position, the switch mechanism 40 is located in the intermediate position.

[0088] With reference to FIG. 5 together, FIG. 12 when the switch mechanism 40 is located in the initial position, the button 43 of the switch body 42 is pressed against and pushed by the stop portion 18. The state of the switch body 42 at this time is called the initial state. Thus, when the switch mechanism 40 is located in the initial position, the switch body 42 is in the initial state. With reference to FIG. 13 , in the state where the switch mechanism 40 is located in the intermediate position, even if the button 43 is in contact with the stop portion 18, the button 43 is not pressed against the stop portion 18. Thus, the button 43 is not pressed. The state of the switch body 42 at this time is called the released state. Thus, when the switch mechanism 40 is located in the intermediate position, the switch body 42 is in the released state.

[0089] With reference to FIG. 12 , FIG. 13 and FIG. 15 , when the latch 26 is located between the engaged position shown in FIG. 12 and the predetermined position shown in FIG. 15 , the switch body 42 of the present embodiment is in the initial state. When the latch 26 is located between the released position shown in FIG. 13When the switch body 42 is between the predetermined position and the release position, it is in the released state. However, normally, even when the button 43 is pressed to a certain extent, the switch body 42 is in the initial state. Therefore, when the latch 26 moves to the release position beyond the predetermined position by a certain extent, the state of the switch body 42 can change to the released state.

[0090] Reference FIG. 12 to FIG. 14 As previously described, the state of the switch body 42 is transmitted to the power system (not shown) via signal line 49. The power system determines whether the charging connector 10 is in a charging-allowed state using a method based on predetermined criteria. For example, when the switch body 42 is in the initial state and the charging connector 10 is in the mating state, the power system supplies power to the charging connector 10. Unless the above charging conditions are met, the power system does not supply power to the charging connector 10.

[0091] Reference FIG. 15 When the power system (not shown) supplies power to the inlet 80 through the charging connector 10, a high-voltage current flows through the terminals 16 of the charging connector 10 (see...). FIG. 1 The charging connector 10 flows between the mating terminals (not shown) of the inlet 80 and the charging connector 10. The inlet 80 and the charging connector 10 have a locking mechanism to prevent electric shock that may be caused by such high voltage current. More specifically, when charging begins, the inlet 80 of this embodiment positions the locking portion 84 above the latch 26 to adjust the upward movement of the latch 26. As a result, the latch 26 is locked, preventing the charging connector 10 from disengaging from the inlet 80. When charging of the mating device (not shown) ends, the locking portion 84 is removed. As a result, the latch 26 is unlocked, and the charging connector 10 can thus be removed from the inlet 80.

[0092] As described above, according to this embodiment, the state of the switch body 42 changes according to the operation of the operation part 24. However, the charging connector 10 needs to meet the following two requirements. The first requirement is that even when the operation part 24 is operated, the state of the switch body 42 does not change to the released state while the latch 26 is locked. The second requirement is that the released state of the switch body 42 is maintained until the docking of the charging connector 10 is completed.

[0093] Reference FIG. 15According to the related art, when the latch 26 is engaged, the locking portion 84 regulates the movement of the locking lever 20 to lock the latch 26. However, considering tolerances, the locking lever 20 in such a locked state has a play. A first requirement is to require that the state of the switch body 42 does not change as long as the locking lever 20 moves within the range of the play. Therefore, in order to satisfy the first requirement, the switch body 42 should be disposed in the vicinity of a portion of the locking lever 20 that moves only slightly according to the operation of the operation portion 24. More specifically, the switch body 42 should be disposed in the vicinity of the rotational axis 68 of the locking lever 20.

[0094] In order to satisfy the second requirement, the switch body 42 should continuously maintain the released state unless the latch 26 is engaged with the mating latch 82. In other words, the switch body 42 should continuously maintain the released state even when the latch 26 moves vertically only slightly. Therefore, in order to satisfy the second requirement, the switch body 42 should be disposed in the vicinity of a portion of the locking lever 20 that moves to a large extent according to the operation of the operation portion 24. More specifically, the switch body 42 should be disposed away from the rotational axis 68 of the locking lever 20.

[0095] As can be seen from the above description, when the charging connector includes a small switch that is commonly used, the charging connector cannot satisfy both the first and second requirements.

[0096] On the contrary, with reference to FIG. 14 and FIG. 15 the temporary holding mechanism 50 of the present embodiment temporarily holds the switch mechanism 40 in an initial position at which the switch body 42 assumes an initial state when the latch 26 is positioned between an engaged position shown in FIG. 14 and a predetermined position shown in FIG. 15 or when the latch 26 approaches the engaged position. Therefore, even in a state where the latch 26 is locked, the initial state of the switch body 42 is maintained as the locking lever 20 moves within the range defined by the play according to the operation of the operation portion 24. Thus, the first requirement is satisfied.

[0097] With reference to FIG. 13 and FIG. 15 when the latch 26 is positioned between the predetermined position shown in FIG. 15 and the released position shown in FIG. 13 or when the latch 26 is away from the engaged position beyond the predetermined position, the cooperative portion 32 presses the pressing portion 45 of the switch mechanism 40 to move the switch mechanism 40 from the initial position to abut against the temporary holding mechanism 50, and thereby changes the state of the switch body 42 from the initial state to the released state. Therefore, the released state of the switch body 42 is maintained until the mating of the charging connector 10 is completed so that the latch 26 is positioned between the engaged position and the predetermined position. Thus, the second requirement is satisfied.

[0098] Summarizing the above description, the moving range of the latch 26 of the present embodiment is divided into two ranges. In one of the two ranges, only the latch 26 is moved. In the remaining one of the two ranges, the switch mechanism 40 is moved in accordance with the movement of the latch 26. The present embodiment provides the charging connector 10 including the switch body 42, the state of which is not changed to the released state even if the operation portion 24 is operated in the locked state, and is maintained in the released state until the mating of the charging connector 10 is completed.

[0099] In addition to the various modifications already described, various modifications can be made to the present embodiment. Hereinafter, some of the modifications of the present embodiment will be described.

[0100] Referring to FIG. 12 , the latch 26 of the present embodiment faces downward. When the operation portion 24 is pushed downward, the latch 26 is moved upward. However, the present application is not limited to this. For example, referring to FIG. 12 and FIG. 16 , the latch 26 can face upward. In this case, the operation portion 24 can be a member separate from the lock lever 20. Alternatively, the operation portion 24 can be a part of the lever body 22, but can be located between the rotation axis 68 and the latch 26 in the front-rear direction. Thus, when the operation portion 24 is pushed downward, the latch 26 can be moved downward.

[0101] Referring to FIG. 12 , the switch mechanism 40 of the present embodiment is located below the lock lever 20. However, the present application is not limited to this. For example, in the case where the latch 26 faces upward, the switch mechanism 40 can be located above the lock lever 20. In this case, the stop portion 18 can be a part of the side cover 13 (see FIG. 3 ) and can be located above the switch mechanism 40. The temporary holding mechanism 50 can press the push button 43 of the switch mechanism 40 located in the initial position (see FIG. 13 ) against the stop portion 18 located above the switch mechanism 40. When the latch 26 is moved downward, the cooperation portion 32 can push the pressing portion 45 downward.

[0102] The rotation axis 68 of the present embodiment is located near the rear end portion of the switch mechanism 40. However, the present application is not limited to this. For example, in the case where the latch 26 faces downward and the switch mechanism 40 is located above the lock lever 20, the rotation axis 68 can be located near the front end portion of the switch mechanism 40. In this case, the temporary holding mechanism 50 can be located near the rotation axis 68, and the cooperation portion 32 and the pressing portion 45 can be located rearward of the temporary holding mechanism 50. In this case, the stop portion 18 can be a part of the side cover 13 (see FIG. 3 ) and can be located above the switch mechanism 40.

[0103] The switch body 42 of the present embodiment assumes an initial state when the button 43 (see FIG. 13 ) is pressed on the locking portion 18, and assumes a released state when the button 43 is separated from the locking portion 18 to some extent. However, the present application is not limited to this. For example, when the latch 26 is moved upward in a state where the switch mechanism 40 is located below the locking lever 20 and the rotation shaft 68 is located near the front end portion of the switch mechanism 40, the cooperation portion 32 can be moved downward to push the pressing portion 45 downward. Thus, the switch body 42 can assume the initial state when the button 43 is separated from the locking portion 18 to some extent, and can assume the released state when the button 43 is pressed against the locking portion 18.

[0104] The switch body 42 of the present embodiment assumes an initial state when the button 43 (see FIG. 13 ) is pressed on the locking portion 18, or assumes an on state in which internal contact points (not shown) thereof are electrically connected to each other, or assumes a released state, or assumes an off state in which the internal contact points are separated from each other when the button 43 is separated from the locking portion 18 to some extent. However, the present application is not limited to this. For example, the switch body 42 can assume the off state or the initial state when the button 43 is pressed against the locking portion 18, and can assume the on state or the released state when the button 43 is separated from the locking portion 18 to some extent.

[0105] The temporary holding mechanism 50 is not limited to the coil spring. For example, the temporary holding mechanism 50 can be another spring such as a torsion spring. In addition, the temporary holding mechanism 50 is not limited to the spring. For example, an anchor can be attached to the front end portion of the switch plate 46. The anchor can be used as the temporary holding mechanism 50.

[0106] The temporary holding mechanism 50 can be formed as described below. First, the side cover 13 (see FIG. 3 ) is modified to be provided with a dome-shaped protrusion (projection). In addition, the switch mechanism 40 is modified to be formed with a recessed portion (receiving portion), a groove, and a wall. The groove is located below the receiving portion. The wall is located between the receiving portion and the groove. When the switch mechanism 40 is located at the initial position, the projection is accommodated in the receiving portion. When the cooperation portion 32 presses the pressing portion 45 upward according to the movement of the locking lever 20, the switch mechanism 40 is moved upward from the initial position, and the projection straddles over the wall to be accommodated in the groove. According to this structure, the above-described projection, receiving portion, groove, and wall function as the temporary holding mechanism 50.

[0107] As can be seen from the above description, the structure of the subassembly 19 can be variously modified according to a combination of conditions including the facing direction of the latch 26, the arrangement of the switch mechanism 40, the position of the rotation shaft 68, and the like.

Claims

1. A charging connector comprising a connector main body, a lock lever, an operation portion, a cooperative portion, a switch mechanism, and a temporary holding mechanism, characterized by: the lock lever being incorporated into the connector main body; the lock lever having a latch; the latch being moved in an up-and-down direction between an engagement position and a release position via a predetermined position in accordance with an operation of the operation portion; the cooperative portion being moved in the up-and-down direction in cooperation with a movement of the latch in the up-and-down direction; the switch mechanism being incorporated into the connector main body so as to be movable in the up-and-down direction; the switch mechanism being located at an initial position when the latch is located at the engagement position; the switch mechanism including a switch main body and a pressing portion; the switch main body being in an initial state when the switch mechanism is located at the initial position; the temporary holding mechanism temporarily holding the switch mechanism at the initial position when the latch is located between the engagement position and the predetermined position; and the cooperative portion pressing the pressing portion of the switch mechanism to move the switch mechanism from the initial position to abut against the temporary holding mechanism when the latch is located between the predetermined position and the release position, thereby changing a state of the switch main body from the initial state to a release state. the charging connector including a sub-assembly; the sub-assembly including the lock lever, the operation portion, the cooperative portion, the switch mechanism, and the temporary holding mechanism; and the sub-assembly being incorporated into the connector main body; the switch mechanism including a switch plate; the switch main body being supported by the switch plate; and the switch plate being attached to the lock lever for rotation.

2. The charging connector according to claim 1, characterized in that: the temporary holding mechanism is a coil spring; and one of opposite ends of the coil spring is attached to the switch mechanism, and the other of the opposite ends of the coil spring is attached to the lock lever.

3. The charging connector according to claim 1, characterized in that: the lock lever includes a lever body and a reinforcing member; and the cooperative portion is a part of the reinforcing member. ​

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