Charging inlet assembly for vehicle

Abstract

A charging inlet assembly (100) for an electric vehicle includes a charging inlet housing (102) having a terminal channel (154) that holds charging terminals (112, 114). The charging inlet assembly includes a control module (200) at the rear of the charging inlet housing. The control module includes a circuit board assembly (210) received in the rear chamber (153). The circuit board assembly includes a fixed portion (220) and a flexible portion (230) movable relative to the fixed portion. The fixing portion is fixed relative to the charging inlet housing. The flexible portion is movable relative to the charging inlet housing. The flexible portion includes a temperature sensor (250) configured to be thermally coupled to the charging terminal. The temperature sensor is movable with the flexible portion relative to the charging terminal.

Description

Technical Field

[0001] This article primarily deals with vehicle charging systems. Background Technology

[0002] Electric vehicles (EVs) and hybrid electric vehicles (HEVs) include a battery system for operating the vehicle. The battery system is charged by the vehicle's charging system. For example, a charging connector, connected to a power source, connects to the vehicle's charging inlet assembly to charge the battery. The charging inlet assembly includes charging terminals configured to connect to the charging connector. It is necessary to monitor the temperature of the charging terminals during charging to avoid damaging components of the charging inlet assembly. Typically, the charging inlet assembly includes a temperature sensor for monitoring the temperature of the charging terminals. However, the performance of the temperature sensor is negatively affected by the thermal resistance between the temperature sensor and the charging terminals. For example, thermal resistance can occur due to insufficient thermal connection between the temperature sensor and the charging terminals, such as due to mounting the temperature sensor on a circuit board too far from the charging terminals. Additionally, the circuit board and temperature sensor increase the overall cost of the charging inlet assembly.

[0003] There is still a need for reliable and cost-effective vehicle charging systems for electric vehicles. Summary of the Invention

[0004] In one embodiment, a charging inlet assembly for an electric vehicle is provided, the charging inlet assembly including a charging inlet housing having a front portion and a rear portion. The charging inlet housing has a terminal channel between the front and rear portions. The charging inlet housing has a rear chamber at the rear portion. The charging inlet assembly includes a charging terminal received in the corresponding terminal channel and held within the charging inlet housing. The charging terminal has pins configured to connect to a charging plug. The charging inlet assembly includes a control module located at the rear of the charging inlet housing. The control module includes a circuit board assembly received in the rear chamber. The circuit board assembly includes a fixed portion and a flexible portion movable relative to the fixed portion. The fixed portion is fixed relative to the charging inlet housing. The flexible portion is movable relative to the charging inlet housing. The flexible portion includes a temperature sensor configured to be thermally coupled to the charging terminal. The temperature sensor is movable relative to the charging terminal together with the flexible portion. Attached Figure Description

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

[0006] Figure 1 This is a front perspective view of the charging inlet assembly according to an exemplary embodiment.

[0007] Figure 2 This is a rear perspective view of the charging inlet assembly according to an exemplary embodiment.

[0008] Figure 3 The diagram illustrates a terminal housing, a rear cover, a first charging terminal, a second charging terminal, and a control module including an interface connector, according to an exemplary embodiment.

[0009] Figure 4 A portion of the control module is shown, illustrating a circuit board assembly according to an exemplary embodiment in a pre-connected or unconnected position.

[0010] Figure 5 A portion of the control module is shown, illustrating a circuit board assembly according to an exemplary embodiment in an actuated or connected position.

[0011] Figure 6 This is a side view of a portion of the control module, showing a circuit board assembly according to an exemplary embodiment in a pre-connected or unconnected position.

[0012] Figure 7 This is a side view of a portion of the control module, showing a circuit board assembly according to an exemplary embodiment in an actuated or connected position.

[0013] Figure 8 This is a front view of a portion of the control module, showing the circuit board assembly according to an exemplary embodiment in the connection position.

[0014] Figure 9 This is a side view of a portion of the control module, showing a circuit board assembly according to an exemplary embodiment in the connection position. Detailed Implementation

[0015] Figure 1 This is a front perspective view of the charging inlet assembly 100 according to an exemplary embodiment. Figure 2 This is a rear perspective view of the charging inlet assembly 100 according to an exemplary embodiment. The charging inlet assembly 100 is configured to mate with a complementary charging component (not shown), such as a charging connector or plug charger.

[0016] Charging inlet assembly 100 defines a power connector configured to electrically connect to a plug charger for charging the battery system of a vehicle such as an electric vehicle (EV) or a hybrid electric vehicle (HEV). In an exemplary embodiment, charging inlet assembly 100 is configured to mate with a North American Charging Standard (NACS) charging plug. For example, charging inlet assembly 100 has a NACS inlet interface and leads. In alternative embodiments, other inlet configurations, such as Type 1J1772, Combined Charging System Type 1 (CCS1), or Combined Charging System Type 2 (CCS2), may be used.

[0017] The charging inlet assembly 100 includes a charging inlet housing 102 configured for mounting in a vehicle. The charging inlet housing 102 forms part of a power connector for mating with a charging connector. For example, the charging inlet housing 102 includes a socket 104 for receiving a charging plug. Figure 1 The charging inlet assembly 100 includes a plurality of charging terminals 110 for connection to a charging plug. Figure 1 ). Power cable 120 ( Figure 2 It is electrically connected to the charging terminal 110 and wired within the vehicle, for example, to the battery.

[0018] In an exemplary embodiment, charging terminal 110 is configured for both AC charging and DC charging. In an exemplary embodiment, charging terminal 110 includes a first power terminal 112, a second power terminal 114, a ground terminal 115, a control pilot terminal 116, and a proximity pilot terminal 118. The first power terminal 112 can be used for positive current (DC+) or split-phase AC (line 1) or single-phase AC (line). The second power terminal 114 can be used for negative DC (DC-) or split-phase AC (line 2) or single-phase AC (neutral). Ground terminal 115 is associated with a full-current protective grounding system. Control pilot terminal 116 is used for charging status / current signaling. Proximity pilot terminal 118 is used for vehicle connector status signaling. Control pilot terminal 116 and proximity pilot terminal 118 can be connected to a control module 200 configured to control charging operations, such as on / off, charging rate, current, voltage, etc.

[0019] In an exemplary embodiment, power cable 120 is electrically connected to a corresponding charging terminal 110. Power cable 120 can be routed to other components within the vehicle, such as a battery, on-board charger, battery control unit, vehicle control interface module, body (for grounding), etc. In an exemplary embodiment, power cable 120 can be configured to transmit AC power and / or DC power. For example, AC power can be transmitted to the on-board charger, while DC power and / or AC power can be transmitted to the battery for charging. In an exemplary embodiment, the power cable includes both a DC cable 122 and an AC cable 124. DC cable 122 can transmit high voltage for charging the battery, and AC cable 124 can transmit low voltage for charging the battery or on-board charger. DC and AC cables 122, 124 are connected to corresponding charging terminals 112, 114 within the charging inlet housing 102. Internal connections are made to facilitate cable routing.

[0020] In an exemplary embodiment, the control module 200 includes an interface connector 202. Figure 2Interface connector 202 can be electrically connected to ground terminal 115 and / or control guide terminal 116 and / or proximity guide terminal 118. Interface connector 202 can be connected to other components, such as temperature sensors for monitoring the operating temperature of charging terminals 112, 114. Connectors or wires (not shown) can be electrically connected to interface connector 202 to connect to another component, such as the battery control unit (not shown) of the battery system. Data, such as data related to charging operation, is transmitted between charging inlet assembly 100 and the battery system. For example, the data may relate to charging start / stop, operating temperature of charging terminals 112, 114, or other charging data. A proximity signal can be sent to the battery system to indicate when the charging device engages with the power connector of charging inlet assembly 100.

[0021] In an exemplary embodiment, the charging inlet housing 102 is a multi-piece housing. For example, the charging inlet housing 102 includes a front housing 140, a terminal housing 150, and a rear cover 160. The housing components are assembled together to form the charging inlet housing 102. The front housing 140 forms a charging plug interface 106 at the front of the charging inlet housing 102. The charging plug interface 106 is configured to mate with a charging plug. The front housing 140 is configured to be mounted to a vehicle. The terminal housing 150 holds and surrounds the charging terminal 110. The front housing 140 and / or the terminal housing 150 and / or the rear cover 160 may hold and surround components of the control module 200. For example, circuit board assemblies and corresponding electrical components and temperature sensors may be received in the rear chamber of the terminal housing 150 and held in the terminal housing 150 by the rear cover 160. An interface connector 202 may be disposed at the rear of the terminal housing 150 and pass through the rear cover 160 for connection to an electrical connector. The rear cover 160 holds and surrounds the power cable 120.

[0022] The front housing 140 includes a front wall 142 and a hub 144 extending from the rear of the front wall 142. A terminal housing 150 is configured to engage with the hub 144. For example, the terminal housing 150 may be clamped, latched, secured with fasteners, or otherwise secured to the hub 144. The hub 144 surrounds the socket 104. In an exemplary embodiment, the front wall 142 includes a mounting flange 146 for engaging the charging inlet assembly 100 to the vehicle. In various embodiments, the mounting flange 146 may be a single piece engaged with the front wall 142. The front housing 140 may include a seal to seal the charging inlet assembly 100 to the vehicle.

[0023] Figure 3A terminal housing 150, a rear cover 160, a first charging terminal 112 and a second charging terminal 114, and a control module 200 including an interface connector 202 are shown. The control module 200 and the charging terminals 112, 114 are configured to be received within the terminal housing 150. The rear cover 160 is configured to be coupled to the terminal housing 150 to cover the control module 200 and the charging terminals 112, 114.

[0024] Terminal housing 150 includes a base 152 having a plurality of holes through which terminal channels 154 are formed, receiving corresponding charging terminals 110. The base 152 may be generally circular. However, other shapes are possible in alternative embodiments. The base 152 includes a rear chamber 153 for receiving the control module 200. For example, the rear chamber 153 is located at the rear of the base 152. Terminal housing 150 includes a sealing recess 155 at the rear, configured to receive an interface seal 157. The sealing recess 155 may extend circumferentially around the terminal housing 150. The interface seal 157 is configured to be hermetically coupled to the terminal housing 150. The interface seal 157 may mat with a rear cover 160 to provide a sealed interface between the terminal housing 150 and the rear cover 160. The terminal housing 150 includes a front mounting bracket 156 at the front of the terminal housing 150 and a rear mounting bracket 158 ​​at the rear of the terminal housing 150. The front mounting bracket 156 is configured to be coupled to the front housing 140. Figure 2 The rear mounting bracket 158 ​​is configured to attach to the rear cover 160. Mounting brackets 156, 158 may include latches, clips, fasteners or other securing devices to secure the terminal housing 150 to the front housing 140 and the rear cover 160.

[0025] The rear cover 160 includes a main wall 162 and a cable extension 164 extending rearward from the main wall 162. The cable extension 164 includes a cable channel 166 for receiving a corresponding cable. In the illustrated embodiment, the main wall 162 is generally circular in shape. However, other shapes are possible in alternative embodiments. In various embodiments, each cable extension 164 may include multiple cable channels 166 for receiving a corresponding cable. In an exemplary embodiment, the rear cover 160 includes a recess 168 for receiving components of the charging inlet assembly 100, such as charging terminals 110 and / or busbars and / or connectors. The recess 168 may lead to the cable channel 166. In the illustrated embodiment, the cable extension 164 is located near the bottom of the rear cover 160. Other locations are possible in alternative embodiments.

[0026] In an exemplary embodiment, the rear cover 160 includes an opening 170. The opening 170 may receive fasteners, such as bolts for attaching components to the charging inlet assembly 100. In the illustrated embodiment, the opening 170 is positioned along the side of the cable extension 164. In alternative embodiments, other locations are also possible. The opening 170 may lead to one or more of the recess 168 and / or cable channels 166.

[0027] In an exemplary embodiment, the rear cover 160 includes a configuration to receive a ground terminal 115. Figure 1 The grounding terminal channel 172 may be open at the rear to receive the grounding terminal 115. In the illustrated embodiment, the grounding terminal channel 172 is located between the cable extensions 164. In alternative embodiments, other locations are also possible.

[0028] In an exemplary embodiment, the rear cover 160 includes a connector shroud 174 at its rear. The connector shroud 174 may surround the interface connector 202. The connector shroud 174 includes a port or slot configured to receive a mating connector configured to mate with the interface connector 202.

[0029] In an exemplary embodiment, the rear cover 160 includes a mounting bracket 178 at the front of the rear cover 160. The mounting bracket 178 is configured to mate with a rear mounting bracket 158 ​​of the terminal housing 150 to secure the rear cover 160 to the terminal housing 150. The mounting bracket 178 may include a latch, clip, fastener, or other securing device to secure the mounting bracket 178 to the rear mounting bracket 158.

[0030] The control module 200 is configured to be received in the space between the terminal housing 150 and the rear cover 160. For example, the control module 200 may be received in the rear chamber 153 at the rear of the base 152. In an exemplary embodiment, the control module 200 includes a circuit board assembly 210. An interface connector 202 is coupled to the circuit board assembly 210. In an exemplary embodiment, the circuit board assembly 210 is configured to be connected to the charging terminal 110. For example, the circuit board assembly 210 may monitor the temperature of the charging terminals 112, 114. The circuit board assembly 210 may receive signals from the control guide terminal 116 and / or the proximity guide terminal 118. In various embodiments, the control guide terminal 116 and the proximity guide terminal 118 may be mounted to the circuit board assembly 210 and extend to the front of the charging inlet housing 102 to mate with a charging plug. In an exemplary embodiment, the circuit board assembly 210 includes an opening 212 that receives the charging terminals 110, such as the charging terminals 112, 114 and / or the ground terminal 115. When the control module 200 is located in the rear chamber 153, the opening 212 can be aligned with the terminal channel 154. The circuit board assembly 210 may include a temperature sensor 250 at the opening 212 to sense the temperature of the charging terminals 112, 114 during charging operation.

[0031] In an exemplary embodiment, the circuit board assembly 210 includes various portions. In an exemplary embodiment, the circuit board assembly 210 includes a fixed portion 220 and a flexible portion 230. The flexible portion 230 is movable relative to the fixed portion 220. For example, the flexible portion 230 includes a flexible element 240 connected to the fixed portion 220, which allows the flexible portion 230 to move relative to the fixed portion 220. The fixed portion 220 is configured to be fixed relative to the charging inlet housing 102. For example, the fixed portion 220 is configured to be coupled to the charging inlet housing 102, such as the terminal housing 150. The fixed portion 220 can be secured to the terminal housing 150 using clips, latches, fasteners, epoxy resin, snap-fit ​​features, interference fits, or other fixing features. The flexible portion 230 is configured to be movable within a rear chamber 153. For example, the flexible portion 230 may be movable in place relative to the charging terminals 112, 114 (e.g., movable relative to the fixed portion 220) to thermally connect to the charging terminals 112, 114 and / or for terminal position assurance, such as locking the charging terminals 112, 114 in the charging inlet housing 102. In an exemplary embodiment, a temperature sensor 250 is associated with the flexible portion 230 and may move with the flexible portion 230 relative to the charging terminals 112, 114. The temperature sensor 250 is configured to thermally connect to the charging terminals 112, 114 when the flexible portion 230 moves from a first position to a second position.

[0032] In an exemplary embodiment, the control module 200 includes control contacts 204. The control contacts 204 are disposed at the interface connector 202, for example, for mating with a mating connector. In an exemplary embodiment, one or more of the control contacts 204 may be electrically connected to control guide terminals 116 and / or proximate guide terminals 118 to transmit signals between guide terminals 116, 118 and the interface connector 202. In an exemplary embodiment, one or more of the control contacts 204 may be electrically connected to a temperature sensor 250 for monitoring the temperature of charging terminals 112, 114. Optionally, one or more of the control contacts 204 may be electrically connected to a ground terminal 115. Figure 1 In an exemplary embodiment, the control contact 204 may be formed as a lead frame molded from a plastic material to form the control module 200. In other embodiments, the control contact 204 may be sewn or otherwise inserted into a plastic housing or carrier forming the control module 200. In yet another embodiment, the control contact 204 may terminate circuitry on a printed circuit board of the circuit board assembly 210.

[0033] The control module 200 and interface connector 202 can be communicatively coupled to another charging component, such as a charging connector or plug, to control charging activities. The control module 200 can turn the power supply on, off, increase, and / or decrease the power supply. Charging operations can be controlled based on control and / or proximity signals from the guide terminals 116, 118. Charging operations can be controlled based on the operating temperature of the charging terminal 110. For example, as the temperature rises or approaches an allowable operating temperature, the power supply can be reduced. For example, the voltage or current can be reduced. If the operating temperature of the charging terminal 110 exceeds a threshold temperature, the charging operation can be stopped.

[0034] In an exemplary embodiment, the first charging terminal 112 and the second charging terminal 114 may be similar to each other. For example, the first charging terminal 112 and the second charging terminal 114 may be mirror versions of each other. The charging terminal 112 extends between a mating end 180 and a terminating end 182. The charging terminal 112 includes a mating pin 184 at the mating end 180. The mating pin 184 is configured to be loaded through an opening 212 in the control module 200 and configured to be received in a terminal channel 154 of the terminal housing 150. In an exemplary embodiment, the charging terminal 112 includes a terminal seal 186 surrounding the mating pin 184. The terminal seal 186 is configured to seal to the terminal housing 150 in the terminal channel 154. In an exemplary embodiment, the charging terminal 112 includes a pad or busbar 188 at the terminating end 182. The busbar 188 is configured to be directly or indirectly connected to a corresponding power cable 120. For example, the terminal busbar 188 may be welded, crimped, or bolted to the power cable 120.

[0035] Figure 4 A portion of a control module 200 according to an exemplary embodiment is shown, which shows a circuit board assembly 210 in a pre-connected or unconnected position. Figure 5 A portion of the control module 200 is shown, which illustrates a circuit board assembly 210 according to an exemplary embodiment in an actuated or connected position. Figure 6 This is a side view of a portion of the control module 200, showing the circuit board assembly 210 according to an exemplary embodiment in a pre-connected or unconnected position. Figure 7 This is a side view of a portion of the control module 200, showing a circuit board assembly 210 according to an exemplary embodiment in an actuated or connected position. The circuit board assembly 210 includes a fixed portion 220 and a flexible portion 230. Multiple flexible elements 240 connect the flexible portion 230 to the fixed portion 220. The flexible elements 240 allow the flexible portion 230 to remain in an unconnected position. Figure 4 and Figure 6 Move to the connection position ( Figure 5 and Figure 7 ).

[0036] A circuit board assembly 210 extends between a top 214 and a bottom 216. The circuit board assembly 210 includes a side 218 between the top 214 and the bottom 216. In the illustrated embodiment, a fixed portion 220 is located at the bottom 216, and a flexible portion 230 is located at the top 214. An opening 212 is located between the fixed portion 220 and the flexible portion 230 to receive charging terminals 112, 114 between the fixed portion 220 and the flexible portion 230. Multiple flexible elements 240 are located at one or both sides 218, such as extending along the multiple sides of the opening 212 and along the multiple sides of the charging terminals 112, 114. In an exemplary embodiment, the flexible portion 230 is movable generally toward the fixed portion 220 in a connection direction (indicated by arrow A), for example, in a downward direction. The flexible portion 230 is configured to move toward the charging terminals 112, 114 to mate with the charging terminals 112, 114. When the flexible part 230 moves in the connection direction, the size (e.g., height) of the opening 212 can be changed (e.g., reduced).

[0037] The fixing portion 220 includes a fixing portion substrate 222 and at least one control component 224 mounted to the fixing portion substrate 222. In an exemplary embodiment, the fixing portion substrate 222 includes a rigid circuit board. In an alternative embodiment, the fixing portion substrate 222 includes a lead frame, such as an overmolded lead frame. In an exemplary embodiment, the control component 224 includes a control guide terminal 116 and / or a proximity guide terminal 118. For example, the control guide terminal 116 and / or the proximity guide terminal 118 may extend forward from the front surface of the fixing portion substrate 222. The control guide terminal 116 and / or the proximity guide terminal 118 may be mounted to the fixing portion substrate 222, for example, soldered to circuitry or conductors of the fixing portion substrate 222. The control component 224 may include a capacitor, resistor, chip, integrated circuit, microprocessor, memory module, communication module, or other type of control component. A flexible element 240 is electrically connected to the fixing portion substrate 222, for example, at one or more sides 218. The flexible element 240 may be soldered to circuitry or conductors of the fixing portion substrate. Data can be transmitted to / from the control component 224 on the flexible element 240. For example, data from the control guide terminal 116 and / or the proximity guide terminal 118 can be transmitted to the flexible portion 230 via the flexible element 240.

[0038] The flexible portion 230 includes a flexible portion substrate 232 and at least one control component 234 mounted to the flexible portion substrate 232. The flexible portion 230 includes a flexible element 240 connecting the flexible portion substrate 232 and the fixed portion substrate 222. In an exemplary embodiment, the flexible portion substrate 232 includes a rigid circuit board. In an alternative embodiment, the flexible portion substrate 232 includes a lead frame, such as an overmolded lead frame. In other alternative embodiments, the flexible portion substrate 232 includes flexible circuitry. An interface connector 202 may be coupled to the flexible portion substrate 232, for example, at the top 214.

[0039] In an exemplary embodiment, control component 234 includes a temperature sensor 250. For example, temperature sensor 250 may be coupled to the flexible portion substrate 232, such as to the front or rear surface of the flexible portion substrate 232. Temperature sensor 250 may be located at opening 212, such as near charging terminals 112, 114. Temperature sensor 250 may be mounted to the flexible portion substrate 232, such as soldered to circuitry or conductors of the flexible portion substrate 232. Temperature sensor 250 may move with the flexible portion substrate 232, such as in a connection direction. Control component 234 may include a capacitor, resistor, chip, integrated circuit, microprocessor, memory module, communication module, or other types of control components.

[0040] The flexible element 240 is electrically connected to the flexible portion substrate 232, such as at one or more sides 218. In various embodiments, the flexible element 240 is a separate element from the flexible portion substrate 232 and is configured to be electrically connected to it. In alternative embodiments, the flexible element 240 may be integral with the flexible portion substrate 232, such as being an extension from a major portion of the flexible portion substrate 232. In an exemplary embodiment, the flexible element 240 is a flexible cable having ends terminating at opposite ends of the fixed substrate 222 and the flexible substrate 232. In other embodiments, the flexible element 240 is a flexible printed circuit having ends terminating at opposite ends of the fixed substrate 222 and the flexible substrate 232. In alternative embodiments, the flexible element 240 is a wire having ends terminating at opposite ends of the fixed substrate 222 and the flexible substrate 232. The flexible element 240 may be soldered to circuitry or conductors on the flexible portion substrate 232. Data may be transmitted on the flexible element 240 to / from the fixed portion 230. For example, data from control guide terminal 116 and / or proximity guide terminal 118 can be transmitted to flexible portion 230 via flexible element 240. In the illustrated embodiment, two flexible elements 240 are provided, one at each side 218. However, in alternative embodiments, more or fewer flexible elements 240 may be used, such as a single flexible element 240 at one of the sides 218.

[0041] In an exemplary embodiment, a thermal pad 260 is provided as a thermal interface between the charging terminals 112, 114 and the temperature sensor 250. The thermal pad 260 may be mounted to or supported by the flexible portion substrate 232. In an exemplary embodiment, the thermal pad 260 is a thermally conductive insulator. For example, the thermal pad 260 is made of a thermally conductive material that is also electrically insulating, to electrically insulate the temperature sensor 250 from the charging terminals 112, 114. In various embodiments, the thermal pad 260 is made of alumina (Al2O3), aluminum nitride (AlN), hexagonal boron nitride (BN), or other thermally conductive and electrically insulating materials. The thermal pad 260 may be made of a silicone elastomer supported by glass fibers having ceramic oxide filler. The thermal pad 260 may be a thermally conductive silicone rubber element. The thermal pad 260 may be movable with the flexible portion substrate 232, such as in the connection direction. In an exemplary embodiment, the thermal pad 260 is compressible, for example, to conform or deform when pressed against the charging terminals 112, 114, to provide an effective thermal interface with the charging terminals 112, 114.

[0042] In an exemplary embodiment, each charging terminal 112, 114 includes a terminal locking element 185. The terminal locking element 185 can be used to lock the charging terminals 112, 114 in the charging inlet assembly 100. In an exemplary embodiment, the terminal locking element 185 includes a protrusion extending from the outside of the charging terminals 112, 114. For example, the charging terminals 112, 114 may include one or more flanges defining the terminal locking element 185. The flanges may extend partially or completely circumferentially around the charging terminals 112, 114. In other embodiments, the terminal locking element 185 includes a groove or slot formed in the outer surface of the charging terminals 112, 114. A latch or other type of locking feature is configured to mate with the terminal locking element 185 to secure the charging terminals 112, 114 in the charging inlet assembly 100.

[0043] In an exemplary embodiment, the control module 200 includes a terminal position assurance (TPA) element 270 configured to interact with charging terminals 112, 114 to ensure that the charging terminals 112, 114 are properly positioned or disposed within the charging inlet housing 102. In an exemplary embodiment, the TPA element 270 may mate with a terminal locking element 185 to ensure that the charging terminals 112, 114 are properly positioned. For example, the TPA element 270 may not mate with the terminal locking element 185 unless the charging terminals 112, 114 are properly positioned. In other words, the TPA element 270 can only mate with the terminal locking element 185 when the charging terminals 112, 114 are properly positioned. In an exemplary embodiment, the TPA element 270 helps to reduce movement of the charging terminals 112, 114 within the charging inlet housing 102. In an exemplary embodiment, the TPA element 270 extends from the flexible portion substrate 232. The TPA element 270 extends into the opening 212. In an exemplary embodiment, the TPA element 270 is a latch configured to engage the terminal locking element 185, such as by engaging a flange or being received in a recess. The TPA element 270 may be located near the temperature sensor 250 and / or the thermal pad 260. The TPA element 270 may support the temperature sensor 250 and / or the thermal pad 260. The TPA element 270 may be movable with the flexible portion substrate 232, such as in the connection direction.

[0044] During assembly, the circuit board assembly 210 is assembled in the charging inlet housing 102. A fixing portion 220 is fixed in the charging inlet housing 102. For example, a fixing portion substrate 222 is coupled to the charging inlet housing 102, such as a terminal housing 150. The charging inlet housing 102 includes support elements, such as walls, positioning posts, shoulders, brackets, or other support elements, to position and secure the fixing portion 220 in the rear chamber 153. A flexible portion 230 is connected to the fixing portion 220 via a flexible element 240, which allows the flexible portion 230 to move relative to the fixing portion 220. An opening 212 is formed between the fixing portion 220 and the flexible portion 230. Charging terminals 112, 114 are located in the opening 212. Optionally, the charging terminals 112, 114 can be loaded into the opening 212 after the circuit board assembly 210 is located in the rear chamber 153. Alternatively, after the charging terminals 112, 114 are located in the charging connector housing 102, the circuit board assembly 210 is loaded into the rear chamber 153.

[0045] During assembly, the flexible portion 230 is configured to connect to the charging terminals 112, 114. For example, the flexible portion 230 can move in the connection direction (arrow A) to connect to the charging terminals 112, 114. When connected, as the flexible portion 230 moves in the connection direction, the temperature sensor 250 and the thermal pad 260 connect to the charging terminals 112, 114. Before moving the flexible portion 230 in the connection direction, the temperature sensor 250 and the thermal pad 260 have a gap with the charging terminals 112, 114 to allow the charging terminals 112, 114 and / or the circuit board assembly 210 to be assembled into the charging inlet housing 102. When connected, the thermal pad 260 can press against the charging terminals 112, 114 to form an effective thermal interface between the temperature sensor 250 and the charging terminals 112, 114. When connected, as the flexible portion 230 moves in the connection direction, the TPA element 270 connects to the terminal locking element 185. Before the flexible portion 230 is moved along the connection direction, the TPA element 270 has a gap with the terminal locking element 185 of the charging terminals 112, 114 to allow the charging terminals 112, 114 and / or the circuit board assembly 210 to be assembled into the charging inlet housing 102.

[0046] The circuit board assembly 210 is flexible for at least a portion of itself between the top 214 and the bottom 216. For example, the circuit board assembly 210 is flexible at least at the flexible element 240. The flexible element 240 spans one or both of the sides 218. The flexible element 240 may span approximately 20% of the total height of the circuit board assembly 210. However, the flexible element 240 may span a larger amount, such as approximately 30% or more of the total height of the circuit board assembly 210. The flexible element 240 reduces the overall size of the rigid circuit board(s) of the circuit board assembly 210, which reduces the overall cost of the circuit board assembly 210. The fixed portion 220 is located below the charging terminals 112, 114 and extends to the bottom 216. The flexible portion 230 is located above the charging terminals 112, 114 and extends to the top 214. The flexible element 240 of the flexible portion 230 extends along at least one side of the charging terminals 112, 114 to connect to the fixed portion 220 below the charging terminals 112, 114. In an exemplary embodiment, the flexible element 240 is flexed to allow the flexible portion 230 to move in the connection direction. The flexible portion 230 moves toward the fixed portion 220. The flexible portion 230 moves toward the charging terminals 112, 114.

[0047] Figure 8 This is a front view of a portion of the control module 200, showing the circuit board assembly 210 in a connected position according to an exemplary embodiment. Figure 9 This is a side view of a portion of the control module 200, showing the circuit board assembly 210 according to an exemplary embodiment in a connected position. In the illustrated embodiment, the charging terminal 112 includes a mounting pad 187. The mounting pad 187 is configured to press against a thermal pad 260 when the charging terminal 112 is inserted into the terminal channel of the charging inlet housing 102. The mounting pad 187 is configured to compress the thermal pad 260 between the mounting pad 187 and the temperature sensor 250 to improve the efficiency of the thermal connection.

Claims

1. A charging inlet assembly (100) for an electric vehicle, comprising: The charging inlet housing (102) has a front part and a rear part, the charging inlet housing has a terminal channel (154) between the front part and the rear part, and the charging inlet housing has a rear chamber (153) at the rear part; Charging terminals (112, 114) are received in the corresponding terminal channels and held in the charging inlet housing, the charging terminals having pins (184) configured to connect to a charging plug; and A control module (200) located at the rear of the charging inlet housing includes a circuit board assembly (210) received in the rear chamber. The circuit board assembly includes a fixed portion (220) and a flexible portion (230) movable relative to the fixed portion. The fixed portion is fixed relative to the charging inlet housing, and the flexible portion is movable relative to the charging inlet housing. The flexible portion includes a temperature sensor (250) configured to be thermally coupled to the charging terminal. The temperature sensor is movable relative to the charging terminal together with the flexible portion.

2. The charging inlet assembly (100) according to claim 1, wherein, The flexible portion (230) is electrically connected to the fixed portion (220) via a flexible element (240).

3. The charging inlet assembly (100) according to claim 2, wherein, The flexible element (240) is one of a flexible cable, a flexible printed circuit, or a wire.

4. The charging inlet assembly (100) according to claim 1, wherein, The fixing portion (220) includes a control guide terminal (116) extending to the front of the charging inlet housing (102) to mate with the charging plug and a proximity guide terminal (118).

5. The charging inlet assembly (100) according to claim 1, wherein, The fixed portion (220) includes a fixed portion substrate (222) and at least one control component (224) mounted to the fixed portion substrate. The fixed portion substrate is coupled to and fixed relative to the charging inlet housing (102). The flexible portion (230) includes a flexible portion substrate (232) and at least one control component (234) mounted to the flexible portion substrate. The flexible portion includes at least one flexible element (240) between the fixed portion substrate and the flexible portion substrate to allow the flexible portion substrate to move relative to the fixed portion substrate.

6. The charging inlet assembly (100) according to claim 1 further includes a thermal pad (260) between the temperature sensor (250) and the charging terminals (112, 114), the thermal pad being made of a thermally conductive material and an electrically insulating material.

7. The charging inlet assembly (100) according to claim 6, wherein, The heat pad (260) is compressible.

8. The charging inlet assembly (100) according to claim 6, wherein, Each charging terminal (110) includes a mounting pad (187) that presses against the thermal pad (260) when the charging terminal is inserted into the terminal channel (154) of the charging inlet housing (102).

9. The charging inlet assembly (100) according to claim 1, wherein, Each charging terminal (110) includes a terminal locking element (185), and the flexible portion (230) includes a terminal position guarantee element (270) configured to engage the corresponding terminal locking element of the charging terminal to lock the charging terminal in the terminal channel (154) to ensure the correct positioning of the charging terminal in the terminal channel.

10. The charging inlet assembly (100) according to claim 1, wherein, The fixed part (220) includes a stamped lead frame.

11. The charging inlet assembly (100) according to claim 1, wherein, The flexible portion (230) includes a rigid flexible portion substrate (232) and a flexible element (240) between the fixed portion (220) and the flexible portion substrate (232).

12. The charging inlet assembly (100) according to claim 1, wherein, The circuit board assembly (210) extends between a top (214) and a bottom (216), and at least a portion of the circuit board assembly is flexible between the top and the bottom.

13. The charging inlet assembly (100) according to claim 12, wherein, The fixed portion (220) is located below the charging terminals (112, 114) and extends to the bottom (216), the flexible portion (230) is located above the charging terminals and extends to the top (214), and the flexible portion extends along at least one side (218) of the charging terminals to connect to the fixed portion below the charging terminals.

14. The charging inlet assembly (100) according to claim 1, wherein, The control module (200) includes an interface connector (202) connected to the circuit board assembly (210).

15. The charging inlet assembly (100) according to claim 1, wherein, The charging terminals (112, 114) are arranged to mate with a standard NACS charging plug.

16. The charging inlet assembly (100) according to claim 1, wherein, The charging inlet housing (102) includes a front housing (140) having a charging plug interface (106), a terminal housing (153) holding the charging terminals (112, 114), and a rear cover (160) connected to the terminal housing. The front housing, the terminal housing, and the rear cover are connected together to form separate and independent components of the charging inlet housing.

17. A charging inlet assembly (100) for an electric vehicle, comprising: The charging inlet housing (102) has a front part and a rear part, the charging inlet housing has a terminal channel (154) between the front part and the rear part, and the charging inlet housing has a rear chamber (153) at the rear part; Charging terminals (112, 114) are received in the corresponding terminal channels and held in the charging inlet housing, the charging terminals having pins (184) configured to connect to a charging plug; and A control module (200) located at the rear of the charging inlet housing includes a circuit board assembly (210) received in the rear chamber. The circuit board assembly includes a fixed portion (220) and a flexible portion (230) movable relative to the fixed portion. The fixed portion includes a fixed portion substrate and at least one control component mounted to the fixed portion substrate. The fixed portion substrate is coupled to and fixed relative to the charging inlet housing. The flexible portion includes a flexible portion substrate (232) and at least one control component mounted to the flexible portion substrate. The flexible portion includes at least one flexible element (240) between the fixed portion substrate and the flexible portion substrate to allow the flexible portion substrate to move relative to the fixed portion substrate. The flexible portion includes a temperature sensor (250) configured to be thermally coupled to the charging terminal and is movable relative to the charging terminal together with the flexible portion.

18. The charging inlet assembly (100) according to claim 17, wherein, The flexible element (240) is one of a flexible cable, a flexible printed circuit, or a wire.

19. The charging inlet assembly (100) according to claim 17 further includes a thermal pad (260) between the temperature sensor (250) and the charging terminals (112, 114), the thermal pad being made of a thermally conductive material and an electrically insulating material.

20. The charging inlet assembly (100) according to claim 17, wherein, Each charging terminal (110) includes a terminal locking element (185), and the flexible portion (230) includes a terminal position guarantee element (270) configured to engage a corresponding terminal locking element of the charging terminal to lock the charging terminal in the terminal channel to ensure the correct positioning of the charging terminal in the terminal channel.

21. A charging inlet assembly (100) for an electric vehicle, comprising: The charging inlet housing (102) has a front part and a rear part, the charging inlet housing has a terminal channel (154) between the front part and the rear part, and the charging inlet housing has a rear chamber (153) at the rear part; Charging terminals (112, 114) are received in corresponding terminal channels and held in the charging inlet housing. Each charging terminal has a base and pins extending from the base, the pins being configured to connect to a charging plug. The base has a terminal locking element (185). and The control module (200) at the rear of the charging inlet housing includes a circuit board assembly (210) received in the rear chamber (153). The circuit board assembly includes a fixed portion (220) and a flexible portion (230) movable relative to the fixed portion. The fixed portion is fixed relative to the charging inlet housing, and the flexible portion is movable relative to the charging inlet housing. The flexible portion includes a temperature sensor (250) configured to be thermally coupled to the charging terminal. The temperature sensor is movable relative to the charging terminal along with the flexible portion. The flexible portion includes a terminal position guaranteeing element (270) configured to engage a corresponding terminal locking element of the charging terminal to lock the charging terminal in the terminal channel to ensure proper positioning of the charging terminal in the terminal channel.

22. The charging inlet assembly (100) according to claim 21, wherein, The flexible portion (230) is electrically connected to the fixed portion (220) via a flexible element (240), which is one of a flexible cable, a flexible printed circuit, or a wire.

23. The charging inlet assembly (100) according to claim 21, wherein, The fixed portion (220) includes a fixed portion substrate (222) and at least one control component (224) mounted to the fixed portion substrate. The fixed portion substrate is coupled to and fixed relative to the charging inlet housing (102). The flexible portion (230) includes a flexible portion substrate (232) and at least one control component (234) mounted to the flexible portion substrate. The flexible portion includes at least one flexible element (240) between the fixed portion substrate and the flexible portion substrate to allow the flexible portion substrate to move relative to the fixed portion substrate.

24. The charging inlet assembly (100) according to claim 21 further includes a thermal pad (260) between the temperature sensor (250) and the charging terminals (112, 114), the thermal pad being made of a thermally conductive material and an electrically insulating material.

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