Charging inlet assembly with power harness

Abstract

A power harness (200) for a charging inlet assembly (100) includes a harness housing (230) that holds a power cable (202) in a cable trough (244). A ring insert (212) of the power cable is aligned with a bore (252) of a hub (250) of the housing (110) that receives a threaded bolt (300) having an insulating cover (310) and an insulating cap (320). A contact ring (270) is received in the hub with a first end (272) connected to the ring insert and a second end (274) electrically connected to the charging terminal (126). A threaded socket (350) is received in the hub and threadedly coupled to the charging terminal through the contact ring. An outer end (234) of the threaded socket has a threaded socket that receives a threaded shaft of the threaded bolt.

Description

Technical Field

[0001] The subject matter herein relates generally to charging inlet assemblies. Background Art

[0002] The charging inlet assembly is used to charge the vehicle, for example, for charging the battery system of an electric vehicle (EV) or a hybrid electric vehicle (HEV). The charging inlet assembly includes a power connector for connecting to a charging connector. Conventional charging inlet assemblies include AC terminals and DC terminals. The AC terminals and DC terminals are housed in an inlet housing that docks with the charging connector. The inlet housing is connected to the vehicle. The cable harness is connected to the AC terminal and the DC terminal and extends to other system components, such as a battery. Problems arise at the electrical connection between the cable harness and the charging terminal. For example, high resistance at the interface may cause increased heating and reduced current through the transition section. In addition, there is limited space for routing and connecting the cable harness to the charging terminal. In addition, the maintenance of the charging inlet assembly and the terminals and cable harness is difficult. Maintenance typically involves disassembling and removing the charging inlet assembly and the cable harness from the vehicle for maintenance, which is time-consuming and costly to repair. Some known systems allow the terminals to be removed from the housing individually, which is time-consuming. However, other known systems do not allow the terminals to be removed from the charging inlet assembly, resulting in replacement of the entire assembly.

[0003] There remains a need for an improved charging inlet assembly. Summary of the invention

[0004] In one embodiment, a power harness for a charging inlet assembly of a vehicle is provided. The power harness includes a power cable having a cable body extending to a termination end. The power cable includes a ring plug electrically connected to the cable body. The power harness includes a harness housing having a chamber and a hub, the chamber including a cable groove, and the hub having a hole passing through the harness housing. The cable groove receives the termination end of the power cable. The ring plug is aligned with the hole. The harness housing has a mating end, and the mating end is configured to mate with the housing of the charging inlet assembly. The power harness includes a threaded bolt received in the hub and passing through the hole. The threaded bolt passes through the ring plug. The threaded bolt includes a head and a threaded shaft. The threaded bolt includes an insulating cover on the head. The threaded bolt includes an insulating cap at the distal end of the threaded shaft. The power harness includes a contact ring, which is received in the hub and aligned with the ring plug in the hole. The contact ring has an opening between a first end and a second end. The first end engages and is electrically connected to the ring plug. The second end is configured to be electrically connected to a charging terminal of the charging inlet assembly. The power harness includes a threaded socket received in the hub and aligned with the ring insert in the hole. The threaded socket is received in the opening of the contact ring and passes through the contact ring. The threaded socket extends between an inner end and an outer end. The inner end has an external thread that is configured to be threadably connected to a charging terminal of the charging inlet assembly. The outer end has a threaded hole that receives a threaded shaft of a threaded bolt. The threaded bolt can be threadably connected to the threaded socket. BRIEF DESCRIPTION OF THE DRAWINGS

[0005] The present invention will now be described by way of example with reference to the accompanying drawings, in which:

[0006] Figure 1 is a front view of a charging inlet assembly including an AC charging module and a DC charging module according to an exemplary embodiment.

[0007] Figure 2 is a rear perspective view of a charging inlet assembly according to an exemplary embodiment showing an AC charging module and a DC charging module.

[0008] Figure 3 is an exploded view of a charging inlet assembly according to an exemplary embodiment.

[0009] Figure 4 is a cross-sectional view of a charging inlet assembly in an exemplary embodiment showing a power harness coupled to a housing and charging terminals of the charging inlet assembly. DETAILED DESCRIPTION

[0010] Figure 1 is a front view of a charging inlet assembly 100 including an AC charging module 102 and a DC charging module 104 according to an exemplary embodiment. Figure 2is a rear perspective view of charging inlet assembly 100 showing AC charging module 102 and DC charging module 104 according to an exemplary embodiment.

[0011] The charging inlet assembly 100 is used as a charging inlet of a vehicle such as an electric vehicle (EV) or a hybrid electric vehicle (HEV). The charging inlet assembly 100 is configured to be mated to receive a charging connector (not shown). In an exemplary embodiment, the charging inlet assembly 100 is configured to be mated with various types of charging connectors, such as a DC fast charging connector (e.g., SAE combo CCS charging connector) in addition to an AC charging connector (e.g., SAE J1772 charging connector).

[0012] The charging port assembly 100 includes a housing 110 configured to be installed in a vehicle. The housing 110 holds the AC charging module 102 and the DC charging module 104 for mating with the charging connector. In various embodiments, the AC charging module 102 and / or the DC charging module 104 are removable from the housing 110. For example, the charging modules 102, 104 may be coupled to the housing 110 using fasteners, latches, clips, or other fixing devices. The charging modules 102, 104 may include a plurality of components that are individually coupled to the housing 110 and removable from the housing 110. The charging modules 102, 104 may be removed from the housing 110 to separate components of the charging modules 102, 104 (e.g., charging pins, cables, circuit boards, etc.) from the housing 110, for example, for repairing and / or replacing charging module components or other components of the charging inlet assembly 100.

[0013] In an exemplary embodiment, housing 110 includes an AC portion 112 that receives AC charging module 102 and a DC portion 114 that receives DC charging module 104. AC portion 112 is configured to mate with an AC charging connector or the AC portion of a charging connector. DC portion 114 is configured to mate with a DC charging connector or the DC portion of a charging connector. AC portion 112 includes AC terminal passage 116. DC portion 114 includes DC terminal passage 118.

[0014] The AC charging module 102 includes an AC terminal 120 at the AC portion 112. The AC terminal 120 is held in the housing 110 by the AC charging module 102. The AC terminal 120 is received in a corresponding AC terminal channel 116. The AC terminal 120 is configured to mate with a charging connector. In the illustrated embodiment, five AC terminals 120 are provided, including a pair of AC charging terminals, a ground terminal, a proximity terminal, and a pilot terminal. Optionally, the AC terminal 120 can be terminals of different sizes. In an exemplary embodiment, the AC terminal 120 includes a pin at the mating end of the AC terminal 120. The AC cable 122 ( Figure 2 ) terminates at an AC terminal 120 and extends from the charging inlet assembly 100 to another component of the vehicle, such as a battery system of the vehicle. In various embodiments, the AC cable 122 may extend in a straight line away from the AC charging module 102 and the housing 110. In other various embodiments, the AC cable 122 may extend away from the AC charging module 102 and the housing 110 at 90° (e.g., a right angle) or at other angles.

[0015] In an exemplary embodiment, the AC portion 112 of the charging inlet assembly 100 defines a low voltage connector that is configured to be coupled to the low voltage portion of the charging connector. The low voltage connector (e.g., AC terminal 120 and AC cable 122) is configured to be coupled to other components in the system, such as a battery distribution unit, to control the charging of the vehicle. The low voltage connector can send / receive signals related to charging, such as connection status, charging status, charging voltage, etc. The low voltage connector can be a socket connector configured to receive a charging plug. A seal can be provided at the interface of the low voltage connector.

[0016] The DC charging module 104 includes a DC charging terminal 126 at the DC portion 114. The charging terminal 126 is received in the corresponding charging terminal channel 118 and retained in the housing 110. The charging terminal 126 is configured to mate with a charging connector. In the illustrated embodiment, two charging terminals 126 are provided. In an exemplary embodiment, the charging terminal 126 includes a pin at the mating end of the charging terminal 126. In an exemplary embodiment, the power harness 200 is terminated to the charging terminal 126 and extends from the charging inlet assembly 100 to another component of the vehicle, such as a battery system of the vehicle. The power harness 200 includes a DC power cable 202, which may be a solid bus bar, a stranded cable, or other type of power cable. In various embodiments, the power cable 202 may extend straight away from the housing 110, such as backward. In other various embodiments, the power cable 202 may extend away from the housing 110 at other angles, such as 90° (e.g., downward) or at other angles.

[0017] In an exemplary embodiment, the DC portion 114 of the charging inlet assembly 100 defines a high voltage connector that is configured to be coupled to the high voltage portion of the charging connector. The high voltage connector (e.g., the charging terminal 126 and the power cable 202) is configured to be coupled to other components in the system, such as a battery and / or a battery distribution unit of the vehicle. The high voltage connector is used for fast charging of the battery. The high voltage connector can be a socket connector configured to receive a charging plug. A seal can be provided at the interface of the high voltage connector.

[0018] The housing 110 includes a front portion 130 and a rear portion 132. The front portion 130 of the housing 110 faces outward and is presented to an operator to connect a charging connector. The rear portion 132 faces the interior of the vehicle and is generally inaccessible without removing the housing 110 from the vehicle. The housing 110 includes a panel 134 at the front portion 130. In an exemplary embodiment, an AC socket 136 is formed in the panel 134 at the AC portion 112, and a DC socket 138 is formed in the panel 134 at the DC portion 114. The AC socket 136 includes a space around the AC terminal 120 that receives the charging connector. During charging, the AC charging connector is inserted into the AC socket 136 to electrically connect to the AC terminal 120. The DC socket 138 includes a space around the charging terminal 126 to receive the charging connector. The DC charging connector is configured to be inserted into the DC socket 138. During charging, the DC charging connector is inserted into the DC socket 138 to electrically connect to the charging terminal 126. A panel 134 may surround an AC outlet 136 and a DC outlet 138 at the front 130 .

[0019] In the exemplary embodiment, the housing 110 includes a mounting flange 140 ( Figure 1 ). The mounting flange 140 includes a mounting tab 142 for mounting the housing 110 to the vehicle. The mounting tab 142 has an opening 144 that receives a fastener (not shown) to secure the charging inlet assembly 100 to the vehicle. Other types of mounting features may be used to secure the charging inlet assembly 100 to the vehicle. The housing 110 and / or the mounting flange 140 may include a seal (not shown) to seal the charging inlet assembly 100 to the vehicle.

[0020] In various embodiments, the charging inlet assembly 100 may include a terminal cover (not shown) at the front of the housing 110 to cover portions of the housing 110, such as the DC portion 114 and / or the AC portion 112. The housing 110 may include one or more rear covers at the rear of the housing 110 to close access to the rear of the housing 110. The cover(s) may be clipped or latched to the main portion of the housing 110, such as using a clip or latch. In alternative embodiments, other types of fixing features, such as fasteners, may be used.

[0021] In an exemplary embodiment, the housing 110 includes a tube 150 at the rear portion 132. The tube 150 surrounds the corresponding terminal channels 116, 118. The terminals 120, 126 are received in the corresponding tubes 150. The power harness 200 is mounted to the housing 110 at the tube 150 that holds the DC charging terminal 126. The tube 150 can be generally cylindrical; however, in alternative embodiments, the tube 150 can have other shapes.

[0022] Figure 3 is an exploded view of a charging inlet assembly 100 according to an exemplary embodiment. Figure 3 A pair of power harnesses 200 are shown that are configured to be coupled to corresponding charging terminals 126. Each power harness 200 includes a power cable 202 and components that mechanically and electrically connect the power cable 202 to the charging terminal 126. The power harness 200 provides a separable interface in the power transmission line between the charging inlet assembly 100 and another component, such as a battery.

[0023] In an exemplary embodiment, the power harness 200 is connected to the charging terminal 126 and / or the housing 110 using a threaded fastener, such as a threaded bolt received in a threaded insert, to mechanically and electrically connect the power cable 202 to the charging terminal 126. In an exemplary embodiment, the power harness 200 is compact and configured to occupy not much more space (e.g., height and / or width and / or length) than the power cable 202. In an exemplary embodiment, the power harness 200 forms a sealed interface with the housing 110. In an exemplary embodiment, the power harness 200 is touch-safe, wherein any and all live conductive elements are insulated to prevent short circuits, arc discharges, or injuries caused by contact with live elements. The power harness 200 is touch-safe in both the mated state and the unmated state. In an exemplary embodiment, the power harness 200 is vibration-resistant to maintain a reliable electrical connection along the power transmission line. In an exemplary embodiment, the power harness 200 can be mated in various orientations relative to the housing 110. For example, the power cable 202 may extend away from the connection at different angles, such as 180°, 90°, or other angles. However, in alternative embodiments, the power harness 200 may have a single mating orientation.

[0024] In an exemplary embodiment, the housing 110 is open at the rear 132 to receive the charging terminal 126. For example, the tube 150 includes an opening 152 at the rear 132. The charging terminal 126 can be rear-loaded into the terminal channel 118. In an exemplary embodiment, a cover 154 is coupled to the tube 150 at the rear 132 to close the opening 152 after the charging terminal 126 is loaded into the terminal channel 118. In an exemplary embodiment, a cover seal 156 is provided to seal the opening 152. When the cover seal 156 is coupled to the housing 110, the cover seal 156 can be coupled to the cover 154 to dock with the housing 110. Optionally, the cover 154 can be latchably coupled to the housing 110. In an exemplary embodiment, the tube 150 includes a side port 160 that provides access to the terminal channel 118. The power harness 200 is coupled to the housing 110 at the side port 160. For example, a portion of the power harness 200 can be inserted into the side port 160 to interface with the charging terminal 126. In the illustrated embodiment, the side port 160 is cylindrical; however, in alternative embodiments, the side port 160 can have other shapes. Optionally, a keying feature can be provided at the side port 160 for keying with the power harness 200.

[0025] Each charging terminal 126 extends between a mating end 180 and a terminating end 182. The charging terminal 126 includes a pin 184 at the mating end 180. The pin 184 is configured to mate with the charging connector during vehicle charging. In an exemplary embodiment, a terminal seal 186 surrounds the charging terminal 126. The terminal seal 186 is configured to be sealingly coupled to the housing 110. For example, the terminal seal 186 can be inserted into the terminal channel 118 to seal the terminal channel 118 between the front 130 and the rear 132 of the housing 110. In an exemplary embodiment, the charging terminal 126 includes a threaded hole 190 at the terminating end 182. The threaded hole 190 is configured to receive a threaded portion of the power harness 200 to mechanically and / or electrically connect to the power harness 200. In the illustrated embodiment, the threaded hole 190 extends transversely across the charging terminal 126. For example, the threaded hole 190 extends perpendicular to the longitudinal axis of the charging terminal 126. In an exemplary embodiment, the termination end 182 includes a connection surface 192 that is configured to connect to the power harness 200. In the illustrated embodiment, the connection surface 192 is planar. The connection surface 192 extends along one side of the charging terminal 126. A portion of the power harness 200 can abut against the connection surface 192 to make an electrical connection with the termination end 182 of the charging terminal 126. In various embodiments, the end of the charging terminal 126 can be flat. A temperature sensor 194 can be connected to the flat end of the charging terminal 126 to monitor the temperature of the charging terminal 126. In alternative embodiments, the temperature sensor 194 can be connected to other surfaces of the charging terminal 126.

[0026] The power harness 200 can be identical and inverted 180° relative to each other, for example for mounting to opposite sides of the housing 110. The power harness 200 includes a power cable 202, a harness housing 230, a contact ring 270, a threaded bolt 300, and a threaded socket 350. The harness housing 230 receives the power cable 202, the contact ring 270, the threaded bolt 300, and the threaded socket 350. The harness housing 230 is configured to mate with the housing 110, such as at the side port 160 of the tube 150. The threaded socket 350 is configured to be threadably connected to the charging terminal 126. For example, the threaded socket 350 can be screwed into the threaded hole 190. The threaded socket 350 keeps the contact ring 270 in electrical contact with the charging terminal 126. The threaded bolt 300 is configured to be threadably connected to the threaded socket 350. The threaded bolt 300 is used to mechanically connect the power harness 200 to the housing 110. The contact ring 270 is used to electrically connect the power cable 202 to the charging terminal 126 .

[0027] In an exemplary embodiment, the power cable 202 is a flat cable. The power cable 202 can be made of a flat, wound braided metal strip. For example, the braided metal strip can be aluminum or copper. In an alternative embodiment, the power cable 202 can be a metal plate or strip, such as a bus bar. In various embodiments, the power cable 202 can be a stranded cable. The cross-section of the power cable 202 can be generally rectangular, such as having a generally planar top surface and bottom surface. However, in various embodiments, the outer edges of the power cable 202 can be curved. In various embodiments, the width of the power cable 202 is at least twice the height of the power cable 202. Optionally, the width of the power cable 202 can be four times or more the height. In an alternative embodiment, the power cable 202 can be round instead of flat.

[0028] The power cable 202 includes a cable body 204 and a jacket 206 surrounding the cable body 204. The jacket 206 is made of a dielectric or other insulating material to make the power cable 202 safe to touch. In an exemplary embodiment, the cable body 204 is exposed at the termination end 208 of the power cable 202. The power cable 202 includes an opening 210 at the termination end 208. A ring plug 212 is received in the opening 210. The ring plug 212 is electrically connected to the cable body 204. The ring plug 212 is configured to be coupled to the contact ring 270 when assembled to form a direct electrical path between the contact ring 270 and the cable body 204. Optionally, the ring plug 212 includes a flange 214 along the upper surface and / or lower surface of the cable body 204. In various embodiments, the ring plug 212 is made of a different metal or metal alloy than the cable body 204. For example, the cable body 204 can be aluminum and the ring plug 212 can be copper. The ring insert 212 includes an opening 216 through the center of the ring insert 212. The opening 216 is configured to receive the threaded bolt 300.

[0029] In an exemplary embodiment, the power cable 202 includes a cable seal 220 surrounding the cable body 204 and the jacket 206. The inner surface of the cable seal 220 is configured to seal against the jacket 206 of the power cable 202. In various embodiments, the cable seal 220 can be a rubber material. The outer surface of the cable seal 220 is configured to seal to the harness housing 230. In an exemplary embodiment, the power cable 202 includes a cable sealing cap 222 surrounding the cable body 204 and the jacket 206. The cable sealing cap 222 is used to position the cable seal 220 on the termination end 208 of the power cable 202. The cable sealing cap 222 is used to hold the cable seal 220 in the harness housing 230. In an exemplary embodiment, the cable sealing cap 222 includes a latch 224, which is configured to be latchably coupled to the harness housing 230. The front portion of the cable sealing cap 222 can be inserted into a portion of the harness housing 230.

[0030] The harness housing 230 is made of a dielectric material such as a plastic material. Alternatively, the harness housing 230 can be an injection molded component. The harness housing 230 includes a wall forming a chamber 232, and the chamber 232 receives the power cable 202, the contact ring 270, and the threaded bolt 300. In an exemplary embodiment, the harness housing 230 includes an outer end 234 and an inner end 236. The inner end 236 faces the housing 110. The harness housing 230 includes a side 238 extending between the front 240 and the rear 242. The harness housing 230 includes an opening at the rear 242, which defines a cable trough 244 that provides a passage to the chamber 232. The power cable 202 is received in the cable trough 244. In various embodiments, the cable trough 244 can be oriented substantially vertically; however, in alternative embodiments, other orientations are possible. The cable sealing cap 222 can be inserted into the cable trough 244 and connected to the harness housing 230 at the rear 242. The cable seal 220 may be sealed to the inner surface of the harness housing 230 at the cable groove 244 .

[0031] In an exemplary embodiment, the harness housing 230 includes a hub 250 having a hole 252 passing through the hub 250. The hole 252 leads to the chamber 232 and defines a portion of the chamber 232. In various embodiments, the hub 250 is generally cylindrical. However, in alternative embodiments, the hub 250 may have other shapes. The hole 252 passes through the harness housing 230, for example, along the mating axis. In an exemplary embodiment, the power cable 202 is positioned in the harness housing 230, wherein the ring plug 212 is aligned with the hole 252, for example, along the mating axis, to receive the threaded bolt 300. The hole 252 includes an outer opening 254 and an inner opening 256. The threaded bolt 300 is received in the hub 250 and passes through the hole 252. For example, the threaded bolt 300 can pass through the outer opening 254 and / or the inner opening 256. The contact ring 270 is received in the hub 250. For example, the contact ring 270 can be loaded into the hole 252 through the outer opening 254. The threaded bolt 300 may be loaded into the bore 252 through the outer opening 254 , behind the contact ring 270 .

[0032] The contact ring 270 extends between a first end 272 and a second end 274. The first end 272 may be an outer end of the contact ring 270, and the second end 274 may be an inner end of the contact ring 270. The second end is configured to face the charging terminal 126. The contact ring 270 includes an opening 276 passing through the contact ring 270 between the first end 272 and the second end 274. The opening 276 is configured to receive the threaded socket 350. In an exemplary embodiment, the contact ring 270 includes a recess 278 at the first end 272. The recess 278 is configured to receive a portion of the threaded socket 350 and is used to control the relative positioning of the contact ring 270 and the threaded socket 350. For example, the threaded socket 350 may be bottomed out within the recess 278 to axially position the threaded socket 350 along the contact ring 270. When assembled, the contact ring 270 is received in the hub 250 and aligned with the ring insert 212 of the power cable 202 in the hole 252. For example, the opening 276 is aligned with the opening 216 along the mating axis of the hole 252. The first end 272 of the contact ring 270 is configured to engage and electrically connect to the ring insert 212. The second end 274 is configured to engage and electrically connect to the connection surface 192 of the charging terminal 126. The threaded socket 350 is configured to press the ring insert 212 into physical and electrical contact with the charging terminal 126. When the threaded bolt 300 is tightened into the threaded socket 350, the ring insert 212 is pressed into physical and electrical contact with the contact ring 270.

[0033] The threaded bolt 300 includes a head 302 and a threaded shaft 304 extending from the head 302. The threaded shaft 304 includes threads at a distal end 308 of the threaded shaft 304. In an exemplary embodiment, the threaded bolt 300 is touch-safe. For example, the threaded bolt 300 includes an insulating cover 310 on the head 302 and an insulating cap 320 extending from the distal end 308 of the threaded shaft 304.

[0034] The insulating cover 310 may be overmolded onto the head 302. Alternatively, the insulating cover 310 may be preformed and snap-fit, press-fit, adhered, or otherwise secured to the head 302. The insulating cover 310 covers the head 302 to prevent access to the metal or conductive portions of the threaded bolt 300. The insulating cover 310 includes a drive feature 312 for driving or rotating the threaded bolt 300. For example, the drive feature 312 may be a flat surface at the top of the insulating cover 310 that allows a socket wrench or other tool to rotate the threaded bolt 300 clockwise or counterclockwise to tighten or loosen the threaded bolt 300 during assembly with the second wiring harness connector 400. Other types of drive features, such as one or more slots, may be used in alternative embodiments to receive a screwdriver or other type of tool for tightening and loosening the threaded bolt 300.

[0035] The insulating cap 320 may be overmolded onto the threaded shaft 304. Alternatively, the insulating cap 320 may be preformed and snap-fit, press-fit, adhered, or otherwise secured to the distal end 308 of the threaded shaft 304. The insulating cap 320 covers the threaded shaft 304 to prevent contact with metal or conductive portions of the threaded bolt 300.

[0036] In an exemplary embodiment, the power harness 200 includes a bolt seal 330 to seal between the threaded bolt 300 and the harness housing 230. In the illustrated embodiment, the bolt seal 330 is coupled to the insulating cover 310 at the head 302 of the threaded bolt 300. The outer surface of the bolt seal 330 is configured to seal to the harness housing 230, for example, to the hub 250, when the threaded bolt 300 is received in the hub 250. For example, the diameter of the bolt seal 330 can be equal to the diameter of the hub 250 at the outer opening 254.

[0037] In an exemplary embodiment, the power harness 200 includes a bolt retainer 340 to retain the threaded bolt 300 in the harness housing 230. The bolt retainer 340 can be coupled to the harness housing 230 outside the threaded bolt 300, for example, outside the head 302 and the insulating cover 310. The bolt retainer 340 can be coupled to the hub 250. The bolt retainer 340 includes a latch 342, which is configured to be latchably coupled to the harness housing 230 to fix the bolt retainer 340 to the harness housing 230. In an exemplary embodiment, the bolt retainer 340 includes an opening 344 to provide access to the threaded bolt 300, for example, for engaging the drive feature 312 to rotate the threaded bolt 300. However, in alternative embodiments, the bolt retainer 340 can be closed to prevent access to the threaded bolt 300. In an exemplary embodiment, the bolt retainer 340 includes one or more retaining features 346 to retain the threaded bolt 300 in the harness housing 230. In the illustrated embodiment, retention feature 346 is a lip or edge that extends into opening 344. The lip is configured to seat against head 302 and / or insulating cover 310 to prevent removal of threaded bolt 300 through opening 344. Other types of retention features may be used in alternative embodiments.

[0038] The threaded socket 350 extends between the inner end 352 and the outer end 354. The threaded socket 350 includes a base 356 at the outer end 354. Optionally, the base 356 has a larger diameter than other portions of the threaded socket 350. For example, the threaded socket 350 is stepped outward at the base 356. In an exemplary embodiment, the threaded socket 350 includes a threaded column 358 extending from the base 356. The threaded column 358 includes an external thread 360 along an outer surface of the threaded column 358. The external thread 360 may extend to a distal end 362 of the threaded column 358. The threaded column 358 is configured to be threadably coupled to the charging terminal 126. For example, the threaded column 358 may be received in the threaded hole 190. In an exemplary embodiment, the threaded socket 350 includes a threaded hole 364 at the outer end 354. The threaded hole 364 includes an internal thread 366. The threaded bolt 300 is configured to be received in the threaded hole 364. The threaded shaft 304 of the threaded bolt 300 is coupled to the internal threads 366 of the threaded hole 364. In an exemplary embodiment, the threaded socket 350 includes a drive element 368 at the outer end 354. The drive element 368 is used to drive the rotation of the threaded socket 350, such as for mating to or unmating from the charging terminal 126. The drive element 368 can receive a tool, such as a screwdriver, an Allen wrench, a torque drill, or other types of tools, to rotate the threaded socket 350.

[0039] In an exemplary embodiment, the power harness 200 includes a mating seal 380 coupled to the harness housing 230 at the mating end 260 of the harness housing 230. In the illustrated embodiment, the mating end 260 is disposed at the inner end 236. The mating end 260 is located at the inner opening 256 of the hub 250. The mating end 260 is configured to mate with the housing 110, for example at the side port 160. In the illustrated embodiment, the mating seal 380 is cylindrical and configured to be inserted into the inner opening 256 of the hub 250 to seal against the hub 250. Optionally, the inner surface of the mating seal 380 can be sealed to the hub 250, and the outer surface of the mating seal 380 is configured to seal to the side port 160. However, in alternative embodiments, the outer surface can be sealed to the hub 250, and the inner surface can be sealed to the side port 160.

[0040] In an exemplary embodiment, the power harness 200 includes a seal retainer 390 to retain the mating seal 380 in the harness housing 230. The seal retainer 390 can be coupled to the harness housing 230 inside the mating seal 380. The seal retainer 390 can be coupled to the hub 250. The seal retainer 390 includes a latch 342 that is configured to latchably couple to the harness housing 230 to secure the seal retainer 390 to the harness housing 230.

[0041] Figure 4is a cross-sectional view of the charging inlet assembly 100 in an exemplary embodiment, showing the power harness 200 coupled to the housing 110 and the charging terminal 126 of the charging inlet assembly 100 .

[0042] During assembly, the charging terminal 126 is loaded into the terminal channel 118. The pin 184 at the mating end 180 of the charging terminal 126 is located in the DC jack 138 for mating with the charging connector. The terminal seal 186 is sealed to the housing 110 within the terminal channel 118. A latch or other feature can engage the charging terminal 126 to retain the charging terminal 126 in the terminal channel 118. The termination end 182 is located in the rear portion of the terminal channel 118. In an exemplary embodiment, the threaded hole 190 at the termination end 182 is aligned with the side port 160 for mating with the power harness 200. The cover 154 is coupled to the tube 150 to close the tube 150. The cover seal 156 is sealed to the housing 110.

[0043] During assembly, the threaded socket 350 and the contact ring 270 are coupled to the charging terminal 126. For example, the threaded socket 350 is loaded through the opening 276 in the contact ring 270. The base 356 of the threaded socket 350 is received in the recess 278. The inner end 352 of the threaded socket 350 extends forward of the second end 274 of the contact ring to interface with the charging terminal 126. For example, the threaded column 358 is received in the threaded hole 190 and can be threadably coupled to the threaded hole 190. As the threaded socket 350 is tightened, the base 356 presses against the contact ring 270 to pull the contact ring 270 into electrical contact with the connection surface 192 of the charging terminal 126. In an exemplary embodiment, the outer end 354 of the threaded socket 350 is flush with or recessed in the first end 272 of the contact ring 270 to allow the first end 272 of the contact ring 270 to interface with the ring insert 212 of the power cable 202.

[0044] During assembly, the threaded bolt 300 is aligned with the threaded socket 350. The hub 250 of the harness housing 230 is aligned with the hub at the side port 160 of the housing 110. In an exemplary embodiment, the mating interface is cylindrical, allowing for mating at various angular orientations relative to each other. In the illustrated embodiment, the power cable 202 is oriented 180° relative to the charging terminal 126; however, the power harness 200 and / or the second harness connector 400 can be oriented at other angular orientations (such as right angles).

[0045] During mating, the threaded bolt 300 is inserted into the threaded hole 364 of the threaded socket 350. For example, the insulating cap 320 at the end of the threaded bolt 300 is inserted into the threaded hole 364. When the threaded shaft 304 engages with the thread 366 of the threaded hole 364, the threaded bolt 300 is rotated to tighten the threaded bolt 300 to the threaded socket 350. In an exemplary embodiment, the end of the threaded bolt 300 extends from the outside of the harness housing 230, for example, beyond the inner end of the hub 250. The portion of the threaded bolt 300 exposed outside the harness housing 230 is the insulating cap 320. The metal or conductive portion of the threaded bolt 300 is not exposed. In this way, the power harness 200 is touch-safe in the unmated state. The insulating cover 310 covers the top end of the threaded bolt 300, so that the power harness 200 is touch-safe. In an exemplary embodiment, the exposed portion at the termination end 208 of the power cable 202 is housed or encapsulated in the housing 230, further making the power harness 200 touch-safe.

[0046] When mated, the charging inlet assembly 100 is sealed relative to the external environment. For example, the hub of the side port 160 is inserted into the inner end of the hub 250 of the power harness 200. In the illustrated embodiment, the power harness 200 carries a mating seal 380 to dock with the side port 160 during mating. In this way, a sealed interface is provided between the power harness 200 and the housing 110. In an exemplary embodiment, other openings in the housing 230 are sealed, for example, by bolt seals 330 and cable seals 220 of the power harness 200.

[0047] In the exemplary embodiment, the hub 250 includes an inner hub ring 262 and an outer hub ring 264. A recess 266 is formed between the inner hub ring 262 and the outer hub ring 264. The hub at the side port 160 of the housing 110 is configured to be received in the recess 266 between the inner hub ring 262 and the outer hub ring 264. The mating seal 380 is received in the recess 266 to interface with the side port 160. In the illustrated embodiment, the mating seal 380 is disposed on the inner hub ring 262. The seal retainer 390 is coupled to the inner hub ring 262 to retain the mating seal 380 on the inner hub ring 262. The inner surface of the mating seal 380 is sealed to the inner hub ring 262, and the outer surface of the mating seal 380 is sealed to the inner surface of the side port 160. However, in alternative embodiments, the mating seal 380 may be disposed on the outer hub ring 264 and seal against the outer surface of the side port 160.

[0048] The threaded bolt 300 and the threaded socket 350 are used to mechanically connect the power harness 200 to the housing 110 and the charging terminal 126. For example, the threaded socket 350 tightly holds (e.g., presses) the contact ring 270 against the connection surface 192 of the charging terminal 126. The threaded shaft 304 of the threaded bolt 300 is received in the threaded hole 364 of the threaded socket 350. The threaded bolt 300 is rotated to tighten the threaded shaft 304 in the threaded hole 364. The threaded bolt 300 tightly holds (e.g., presses) the ring plug 212 against the contact ring 270. As the threaded bolt 300 is tightened, the power harness 200 is electrically connected to the charging terminal 126. For example, the threaded connection between the threaded bolt 300 and the threaded socket 350 presses the ring plug 212 of the power cable 202 into electrical connection with the contact ring 270. The power cable 202 is electrically connected to the charging terminal 126 via the ring plug 212 and the contact ring 270. In an exemplary embodiment, the contact ring 270 and the ring insert 212 are made of copper and are highly conductive. A low resistance interface is created between the contact ring 270 and the ring insert 212. In this way, an efficient power transmission path is created between the power harness 200. A compact, strong, sealed, vibration-resistant, and touch-safe electrical connection is formed between the power harness 200.

Claims

1. A power harness (200) for a charging inlet assembly (100) of a vehicle, the power harness comprising: A power cable (202) having a cable body (204) extending to a termination end (182), the power cable including a ring insert (212) electrically connected to the cable body; A harness housing (230) having a chamber (232), the chamber (232) including a cable trough (244) and a hub (250), the hub (250) having a hole (252) passing through the harness housing, the cable trough receiving the terminating end of the power cable, the ring plug aligned with the hole, the harness housing having a mating end (180), the mating end (180) configured to mate with the housing (110) of the charging inlet assembly; a threaded bolt (300) received in the hub and passing through the hole (190), the threaded bolt passing through the ring insert, the threaded bolt including a head (302) and a threaded shaft (304), the threaded bolt including an insulating cap (310) on the head, the threaded bolt including an insulating cap (320) at a distal end (308) of the threaded shaft; a contact ring (270) received in the hub and aligned with the ring insert in the aperture, the contact ring having an opening (144) between a first end (272) engaging and electrically connected to the ring insert and a second end (274) configured to electrically connect to a charging terminal (126) of the charging inlet assembly; and A threaded socket (350) is received in the hub and aligned with the ring insert in the hole, the threaded socket is received in the opening of the contact ring and passes through the contact ring, the threaded socket extends between an inner end (352) and an outer end (354), the inner end has an external thread (360), the external thread (360) is configured to be threadably connected to the charging terminal of the charging inlet assembly, and the outer end has a threaded hole, the threaded hole receives the threaded shaft of the threaded bolt, and the threaded bolt can be threadably connected to the threaded socket.

2. The power harness (200) according to claim 1, wherein: The inner end (236) of the threaded socket (350) extends in front of the second end (274) of the contact ring (270) to dock with the charging terminal (126).

3. The power harness (200) according to claim 1, wherein: The second end (274) of the contact ring (270) extends in front of the mating end (180) of the wiring harness housing (230) for being received in the housing (110) of the charging inlet assembly (100) to dock with the charging terminal (126) of the charging inlet assembly.

4. The power harness (200) according to claim 1, wherein: The outer end (234) of the threaded socket (350) is flush with or recessed into the first end (272) of the contact ring (270) to allow the first end of the contact ring to interface with the ring insert (212).

5. The power harness (200) according to claim 1, wherein: The threaded socket (350) is configured to be threadedly coupled to the charging terminal (126) of the charging inlet assembly (100) before the threaded bolt (300) is threadedly coupled to the threaded hole (190) of the threaded socket.

6. The power wiring harness according to claim 1, wherein: The power cable (202) includes a cable seal (220) surrounding and sealing to the power cable, the power cable including a cable sealing cap (222) retaining the cable seal on a terminating end (182) of the cable body (204).

7. The power harness (200) according to claim 1, wherein: The threaded bolt (300) includes a bolt seal (330) that seals between the threaded bolt and the housing (110).

8. The power harness (200) according to claim 1 further includes a mating seal (380) at a mating end (180) of the harness housing (230), the mating seal being configured to seal between the harness housing and a housing (110) of the charging inlet assembly (100).

9. The power harness (200) according to claim 1, wherein: The hole (252) is open at the top of the wiring harness housing (230) and is open at the bottom of the wiring harness housing, the insulating cover (310) makes the threaded bolt (300) touch-proof when passing through the open top of the wiring harness housing, and the insulating cover (320) makes the threaded bolt touch-proof when passing through the open bottom of the wiring harness housing.

10. The power harness (200) according to claim 1, wherein: When the threaded bolt is tightened, the threaded bolt (300) presses the contact ring (270) into the mating wiring harness.

11. The power harness (200) according to claim 1, further comprising a bolt retainer (340) coupled to the harness housing (230) outside the threaded bolt (300) to retain the threaded bolt in the hub (250).

12. The power harness (200) according to claim 1, wherein: The hub (250) includes an inner hub ring (262), an outer hub ring (264) and a recess between the outer hub ring and the inner hub ring, a mating seal (380) being received in the recess and sealed to the inner hub ring, the recess being configured to receive a mating hub of the housing (110) to interface with the mating seal.

13. The power harness (200) according to claim 1, wherein: The insulating cap (320) of the threaded bolt (300) extends beyond the end of the harness housing (230) to the outside of the harness housing to cooperate with the threaded socket (350).

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