Socket connector for charging port assembly

Abstract

A receptacle connector (102) for a charging port assembly (100) includes a housing (110) and a terminal assembly (114) coupled to the housing, the terminal assembly (114) including a cap (202) extending from a pin (200). The pins are disposed in terminal channels (136) of the housing for mating with the charging connector. The pin has a rear flange (230) and a rear mounting post to which a base (250) of the cap is coupled. A pad (252) extends from the base and is configured to be coupled to a power cable (142). The receptacle connector includes a secondary lock assembly (144) having a locking wall (184) that engages and blocks rearward movement of the rear flange of the pin in the locked position. The locking wall is disengaged from the rear flange of the pin in the unlocked position.

Description

[0001] This application is a divisional application of the invention patent application with application number 202080013802.X, application date January 6, 2020, and invention name “Socket connector for charging port assembly”. Technical Field

[0002] The subject matter herein relates generally to charging port assemblies. Background Art

[0003] In order to charge the battery of an electric vehicle (EV) or a hybrid electric vehicle (HEV), the vehicle is provided with a charging port assembly. The charging connector is configured to cooperate with the charging port assembly. The terminal is held in a socket connector of the housing of the charging port assembly. The terminal extends through a channel in the housing and enters a cavity at the rear of the housing for connection to a corresponding power cable. In known charging port assemblies, safety features are provided in the housing, such as secondary locking features along the terminals, to ensure that the terminals are correctly positioned and fixed in the housing. Other safety features in known charging port assemblies include temperature sensors along the terminals to monitor the temperature of the terminals during charging so that the system is shut down if the terminals overheat. In addition, it is required to seal the terminals inside the housing to prevent moisture from entering the charging port assembly. Providing a seal for the terminals and connecting the safety components to the terminals along the terminals increases the overall length of the terminals. The length of the terminals adversely affects the overall size of the charging port assembly by increasing the depth of the housing.

[0004] In addition, it is desirable to increase the amount of power transmitted through the terminals for charging the battery. The material of the terminals and the interface between the terminals and the power cable affect the impedance of the system. In addition, due to the rigidity of the power cable, routing the power cable from the terminals to the outside of the charging port assembly may be difficult and may require a larger cavity to accommodate the routing of the power cable, increasing the overall size of the charging port assembly.

[0005] A problem that needs to be solved is to provide a charging port assembly that can be manufactured in a cost effective and reliable manner, having a low profile for use in a vehicle. Summary of the invention

[0006] The problem is solved by a socket connector for a charging port assembly, which includes a housing extending between a front and a rear. The housing has a cavity at the rear. The housing has a terminal channel between the front and the rear. The housing has a primary latch extending into the terminal channel. The socket connector includes a terminal assembly connected to the housing. The terminal assembly includes a pin and a cap extending from the pin. The pin extends between the front and the rear. The pin has a mating shaft disposed in the terminal channel at the front for mating with the charging connector. The pin has a mounting head disposed in the terminal channel at the rear. The mounting head has a latch groove for receiving the primary latch to hold the pin in the terminal channel. The mounting head has a rear flange at the rear and a rear mounting column extending rearward from the rear flange. The cap extends from the pin in the cavity. The cap has a base, which includes an opening for receiving the rear mounting column of the pin and a base wall surrounding the opening. The cap has a pad extending from the base, which is configured to be connected to a power cable. The socket connector includes a secondary lock assembly in the cavity. The secondary lock assembly is coupled to the terminal assembly. The secondary lock assembly has a secondary lock body including a locking wall. The secondary lock is movable between a locked position and an unlocked position. In the locked position, the locking wall engages a rear flange of the pin and blocks its rearward movement. The locking wall disengages the rear flange of the pin in the unlocked position. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The present invention will now be described by way of example with reference to the accompanying drawings, in which:

[0008] Figure 1 is a front perspective view of a charging port assembly with a receptacle connector according to an exemplary embodiment.

[0009] Figure 2 is a front perspective view of a charging port assembly according to an exemplary embodiment.

[0010] Figure 3 is a rear perspective view of a portion of a charging port assembly according to an exemplary embodiment.

[0011] Figure 4 is a side view of a terminal assembly of a charging port assembly according to an exemplary embodiment.

[0012] Figure 5 is another side view of a terminal assembly according to an exemplary embodiment.

[0013] Figure 6 is a cross-sectional view of a charging port assembly according to an exemplary embodiment.

[0014] Fig. 7A is an enlarged cross-sectional view of a charging port assembly showing a secondary lock assembly in a locked position according to an exemplary embodiment.

[0015] Figure 7Bis an enlarged cross-sectional view of a charging port assembly showing a secondary lock assembly in an unlocked position according to an exemplary embodiment.

[0016] Figure 8 is a rear view of a charging port assembly showing a secondary lock assembly in a locked position according to an exemplary embodiment.

[0017] Fig. 9 is a cross-sectional view of a charging port assembly showing a secondary lock assembly in an unlocked position according to an exemplary embodiment.

[0018] Fig.10 is a rear perspective view of a charging port assembly according to an exemplary embodiment.

[0019] Fig.11 is a rear view of a charging port assembly according to an exemplary embodiment.

[0020] Fig.12 is a rear perspective view of a charging port assembly according to an exemplary embodiment.

[0021] Fig.13 is a rear view of a charging port assembly according to an exemplary embodiment. DETAILED DESCRIPTION

[0022] Figure 1 is a front perspective view of a charging port assembly 100 according to an exemplary embodiment. Figure 2 is a front perspective view of a charging port assembly 100 according to an exemplary embodiment. The charging port assembly 100 is used for a charging port of a vehicle, such as an electric vehicle (EV) or a hybrid electric vehicle (HEV). The charging port assembly 100 includes a receptacle connector 102 that is configured to be mated with a charging connector (not shown). In an exemplary embodiment, the receptacle connector 102 is configured to mate with a DC fast charging connector, such as an SAE combination CCS charging connector, in addition to mating with an AC charging connector, such as an SAE J1772 charging connector.

[0023] The charging port assembly 100 includes a housing 110 that holds a terminal assembly 112 and a terminal assembly 114. The housing 110 defines a socket connector 102. The terminal assemblies 112, 114 form a portion of the socket connector 102 and are configured to mate with a charging connector. In an exemplary embodiment, the terminal assembly 112 is an AC terminal assembly and the terminal assembly 114 is a DC terminal assembly. The terminal assembly 112 is disposed in a first connector port 116 of the socket connector 102, and the terminal assembly 114 is disposed in a second connector port 118 of the socket connector 102.

[0024] The charging port assembly 100 includes a mounting flange 120 coupled to the housing 110. The mounting flange 120 is used to couple the charging port assembly 100 to the vehicle. The mounting flange 120 includes a mounting tab 122 having an opening 124 for receiving a fastener (not shown) for securing the charging port assembly 100 to the vehicle. Other types of mounting features may be used to secure the charging port assembly 100 to the vehicle. The mounting flange 120 may include a seal to seal the charging port assembly 100 to the vehicle.

[0025] The charging port assembly 100 includes a cover 126 hingedly coupled to the mounting flange 120 and / or the housing 110. The cover 126 is used to cover the second connector port 118. Figure 1 The cover 126 is shown in a closed position. Figure 2 The cover is shown in an open position.

[0026] In an exemplary embodiment, the housing 110 includes a socket 130 for receiving a charging connector at a front 132 of the housing 110. An extension 134 extends into the socket 130. The extension 134 holds the terminal assemblies 112, 114. The extension 134 includes a terminal channel 136 that receives the corresponding terminal assemblies 112, 114. In the illustrated embodiment, the housing 110 includes a cylindrical upper extension 134 and an elliptical lower extension 134. In alternative embodiments, the extension 134 may have other shapes. In alternative embodiments, more or fewer extensions 134 may be provided. In the illustrated embodiment, the upper extension 134 includes three terminal channels 136 that hold three corresponding terminal assemblies 112, and the lower extension 134 includes two terminal channels 136 that hold two corresponding terminal assemblies 112. However, in alternative embodiments, the extension 134 may have more or fewer terminal channels 136 that hold the corresponding terminal assemblies 112, 114.

[0027] Figure 31 is a rear perspective view of a portion of a charging port assembly 100 according to an exemplary embodiment. The housing 110 extends to a rear portion 138. The housing 110 has a cavity 140 at the rear portion 138. The terminal assemblies 112, 114 extend into the cavity 140, and the power cable 142 is terminated to the terminal assemblies 112, 114 in the cavity 140. In an exemplary embodiment, the terminal assemblies 112, 114 are short, for example extending a shorter distance into the cavity 140 to allow a low profile or reduced depth housing 110. The power cable 142 can be efficiently routed from the terminal assembly 114 to reduce the depth of the housing 110. The power cable 142 is routed away from the charging port assembly 100, for example to a battery or to other components of the vehicle. Optionally, a cover (not shown) can be coupled to the rear portion 138 of the housing 110 to enclose the cavity 140. The cover may include a cable exit (eg, an opening) that receives the power cable 142 and allows the power cable 142 to exit the cavity 140 .

[0028] In an exemplary embodiment, the charging port assembly 100 includes a secondary lock assembly 144 for locking the terminal assembly 114 in the housing 110. The secondary lock assembly 144 can slide between a locked position and an unlocked position in the housing 110. In the locked position, the secondary lock assembly 144 engages the terminal assembly 114 and blocks the terminal assembly 114 from exiting the terminal passage 136 ( Figure 2 In an exemplary embodiment, the charging port assembly 100 includes a secondary lock assembly 146 for locking the terminal assembly 112 ( Figure 2 ) is locked in the housing 110. The secondary lock assembly 146 can slide between a locked position and an unlocked position in the housing 110. In the locked position, the secondary lock assembly 144 engages the terminal assembly 112 and blocks the terminal assembly 112 from exiting the terminal passage 136 ( Figure 2 ).

[0029] In an exemplary embodiment, the charging port assembly 100 includes a sensor assembly 148 associated with the secondary lock assembly 144. The sensor assembly 148 is used to sense the temperature of one or more terminal assemblies 114. If the terminal assembly 114 overheats, the sensor assembly 148 can be used to shut down the charging system. In various embodiments, a sensor assembly (not shown) can be associated with the secondary lock assembly 146 for sensing the temperature of the terminal assembly 112.

[0030] Figure 4 is a side view of a terminal assembly 114 according to an exemplary embodiment. Figure 51 is another side view of the terminal assembly 114 according to an exemplary embodiment. The terminal assembly 114 includes a pin 200 and a cap 202 extending from the pin 200. The cap 202 can be separate and discrete from the pin 200 and is configured to be mechanically and electrically coupled to the pin 200. In various other embodiments, the cap 202 is integral with the pin 200, for example, formed together with the pin 200. The pin 200 is configured to mate with a charging connector. The cap 202 is configured to terminate to the power cable 142 (at Figure 3 ). For example, the power cable 142 can be welded to the cap 202, or can be secured by other processes, such as crimping, soldering, etc. In an exemplary embodiment, the cap 202 is configured to be press-fit onto the pin 200. However, in alternative embodiments, the cap 202 can be secured to the pin 200 by other processes, such as friction stir welding, riveting, bolting, etc. The terminal assembly 114 extends along the longitudinal axis 204.

[0031] The pin 200 is conductive. For example, the pin can be made of a metal material, such as a copper material. In an exemplary embodiment, the pin 200 is threaded. The pin 200 can be made of a metal alloy (such as a copper alloy) with an additive to increase machinability. The pin 200 extends between a front portion 210 and a rear portion 212. The pin 200 has a mating shaft 214 at the front portion 210 that is configured to mate with a charging connector. The mating shaft 214 can be cylindrical. In an exemplary embodiment, the pin 200 includes a cap 216 at the end 218 of the pin 200. The cap 216 is made of a dielectric material, such as a plastic material. The cap 216 makes the terminal assembly 114 safe to touch at the front of the housing 110.

[0032] The pin 200 includes a mounting head 220 at a rear portion 212 of the pin 200. The mounting head 220 is used to mount the pin 200 in the housing 110. The cap 202 is coupled to the mounting head 220. In the illustrated embodiment, the mounting head 220 has a larger diameter than the mating shaft 214. In an exemplary embodiment, the mounting head 220 includes a latch groove 222 formed circumferentially around the mounting head 220, such as near the front end of the mounting head 220. In an exemplary embodiment, the mounting head 220 includes a pin locating shoulder 224 formed circumferentially around the mounting head 220. The pin locating shoulder 224 is used to locate the pin 200 in the terminal channel 136. In an exemplary embodiment, the mounting head 220 includes a seal groove 226 that receives a seal 228. The seal 228 can be located near the rear end of the mounting head 220. The seal 228 may have a diameter approximately equal to or slightly larger than the diameter of the mounting head 220 for interfacing and sealing against the inner surface of the terminal passage 136 .

[0033] The pin 200 includes a rear flange 230 at the rear 212. The rear flange 230 can define a rear end of the mounting head 220. The rear flange 230 can be located in the terminal channel 136. Optionally, the seal 228 can be immediately in front of the rear flange 230. For example, the seal 228 can be received in the sealing channel in front of the rear flange 230. The rear flange 230 has a rear surface 234 facing the cap 202. The rear surface 234 can be perpendicular to the longitudinal axis 204. In an exemplary embodiment, the cap 202 extends from the pin 200 and / or is connected to the pin 200 at the rear flange 230. The cap 202 can engage the rear surface 234.

[0034] In an exemplary embodiment, the pin 200 includes a rear mounting post 236 (shown in phantom) extending rearwardly from the rear flange 230. The cap 202 can be press-fit onto the rear mounting post 236. The rear mounting post 236 has a reduced diameter compared to the rear flange 230. The rear mounting post 236 can be cylindrical, for example, to allow the cap 202 to be rotatably positioned on the pin 200. However, in alternative embodiments, the rear mounting post 236 can have other shapes.

[0035] In an exemplary embodiment, the mating shaft 214 has a length 240 between the end 218 and the mounting head 220. The mounting head 220 has a length 242 between the mating shaft 214 and the rear surface 234 of the rear flange 230. In an exemplary embodiment, the length 242 of the mounting head 220 is shorter than the length 240 of the mating shaft 214. Having a shorter mounting head 220 positions the cap 202 closer to the mating shaft 214, reducing the overall length of the terminal assembly 114.

[0036] The cap 202 includes a base 250 and a pad 252 extending from the base 250. The base 250 is coupled to the pin 200. In the illustrated embodiment, the base 250 is cylindrical; however, in alternative embodiments, the base 250 may have other shapes. The base 250 has a base wall 254 (at Figure 4 25). The opening 256 receives the rear mounting post 236. The base wall 254 extends between the front 258 of the cap 202 and the cap wall 260 at the rear end of the base 250. The pad 252 extends from the cap wall 260. In the illustrated embodiment, the cap wall 260 is oriented perpendicular to the longitudinal axis 204. In the exemplary embodiment, the base 250 is undercut in front of the cap wall 260 to form a receiving portion 262 in front of the cap wall 260. The receiving portion 262 extends along the base wall 254. The receiving portion 262 is located behind the rear flange 230.

[0037] The base 250 has a base diameter 270 ( Figure 5The rear flange 230 has a rear flange diameter 272 that is larger than the base diameter 270. The terminal assembly 114 is stepped inwardly from the rear flange 230 to the cap wall 260 at the receiving portion 262 to receive the secondary lock assembly 144 (at Figure 3 ). The rear surface 234 and the base wall 254 are exposed and configured to be engaged by the secondary lock assembly 144. The rear surface 234 forms a locking surface for the secondary lock assembly 144.

[0038] The pad 252 includes a first surface 280 and a second surface 282 opposite the first surface 280. Optionally, the first surface 280 and the second surface 282 may be planar surfaces. The first surface 280 and the second surface 282 are oriented parallel to the longitudinal axis 204. The first surface 280 and the second surface 282 may be perpendicular to the cap wall 260. The pad 252 may be rectangular in shape; however, in alternative embodiments, the pad 252 may have other shapes. In various embodiments, the pad 252 is a welding pad, and the power cable 142 ( Figure 3 ) is configured to be welded to the pad 252, for example, to the first surface 280 and / or the second surface 282. In various other embodiments, the pad 252 can be attached to the power cable 142 by other means, such as by crimping. For example, the pad 252 can be bent into a barrel shape or a hole shape, configured to be crimped around the power cable 142 and compressed.

[0039] Figure 6 is a cross-sectional view of a charging port assembly 100 according to an exemplary embodiment. Figure 6 A terminal assembly 114 is shown coupled to the housing 110 . Figure 6 A secondary lock assembly 144 is shown connected to the terminal assembly 114 in the cavity 140. The terminal assembly 114 is shorter (e.g., extends a shorter distance into the cavity 140) to reduce the overall profile or width of the charging port assembly 100. The terminal assembly 114 is received in a corresponding terminal channel 136. The extension 134 defines the terminal channel 136. The extension 134 extends between the front edge 150 and the rear edge 152. The terminal channel 136 includes a front end 154 and a rear end 156. The mating axis 214 of the pin 200 is located in the front end 154, and the mounting head 220 of the pin 200 is located in the rear end 156. The middle wall 158 separates the front end 154 and the rear end 156 of the terminal channel 136.

[0040] The terminal passage 136 includes a hole 160 at the front end 154 of the terminal passage 136, which is configured to receive a portion of the charging connector. The hole 160 is oversized relative to the mating axis 214 so that a space is defined around the mating axis 214 that receives the charging conductor of the charging connector.

[0041] The housing 110 includes a primary latch 162 extending into the terminal passage 136 to engage and retain the terminal assembly 114 in the terminal passage 136. The primary latch 162 can be a deflectable latch. The primary latch 162 can be integral with the housing 110, such as being co-molded with the housing 110. In the illustrated embodiment, the primary latch 162 is located at the middle wall 158. The primary latch 162 can be latchably received in the latch groove 222 to axially fix the pin 200 in the terminal passage 136. The primary latch 162 resists the terminal assembly 114 from being pulled back out of the terminal passage 136. Optionally, the pin 200 is rotatable in the terminal passage 136. For example, the pin 200 can be rotated with the primary latch 162 in the latch groove 222.

[0042] The housing 110 includes a housing shoulder 164 extending into the terminal passage 136 to engage and position the terminal assembly 114 in the terminal passage 136. The terminal passage 136 is stepped inward to define the housing shoulder 164. The pin positioning shoulder 224 of the pin 200 engages the housing shoulder 164 to position the terminal assembly 114 in the terminal passage 136. The terminal assembly 114 can bottom out against the housing shoulder 164. For example, once the positioning shoulder 224 engages the housing shoulder 164, the housing shoulder 164 can stop the terminal assembly 114 from advancing further forward. The housing shoulder 164 can be a step, rib, tab, or other raised feature. The housing shoulder 164 can extend circumferentially around the terminal passage 136, or extend circumferentially partially around the terminal passage 136.

[0043] The terminal passage 136 includes an inner surface 166 along the rear end 156. The mounting head 220 may engage the inner surface 166 with an interference fit, for example, to securely hold the pin 200 in the terminal passage 136. In an exemplary embodiment, the seal 228 seals to the inner surface 166, for example, adjacent the rear edge 152.

[0044] In an exemplary embodiment, the terminal assembly 114 is positioned in the terminal passage 136 such that the cap 202 and the secondary lock assembly 144 are positioned immediately behind the rear edge 152 of the extension 134. The rear flange 230 of the pin 200 is positioned in the terminal passage 136. For example, the rear surface 234 is coplanar with the rear edge 152. In an exemplary embodiment, the rear mounting post 236 and the cap 202 extend into the cavity 140, whereas the remainder of the pin 200 is forward of the rear edge 152 in the terminal passage 136. The rear mounting post 236 is received in the opening 256 of the base 250, and the base 250 is press-fit onto the rear mounting post 236 in a press-fit connection. The press-fit connection establishes a low impedance interface between the pin 200 and the cap 202. Optionally, the cap 202 presses the pin 200 until the front portion 258 bottoms out against and engages the rear flange 230.

[0045] The power cable 142 is coupled to the pad 252 in the cavity 140. In an exemplary embodiment, the power cable 142 is ultrasonically welded to the pad 252, establishing a low impedance interface between the terminal assembly 114 and the power cable 142. In various other embodiments, the power cable 142 may be crimped or otherwise mechanically and electrically terminated to the pad 252.

[0046] The secondary lock assembly 144 is used as a safety feature as a terminal position assurance device and a locking device for the terminal assembly 114. The secondary lock assembly 144 is movable between a locked position and an unlocked position. In the locked position, the secondary lock assembly 144 engages the terminal assembly 114 and blocks the terminal assembly 114 from exiting the terminal passage 136. However, if the terminal assembly 114 is not fully loaded into the terminal passage 136 (for example, only partially loaded into the terminal passage 136), the secondary lock assembly 144 cannot move to the locked position because the mounting head 220 will block the secondary lock assembly 144 from sliding to the locked position. Therefore, if the secondary lock assembly 144 is blocked from moving to the locked position, the secondary lock assembly 144 provides a visual indication to the assembler that the terminal assembly 144 is not fully loaded. In an exemplary embodiment, a rear cover (not shown) configured to be coupled to the rear end of the housing 110 includes an interference feature aligned with the secondary lock assembly 144. If the secondary lock assembly 144 is in the unlocked position, the interference feature interferes with the secondary lock assembly 144. As such, if the secondary lock assembly 144 is in the unlocked position, the rear cover cannot be coupled to the housing 110. Only when the secondary lock assembly 144 is moved to the locked position does the interference feature release the secondary lock assembly 144, allowing the rear cover to be fully seated on the housing 110.

[0047] Fig. 7A is an enlarged cross-sectional view of the charging port assembly 100 showing the secondary lock assembly 144 in a locked position according to an exemplary embodiment. Figure 7B is an enlarged cross-sectional view of the charging port assembly 100 according to an exemplary embodiment, showing the secondary lock assembly 144 in an unlocked position. The secondary lock assembly 144 includes a secondary lock body 170 having a front portion 172 and a rear portion 174. The secondary lock body 170 includes an opening 176 for receiving the terminal assembly 114. Optionally, the opening 176 can receive a portion of the housing 110, such as the rear end of the extension 134. The secondary lock assembly 144 includes a first side portion 180 and a second side portion 182. The first side portion 180 is used to lock the terminal assembly 114 in the terminal channel 136. The first side portion 180 is slid toward the extension 134 in the locked position. The second side portion 182 is slid toward the extension 134 in the unlocked position.

[0048] The secondary lock body 170 includes a locking wall 184 at the first side 180. In the locked position, the locking wall 184 is located behind the terminal assembly 114 to block the terminal assembly 114 from being removed from the terminal passage 136. The locking wall 184 is disposed behind the rear surface 234 of the rear flange 230. The locking wall 184 is disposed behind the rear edge 152 of the extension 134. In an exemplary embodiment, the locking wall 184 is received in the receiving portion 262 adjacent to the base wall 254. The locking wall 184 can abut against the base wall 254. In an exemplary embodiment, the secondary lock assembly 144 is axially aligned with the cap 202 and the rear mounting post 236 along the longitudinal axis 204. The secondary lock assembly 144 engages the cap 202. In the unlocked position, the locking wall 184 moves away (e.g., moves to the right in the illustration) from the rear flange 230 and the extension 124.

[0049] The secondary lock body 170 includes a positioning wall 186 at the first side portion 180. The positioning wall 186 is used to position the secondary lock body 170 relative to the housing 110. In an exemplary embodiment, the positioning wall 186 is configured to engage the extension 134. The positioning wall 186 can extend forward from the locking wall 184.

[0050] In an exemplary embodiment, the secondary lock body 170 includes a channel 188, for example, in the locking wall 184, which receives the sensor assembly 148. The channel 188 can be open at the first side 180 to receive the sensor assembly 148. In an exemplary embodiment, the sensor assembly 148 includes a temperature sensor 190. In the illustrated embodiment, the temperature sensor 190 is disposed at the end of a wire 192. However, in alternative embodiments, the temperature sensor 190 can be mounted to a circuit board. The temperature sensor 190 is located in the channel 188 of the locking wall 184 adjacent to the terminal assembly 114 to sense the temperature of the terminal assembly 114. For example, the temperature sensor 190 is located adjacent to the cap 202 and / or the rear flange 230 to sense the temperature of the cap 202 and / or the pin 200. In various embodiments, the secondary lock assembly 144 can include an electrical insulator (not shown) in the channel 188 to provide an insulating interface for the secondary lock body 170 and / or the cap 202 to electrically insulate the sensor assembly 148 from the terminal assembly 114. In an exemplary embodiment, the electrical insulator is made of a thermally conductive material to allow the temperature sensor 190 to measure the temperature of the cap 202 and / or the pin 200. In various embodiments, the insulator can be made of a silicone material. In various embodiments, the insulator can engage the base wall 254.

[0051] Figure 8 is a rear view of the charging port assembly 100 showing the secondary lock assembly 144 in a locked position according to an exemplary embodiment. Fig. 9is a cross-sectional view of the charging port assembly 100 according to an exemplary embodiment, showing the secondary lock assembly 144 in an unlocked position. The secondary lock assembly 144 includes a latch 196 that is configured to latchably engage a latch feature 198 of the housing 110 to secure the secondary lock assembly 144 in a locked position. The latch 196 is deflectable and can be unlatched. In an exemplary embodiment, the secondary lock assembly 144 includes a guide slot 178 that slides on a guide post 179 of the housing 110 to guide movement of the secondary lock assembly 144 between the unlocked position and the locked position.

[0052] Figure 8 and Fig. 9 A power cable 142 is shown relative to the terminal assembly 114 according to an exemplary embodiment. Figure 8 The power cables 142 are shown extending from the pads 252 of the terminal assembly 114 . Fig. 9 The pin 200 and cap 202 of the terminal assembly 114 are shown. In the illustrated embodiment, the power cable 142 extends outwardly away from the terminal assembly 114, such as parallel to the longitudinal axis of the terminal assembly 114. However, in alternative embodiments, the power cable 142 can extend in other directions, such as perpendicular to the longitudinal axis of the terminal assembly 114. For example, Figures 10 to 13 Alternative orientations of the power cables 142 relative to the terminal assembly 114 are shown for various power cables routed from the housing 110 .

[0053] Fig.10 is a rear perspective view of the charging port assembly 100 according to an exemplary embodiment. Fig.11 is a rear view of the charging port assembly 100 according to an exemplary embodiment. Fig.12 is a rear perspective view of the charging port assembly 100 according to an exemplary embodiment. Fig.13 is a rear view of the charging port assembly 100 according to an exemplary embodiment. Figure 3 The terminal assembly 114 is configured to be disposed at different orientations relative to the housing 110 for various power cables routed from the housing 110 .

[0054] In an exemplary embodiment, the terminal assembly 114 can be rotated within the terminal channel 136 to change the position of the pad 252 within the cavity 140 (e.g., horizontally, vertically, or in other orientations). The cap 202 can be selectively coupled to the rear mounting post 236 at different rotational positions on the rear mounting post 236 (e.g., horizontally, vertically, or in other orientations). Figure 4) to change the angular position of the pad 252 in the cavity 140 (e.g., at 0°, 90°, 180°, 270°, or at other angular positions). By changing the angular orientation of the pad 252 in the cavity 140, the cable exit direction can be changed. The power cable 142 is configured to connect with the pad 252 at different orientations for different wiring schemes from the housing 110. For example, the power cable 142 can be oriented parallel to the longitudinal axis 204, can be oriented perpendicular to the longitudinal axis 204, or can be oriented at other angles relative to the terminal assembly 114.

[0055] Different vehicles may require the power cable 142 to be routed in different directions (e.g., down, up, right, left, rearward, etc.) from the housing 110. To reduce the length of the power cable 142, and to reduce the depth of the cavity 140 required to route (e.g., bend or maneuver) the power cable 142 from the terminal assembly 114, the pad 252 of the terminal assembly 114 supports multiple cable exit directions. Figure 3 The power cable 142 is shown exiting the terminal assembly 114 and the housing 110 in a rearward direction. Fig.10 and Fig.11 The power cable 142 is shown exiting the terminal assembly 114 and the housing 110 in a downward direction. Fig.12 and Fig.13 The power cable 142 is shown exiting the terminal assembly 114 and the housing 110 in a lateral direction. In an exemplary embodiment, the housing 110 includes a cable exit 128 that provides a port to guide the power cable 142 through the housing 110 between the cavity 140 and the charging port assembly 100. In different embodiments, the cable exit 128 can be in various suitable locations (e.g., along the bottom, the side, etc.).

[0056] The depth of the charging port assembly 100 is reduced by limiting or reducing the length of the terminal assembly 114, controlling the position of the secondary lock assembly 144, and controlling the routing of the power cable 142 from the pad 252. The cable exit direction of the cable exit 128 can be from the bottom or the side to reduce the overall depth of the charging port assembly 100. In various embodiments, coupling the secondary lock assembly to the cap 202 rather than to a dedicated locking collar or other section of the pin reduces the overall length of the terminal assembly 114.

[0057] CROSS-REFERENCE TO RELATED APPLICATIONS

[0058] This application claims the benefit of U.S. Provisional Application No. 62 / 791,074, filed on January 11, 2019, and entitled “Ultrasonic Weld Pad with Secondary Lock Engagement on Charging Inlets,” the subject matter of which is incorporated herein by reference in its entirety.

Claims

1. A socket connector (102) for a charging port assembly (100), include: a housing (110) extending between a front portion (132) and a rear portion (138), the housing having a cavity (140) at the rear portion, the housing having a terminal passage (136) between the front portion and the rear portion, the housing having a primary latch (162) extending into the terminal passage; a terminal assembly (114) coupled to the housing, the terminal assembly comprising a pin (200) and a cap (202) extending from the pin in the cavity, the pin extending between a front portion (210) and a rear portion (212), the pin having a mating axis (214) at the front portion, the mating axis being disposed in the terminal channel for mating with a charging connector, the pin having a mounting head (220) at the rear portion, the mounting head having a latch groove (222) for receiving the primary latch to retain the pin in the terminal channel, the primary latch defining a primary lock for retaining the terminal assembly in the housing, the mounting head having a rear flange (230) at the rear portion, the cap having a base (250) and a pad (252) extending from the base, the pad being configured to be coupled to a power cable (142); A secondary lock assembly (144) is located in the cavity, the secondary lock assembly defines a secondary lock for retaining the terminal assembly in the housing, the secondary lock assembly is connected to the terminal assembly, the secondary lock assembly has a secondary lock body (170) including a locking wall (184), the secondary lock is movable between a locked position and an unlocked position, the locking wall is disposed behind the rear flange and engages the rear flange in the locked position to block the rearward movement of the rear flange of the pin, and the locking wall is disengaged from the rear flange of the pin in the unlocked position.

2. The socket connector (102) according to claim 1, in, The secondary lock assembly (144) engages the cap (202).

3. The socket connector (102) according to claim 1, in, The housing (110) includes an extension (134) defining the terminal passage (136), the extension having a rear edge (152), the pin (200) being received in the terminal passage such that the rear flange (230) is coplanar with the rear edge, and the locking wall (184) engages the rear edge in the locked position.

4. The socket connector (102) according to claim 3, in, The base (250) engages the rear flange (230).

5. The socket connector (102) of claim 1 further comprises a seal (228) coupled to the mounting head (220) of the pin (200), the seal being disposed in the terminal channel (136) and sealing against the housing (110), the cap (202) being coupled to the pin adjacent to the seal.

6. The socket connector (102) according to claim 5, in, The seal (228) is positioned immediately forward of the rear flange (230).

7. The socket connector (102) according to claim 1, in, The terminal assembly (114) extends along a longitudinal axis (204) and the secondary lock assembly (144) is axially aligned with the cap (202) along the longitudinal axis.

8. The socket connector (102) according to claim 1, in, The pin (200) includes a rear mounting post (236) extending rearwardly from the rear flange (230), the base (250) is coupled to the rear mounting post, the terminal assembly (114) extends along a longitudinal axis (204), and the secondary lock assembly (144) is axially aligned with the rear mounting post along the longitudinal axis.

9. The socket connector (102) according to claim 1, in, The secondary lock assembly (144) includes a sensor assembly (148) received in the secondary lock body (170), the sensor assembly having a temperature sensor (190) disposed adjacent the cap (202).

10. The socket connector (102) according to claim 1, in, The mounting head (220) includes a rear mounting post (236) extending rearwardly from the rear flange (230), and the base (250) of the cap (202) includes an opening (176) for receiving the rear mounting post and a base wall (254) surrounding the opening.

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