Charging port assembly

Abstract

A charge port assembly (100) for an electric vehicle includes a housing (110) having a power connector (102) including AC terminals (300) and DC terminals (200). An AC terminal assembly (302) is coupled to the housing and includes an AC busbar (304) electrically connected to the AC terminals at a separable mating interface (344). A DC connector (400) is mechanically and electrically connected to DC contacts of the DC connector at a separable mating interface.

Description

[0001] This application is a divisional application of the invention patent application filed on September 15, 2021, with application number 202111079322.6 and invention title "Charging Port Assembly". Technical Field

[0002] This article mainly deals with charging port components. Background Technology

[0003] Electric vehicles (EVs) and hybrid electric vehicles (HEVs) include a battery system for operating the vehicle. The battery system is charged via a charging connector that connects to the vehicle's charging port assembly. Known charging port assemblies for vehicles have disadvantages. For example, known charging port assemblies are bulky and occupy a significant amount of space within the vehicle's dashboard. Reducing the overall size of known charging port assemblies is desirable. Furthermore, wiring the power cables from the charging port assembly is difficult and increases the overall size required for the charging port assembly within the vehicle. Additionally, repairing and replacing parts of the charging port assembly is difficult and may require disassembly and removal from the vehicle to completely replace the charging port assembly with a new one. For example, cable harnesses, housings, and terminals may be replaced after removing the entire charging port assembly.

[0004] The problem to be solved is to provide a robust and reliable charging port assembly. Summary of the Invention

[0005] The aforementioned problem is addressed by a charging port assembly for an electric vehicle, comprising a housing extending between a front and a rear portion. The housing has a chamber at the rear. The housing has a power connector at the front for receiving a charging connector. The power connector includes an AC terminal channel and a DC terminal channel between the front and rear portions. AC terminals are coupled to the housing. Each AC terminal includes a mating pin and a terminating terminal opposite the mating pin. The mating pin is located in the corresponding AC terminal channel to mate with the charging connector. The terminating terminal is located in the chamber at the rear of the housing. The charging port assembly includes an AC terminal assembly received within the housing. The AC terminal assembly includes AC buses electrically connected to the corresponding AC terminals. Each AC bus includes a separable mating interface configured to electrically connect to an AC contact of an AC connector, which is removably coupled to the housing. The charging port assembly includes DC terminals coupled to the housing. Each DC terminal includes a mating pin and a terminating terminal opposite the mating pin. The mating pin is located in the corresponding DC terminal channel to mate with the charging connector. The terminating terminal is located in the chamber at the rear of the housing. The termination end includes a threaded element configured to mate with a mating threaded element of the DC connector for mechanical and electrical connection to the DC contacts of the DC connector, which is removably coupled to the housing.

[0006] The aforementioned problem is also addressed by a charging port assembly for an electric vehicle, comprising: a housing extending between a front and a rear portion, the housing having a chamber in the rear portion, the housing having a power connector in the front portion for receiving a charging connector, the power connector including an AC terminal channel and a DC terminal channel between the front and the rear portions; AC terminals coupled to the housing, each of the AC terminals including a mating pin and a termination terminal opposite the mating pin, the mating pin being located in a corresponding AC terminal channel to mate with the charging connector, the termination terminal being located in the chamber in the rear portion of the housing; an AC terminal assembly received in the housing, the AC terminal assembly including AC buses electrically connected to the corresponding AC terminals, each of the AC buses including a mating interface; an AC connector having an AC connector housing coupled to the rear portion of the housing, the AC connector including an AC contact held by the AC connector housing, the AC connector including an extension extending to the AC connector... An AC power cable is housed within and terminated to the AC contacts, each AC contact having a separable contact interface. When the AC connector is attached to the housing, the contact interface mates with a mating interface of a corresponding AC bus. When the AC connector is disconnected from the housing, the contact interface disengages from the AC bus. A DC terminal is attached to the housing, each of the DC terminals including a mating pin and a termination end opposite the mating pin. The mating pin is located in a corresponding DC terminal channel to mate with the charging connector. The termination end is located in the chamber at the rear of the housing. A DC connector has at least one DC connector housing attached to the rear of the housing. The DC connector includes DC contacts held by the at least one DC connector housing. The DC connector includes a DC power cable extending into the at least one DC connector housing and terminating to the DC contacts. Each DC contact has a separable contact interface configured to be electrically connected to a corresponding DC terminal.

[0007] The aforementioned problem is also addressed by a charging port assembly for an electric vehicle, comprising: a housing extending between a front and a rear portion, the housing having a chamber in the rear portion, the housing having a power connector in the front portion for receiving a charging connector, the power connector including a DC terminal channel between the front and the rear portions; a DC terminal coupled to the housing, the DC terminal including mating pins and terminating ends opposite the mating pins, the mating pins being located in the corresponding DC terminal channel to mate with the charging connector, the terminating ends being located in the chamber in the rear portion of the housing, the terminating ends including threaded elements; and a DC connector, the DC connection... The device has at least one DC connector housing coupled to the rear of the housing, the DC connector including a DC contact held by the at least one DC connector housing, the DC connector including a DC power cable extending into the at least one DC connector housing and terminating at the DC contact, the DC contact having a mating end, the DC connector including a mating threaded element coupled to the mating end of the DC contact and configured to be threadedly coupled to a threaded element at the termination end of the DC terminal to define a separable mating interface between the DC contact and the DC terminal for mating and contacting the DC connector with the housing. Attached Figure Description

[0008] The invention will now be described by way of example with reference to the accompanying drawings, in which:

[0009] Figure 1 This is a front perspective view of a charging port assembly according to an exemplary embodiment.

[0010] Figure 2 This is a rear perspective view of a charging port assembly according to an exemplary embodiment.

[0011] Figure 3 This is a partial exploded view of the charging port assembly according to an exemplary embodiment.

[0012] Figure 4 This is a partial exploded view of the charging port assembly according to an exemplary embodiment.

[0013] Figure 5 This is an exploded view of a charging port assembly according to an exemplary embodiment.

[0014] Figure 6 This is an exploded view of the DC terminal of a charging port assembly according to an exemplary embodiment.

[0015] Figure 7 This is an exploded view of the DC connector of the charging port assembly according to an exemplary embodiment.

[0016] Figure 8This is a partial cross-sectional view of a portion of a charging port assembly according to an exemplary embodiment, showing a DC connector coupled to a DC terminal.

[0017] Figure 9 This is a cross-sectional view of a portion of a charging port assembly according to an exemplary embodiment, showing a portion of a DC connector coupled to one of the DC terminals.

[0018] Figure 10 This is a cross-sectional view of a portion of a charging port assembly according to an exemplary embodiment.

[0019] Figure 11 This is a cross-sectional view of a portion of a charging port assembly according to an exemplary embodiment.

[0020] Figure 12 This is a perspective view of the AC terminal assembly of a charging port assembly according to an exemplary embodiment.

[0021] Figure 13 This is an exploded view of the AC connector of the charging port assembly according to an exemplary embodiment.

[0022] Figure 14 This is a front perspective view of a charging port assembly according to an exemplary embodiment.

[0023] Figure 15 This is according to an exemplary embodiment. Figure 14 The rear perspective view of the charging port assembly shown.

[0024] Figure 16 This is according to an exemplary embodiment. Figure 14 The side view of the charging port assembly shown.

[0025] Figure 17 This is according to an exemplary embodiment. Figure 14 An exploded view of the charging port assembly is shown.

[0026] Figure 18 This is according to an exemplary embodiment. Figure 14 An exploded view of the DC connector and corresponding DC terminals of the charging port assembly shown. Detailed Implementation

[0027] Figure 1 This is a front perspective view of the charging port assembly 100 according to an exemplary embodiment. Figure 2This is a rear perspective view of a charging port assembly 100 according to an exemplary embodiment. The charging port assembly 100 includes a power connector 102 configured to be electrically connected to a charging connector (not shown) to charge the battery system of a vehicle, such as an electric vehicle (EV) or a hybrid electric vehicle (HEV). In an exemplary embodiment, in addition to an AC charging connector (e.g., an SAE J1772 charging connector), the power connector 102 is configured to mate with a DC fast charging connector (e.g., an SAE combo CCS charging connector).

[0028] The charging port assembly 100 includes a housing 110 that holds the various components of the charging port assembly 100. In an exemplary embodiment, the housing 110 is a multi-piece housing that includes a main housing 112, a rear housing 120 coupled to the rear portion of the main housing 112, and a front housing 130 coupled to the front portion of the main housing 112. The rear housing 120 is coupled to the rear portion of the main housing 110 to enclose the various components of the charging port assembly 100. For example, a cavity or chamber may be defined by the main housing 112 and / or the rear housing 120.

[0029] The housing 110 holds the DC terminal 200 and AC terminal 300, which form part of the power connector 120. For example, the DC terminal 200 is received in a corresponding terminal channel 114 of the main housing 112, while the AC terminal 300 is received in a corresponding terminal channel 116 of the main housing 112. The DC terminal 200 can be coupled to the main housing 112 in the terminal channel 114, and the AC terminal 300 can be coupled to the main housing 112 in the terminal channel 116. The DC terminal 200 and / or the AC terminal 300 are configured to mate with a charging connector.

[0030] DC terminal 200 is configured to be electrically connected to a removable DC connector 400. In an exemplary embodiment, DC connector 400 is coupled to the rear housing 120 of charging port assembly 100 at a detachable interface. Figure 2 The DC connector 400 is removable to allow for the repair or replacement of components of the charging port assembly 100 without removing the housing 110 from the vehicle.

[0031] AC terminal 300 is configured to be electrically connected to a removable AC connector 500. In an exemplary embodiment, AC connector 500 is coupled to the rear housing 120 of charging port assembly 100 at a separable mating interface. AC connector 500 is removable to allow for the repair or replacement of components of charging port assembly 100 without removing housing 110 from the vehicle.

[0032] Front shell 130 ( Figure 1The front housing 130 is coupled to the main housing 110 at the front of the charging port assembly 100. The front housing 130 can be clipped onto the main housing 110, for example, using a clip or latch. In alternative embodiments, other types of securing features, such as fasteners, can be used. Alternatively, the front housing 130 can be integral with the main housing 110. The front housing 130 is used to attach the charging port assembly 100 to the vehicle. The front housing 130 includes a mounting protrusion 132 with an opening 134 that receives a fastener (not shown) for securing the charging port assembly 100 to the vehicle. Other types of mounting features can be used to secure the charging port assembly 100 to the vehicle. The front housing 130 may include a seal to seal the charging port assembly 100 to the vehicle. Optionally, the charging port assembly 100 may include a terminal cover (not shown) hingedly coupled to the front housing 130 and / or the main housing 110. The terminal cover is used to cover corresponding terminals 200.

[0033] Figure 3 This is a partial exploded view of a charging port assembly 100 according to an exemplary embodiment, showing a DC connector 400 and an AC connector 500 prepared to be connected to the rear of the charging port assembly 100. Figure 4 This is a partial exploded view of the charging port assembly 100 according to an exemplary embodiment. A DC connector 400 is configured to be coupled to a rear housing 120 at a first detachable interface 402. An AC connector 500 is configured to be coupled to a rear housing 120 at a second detachable interface 502.

[0034] In an exemplary embodiment, the charging port assembly 100 further includes a low-voltage (LV) connector 600 configured to be removably coupled to the rear housing 120 at a third separable interface 602. The LV connector 600 can be electrically connected to a battery control unit (not shown) of the battery system. The LV connector 600 can transmit data between the charging port assembly 100 and the battery system, such as data related to charging operation. For example, the LV connector 600 can transmit data related to charging start / stop, operating temperature of the DC terminal 200 and / or AC terminal 300, or other charging data. The LV connector 600 includes a housing 610 that holds LV contacts (not shown). The LV contacts are electrically connected to corresponding LV wires 612. The LV housing 610 is configured to be coupled to an LV connector shield 620 of the rear housing 120 to mate with the LV contacts 622 of the charging port assembly 100. The LV housing 610 can be latchably coupled to the LV connector shield 620 to allow the LV connector 600 to be removed from the rear housing 120. In an exemplary embodiment, the LV connector housing 620 includes an LV socket 624, and a portion of the LV connector 600 is inserted into the LV socket 624. In an alternative embodiment, the LV connector housing 620 may form a plug instead of a socket. In alternative embodiments, other types of mating interfaces may be provided.

[0035] In an exemplary embodiment, the DC connector 400 is electrically connected to a battery system, for example, for charging a vehicle's battery. The DC connector 400 transmits DC power from the charging port assembly 100 to the battery system via a DC power cable 404. Figure 3 The DC connector 400 is shown disengaged from the rear housing 120, while Figure 4 A DC connector 400 mating to a rear housing 120 is shown, but a portion of the DC connector is left open to show components of the DC connector 400. The DC connector 400 includes a DC connector housing 410 that holds DC contacts 450 electrically connected to a DC power cable 404. In various embodiments, the DC connector housing 410 holds two DC contacts 450 terminated at the ends of a pair of DC power cables 404. However, in alternative embodiments, separate DC connector housings 410 may be provided, each holding a separate DC contact terminated at the corresponding DC power cable, wherein the DC connector housing 410 can be individually and separately coupled to the rear housing 120.

[0036] In an exemplary embodiment, the rear housing 120 of the charging port assembly 100 includes a DC connector shroud 140. The DC connector shroud 140 includes a wall 142 defining one or more receptacles 144 configured to receive a portion of a DC connector 400. The DC connector shroud 140 includes an opening 146 through the housing 120, aligned with a terminal channel 114. The opening 146 is aligned with a DC terminal 200. In various embodiments, the DC terminal 200 may extend through the opening 146 into the receptacle 144 to mate with the DC connector 400 at a separable mating interface 402. In an exemplary embodiment, the DC connector shroud 140 is rear-open to allow mating and disengaging of the DC connector 400 along a mating axis parallel to the DC terminal 200. Optionally, a DC power cable 404 may extend from the DC connector 400 in a direction perpendicular to the mating axis, for example, for a low-profile cable lead-out direction. In an exemplary embodiment, the DC connector housing 140 includes a securing feature 148 for securing the DC connector 400 to the rear housing 120. For example, in various embodiments, the securing feature 148 may include a latch. The latch is deflectable to release the latch from the DC connector 400 and allow removal of the DC connector from the rear housing 120. In alternative embodiments, other types of securing features 158 may be provided, such as latch protrusions, threaded holes, fasteners, clips, etc.

[0037] In an exemplary embodiment, the AC connector 500 is electrically connected to a battery system, for example, for charging a vehicle battery. The AC connector 500 transmits AC power from the charging port assembly 100 to the battery system via an AC power cable 504. The AC connector 500 includes an AC connector housing 510 that holds AC contacts 550 electrically connected to the AC power cable 504. In various embodiments, the AC connector housing 510 holds three AC contacts 550 (e.g., line, ground, neutral) at the end of the AC power cable 504. However, in alternative embodiments, separate AC connector housings 510 may be provided, each holding an end to a separate AC contact of a corresponding AC power cable, wherein the AC connector housing 510 may be individually and separately connected to the rear housing 120.

[0038] In an exemplary embodiment, the rear housing 120 of the charging port assembly 100 includes an AC connector shield 150. The AC connector shield 150 includes a wall 152 defining one or more receptacles 154 configured to receive a portion of an AC connector 500. In an exemplary embodiment, the AC connector shield 150 is laterally open to allow the AC connector 500 to engage and disengage along a mating axis oriented in a lateral direction. The mating axis may be perpendicular to the mating axis. Optionally, an AC power cable 504 may extend from the AC connector 500 in a direction parallel to the mating axis 157, for example, for a low-profile cable lead-out direction. In an exemplary embodiment, the AC connector shield 150 includes a securing feature 158 for securing the AC connector 500 to the rear housing 120. For example, in various embodiments, the securing feature 158 may include a latching protrusion. In alternative embodiments, other types of securing features 158 may be provided, such as deflectable latches, threaded holes, fasteners, clips, etc.

[0039] Figure 5 This is an exploded view of the charging port assembly 100 according to an exemplary embodiment. Figure 5 Various components are shown that are configured to be received in the housing 110 of the charging port assembly 100. Figure 5 A front housing 130 and a main housing 112 are shown at a rear housing 120 located behind the main housing 112. In an exemplary embodiment, the front housing 130 is attached to the main housing 112 using fasteners 138. The rear housing 120 is configured to be attached to the main housing 112 using fasteners 122. In an exemplary embodiment, a peripheral seal 124 is configured to be located between the rear housing 120 and the main housing 112. A DC terminal 200 is aligned with a terminal channel 114, while an AC terminal 300 is aligned with a terminal channel 116. The DC terminal 200 can be loaded into the terminal channel 114 from the external rear of the main housing 112. The AC terminal 300 can be loaded into the terminal channel 116 from the external rear of the main housing 112.

[0040] In an exemplary embodiment, AC terminal 300 is part of AC terminal assembly 302. AC terminal assembly 302 is received in housing 110, for example, in a rear chamber 118 at the rear of main housing 112. Rear housing 120 is configured to close rear chamber 118 when rear housing 112 is coupled to main housing 112. AC terminal assembly 302 includes AC terminal 300 extending from AC terminal 300 and AC bus 304. In various embodiments, AC terminal assembly 302 includes bus holder 306 configured to retain AC bus 304. Bus holder 306 can position AC bus 304 relative to each other. Bus holder 306 can isolate AC bus 304 from each other.

[0041] In an exemplary embodiment, in addition to AC terminal 300, AC terminal assembly 302 includes pilot terminal 310 and proximity terminal 312. Pilot terminal 310 and proximity terminal 312 are received in corresponding terminal channels 116 in the main housing 112. Pilot terminal 310 and proximity terminal 312 are configured to mate with a charging connector when the charging connector is plugged into the charging port assembly 100. In an exemplary embodiment, AC terminal assembly 302 includes a printed circuit board (PCB) 314 and an LV mating connector 626 coupled to the PCB 314. LV mating connector 626 holds an LV contact 622. LV contact 622 is electrically connected to the PCB 314. Pilot terminal 310 and proximity terminal 312 are electrically connected to the LV contact 622 via the PCB 314. Optionally, one or more of AC terminal 300 and / or AC bus 304 may be coupled to the PCB 314.

[0042] Figure 6 This is an exploded view of a DC terminal 200 according to an exemplary embodiment. Each DC terminal 200 includes a mating pin 202 at a front portion 210 and a termination end 204 at a rear portion 212. The terminal 200 extends along a longitudinal axis 206. The mating pin 202 is configured to mat with a charging connector. The termination end 204 is configured to electrically connect to a DC connector 400 at a separable mating interface 402 (e.g., ...). Figure 2 (As shown).

[0043] DC terminal 200 is conductive. For example, DC terminal 200 can be made of a metallic material, such as copper. In an exemplary embodiment, DC terminal 200 is machined using a screw. DC terminal 200 can be made of a metal alloy (e.g., a copper alloy) with additives that increase machinability. In an exemplary embodiment, DC terminal 200 is generally cylindrical; however, DC terminal 200 can have various diameters along its length.

[0044] The mating pin 202 is located at the front portion 210 of the DC terminal 200 to mate with the charging connector. In an exemplary embodiment, a protective cover 220 is disposed at the end of the mating pin 202. The protective cover 220 may be made of a dielectric material, such as plastic or rubber. The protective cover 220 prevents unintentional contact with the DC terminal 200.

[0045] In an exemplary embodiment, the seal 222 is configured to connect to the DC terminal 200 behind the mating pin 202. When the DC terminal 200 is loaded into the terminal channel 114 (e.g., Figure 5 As shown, seal 222 is used to seal the inner surface of terminal channel 114. In various embodiments, seal 222 is annular.

[0046] In an exemplary embodiment, the DC terminal 200 includes a threaded element 228 at a termination end 204. The threaded element 228 is configured to mate with a mating threaded element of the DC connector 400. In the illustrated embodiment, the threaded element 228 is a female threaded element with internal threads; however, in an alternative embodiment, the threaded element 228 may be a male threaded element with external threads. In an exemplary embodiment, the DC terminal 200 includes a hole 230 at the termination end 204. A threaded insert 232 is received in the hole 230. The threaded insert 232 has an internally threaded hole 234 at its rear. The threaded hole 234 is configured to receive a threaded fastener to electrically connect the DC terminal 200 to the DC connector 400. In an exemplary embodiment, a tamper-evident cover 236 is configured to engage with the rear end of the threaded insert 232. The tamper-evident cover 236 prevents unintentional contact with the termination end 204 of the DC terminal 200. In an exemplary embodiment, the threaded insert 232 includes an opening 240 therethrough. An opening 240 is provided along the side of the threaded insert 232. The DC terminal 200 includes an opening 242 at the termination end 204. The opening 240 of the threaded insert 232 is configured to align with the opening 242 to receive a pin 244 for retaining the threaded insert 232 in a hole 230. The pin 244 may be a spring pin configured to engage the openings 240 and 242 by an interference fit. The pin 244 prevents rotation of the threaded insert 232 relative to the DC terminal 200 within the hole 230. The threaded insert 232 is made of a conductive material, such as a sheet. The threaded insert 232 may be made of a different material than the DC terminal 200, such as a harder material, to form and retain threads within the threaded hole 234. The threaded insert 232 is configured to be electrically connected to the DC terminal 200 to allow electrical connection between the DC terminal 200 and the DC connector 400. In various embodiments, the pin 244 electrically connects the threaded insert 232 to the DC terminal 200.

[0047] In alternative embodiments, the DC terminal 200 may have other sizes, shapes, or features. For example, in various embodiments, instead of having a separate threaded insert 232, the termination end 204 of the DC terminal 200 may have a threaded hole 234 formed directly in the material of the DC terminal 200. In such embodiments, the DC connector 400 may be mechanically and electrically connected directly to the DC terminal 200, rather than via a threaded insert 232. In other alternative embodiments, the DC terminal 200 may include a stud extending from the rear of the termination end 204, instead of a threaded hole. In various other embodiments, the DC terminal 200 may have other types of separable mating interfaces instead of a threaded mating interface. For example, the DC terminal 200 may include pins, receptacles, blades, sockets, or other types of separable mating interfaces.

[0048] Figure 7 This is an exploded view of a DC connector 400 according to an exemplary embodiment. The DC connector 400 includes a DC contact 450 coupled to an end of a DC power cable 404. The DC contact 450 and the DC power cable 404 can be housed in a cavity 412 of a DC connector housing 410. In an exemplary embodiment, the DC connector 400 includes a threaded element 420 configured to be threadedly connected to a threaded element 228 of a DC terminal 200. In the illustrated embodiment, the threaded element 420 is a male threaded element with external threads; however, in an alternative embodiment, the threaded element 420 may be a female threaded element with internal threads. In the illustrated embodiment, the threaded element 420 is a threaded fastener and may be referred to hereinafter as threaded fastener 420. The threaded fastener 420 is configured to be coupled to the DC contact 450. The threaded fastener 420 is configured to be coupled to the DC terminal 200 at a separable mating interface (e.g., ...). Figure 6 (As shown). For example, a threaded fastener 420 may be received in a threaded hole 234 of the DC terminal 200 to mechanically and electrically connect the DC contact 450 to the DC terminal 200. In an exemplary embodiment, the DC connector 400 includes a contact retainer 440 for retaining the DC contact 450. The contact retainer 440 may be received in a cavity 412 to position the DC contacts 450 relative to each other. In an exemplary embodiment, the contact retainer 440 is made of a dielectric material, such as a plastic material, to electrically isolate the DC contacts 450 from each other.

[0049] Each DC contact 450 extends between a mating end 452 and a terminating end 454. In various embodiments, the DC contacts 450 may be shaped differently to position the DC contacts 450 within the DC connector housing 410. For example, the mating ends 452 of the DC contacts 450 may be horizontally aligned with each other, and one of the DC contacts 450 may transition such that the terminating ends 454 are vertically aligned with each other. The terminating ends 454 mate to terminate a DC power cable 404. In an exemplary embodiment, the DC contacts 450 may be soldered to the DC power cable 404. However, in alternative embodiments, the DC contacts 450 may be terminated by other means, such as crimping to the end of the DC power cable 404. In an exemplary embodiment, the mating end 452 includes an opening 456 configured to receive a threaded fastener 420. Optionally, the opening 456 may be threaded. Alternatively, the opening 456 may be a smooth hole to allow the threaded fastener 420 to pass through it to mate and disengage with the DC terminal 200.

[0050] In an exemplary embodiment, the threaded fastener 420 is a bolt with external threads. Each threaded fastener 420 includes a head 422 and a shank 424. The shank 424 includes external threads 426. In an exemplary embodiment, the head 422 includes a tamper-evident cap 428 covering the head 422. The tamper-evident cap 428 prevents accidental contact with the threaded fastener 420. Optionally, the end of the shank 424 includes a tamper-evident feature, such as a cap. The head 422 is shaped to include features for rotating the threaded fastener 420 for threading the threaded fastener 420 to the DC terminal 200. For example, the head 422 may include an angled surface, such as a receptacle, that can be tool-engaged to rotate the threaded fastener 420. In an alternative embodiment, the threaded fastener 420 is not a screw, but a nut with internal threads, such as for threading to a screw extending from the DC terminal 200.

[0051] DC connector housing 410 extends between a front portion 414 and a rear portion 416. The DC connector housing 410 includes a sidewall 418 between the front portion 414 and the rear portion 416. The sidewall 418 surrounds a cavity 412. During assembly, DC contacts 450 and DC power cables 404 are loaded into the DC connector housing 410. For example, the DC contacts 450 and DC power cables 404 are loaded into ports 460, which are formed in the sidewall 418 on one or more sides of the DC connector housing 410. In the illustrated embodiment, ports 460 are located on the same side of the DC connector housing 410. However, in alternative embodiments, ports 460 may be located on opposite sides and / or top and / or bottom. In an exemplary embodiment, a cable seal 406 is provided at the end of each DC power cable 404. The cable seal 406 may be loaded into the port 460 to provide a seal between the DC power cable 404 and the DC connector housing 410. In an exemplary embodiment, a strain relief member 408 is disposed at an end of the DC power cable 404. The strain relief member 408 may be latchably coupled to the DC connector housing 410 to secure the strain relief member 408 relative to the DC connector housing 410. The strain relief member 408 provides strain relief for the DC power cable 404.

[0052] During assembly, the contact retainer 440 is configured to be loaded into cavity 412, for example through rear portion 416 of DC connector housing 410. DC contact 450 can be coupled to contact retainer 440. Contact retainer 440 holds the relative position of mating end 452 of DC contact 450. In an exemplary embodiment, contact retainer 440 aligns mating end 452 with port 462 at front portion 414 of DC connector housing 410. Contact retainer 440 positions mating end 452 to receive threaded fastener 420. In an exemplary embodiment, threaded fastener 420 can be loaded through an opening in rear portion 416 of DC connector housing 410 to mechanically and electrically connect DC contact 450 to corresponding DC terminal 200 after DC connector 400 is coupled to rear housing 120 of charging port assembly 100.

[0053] In an exemplary embodiment, a cover seal 470 may be disposed at the front portion 414 of the DC connector housing 410. The cover seal 470 surrounds the port 462. The cover seal 470 is configured to engage the rear housing 120 to seal the DC connector 400 to the rear housing 120. In an exemplary embodiment, a peripheral seal 472 is received in an opening at the rear portion 416 of the DC connector housing 410. A rear cover 474 is engaged with the rear portion 416 of the DC connector housing 410 to close the opening. The rear cover 474 engages the peripheral seal 472 to seal the opening. In an exemplary embodiment, a latching feature 476 may be used to secure the DC connector housing 410 to the rear housing 120.

[0054] Figure 8 This is a partial cross-sectional view of a portion of the charging port assembly 100, showing the DC connector 400 connected to the DC terminal 200. Figure 9 This is a cross-sectional view of a portion of the charging port assembly 100, showing a portion of the DC connector 400 coupled to one of the DC terminals 200. When the DC connector 400 is coupled to the rear housing 120 of the charging port assembly 100, the DC contact 450 can be electrically connected to the DC terminal 200 at a separable mating interface. For example, a threaded fastener 420 can be used to engage the DC contact 450 to the DC terminal 200. The threaded fastener 420 can be removed to allow the DC connector 400 2B to be disengaged from the rear housing 120.

[0055] In an exemplary embodiment, the threaded fastener 420 is loaded into the contact retainer 440 behind the rear portion 416 of the DC connector housing 410. The screw 424 of each threaded fastener 420 is loaded through an opening 456 and a corresponding DC contact 450. The screw 424 is loaded into the threaded hole 234 of the threaded insert 232 at the termination end 204 of the DC terminal 200. The threaded fastener 420 is rotated into the threaded insert 232. As the threaded fastener 420 rotates, a pin 244 prevents rotation of the threaded insert 232. The threaded fastener 420 is tightened to mechanically and electrically connect the DC contact 450 to the DC terminal 200. For example, the mating end 452 of the DC contact 450 can be driven inward toward the termination end 204 of the DC terminal 200 to achieve direct physical contact between the DC contact 450 and the DC terminal 200. Additionally or alternatively, an electrical path is formed from the threaded insert 232 to the threaded fastener 420. The head 422 of the threaded fastener 420 is compressed against the DC contact 450 to form an electrical connection between the threaded fastener 420 and the DC contact 450.

[0056] Figure 10This is a cross-sectional view of a portion of the charging port assembly 100, showing an alternative connection between the threaded fastener 420 and the DC terminal 200. In the illustrated embodiment, a contact sleeve 458 is located in an opening 456 of the DC contact 450 to provide a reliable electrical connection between the threaded fastener 420 and the DC contact 450. The contact sleeve 458 may include a plurality of compressible elements extending into an inner bore of the contact sleeve. The compressible elements may be contact springs, which may be cantilever beams, supported beams, or fixed beams. The compressible elements extend between the DC contacts 450 in the threaded fastener 420 to form an electrical connection between the DC contacts 450 and the threaded fastener 420. In the illustrated embodiment, the contact sleeve 458 is generally tubular, having a contact spring that is bent inward or shaped to engage the threaded fastener 420. For example, the contact sleeve 458 may be hourglass-shaped. In various embodiments, the contact sleeve 458 is a Louvertac contact.

[0057] Figure 11 This is a cross-sectional view of a portion of the charging port assembly 100, showing an alternative connection between the threaded fastener 420 and the DC terminal 200. In the illustrated embodiment, the opening 456 and the DC contact 450 are tapered, and the rod 424 of the threaded fastener 420 is also tapered. When the threaded fastener 420 is threaded onto the DC terminal 200, the tapered rod 424 is driven downward and presses against the tapered opening 456 of the DC contact 450 to provide a reliable electrical connection between the threaded fastener 420 and the DC contact 450.

[0058] Figure 12 This is a perspective view of the AC terminal assembly 302 according to an exemplary embodiment. Figure 12 AC terminal 300, pilot terminal 310 and proximity terminal 312 extending in front of PCB 314 are shown. Figure 12 An AC bus 304 extending behind PCB 314 is shown. AC bus 304 is received in a bus retainer 306. Bus retainer 306 is coupled to PCB 314 to support AC bus 304 relative to PCB 314. In an exemplary embodiment, a grounding non-protrusion 320 is electrically connected to one of the AC buses 304 (e.g., a ground bus) and electrically connected to PCB 314. Pilot terminal 310 and proximity terminal 312 may be electrically connected to the LV contact 622 of LV mating connector 626. In an exemplary embodiment, AC terminal 300, pilot terminal 310, and proximity terminal 312 may be integrated with AC terminal assembly 302, such that all terminals can be loaded as a unit into housing 110. For example, the position of the ends of the terminals may be controlled relative to each other to facilitate assembly with housing 110.

[0059] In an exemplary embodiment, each AC terminal 300 includes a mating pin 330 at its front and a termination terminal 332 at its rear. The mating pin 330 is configured to receive a corresponding terminal channel 116 in the housing 110 (e.g., Figure 1 As shown, it mates with a charging connector. Termination terminal 332 is configured to connect to the corresponding AC bus 304. For example, termination terminal 332 can be soldered to AC bus 304. Alternatively, termination terminal 332 can be connected to AC bus 304 by other means, such as crimping, threading, etc. In various embodiments, a protective cover 334 can be provided at the end of the mating pin 330.

[0060] AC busbars 304 are held relative to each other by busbar retainers 306. Each AC busbar 304 extends between a first mating end 340 and a second mating end 342. Each AC busbar 304 includes a plate that can be stamped into a suitable shape to position the first mating end 340 for electrical connection with AC terminal 300 and the second mating end 342 for electrical connection with AC connector 500. In the illustrated embodiment, the AC busbar 304 is a right-angled busbar having a first mating end 340 oriented substantially perpendicular to the second mating end 342. For example, the first mating end 340 may extend substantially parallel to the AC terminal 300, and the second mating end 342 may extend substantially perpendicular to the AC terminal 300. In an exemplary embodiment, the second mating end 342 includes a separable mating interface 344 for mating with the AC connector 500. In the illustrated embodiment, the second mating end 342 forms a blade contact configured to insert into a receptacle contact of the AC connector 500. In alternative embodiments, other types of separable mating interfaces may be provided.

[0061] Figure 13 This is an exploded view of an AC connector 500 according to an exemplary embodiment. The AC connector 500 includes AC contacts 550 coupled to an end of an AC power cable 504. The AC contacts 550 and the AC power cable 504 can be housed within a cavity 512 of an AC connector housing 510. In an exemplary embodiment, the AC connector 500 includes separate contact channels 540 for retaining the AC contacts 550. The AC contacts 550 can be aligned with each other, for example, by vertical stacking. In an exemplary embodiment, the AC connector housing 510 is made of a dielectric material, such as a plastic material, to electrically isolate the AC contacts 550 from each other.

[0062] Each AC contact 550 extends between a mating end 552 and a termination end 554. In various embodiments, the mating end 552 of the AC contact 550 includes a receptacle 556 configured to receive a mating end 342 of a corresponding AC terminal 300. In alternative embodiments, other types of separable mating ends may be provided, such as plug contacts, blade contacts, deflectable beam contacts, etc. The termination end 554 mates to terminate an AC power cable 504. In an exemplary embodiment, the AC contact 550 has a crimping sleeve 558 that can be crimped to the end of the AC power cable 504. However, in alternative embodiments, the AC contact 550 may be terminated by other means, such as soldering to the end of the AC power cable 504.

[0063] The AC connector housing 510 extends between a mating end 514 and a cable end 516 opposite to the mating end 514. However, in an alternative embodiment, the AC connector housing 510 may be a right-angle connector housing having a cable end 516 oriented perpendicular to the mating end 514. The AC connector housing 510 includes a sidewall 518 between the mating end 514 and the cable end 516. The sidewall 518 surrounds a cavity 512. In an exemplary embodiment, the AC connector housing 510 includes a lever 520 for securing the AC connector 500 to the rear housing 120. The lever 520 is actuated to insert the AC connector 500 into the AC connector guard 150 of the rear housing 120. For example, rotation of the lever 520 holds the AC connector 500 on the AC connector guard 150. In an exemplary embodiment, the AC connector housing 510 may include one or more contact position ensuring devices 522 to ensure that the AC contact 550 is correctly positioned within the AC connector housing 510. In an exemplary embodiment, the AC connector housing 510 includes a peripheral seal 524 to provide a seal between the AC connector 500 and the AC connector shield 150. The peripheral seal 524 may be received in a cavity 512. A peripheral seal retainer 526 may be used to retain the peripheral seal 524 in the cavity 512.

[0064] During assembly, AC contacts 550 and AC power cables 504 are loaded into the AC connector housing 510. For example, AC contacts 550 and AC power cables 504 can be loaded into the cavity 512 via cable ends 516. In an exemplary embodiment, a cable seal 506 is provided at the end of each AC power cable 504. The cable seal 506 can be loaded into the cavity 512 to provide a seal between the AC power cable 504 and the AC connector housing 510. In an exemplary embodiment, a strain eliminator 508 is provided at the end of the AC power cable 504. The strain eliminator 508 can be latchably coupled to the AC connector housing 510 to secure the strain eliminator 508 relative to the AC connector housing 510. The strain eliminator 508 provides strain relief for the AC power cable 504.

[0065] Back Figure 3 and Figure 4 During assembly, DC terminal 200 is received in housing 110 and configured to be electrically connected to DC connector 400 at a separable mating interface 402. For example, DC connector 400 may be inserted into DC connector housing 140. After DC connector 400 is inserted into DC connector housing 140, DC contact 450 is mated with DC terminal 200 using threaded fastener 420. Alternatively, DC terminal 200 may be coupled to DC connector 400 using threaded fastener 420 after DC terminal 200 has been loaded into housing 110. For example, DC terminal 200 may be loaded into housing along with DC connector 400 when DC connector 400 is mated into DC connector housing 140. In such an embodiment, DC contact 450 may be disengaged from DC terminal 200 by loosening threaded fastener 420 to allow removal of DC connector 400 from DC connector housing 140 without removing DC terminal 200 from housing 110. Alternatively, the DC terminal 200 can be removed along with the DC connector 400 by unlatching the DC terminal 200 from the housing 110 to allow the DC connector 400 to be removed from the DC connector housing 140.

[0066] AC component 302 is received in housing 110 and configured to be electrically connected to AC connector 500 at a separable mating interface 502. For example, AC connector 500 can be plugged into AC connector housing 150. When AC connector 500 is attached to AC connector housing 150, AC contact 550 mates with AC bus 304. Lever 520 is used to secure AC connector 500 to AC connector housing 150. AC connector 500 can be removed from AC connector housing 150 by opening lever 520 and unplugging AC connector 500 from AC connector housing 150.

[0067] Figure 14 This is a front perspective view of the charging port assembly 1100 according to an exemplary embodiment. Figure 15 This is a rear perspective view of the charging port assembly 1100 according to an exemplary embodiment. Figure 16 This is a side view of the charging port assembly 1100 according to an exemplary embodiment. The charging port assembly 1100 is similar to... Figure 1 The charging port assembly 1100 shown may include similar components; however, the charging port assembly 1100 includes a pair of DC connectors 1400 (such as...). Figure 15 Instead of a single DC connector shown with the charging port assembly 100, the charging port assembly 1100 includes a power connector 1102 configured to electrically connect to a charging connector (not shown) to charge the vehicle's battery system, such as an electric vehicle (EV) or a hybrid electric vehicle (HEV).

[0068] The charging port assembly 1100 includes a housing 1110 that holds the various components of the charging port assembly 1100. In an exemplary embodiment, the housing 1110 is a multi-piece housing that includes a main housing 1112, a rear housing 1120 coupled to the rear of the main housing 1112, and a front housing 1130 coupled to the front of the main housing 1112. The housing 1110 holds a DC terminal 1200 and an AC terminal 1300 that form a portion of the power connector 1102. The DC terminal 1200 is received in a corresponding terminal channel 1114 of the main housing 1112, while the AC terminal 1300 is received in a corresponding terminal channel 1116 of the main housing 1112.

[0069] DC terminal 1200 is configured to be electrically connected to a removable DC connector 1400. For example, DC connector 1400 is removably coupled to rear housing 1120 to allow for the repair or replacement of components of charging port assembly 1100 without removing housing 1110 from the vehicle.

[0070] AC terminal 1300 is configured to be electrically connected to a removable AC connector 1500. The removable AC connector 1500 may be the same as AC connector 500. For example, AC connector 1500 may be coupled to AC terminal assembly 1302. In an exemplary embodiment, charging port assembly 1100 also includes a low-voltage (LV) connector 1600 configured to be removably coupled to rear housing 1120. LV connector 1600 may be the same as LV connector 600.

[0071] Figure 17This is an exploded view of a charging port assembly 1100 according to an exemplary embodiment, showing a DC connector 1400 and an AC connector 1500 prepared for attachment to the rear of the charging port assembly 1100. The DC connector 1400 is configured to attach to a rear housing 1120 at a detachable interface 1402. The AC connector 1500 is configured to attach to the rear housing 1120 at a detachable interface 1502. For example, the AC connector 1500 is configured to be removably attached to an AC connector housing 1150 to mate with an AC terminal assembly 1302.

[0072] Each DC connector 1400 includes a DC connector housing 1410 that holds a DC contact 1450 electrically connected to a corresponding DC power cable 1404. In an exemplary embodiment, the rear housing 1120 of the charging port assembly 1100 includes an opening 1146 that receives a corresponding DC contact 1450 and / or a DC terminal 1200. The rear housing 1120 may include a DC connector shield to secure the DC connector housing 1410 to the rear housing 1120. The DC connector 1400 may be fitted to the rear housing 1120 at various angles to control the lead-out direction of the DC power cable 1404. For example, by changing the mounting orientation of the DC connector 1400 relative to the rear housing 1120, the DC power cable 1404 may extend from a first side and / or a second side and / or the bottom of the rear housing 1120.

[0073] Figure 18 This is an exploded view of one of the DC connectors 1400 and a corresponding DC terminal 1200 according to an exemplary embodiment. The DC connector 1400 includes a DC contact 1450 coupled to an end of a DC power cable 1404. In various embodiments, the DC contact 1450 may be a busbar. The DC contact 1450 and the DC power cable 1404 may be housed within a cavity 1412 of a DC connector housing 1410. In an exemplary embodiment, a cable seal 1406 is disposed at the end of the DC power cable 1404. The cable seal 1406 may be housed within the DC connector housing 1410 to provide a seal between the DC power cable 1404 and the DC connector housing 1410. In an exemplary embodiment, a strain relief member 1408 is disposed at the end of the DC power cable 1404. The strain relief member 1408 may be latchably coupled to the DC connector housing 1410 to secure the strain relief member 1408 relative to the DC connector housing 1410. The strain relief member 1408 provides strain relief for the DC power cable 1404.

[0074] In an exemplary embodiment, the DC connector 1400 includes a threaded fastener 1420 for mechanically and electrically connecting a DC contact 1450 and a DC terminal 1200 at a separable mating interface. The threaded fastener 1420 is configured to be received in a threaded hole 1234 of the DC terminal 1200 to mechanically and electrically connect the DC contact 1450 to the DC terminal 1200. The threaded fastener 1420 is configured to extend through and engage with the DC contact 1450. For example, the DC contact 1450 includes a mating end 1452 for receiving the threaded fastener 1420. In an exemplary embodiment, the mating end 1452 includes an opening 1456 configured to receive the threaded fastener 1420. Optionally, the opening 1456 may be threaded. Alternatively, the opening 1456 may be a smooth hole to allow the threaded fastener 1420 to pass through it to mate and dismate with the DC terminal 1200. DC contact 1450 includes a termination end 1454 opposite to mating end 1452. Termination end 1454 is mated to terminate a DC power cable 1404. In an exemplary embodiment, DC contact 1450 may be soldered to DC power cable 1404. However, in an alternative embodiment, DC contact 1450 may be terminated by other means, such as crimping to the end of DC power cable 1404.

[0075] In an exemplary embodiment, the DC connector 1400 includes a contact retainer 1440 for retaining a DC contact 1450. The contact retainer 1440 may be received in a cavity 1412 to position the DC contact 1450 relative to the DC connector housing 1410 and / or the DC terminal 1200. The contact retainer 1440 may receive a termination end 1204 of the DC terminal 1200. In an exemplary embodiment, the contact retainer 1440 is made of a dielectric material, such as a plastic material. In an exemplary embodiment, the contact retainer 1440 includes a port 1462 at its front. The port 1462 can be inserted into the rear housing 1120 after the DC connector 1400 is coupled to the rear housing 1120. In an exemplary embodiment, a cover seal 1470 may be provided at the front 1414 of the DC connector housing 1410. A cover seal 1470 surrounds port 1462 and is configured to engage rear housing 1120 to seal DC connector 1400 to rear housing 1120. In an exemplary embodiment, peripheral seal 1472 is coupled to the outer periphery of contact retainer 1440. Peripheral seal 1472 is received in cavity 1412 at front 1414 and engages DC connector housing 1410 to seal opening at front of DC connector housing 1410. In an exemplary embodiment, rear cover 1474 is coupled to rear portion 1416 of DC connector housing 1410 to close opening 1476. Peripheral seal 1478 is configured to be coupled to rear cover 1474 to seal rear opening 1476.

[0076] A DC terminal subassembly is provided, which can be assembled into the housing 1110 in various orientations, such as 0°, 90°, 180°, or 270° orientations, or other non-right-angle orientations. The DC contact 1450 can be modified to wire around other DC terminals 1200, for example, for 0° and 180° lead-out orientations. The DC terminal 1200 can be assembled into the housing 1110 before or after assembly with the DC contact 1450. After the DC contact 1450 is mated to the DC terminal 1200, the threaded fastener 1420 can be twisted to mechanically and electrically connect the DC contact 1450 to the DC terminal 1200. The threaded fastener 1420 is removable to form a separable interface for servicing / replacing other components.

[0077] In various embodiments, the charging port assembly is configured with a low profile. The charging port assembly reduces the in-vehicle packaging space and provides different wiring designs, allowing use on different vehicle platforms without requiring a major redesign of the entire component or function of the charging port assembly. Various embodiments and configurations of the charging port assembly are provided, allowing replacement of defective components without replacing the entire assembly. The replaceability of the components of the charging port assembly improves vehicle maintainability and reduces the replacement and repair costs of the charging port assembly.

[0078] In various embodiments, the charging port assembly employs threaded connections on the DC circuit terminals to improve assembly ease, simplify package size, and provide flexibility in cable lead-out direction. In various embodiments, the charging port assembly includes a connector on the AC circuit and a connector on the low-voltage (LV) circuit directly connected to the rear of the housing. The connector-based design of the charging port assembly's circuitry simplifies the connection of the wiring harness and terminals / contacts (e.g., three 16mm...). 2 Cable, 2 x 95mm 2 (including cables and 7 signal lines), eliminating the need for complex cabling connections inside the charging port housing. Various embodiments of the connector-based harness assembly integrate busbars on both AC and DC circuits. Various embodiments use ultrasonic welding and / or bolted joints to minimize interface resistance while providing detachable connectors for component repair / replacement. Separating cables / wires from a single harness into multiple separate cable harnesses improves cable management. Various embodiments of the charging port assembly can accommodate multiple DC and AC cable exit directions, for example, with minor modifications to the rear cover.

Claims

1. A charging port assembly for an electric vehicle, comprising: A housing extending between a front and a rear portion, the housing having a chamber at the rear portion and a power connector at the front portion for receiving a charging connector, the power connector including an AC terminal channel and a DC terminal channel between the front and the rear portions; AC terminals connected to the housing, each of the AC terminals including a mating pin and a termination terminal opposite to the mating pin, the mating pin being located in a corresponding AC terminal channel to mate with the charging connector, the termination terminal being located in the cavity at the rear of the housing; An AC terminal assembly is received in the housing, the AC terminal assembly including an AC bus electrically connected to a corresponding AC terminal, each of the AC buses including a mating interface; An AC connector having an AC connector housing connected to the rear of the housing, the AC connector including AC contacts held by the AC connector housing, the AC connector including an AC power cable extending into the AC connector housing and terminating at the AC contacts, each AC contact having a separable contact interface, wherein when the AC connector is connected to the housing, the contact interface mates with a corresponding AC bus interface, and when the AC connector is disconnected from the housing, the contact interface disengages from the AC bus. A DC terminal connected to the housing, each of the DC terminals including a mating pin and a termination terminal opposite to the mating pin, the mating pin being located in a corresponding DC terminal channel to mate with the charging connector, the termination terminal being located in the cavity at the rear of the housing; and A DC connector having at least one DC connector housing coupled to the rear of the housing, the DC connector including DC contacts held by the at least one DC connector housing, the DC connector including a DC power cable extending into the at least one DC connector housing and terminating at the DC contacts, each DC contact having a separable contact interface configured to be electrically connected to a corresponding DC terminal.

2. The charging port assembly according to claim 1, wherein, The at least one DC connector housing includes a single DC connector housing having a cavity for receiving each DC contact and each DC power cable.

3. The charging port assembly according to claim 1, wherein, The at least one DC connector housing includes a plurality of DC connector housings independently connected to the housing, each DC connector housing including a single DC contact in the DC contacts and a single DC power cable in the DC power cable.

4. The charging port assembly according to claim 1, wherein, The DC connector includes a seal that is coupled to the housing of the at least one DC connector, the seal engaging the housing to provide a sealed mating interface between the DC connector and the housing.

5. The charging port assembly according to claim 1, wherein, The termination end of the DC terminal includes a threaded element, and the DC connector includes a threaded element configured to mate with the threaded element of the DC terminal to mechanically and electrically connect the DC contact to the DC terminal.

6. The charging port assembly according to claim 1, wherein, The housing includes a DC connector housing, the DC connector housing including a receptacle configured to detachably receive the DC connector, and the termination ends of the DC terminals are exposed in the DC connector housing to mate with the DC connector.

7. The charging port assembly according to claim 1, wherein, The housing includes an AC connector housing, the AC connector housing including a receptacle configured to detachably receive the AC connector, and the termination ends of the AC terminals are exposed in the AC connector housing to mate with the AC connector.

8. The charging port assembly according to claim 1, wherein, Each of the AC busbars includes a first mating end and a second mating end. The first mating end is electrically connected to the corresponding AC terminal, and the second mating end includes a blade that defines a separable mating interface for the corresponding AC busbar.

9. A charging port assembly for an electric vehicle, comprising: A housing extending between a front and a rear portion, the housing having a chamber at the rear portion and a power connector at the front portion for receiving a charging connector, the power connector including a DC terminal channel between the front and the rear portion; A DC terminal connected to the housing, the DC terminal including mating pins and terminating terminals opposite to the mating pins, the mating pins being located in a corresponding DC terminal channel to mate with the charging connector, the terminating terminals being located in the cavity at the rear of the housing, the terminating terminals including threaded elements; and A DC connector having at least one DC connector housing coupled to the rear of the housing, the DC connector including a DC contact held by the at least one DC connector housing, the DC connector including a DC power cable extending into the at least one DC connector housing and terminating at the DC contact, the DC contact having a mating end, the DC connector including a mating threaded element coupled to the mating end of the DC contact and configured to be threadedly coupled to a threaded element at the termination end of the DC terminal to define a separable mating interface between the DC contact and the DC terminal for mating and contacting the DC connector with the housing.

10. The charging port assembly according to claim 9, wherein, The at least one DC connector housing includes a single DC connector housing having a cavity for receiving each DC contact and each DC power cable.

11. The charging port assembly according to claim 9, wherein, The housing includes a DC connector housing, the DC connector housing including a receptacle configured to detachably receive the DC connector, and the termination ends of the DC terminals are exposed in the DC connector housing to mate with the DC connector.

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