Heating charging inlet assembly

Abstract

A charging inlet assembly includes a circuit board assembly, a filler material, and a heater core. The circuit board assembly includes a heater. The filler material is thermally conductive and disposed around the heater. The heater core is thermally bonded to the filler material. The invention also relates to a vehicle and a method of assembling and operating the charging inlet assembly.

Description

Cross - Reference to Related Applications

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 618,461, filed on January 8, 2024, and U.S. Provisional Application No. 63 / 636,958, filed on April 22, 2024. The entire disclosures of the above applications are incorporated herein by reference. Technical Field

[0002] This disclosure relates to a heated charging inlet assembly, and more particularly, to an electric vehicle charging inlet assembly including a resistive heater sub - assembly. Background Art

[0003] Modern electric vehicles (e.g., cars) rely on wires and electrical connectors to facilitate charging of the battery within the vehicle. The connection system (e.g., connectors and terminals), also referred to as the charging inlet and connector / coupler, plays an important role in ensuring the integrity of these electrical connections as well as the reliability and performance of the vehicle. Moisture and / or ice intrusion in the connection system (e.g., in or near the interface between two connectors or terminals) can prevent one connector or terminal of the connector / coupler from disengaging from the other connector or terminal of the charging inlet, and / or prevent a secure connection between the connector and / or terminal of the connector / coupler and the charging inlet. Known systems for preventing moisture and / or ice intrusion utilize heating systems (e.g., heater circuits) through various charging inlet designs. While known systems for heating the connection system have proven useful for their intended purposes, there is still a need for continuous improvement in the relevant art to address challenges related to melting ice between mating terminals and / or connectors.

[0004] The background art provided herein is for the purpose of presenting the background of the disclosure generally. The work of the presently named inventors within the scope described in this background art section and aspects of the specification that are not otherwise considered prior art as of the filing date of the application are neither expressly nor implicitly admitted to be prior art to the disclosure. Summary of the Invention

[0005] A charging inlet assembly includes: a circuit board assembly, a filler material, and a heater core. The circuit board assembly includes a heater. The filler material is thermally conductive and is disposed around the heater. The heater core is thermally joined to the filler material.

[0006] A method of assembling and operating a charging inlet assembly includes: connecting a circuit board assembly including a heater to a housing having a heater core. The method further includes connecting a terminal position assurance (TPA) member including a fill port to the circuit board assembly and the housing. The method further includes injecting a filler material through the fill port to fill a cavity. In an assembled configuration, the filler material is disposed around the heater and contacts the circuit board assembly and the heater core.

[0007] Further applicable fields of the present disclosure will become apparent from the detailed description, the claims and the drawings. The detailed description and the specific examples are intended for illustrative purposes only and are not intended to limit the scope of the present disclosure. Description of the Drawings

[0008] The present disclosure will be more fully understood from the detailed description and the drawings.

[0009] Figure 1 is a perspective view of an exemplary charging inlet assembly in accordance with the principles of the present disclosure.

[0010] Figure 2 is in accordance with the principles of the present disclosure Figure 1 a perspective view of a charging inlet assembly, wherein for illustrative purposes, a portion of the charging inlet assembly is shown in dashed lines.

[0011] Figure 3 is in accordance with the principles of the present disclosure Figure 1 an exploded perspective view of a charging inlet assembly.

[0012] Figure 4 is in accordance with the principles of the present disclosure Figure 1 a front view of a charging inlet assembly, wherein for illustrative purposes, a portion of the charging inlet assembly is hidden.

[0013] Figure 5 is in accordance with the principles of the present disclosure Figure 1 a partial perspective view of a charging inlet assembly.

[0014] Figure 6 is in accordance with the principles of the present disclosure Figure 1 a cross-sectional view of a charging inlet assembly.

[0015] Figure 7 is a flowchart showing an exemplary method of assembling and operating a charging inlet assembly in accordance with the principles of the present disclosure.

[0016] In the drawings, reference numerals may be reused to identify similar and / or identical elements. Detailed Description Introduction

[0017] Reference Figures 1-3, an exemplary charging inlet assembly 10 (e.g., a connector assembly) is shown. As will be described in more detail below, the charging inlet assembly 10 can be installed in a vehicle 12 (e.g., an automobile) to facilitate power transfer between a charger and various components of the vehicle (e.g., a battery). For example, the inlet assembly 10 can be a male or female connector removably coupled to a mating connector (e.g., a male or female connector, such as a charging connector / coupler, not shown), such that during charger operation, power is transferred to the inlet assembly 10 and various electronic components within the vehicle.

[0018] In various embodiments, the inlet assembly 10 includes an inlet housing 14, a heater subassembly 16, a terminal position assurance (TPA) member 18, and one or more terminals 20, etc. As Figure 1 and Figure 2 shown, in some embodiments, the inlet housing 14 can be a female connector that forms a connector interface 22 (e.g., a cavity), and the terminals 20 are disposed within the connector interface 22. Inlet housing

[0019] Referring Figure 1 and Figure 3 , in various embodiments, the inlet housing 14 can include one or more of a variety of shapes, sizes, configurations, and / or materials. The inlet housing 14 can include a base 30 and a structure 32 extending from the base 30. In some exemplary configurations, the structure 32 can define the connector interface 22. In various embodiments, the inlet housing 14 is connected to the TPA member 18. Now referring Figure 4 –6, in various embodiments, the inlet housing 14 can be secured to the TPA member 18 via one or more mechanical fasteners 34 (e.g., screws, etc.).

[0020] In various embodiments, the inlet housing 14 can include a first end 36A and a second end 36B spaced apart from and opposite the first end 36A. In some exemplary configurations, the base 30 and / or the TPA member 18 can be disposed near the first end 36A. In some cases, the TPA member 18 can be connected to the base 30. The connector interface 22 can be accessible near the second end 36B. Heater subassembly

[0021] Referring Figure 2 , in various embodiments, the heater subassembly 16 can be connected to the inlet housing 14 and / or can be at least partially disposed within the inlet housing 14. The heater subassembly 16 can include a printed circuit board assembly (PCBA) 40, a fill material 42 (e.g., a thermal interface), and a heater core 44 (e.g., a heater core), etc. In various embodiments, the PCBA 40 can include at least one heater 46 (e.g., a resistive heater) and at least one thermistor 48, etc.

[0022] As Figures 2-4 shown, in some embodiments, the PCBA 40 includes four heaters 46 and four thermistors 48. However, it should be understood that within the scope of the present disclosure, the PCBA 40 may include more or fewer than four heaters 46 and more or fewer than four thermistors 48. In some embodiments, the heaters 46 may include resistive heaters. In some exemplary configurations, one or more of the heaters 46 may be arranged in a circuit (e.g., a temperature monitoring circuit) together with one or more of the thermistors 48 and one or more other components of the PCBA 40.

[0023] In various embodiments, the filling material 42 may include a thermally conductive and electrically insulating material. As Figure 6 shown, in some embodiments, the inlet housing 14 defines a cavity 50, and the filling material 42 is disposed in the cavity 50.

[0024] Referring Figure 2 to 3 and, in various embodiments, the heater core 44 may include one or more legs 60 and one or more loop portions 62.. In some embodiments, the heater core 44 includes four legs 60 and one loop portion 62 connected to the legs 60. However, it should be understood that within the scope of the present disclosure, the heater core 44 may include more or fewer than four legs 60 and more or fewer than one loop portion 62. For example, the number of legs 60 may correspond to the number of heaters 46. As Figure 1 and 2 shown, the heater core 44 may be encapsulated (e.g., overmolded) within the inlet housing 14. Terminal Position Assurance Member

[0025] In various embodiments, the TPA member 18 may align the terminals 20 with the inlet housing 14 and be attached to the inlet housing 14 using mechanical fasteners 34 (e.g., screws) or other suitable fastening means to secure the position of the terminals 20 and / or the PCBA 40. As Figure 2 , 4 and 6 shown, in some embodiments, the TPA member 18 and / or the PCBA 40 define one or more filling ports 70 and one or more discharge ports 72. During the construction of the charging inlet assembly 10, material (e.g., the filling material 42) may be injected into the cavity 50 through the filling ports 70 and out through the discharge ports 72. The filling ports 70 and / or the discharge ports 72 may also allow determination (e.g., by visual inspection) of whether the cavity 50 has been sufficiently filled with the filling material 42. For example, when the filling material 42 is visible within the discharge port 72, the user may determine that a sufficient amount of the filling material 42 is disposed within the cavity 50. Assembly Structure of the Charging Inlet Assembly

[0026] Reference Figure 6 , in the assembly structure, the TPA member 18 can be connected to the inlet housing 14 such that a gap 80 is provided between the base 30 and the TPA member 18. The PCBA 40 can be disposed in the gap 80. In various embodiments, the filler material 42 is disposed around the heater 46 and / or the thermistor 48 and / or can bond the heater 46 and / or the thermistor 48. The filler material 42 contacts (e.g., thermally bonds to) the PCBA 40 and the heater core 44.

[0027] In various embodiments, a portion of the legs 60 of the heater core 44 is disposed in the base 30 of the inlet housing 14. An additional portion of the legs 60 is disposed in the structure 32 of the inlet housing 14. The ring portion 62 of the heater core 44 is disposed in the structure 32. In various embodiments, the legs 60 contact (e.g., thermally bond to) the filler material 42. For each respective leg 60, the end portion 90 of the leg 60 is disposed near the heater 46, and the filler material 42 is disposed between the end portion 90 and the heater 46. Operation of the Charging Inlet Assembly

[0028] Continue to refer Figure 6 , during the operation of the charging inlet assembly 10, one or more heaters 46 can transfer heat T to the inlet housing 14 through the filler material 42 and the heater core 44 to melt ice that may accumulate on and / or in the inlet housing 14 and / or the terminals 20. For example, one or more heaters 46 transfer heat T through the filler material 42, the legs 60, and the ring portion 62. In various embodiments, one or more heaters 46 can directly heat the heater core 44 encapsulated in the inlet housing 14 near the connector interface 22, thereby allowing heating in this area and removing any ice that prevents the user from removing the charging connector. Using a thermally conductive and electrically insulating filler material 42 between the heater core 44 and one or more heaters 46 allows for a secure connection and efficient heat transfer between the heater core 44 and one or more heaters 46.

[0029] In various embodiments, the charging inlet assembly 10 is capable of (i) sensing the temperature of one or more heaters 46 in real time, (ii) having a minimal operational delay for the thermistor 48, and (iii) excellent performance of the heater subassembly 16.

[0030] In various embodiments, the close proximity of one or more heaters 46 to the heater core 44 via the fill material 42, and the direct path for heat T to transfer from the one or more heaters 46 to the heater core 44 through the fill material 42, allows the one or more heaters 46 to raise the temperature of the inlet housing 14 and the connector interface 22 above freezing with minimal heat loss and effectively control the temperature of the heaters 46 via a circuit (e.g., a temperature monitoring circuit) of the PCBA 40. Flowchart

[0031] Figure 7 is an example method 200 for assembling and operating a charging inlet assembly 10. Method 200 may begin at 204. At 204, a user may connect a printed circuit board assembly (PCBA) 40 including a heater 46 to an inlet housing 14 having a heater core 44. Then, method 200 proceeds to 208.

[0032] At 208, a user may connect a terminal position assurance (TPA) member 18 including a fill port 70 to the PCBA 40 and the inlet housing 14. Method 200 may proceed to 212. At 212, a user or a machine may inject a fill material 42 through the fill port 70 to fill the cavity 50. In an assembled configuration, the fill material 42 is disposed around the heater 46 and in contact (e.g., thermally bonded) with the PCBA 40 and the heater core 44. Method 200 may proceed to 216.

[0033] At 216, a user or a machine (e.g., a robot) may connect the assembled charging inlet assembly 10 to a vehicle 12. Method 200 may proceed to 220. At 220, during operation of the inlet assembly 10, the heater 46 may transfer heat T to the inlet housing 14 through the fill material 42 and the heater core 44 to melt ice that has accumulated in the inlet housing 14. In various embodiments, the heater core 44 includes at least one leg 60 and a ring portion 62 connected to the leg 60. An end portion 90 of the leg 60 is disposed near the heater 46, and the fill material 42 is disposed between the end portion 90 and the heater 46. Transferring heat T to the inlet housing 14 via the heater 46 includes transferring heat T through the fill material 42, the leg 60, and the ring portion 62. Then method 200 may end.

[0034] The foregoing description is merely illustrative in nature and is in no way intended to limit the present disclosure, its application, or uses. The broad teachings of the present disclosure may be implemented in a variety of forms. Thus, while the present disclosure includes specific examples, the true scope of the present disclosure should not be so limited since other modifications will become apparent upon study of the drawings, the specification, and the following claims. In the written description and the claims, one or more steps in a method may be performed in a different order (or concurrently) without changing the principles of the present disclosure. Similarly, one or more instructions stored on a non-transitory computer-readable medium may be executed in a different order (or concurrently) without changing the principles of the present disclosure. Unless otherwise noted, the numbering or other labeling of instructions or method steps is for convenience of reference only and is not intended to indicate a fixed order.

[0035] Moreover, although each embodiment above is described as having certain features, any one or more of these features described for any embodiment of the present disclosure may be implemented in and / or combined with the features of any other embodiment, even if the combination is not explicitly described. In other words, the described embodiments are not mutually exclusive, and arrangements of one or more embodiments with each other are still within the scope of the present disclosure.

[0036] The terms used herein are merely for the purpose of describing particular example configurations and are not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural referents unless the context clearly dictates otherwise. The terms “comprises,” “comprising,” “includes,” and “having” are inclusive and thus specify the presence of stated features, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and / or combinations thereof. The method steps, processes, and operations described herein should not be construed as necessarily requiring to be performed in the particular order discussed or illustrated, unless specifically identified as an order of performance. Additional or alternative steps may be employed.

[0037] Spatial and functional relationships between elements (e.g., between modules, circuit elements, semiconductor layers, etc.) are described using various terms, including "connected", "joined", "coupled", "adjacent", "proximate", "next to", "on", "above", "below", and "disposed". Unless explicitly described as "direct", when the relationship between a first element and a second element is described in the foregoing disclosure, the relationship encompasses both direct and indirect relationships, where in a direct relationship there are no other intervening elements between the first and second elements, and in an indirect relationship there is one or more intervening elements between the first and second elements. Other words used to describe the relationship between elements should be interpreted in a similar manner (e.g., "between" versus "directly between", "adjacent" versus "directly adjacent", etc.). As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0038] The term "set" does not necessarily exclude the empty set - in other words, in some cases, a "set" may have zero elements. The term "non-empty set" can be used to denote the exclusion of the empty set - in other words, a non-empty set will always have one or more elements. The term "subset" does not necessarily require a proper subset. In other words, a "subset" of a first set can have the same extent (be equal to) the first set. Additionally, the term "subset" does not necessarily exclude the empty set - in some cases, a "subset" may have zero elements.

[0039] The terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers, and / or sections. These elements, components, regions, layers, and / or sections should not be limited by these terms. These terms may only be used to distinguish one element, component, region, layer, or section from another. Terms such as "first", "second", and other numerical terms used herein do not imply an order or sequence, unless explicitly indicated by the context. Thus, a first element, component, region, layer, or section discussed below may be referred to as a second element, component, region, layer, or section without departing from the teachings of the exemplary construction.

[0040] The phrase "at least one of A, B, and C" should be interpreted to mean a logic using the non-exclusive "or" (A or B or C), and should not be interpreted to mean "at least one of A, at least one of B, and at least one of C". The phrase "at least one of A, B, or C" should be interpreted to mean a logic using the non-exclusive "or" (A or B or C).

[0041] The following technical solutions provide an exemplary construction of the heating charging inlet assembly as described above.

[0042] Technical Solution 1: A charging inlet assembly, comprising: a circuit board assembly, the circuit board assembly including a heater; a filling material, the filling material being thermally conductive and disposed around the heater; and a heater core, the heater core being thermally joined to the filling material.

[0043] Technical Solution 2: The charging inlet assembly of Technical Solution 1, further comprising a housing, the housing including: a base; and a structure extending from the base and defining a cavity.

[0044] Technical Solution 3: The charging inlet assembly of Technical Solution 2, further comprising a terminal position assurance (TPA) member connected to the housing, wherein, in an assembled configuration: a void is provided between the base and the TPA member, and the circuit board assembly is disposed in the void.

[0045] Technical Solution 4: The charging inlet assembly of Technical Solution 3, wherein: the housing includes a first end and a second end spaced apart from and opposite to the first end; the base and the TPA member are disposed near the first end; and the cavity is accessible near the second end.

[0046] Technical Solution 5: The charging inlet assembly according to any one of Technical Solutions 3 to 4, wherein: the TPA member includes a filling port in fluid communication with the void and configured to receive the filling material; and in the assembled configuration, the filling material is disposed within the void and contacts the circuit board assembly and the heater core.

[0047] Technical Solution 6: The charging inlet assembly according to any one of Technical Solutions 3 to 5, wherein the TPA member includes a plurality of filling ports configured to receive the filling material.

[0048] Technical Solution 7: The charging inlet assembly according to any one of Technical Solutions 2 to 6, wherein, during operation of the charging inlet assembly, the heater transfers heat to the housing through the filling material and the heater core to melt ice accumulated in the cavity.

[0049] Technical Solution 8: The charging inlet assembly according to any one of Technical Solutions 1 to 7, wherein the filling material is electrically insulating.

[0050] Technical Solution 9: The charging inlet assembly according to any one of Technical Solutions 2 to 8, wherein the heater core includes: legs; and a ring portion connected to the legs.

[0051] Technical Solution 10: The charging inlet assembly according to any one of Technical Solutions 9, wherein the legs engage the filling material.

[0052] Technical Solution 11: The charging inlet assembly according to any one of Technical Solutions 9 to 10, wherein: a portion of the legs is disposed in the base; an additional portion of the legs is disposed in the structure; and the ring portion is disposed in the structure.

[0053] Technical solution 12: A charging inlet assembly according to any one of technical solutions 9 to 11, wherein: the end of the leg is disposed near the heater; and a filling material is disposed between the end and the heater.

[0054] Technical solution 13: A charging inlet assembly according to any one of technical solutions 9 to 12, wherein during operation of the charging inlet assembly, the heater transfers heat through the filling material, the leg, and the ring portion.

[0055] Technical solution 14: A charging inlet assembly according to any one of technical solutions 9 to 13, wherein the heater core includes a plurality of legs connected to the ring portion.

[0056] Technical solution 15: A charging inlet assembly according to any one of technical solutions 9 to 14, wherein: the circuit board assembly includes a plurality of heaters; the heater core includes a plurality of legs connected to the ring portion; and the end portion of each of the plurality of legs is disposed near a corresponding one of the plurality of heaters.

[0057] Technical solution 16: A charging inlet assembly according to any one of technical solutions 1 to 15, wherein the heater is a resistive heater.

[0058] Technical solution 17: A vehicle, comprising: a charging inlet assembly according to any one of technical solutions 1 to 16.

[0059] Technical solution 18: A method of assembling and operating a charging inlet assembly, the method comprising: connecting a circuit board assembly including a heater to a housing having a heater core; connecting a terminal position assurance (TPA) member including a filling port to the circuit board assembly and the housing; and injecting a filling material through the filling port to fill a cavity, wherein in the assembled configuration, the filling material is disposed around the heater and in contact with the circuit board assembly and the heater core.

[0060] Technical solution 19: The method according to technical solution 18, wherein the filling material is thermally conductive and electrically insulating.

[0061] Technical solution 20: The method according to technical solution 18, wherein: the heater core includes: legs; and a ring portion connected to the legs; the end portion of the legs is disposed near the heater; and the filling material is disposed between the end portion and the heater; and the method further comprises: transferring heat through the filling material and the heater core to the housing via the heater to melt ice accumulated in the housing.

Claims

1. A charging inlet assembly, comprising: A circuit board assembly, the circuit board assembly including a heater; A filling material, the filling material being thermally conductive and disposed around the heater; And A heater core, the heater core being thermally joined to the filling material.

2. The charging inlet assembly according to claim 1, wherein It further includes a housing, the housing including: A base; and A structure extending from the base and defining a cavity.

3. The charging inlet assembly according to claim 2, wherein, It further includes a terminal position assurance (TPA) member connected to the housing, Wherein, in the assembled configuration: A gap is provided between the base and the terminal position assurance member, and The circuit board assembly is disposed in the gap.

4. The charging inlet assembly according to claim 3, wherein: The housing includes a first end and a second end spaced apart from and opposite to the first end; The base and the terminal position assurance member are disposed near the first end; and The cavity is accessible near the second end.

5. The charging inlet assembly according to claim 3, wherein: The terminal position assurance member includes a filling port, the filling port being in fluid communication with the gap and configured to receive the filling material; and In the assembled configuration, the filling material is disposed within the gap and in contact with the circuit board assembly and the heater core.

6. The charging inlet assembly according to claim 3, wherein, The terminal position assurance member includes a plurality of filling ports configured to receive the filling material.

7. The charging inlet assembly according to claim 2, characterized in that, During operation of the charging inlet assembly, the heater transfers heat to the housing through the filling material and the heater core to melt ice accumulated in the cavity.

8. The charging inlet assembly according to claim 1, characterized in that The filling material is electrically insulating.

9. The charging inlet assembly according to claim 2, wherein, The heater core includes: Legs; and A ring portion connected to the legs.

10. The charging inlet assembly according to claim 9, wherein, The legs engage the filling material.

11. The charging inlet assembly according to claim 9, wherein: A portion of the legs is disposed in the base; An additional portion of the legs is disposed in the structure; and The ring portion is disposed in the structure.

12. The charging inlet assembly according to claim 9, wherein: An end portion of the legs is disposed near the heater; and The filling material is disposed between the end portion and the heater.

13. The charging inlet assembly according to claim 9, wherein During operation of the charging inlet assembly, the heater transfers heat through the filling material, the legs and the ring portion.

14. The charging inlet assembly according to claim 9, characterized in that, The heater core includes a plurality of legs connected to the ring portion.

15. The charging inlet assembly according to claim 9, wherein: The circuit board assembly includes a plurality of heaters; The heater core includes a plurality of legs connected to the ring portion; and An end portion of each of the plurality of legs is disposed near a corresponding one of the plurality of heaters.

16. The charging inlet assembly according to claim 1, characterized in that, The heater is a resistive heater.

17. A vehicle, comprising: The charging inlet assembly according to claim 1.

18. A method of assembling and operating a charging inlet assembly, the method comprising: Connecting a circuit board assembly including a heater to a housing having a heater core; Connecting a terminal position assurance (TPA) member including a filling port to the circuit board assembly and the housing; and Inject a filling material through the filling port to fill the cavity, wherein, in the assembled configuration, the filling material is disposed around the heater and contacts the circuit board assembly and the heater core.

19. The method according to claim 18, wherein The filling material is thermally conductive and electrically insulating.

20. The method according to claim 18, wherein: The heater core includes: Legs; and A ring portion connected to the legs; End portions of the legs are disposed near the heater; and The filling material is disposed between the end portions and the heater; and The method further includes passing heat through the filling material and the heater core to the housing via the heater to melt ice accumulated in the housing.

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