High voltage power outlet module for a vehicle

Abstract

Disclosed herein is a high voltage power outlet (HVPO) module for a vehicle. The HVPO can have GFCI, over-temperature protection and sensing, or a fuse assembly. A high voltage power outlet module for a ground vehicle includes a housing supporting one or more vehicle connections, a power supply connection, a printed circuit board electrically connected to the power supply connection, an HVPO circuit including one or more high voltage conductive traces on the PCB, at least one high voltage power outlet electrically connected to the one or more high voltage conductive traces, and a circuit interrupter disposed between the power supply connection and the at least one high power outlet.

Description

[0001] Cross-reference to related applications

[0002] This application is related to and entitled to the earlier filing date and priority of the following applications: U.S. Provisional Patent Application Serial No. 63 / 500,596, entitled "High-voltage power outlet with fault detection," filed May 6, 2023, by Charles Nzeylmana and Eduardo Bonilla; and U.S. Provisional Patent Application Serial No. 63 / 554,142, entitled "High-voltage power outlet module for a vehicle," filed February 15, 2024, by Le LaPlant and Eduardo Bonilla, the disclosures of which are incorporated herein by reference. Background Technology

[0003] I. Field of Invention

[0004] This invention relates to an electrical power supply socket in a vehicle, and more particularly to an electrical power supply socket in a vehicle that is connected to the vehicle's power system.

[0005] II. Background of the Invention

[0006] Electrical outlets used to supply power to electrical loads are well known. Residential and building outlets are typically protected by circuit breakers and / or ground fault circuit interrupters (GFCIs). GFCIs disconnect the circuit in the event of a ground fault.

[0007] Ground fault systems have been disclosed in various publications, including US4200897, JPH0870503A, US5544003, US5587864, US5757598, US2004001292(A1) and US2005259371(A1), the contents of which are incorporated herein by reference.

[0008] US4200897, published on April 29, 1980, entitled “Grounding Leakage Current Circuit Breaker”, written by Robert Dawley, describes a grounding leakage current circuit breaker circuit that can be used with power supplies and electrical equipment on construction sites.

[0009] JPH0870503A, published on March 12, 1996, entitled "Circuit for Ground Fault Detector of Electric Vehicles", was written by Toshihiko Sugiura et al., and describes a circuit for ground fault detection of electric vehicles equipped with DC high voltage power supply.

[0010] US5544003, published on August 6, 1996, entitled "Portable Distribution Panel," written by Joe Vaughan, describes a portable electrical panel with ground fault protection.

[0011] US5587864, published on December 24, 1996, entitled “Short-circuit and ground fault protection for electrical systems”, written by Allan Gale, provides a general description of a ground fault detection system that detects unexpected current flow between a hot conductor and ground, as well as between two current-carrying conductors.

[0012] US5757598, published on May 26, 1998, entitled "Ground Fault Circuit Interrupter", was disclosed by Victor Aromin. It discloses a ground fault circuit interrupter (GFCI) that interrupts the current flow through a pair of lines extending between a power source and a load.

[0013] US2004001292(A1), published on January 1, 2004, entitled “Mobile Power Supply System with Disabled GFCI Protection”, written by Richard Vanderkolk et al., describes a mobile system for supplying AC power to electrical loads, which includes a GFCI circuit.

[0014] US2005259371(A1), filed on May 21, 2004 and published on November 24, 2005, entitled “Differential Current Detection,” authored by Christopher Henze et al., describes a fault detection circuit for hybrid and electric vehicles that detects the difference between source current and loop current.

[0015] US2006097673(A1) was published on May 11, 2006, entitled “AC Power Supply Device for Vehicles”, written by Jae-Beom Jun, which describes an AC power supply device for vehicles with a DC-AC inverter.

[0016] Although there are various publications describing power outlet systems with circuit protection, the circuit protection of modern building electrical systems does not provide a sufficient solution for vehicle systems, and the circuit protection currently used for vehicle systems has many shortcomings.

[0017] Therefore, there is a need for an improved onboard power delivery system for automotive, ground, and / or vehicle applications, capable of providing high-voltage power to consumer devices in vehicles in a more efficient, economical, protective, convenient, or reliable manner. There is also a need for a high-voltage power outlet for automotive applications that supports the high demands of the automotive environment, provides further circuit protection, facilitates easier fault detection across multiple outlets, is more convenient or user-friendly, and / or can detect faults at low battery voltages. Finally, there is a need for a high-voltage power outlet for automotive applications that provides improved load protection for both single-outlet and multi-outlet applications. Summary of the Invention

[0018] This article discloses a high-voltage power outlet (HVPO) module that can provide power from vehicle power to user equipment in a more efficient, safer, more economical, more convenient, more improved and / or more reliable manner.

[0019] This article discloses an AC power socket module that provides protection for circuits and loads with single or multiple sockets.

[0020] This article discloses a high-voltage power outlet (HVPO) module with fault detection, which can provide power from vehicle power supply to user equipment in a more efficient, safer, more economical, improved, or more reliable manner.

[0021] This article discloses a power outlet module that can provide high-voltage power from a vehicle to consumer devices in an automotive environment.

[0022] This article discloses a power socket module that can detect faults in both single and multiple sockets.

[0023] This article discloses a power socket module with fault detection that can operate at low battery voltage.

[0024] This article discloses a power socket module in which a control module for high-voltage isolation detection is powered by a vehicle battery (e.g., 12V DC type).

[0025] This article discloses a power socket module with a ground fault circuit interrupter (GFCI) that is powered by a vehicle battery (e.g., a 12V DC type).

[0026] This article discloses a power socket module with a ground fault circuit interrupter (GFCI) that is digitally reset.

[0027] This article discloses a high-voltage power outlet (HVPO) module with over-temperature protection, which can provide power from vehicle power supply to user equipment.

[0028] This document discloses a power outlet module with a removable fuse. The power outlet module can be further implemented as a high-voltage power outlet module with one or more fuses. In some embodiments, one of the multiple outlets can be fuse-protected independently of another outlet or a pair of outlets. In some embodiments, if the current exceeds the fuse's rated current, the AC power outlet or DC outlet can stop the current flow within the HVPO module. The fuse protects connected external devices or loads from excessive current. In some embodiments where the vehicle network is lost, the fuse still protects the external load.

[0029] In various exemplary embodiments, an HVPO module is provided comprising a housing having one, two, three, four, or more receptacles. The receptacles may be rated for 120V and / or 240V or 200V-240V. The housing may have one or more vehicle connectors for securing the housing to a vehicle. The housing may support one, more, or all of the following in a plurality or single manner: vehicle power connection, printed circuit board (PCB), electronic control unit, high-power receptacle, AC power receptacle, DC power receptacle, USB connector, voltage regulator, voltage detector, overcurrent protector, ground fault circuit interrupter (GFCI), fault detector, fuse, GFCI test, shut-off relay, electronic circuit breaker, light-emitting diode (LED), magnetic sensor, electromagnetic sensor, receptacle cover, activation sensor, indicator, communication module, voltage sensor, current sensor, power interruption, switch, reset button, circuit tester, circuit isolation checker, temperature sensor, secondary power connector, conductor, and / or conductive trace.

[0030] The power receptacle module may include a temperature sensor. The temperature sensor may be integrated with the module and may have sensing capabilities adjacent to the HVPO circuitry. The temperature sensor may be located on the PCB, near the receptacle terminals, or adjacent to the HVPO circuitry. The temperature sensing system may be connected to a communication module configured to broadcast temperature data to one or more other HVPO components, modules, or vehicle systems external to the HVPO module.

[0031] The power outlet module may include an electronic circuit breaker. The electronic circuit breaker functions as a circuit breaker by using integrated circuits to measure overcurrent and disconnect power. The system can be reset electronically or via a mechanical button or switch.

[0032] The power outlet module can be further configured as a high-voltage power outlet module for ground vehicles, including automobiles, light and / or heavy trucks.

[0033] To gain a more complete understanding of the claimed invention, reference is now made to the accompanying drawings and a detailed description of the preferred embodiments. Attached Figure Description

[0034] The accompanying drawings, which are part of this specification, illustrate various embodiments that may be used together, alone or in part to explain or illustrate the principles of the device described herein and throughout the specification and claims.

[0035] Figure 1 This is a perspective view of the power socket module, which is further described in the instruction manual.

[0036] Figure 2 yes Figure 1 An exploded perspective view of the power socket module provided in the image.

[0037] Figure 3a and Figure 3b This is a block diagram of an implementation of the power socket module, which is further described in the instruction manual.

[0038] Figure 4 This is a block diagram of an implementation of the power socket module, which is further described in the instruction manual.

[0039] Figure 5 This is an environmental view of an implementation of a power socket module with a fuse.

[0040] Figure 6 This is a perspective view of an embodiment of a power socket module assembly with a fuse.

[0041] Figure 7 This is an environmental view of an implementation of a power socket module assembly having a fuse in a bracket and the fuse being removed from the bracket.

[0042] Figure 8 This is a system block diagram of a power socket module assembly with temperature sensing.

[0043] Figure 9 This is a thermal image of a power socket module assembly with temperature sensing.

[0044] Figure 10 This is an exploded perspective view of the power socket module implementation described further in the specification. Detailed Implementation

[0045] This specification discloses a high-voltage power outlet (HVPO) module. Certain embodiments of the power outlet module are particularly suitable for on-board power applications in vehicles, including ground vehicles, automobiles, trucks, electric vehicles, hybrid vehicles, etc. The power outlet module may include some or all of the components described, depending on the application and regardless of the examples provided in the figures. The power outlet module can further be used as part of the on-board power routing to user or consumer power equipment. The power outlet module may also be adapted to provide circuit protection, current overload protection, over-temperature protection, current fault detection, and / or high-voltage power supply.

[0046] In some configurations, an HVPO module with a Ground Fault Circuit Interrupter (GFCI) is provided. The GFCI on the HVPO can be fully automated during setup and reset. The GFCI can be set each time the vehicle key is recognized, utility mode is entered, the vehicle is started, or maintenance mode is activated. The GFCI can be reset each time the vehicle is turned off. The GFCI can be modeled to support multiple inrush and standby currents. The GFCI on the HVPO can be automatically commanded by the vehicle (e.g., the inverter). The GFCI on the HVPO can operate over a wide temperature range (e.g., from -40 to 105°C ambient temperature). The GFCI can operate without a ground connection or grounding conductor. The GFCI can operate even if the vehicle may be isolated from the earth. The GFCI can be connected to the frame or chassis ground.

[0047] Power outlet modules may have an enclosure. The enclosure serves to support or enclose associated electronic and electrical components, including conductors, connectors, and sockets. The enclosure protects internal components and / or isolates internal components and / or power from the socket user. The enclosure may support one or more of any combination of: vehicle power connections, printed circuit boards (PCBs), high-power sockets, and one or more sockets. The enclosure may also support fault detection systems and / or current interruption systems. Fault detection and / or current interruption can be performed within the enclosure. The encapsulation of electronic and electrical components around and inside the enclosure allows for small form factor. Small form factor is particularly advantageous where vehicle component space is limited. Form factor may allow for enclosure surfaces of 70mm high × 70mm wide or less. Encapsulation also allows for tighter tolerance stacking of system components. Encapsulating system components within the enclosure also reduces variability in circuit testing and fault detection.

[0048] The housing can support one or more power outlets. The power outlet module can have one, two, three, four, or more power outlets. The outlets can conform to NEMA or CEE7 standards for AC plugs and sockets. Outlets can be provided in any suitable configuration. Outlets can be configured as double, single, or any other arrangement. The module can have a combination of single outlets and pairs of outlets, with separate or combined circuit interruption protection for single and paired outlets. Outlets can have different voltage ratings, such as 120V and 240V rated. The outlet can also be configured with suitable sockets. Suitable sockets include female slots or holes. The female conductive receiver can be configured to receive two-, three-, or four-pin connectors. Female slots can also be configured to the type of intended electrical equipment, application, or power rating. Suitable shapes include blade-shaped, round, U-shaped, L-shaped, T-shaped, or combinations of shapes. Slots can be uniformly sized, differently sized, or keyed to suit the intended application and / or polarize the power equipment, appliances, or tools.

[0049] Power outlets can provide single-phase or multi-phase power, true sine wave AC, modified sine wave AC, modified pulse square wave AC, DC power, or any other desired waveform. One or more outlets can be high-power outlets. AC high-voltage power outlets are suitable for 5 amps or more at 90°C, 50Hz to 60Hz, with a rated voltage of 100VAC or higher. Outlets can be adapted to rated voltages of 100VAC, 110VAC, 120VAC, 220VAC, 240VAC, 600VAC, or higher. Outlets can be equipped with components capable of handling high voltage, rated current, and heat generation. DC high-voltage power outlets are suitable for 5 amps or more at 90°C, with a rated voltage of 100VDC or higher. Outlets can be adapted to rated voltages of 1000VDC or higher. Outlets can be adapted to rated currents of >5, 10, 15, 20, 30, 35, 40, 45, or 50 amps or higher. The sockets are suitable for rated currents of 10, 15, 20, 30, 35, 40, 45, or 50 amps or less. High-power socket modules are configured according to their intended use, such as in vehicles, center consoles, dashboards, armrests, passenger compartments, trunks, storage compartments, vehicle exteriors, or pickup truck beds.

[0050] The outlet may be covered by one or more covers. These covers may cover each outlet individually, together as a whole, or in combination, covering individual outlets or groups of outlets. The outlet may have child-proof or tamper-proof protection. Tamper-proof protection may be achieved through a sliding plug blocking structure.

[0051] The power supply to the outlet can be provided by any suitable power source. For ease of understanding, the power source originating from and supplied to the outlet will be referred to as the power supply. The vehicle's power supply can be provided in any suitable manner. Power from the vehicle can be provided by an inverter, traction battery, service battery, auxiliary battery, or any other suitable device. The power supply circuit may have a connector that mates with the vehicle's power supply connector. The connector may be releasable. Releasable mating connectors allow for easy installation, secure connection, and / or maintainability and replaceability. The power supply circuit may also include one or more switches, sensors, relays, circuit breakers, rectifiers, power conditioners, filters, voltage regulators, transformers, or other electrical components useful or desired for transmitting, regulating, or blocking power from the vehicle's power supply to the power outlet or to the module itself.

[0052] Power can be supplied to the module via one or more power lines. These power lines can be leads or harnesses with vehicle power line connectors. The power lines may be mechanically anchored to the housing. The power lines may be electrically connected to the module or PCB. Power supply to the system may include power from the power lines to connectors on the PCB, to conductive traces on the PCB, through one or more sensors, through one or more circuit interruptions, and to one or more power outlets.

[0053] The module may have fault detection. A fault detection system is one or more of the following: hardware, software, electrical components, and / or electronic components configured to detect current traveling in unexpected paths. Fault detection may include a GFCI sensor coupled to a control unit (e.g., an MCU). The GFCI sensor may include a GFCI transformer disposed in the HVPO circuit. Fault detection can be provided by detecting a threshold imbalance between the line current traveling through the hot conductor and the neutral conductor, or through the positive and negative conductors. Fault detection can be implemented on a PCB. Fault detection can be implemented on the current in the conductive traces on the PCB.

[0054] The module may include fault detection testing with a threshold. Fault detection testing can be performed digitally using an MCU. Fault detection can operate based on current imbalance. Fault detection with circuit interruption can disconnect the power supply when the current imbalance exceeds a predetermined threshold; for example, a 15 or 20 amp socket could set the threshold imbalance from 4mA to 6mA. The module may include circuit isolation checks and tests.

[0055] The module may include a temperature sensor system, temperature sensing, and / or over-temperature protection. Temperature sensing can be provided in any suitable manner. Temperature measurement can be adjustable and can be calibrated. Temperature sensing can be implemented using a temperature sensor or sensor assembly connected to a control unit including one or more processors. Example control units include microprocessors, microcontrollers, programmable logic controllers, and microcontroller units (MCUs). Over-temperature protection can be implemented using thresholds stored in the control unit or other memory devices. An exemplary temperature sensor assembly is a thyristor coupled to the control unit. Temperature sensing can be provided in any suitable location. Temperature sensing can be provided in a socket, receptacle, terminal, PCB, or other suitable location. Temperature sensing can be provided on one or more terminals supported by a PCB, on one or more conductive traces, or on the PCB. Temperature sensing may also include an ambient temperature sensor thermally isolated from terminal hotspots and / or over-temperature sensors. Test circuitry, isolation tests, current and overvoltage checks provide ways to test whether the power supply circuitry is functioning correctly. If it is not functioning correctly, the power supply can be interrupted in any suitable manner. Suitable power interruptions can be provided on the PCB, within the module, or at the vehicle power source.

[0056] Vehicle power interruption can be provided via electronic switches, fuses, electronic circuit breakers, relays, circuit breakers, or any other suitable circuit interruption device. Power interruption can be connected to the power supply circuit. For automotive applications, relays, fuses, manual circuit breakers, or electronic circuit breakers can be of automotive quality. Power supply can be interrupted using communication via a vehicle communication network. Vehicle communication networks include LIN, CAN, serial, and others. Vehicle power interruption can be provided by shutting down the inverter, disconnecting the circuit to the module, or any other suitable power interruption device capable of stopping power to the power socket module. The power supply circuit can be reset once the fault condition or test failure is cleared. Reset can be provided digitally by the control unit, directly to an electronic switch, relay, provided to power via the vehicle network, manually provided via a switch, or any other circuit reset mechanism. Circuit interruption can be fully automated during setup and reset. Power availability can be set each time the vehicle is started or the vehicle accessory power supply mode is activated. Power availability can be reset each time the vehicle is shut down. Power availability can be configured to support inrush current and backup current multiple times. The power availability supplied to the socket can be automatically commanded by the vehicle (e.g., via the inverter).

[0057] The module may have one or more connectors for securing the module to a vehicle, such as vehicle connectors. Vehicle connectors may be supported by a housing. Vehicle connectors may be integrally formed with the housing or provided by any other suitable structure. Suitable vehicle connectors include one or more of the following: clamps, connectors, screws, bolts, clips, snaps, brackets, mounting elements, through holes, grooves, anchors, flanges, bearings, adhesives, bonding, welding, or any other suitable connection mechanism or combination.

[0058] The module may include a second power connection for supplying power to one or more module components, referred to as a "module power supply". The module power supply may supply power to a control unit, an MCU and / or to one or more sensing components, relays, communication modules, switches, LEDs, indicators, transformers, voltage regulators or other PCB components.

[0059] The module power supply can be provided by a power source different from the mains power supply. The module power supply can provide a voltage potential source lower than the mains power supply. The module power supply can be routed to the housing via leads or wiring harnesses with connectors. The module power supply can be powered by the vehicle's battery, such as a 12V, 24V, or 48V battery. The module's input power supply can be adjusted to any suitable voltage potential to suit various components, including sensors, control units, MCUs, ICs, or other electronic components. Suitable voltage regulation can be provided via voltage regulator ICs or circuits such as 12V, 9V, 5V, 3.5V, etc.

[0060] The PCB may include one or more control units, microcontrollers, microprocessors, integrated circuit (IC) chips, or application-specific integrated circuit (ASIC) chips. If a microcontroller is used, it may include one or more CPUs (processor cores), memory, and / or programmable input / output peripherals. The control unit may provide onboard computing, data storage, and / or communication services for one or more tests, including fault detection, overvoltage protection, overcurrent protection, low voltage drop, circuit isolation, power supply, temperature, voltage, current, circuit interruption, shutdown, power usage, comparison, calculation, humidity, etc. The control unit may also be used to store tests, test conditions, thresholds, meter and / or alarm values. The control unit may be used to send data or information to vehicle networks, circuit interruption devices, or module indicators.

[0061] A PCB may include conductive traces for routing power or signals from one or more components to one or more other components. These conductive traces may supply power to one or more of the following: power supplies, module power supplies, board assemblies, sensors, switches, relays, voltage regulators, signals, MCU input / output ports, transformers, active electrical components, passive electrical components, connectors, or other board assemblies. The control unit may monitor signals from any onboard sensors at one or more of its input / output (I / O) ports and may output data in response to signals via one or more I / O ports. One or more conductive traces may be used for system testing and / or fault detection. One or more conductive traces may be heavy-duty conductive traces. A PCB with heavy-duty conductive traces is a trace with a total mass greater than 28 grams.

[0062] The module may have one or more fuses. Each fuse has a fuse mechanism. A fuse may have at least two conductors for contact with a fuse holder or receptacle, with the fuse mechanism positioned between them. The fuse may be replaceable. A replaceable fuse is independent of the fuse holder and can be removed from the fuse holder without cutting the fuse connection or other material damage. The module may have a fuse holder or receptacle suitable for receiving the fuse. The fuse may be mounted in the fuse holder via a friction fit between the conductors of the fuse holder. The fuse may be accessible on the HVPO module. An accessible fuse is one that can be repaired without disassembling the power module.

[0063] A fuse mechanism can be any suitable open-circuit device capable of providing an open-circuit state under overcurrent conditions. The fuse mechanism is suitable for operation in automotive environments where high-voltage AC current is applied. Suitable fuse mechanisms include metals capable of sufficiently opening the circuit within a time period over a predetermined applied current and voltage range. This time period is sufficient to protect the circuit under automotive operating conditions. Suitable material selection takes into account the intended application and the potential for power transfer, power characteristics, fuse delay, arcing, and plasma formation during use and under overcurrent conditions. Suitable fuse mechanisms may include fusible materials that achieve opening through the gap between the fuse conductors. Suitable fusible materials include metals capable of providing a sufficiently large gap over a time period within the predetermined applied current and voltage range to open the circuit in the event of component failure within the overcurrent range.

[0064] Fuse can take any suitable form factor. Suitable form factors include blade fuses, coil fuses, tube fuses, post fuses, etc. A blade fuse is a fuse form factor having two or more conductors and a fuse mechanism disposed between them, which typically electrically connects the blades. The blades can be blade-shaped. A blade-shaped blade can be a conductor with one dimension substantially narrower than another. The fuse can be supported by a bracket. The bracket holds the replaceable fuse and removably supports it around the module. The bracket provides a means for holding, accessing, and removing the fuse from the power module.

[0065] The module may have one or more vehicle interfaces. These interfaces may include a vehicle network interface, a vehicle battery interface, a module power interface, a power supply interface, and a high-voltage interface. Interfaces may be provided via one or more connectors. Connectors may be provided on a PCB, adapter board, or other suitable component location.

[0066] Now for reference Figures 1-2 The exemplary power outlet module 102 provided in accordance with the teachings of this disclosure is shown at 100 locations, including a plurality of optional systems and components. The power outlet module 102 has a housing 104, a module wiring harness 114, a power supply cable 110, a PCB 152, a control unit (not shown), a communication module (not shown), a power interface 154, and an outlet panel 150.

[0067] Housing 104 has multiple components, including a socket panel 150 and a rear cover 140. These components are held together by one or more connectors. As shown, the housing is held together by multiple fasteners or screws 158. Housing 104 supports electrical components 142 and electronic components 144. Housing 104 has multiple mounting brackets 108a, 108b, 108c, and 108d for connecting modules to a vehicle. Housing 104 also supports multiple AC power sockets 124, 126, 128, and 130 and DC power sockets 132 and 134. As shown, AC power sockets 124, 126, 128, and 130 are adapted for high-voltage supply and configured as double sockets. The sockets can be paired or unpaired.

[0068] The power outlet module 102 has a module wiring harness 114. The module wiring harness 114 is supported by a housing 104. As shown, the module wiring harness 114 is routed through a rear cover 140 of the housing 104. The module wiring harness 114 has conductors protected by a sheath and connectors connected to the conductors. The connectors are configured to mate with the vehicle's wiring harness and connect to the vehicle's power supply. The wiring harness also has one or more conductors for hardwired communication with the vehicle's network. The module wiring harness 114 can provide module power to a control unit, MCU, and / or to one or more sensing components, relays, communication modules, switches, LEDs, indicators, transformers, voltage regulators, distribution boards, or other PCB components. The module power can be provided by a power source other than the power supply or power cable 110. The vehicle power source can be a battery or other suitable power source.

[0069] The power outlet module 102 has a power supply cable 110. The power supply cable 110 is supported by a housing 104. As shown, the power supply cable 110 is routed through a rear cover 140 of the housing 104. The power supply cable 110 has a conductor protected by a sheath 118 and a connector 112 connected to the conductor. The connector 112 is configured to mate with a power connector of the vehicle's power cable / wiring harness or a vehicle power source. The vehicle power source can be a battery, inverter, or other suitable power source. One or more power supply cables can provide a power source to the power outlet. In the case of using AC and DC high-power outlets, power can be provided by different power cables and / or different power sources.

[0070] As an example and as shown in the figure, one end of the power cable 110 is connected to PCB 152. PCB 152 has a connector 122 for receiving the electrical connection of the power cable. PCB 152 has heavy-duty conductive traces that connect to the PCB power connector. The heavy-duty conductive traces are sized / specificated for the intended power application (e.g., high-power sockets). The heavy-duty conductive traces on the PCB may have a mass greater than 1 ounce. The conductive traces are configured to route power along the PCB, through sensors, switches, circuit interruptions, electrical interfaces, and to one or more power sockets. Separate conductive traces and / or branch conductive traces may be used for single, multiple, or all power sockets.

[0071] As shown in the example, module 102 includes an electrical interface module 154. The electrical interface module 154 provides terminals / terminal blocks to distribute power from PCB 152 to specific receptacles or receptacle panels 150. The electrical interface module 154 has multiple interface conductors 156 for electrical connection to multiple PCB power distribution interfaces or terminals 148a, 148b, 148c, 148d. The power interface conductors 156 are then electrically connected to receptacles in the receptacle panel 150.

[0072] The power interface 154 supports one or more light guides 138. The light guides may provide indicators 138a for the module 102, PCB 144, power interface 154, or receptacle panel 150. The indicators 138a may indicate the status of the power receptacle module 100, including power-on status, status, fault, or error code.

[0073] The power outlet module 102 has an outlet panel or front panel 150. The outlet panel 150 has a power on / off switch 136. The power on / off switch 136 can be used to activate power supply to the outlet, interface, or PCB. The outlet panel also has an indicator 138b. The outlet indicator is provided via a light guide on the power interface. The indicator 138b can indicate the status of the power outlet module 102, including power-on status, fault, and / or error codes.

[0074] As shown in the figure, the power outlet module 102 has a cover 106 connected to the housing 104. In this example configuration, the cover 106 shields the power outlet, switch 136, and indicator 138a when closed. The cover 106 can also be used to indicate the module's electrical ratings or other warnings, such as AC 120V, 20A, and 2.4kW maximum. The cover may be configured with a sensor 146 or a switch. The sensor or switch can be used to trigger an alarm when the cover 106 moves or opens. The sensor 146 can be used to activate or deactivate power to the outlet panel 150 or power interface 154 when the cover moves. The sensor 146 can be a magnetic sensor or a Hall effect sensor. The sensor 146 can communicate the cover's position or movement to the module control unit.

[0075] Figure 10 Alternative embodiments of the power socket module 1000 are described, which may include... Figure 2 Some, most, or all of the elements shown are of the same type, where similar elements are of the same type. For example... Figure 10 As shown, the power outlet module includes a 240V plug or socket 1002, a pair of 120V plugs 1004, a circuit breaker switch and / or reset 1006, and a fuse assembly 1008. The fuse assembly, circuit breaker, and plugs are integrated into the module and are housed in the front panel housing as shown, protected by a cover 1010. The cover, switch, circuit breaker, or other mechanical, electrical, or electronic equipment provides tamper-proof power supply. Tamper-proof power supply can help reduce young children's exposure to high voltage.

[0076] Now for reference Figure 3a and Figure 3b The diagrams at 300 and 301 illustrate exemplary embodiments of high-power receptacle modules 302 and 303, including multiple optional systems, components, and system boundaries. Each module includes a PCB with a control unit 306. While the components of the module / block diagram may be configured within a single module, they may be located on one or more PCBs. Power receptacle modules 302 and 303 are particularly suitable for AC high-voltage power receptacles or DC high-voltage receptacles with current fault detection.

[0077] Modules 302 and 303 include one or more vehicle interfaces. As shown, the vehicle interface includes a power supply interface 330, a vehicle battery or power module interface 332, and a vehicle network module with a network interface 340. The vehicle interface may include any combination of electrical components, including power cables, conductors, wire harnesses, connectors, or any other suitable interface connections. The vehicle interface may be provided via one or more connectors on one or more PCBs.

[0078] Network communication between module 302 or control unit 306 and the vehicle can be provided in any suitable manner, including a network communication module or IC connected to the MCU. Network communication module 320 may have a vehicle network interface connected to vehicle network 340. The communication protocol can be any suitable protocol, including CAN, LIN, TCP / IP, optical, serial, wireless, or other suitable network communication methods.

[0079] Power interface 330 connects to a high-voltage AC power supply. Power interface 330 provides power from the vehicle to the outlet, such as a power cord. The power cord may include a connector attached to a hot wire (H), live wire (L), or active conductor, and a neutral wire (N) conductor for AC power supply.

[0080] As shown in the figure, the module has voltage detection and overcurrent protection 334. Voltage detection and overcurrent protection 334 can be provided in any suitable manner. As shown, voltage detection and overcurrent protection are measured on the power supply line within module 302 and can be measured on the hot line. The data can be captured by control unit 306. The data regarding current and voltage can then be processed by the MCU to interrupt power, indicate system status, or report to the vehicle network.

[0081] The module power interface 332 can be connected to the vehicle battery. The module may have a voltage regulator circuit or voltage regulator 326 electrically connected to the module power interface. The voltage regulator 326 can regulate the battery voltage to a voltage suitable for powering the MCU or other components, such as 12 volts, 9 volts, 5 volts, 3.3 volts, etc.

[0082] The module may include circuit isolation check and test 310. The module may have GFCI sensing or detection 312. GFCI sensing can be provided via a GFCI transformer. Figure 3b As shown, the module may also include a GFCI test module 314. The test module may include current fault generation and detection.

[0083] The module may have a shutdown mechanism 316. The shutdown mechanism 316 can be provided by disconnecting the power supply circuit or stopping the power supply to the module. A power interruption can occur when a current imbalance exceeding a predetermined threshold is detected. For example, when a threshold imbalance of 4mA to 6mA is detected, the shutdown relay can be engaged or disengaged by the MCU on a 15 or 20 amp power supply line. Figure 4 Describes what can be integrated into modules (e.g.) Figure 3a and Figure 3b Multiple power interruptions 400 (at location 316 of 302 or 303). The shut-off mechanism includes a fuse 402, a single-throw relay 404 or a double-throw relay 406, and an electronic circuit breaker 408.

[0084] The module may include temperature sensing, one or more temperature sensors, and / or over-temperature protection 318. Over-temperature protection 318 may be located in thermal contact with receptacle 308, at the power interface, on the PCB, adjacent to conductive traces, or at any other suitable location. Thermal contact may be provided by thermally conductive materials, including metals, copper, aluminum, thermally conductive polymers, etc. Temperature sensing may be provided by a thermistor mounted to the AC hot-line terminal area. The temperature value of the AC line receptacle may be communicated via LIN or other protocols.

[0085] Fault detection 324, overvoltage detection, undervoltage detection, isolation checks and tests 310, overcurrent protection, and temperature sensing provide ways to test whether the power supply circuit is working properly or overloaded. Power can be interrupted if any test or check fails.

[0086] Power supply can be interrupted in any suitable manner, including disconnecting the circuit, cutting off power at the interface, and shutting off power at the power source. Suitable power interruptions can be provided on the PCB or integrated with the power module. On-board power interruption can be provided via a shutdown relay connected in the power supply circuit. On-board power interruption can be provided via an electronic circuit breaker or electronic circuit breaker with on-board current sensing connected in the power supply circuit. For automotive applications, the relay or electronic circuit breaker can be of automotive-grade quality. Vehicle power can also be interrupted at the socket via a fuse. Vehicle power can be interrupted at the power source via the vehicle communication network. Vehicle power interruption can be provided by shutting down the inverter, disconnecting the circuit, or any other suitable power interruption device to stop the power socket module's power supply. Once the fault condition or test failure is cleared, the power supply circuit can be reset. Reset can be provided digitally by the control unit, directly to an electronic switch, relay, provided to power via the vehicle network, manually, or via any other circuit reset mechanism.

[0087] Digital power supply reset can be achieved in any suitable manner. Modules with a modular power supply separate from the mains power supply allow power to the MCU or other control units, sensors, and network communications, even when the power line or outlet is not energized. Among other things, the module control units and sensors can continue to operate to see if the fault or overload condition has been mitigated.

[0088] Now for reference Figure 5 The diagram at position 500 shows an exemplary power outlet module. The outlet module 500 may include one or more of the optional systems, modules, and / or components disclosed in the specification. The module 500 has a housing 502. The housing 502, as shown, has multiple components, including a front panel 504 and a rear cover 506. These components are held together by one or more connectors. As shown, the housing is held together by multiple press-fits. The housing 502 supports the electrical and electronic components of the module 500. The housing 502 has one or more mounting brackets 508, such as vehicle mounts, for connecting the module to a vehicle. The housing also supports at least one high-voltage power outlet 510 for supplying power from a high-voltage power source. As shown, the module has a removable fuse 512. The fuse 512 may be adapted for one-time overload or resettable. A removable fuse is a fuse independent of the housing or fuse holder and removable from the housing or fuse holder without cutting the fuse connection or other material damage.

[0089] Module 500 displays at least one indicator or light source 514. The indicator can be provided in any suitable manner, including via a light guide connected to an LED, transmitter, processor, and / or PCB. The indicator can provide information about the module, PCB, receptacle panel, receptacle, and / or plug. For example, a light source can indicate to the user the status of the power receptacle module, including the front panel's power-on status, condition, fault, disconnection, or error code. The indicator remains operational even when power to the power receptacle plug has been cut off.

[0090] Now for reference Figure 6 and Figure 7 The figure shows an HVPO module with a housing 602, a PCB 604, a fuse socket 606, and a fuse assembly 608. The fuse assembly is supported by the housing 602 and is detachably mounted in the fuse socket to complete the electrical connection on the module. As shown, the fuse assembly 608 includes a fuse 610 and a bracket 612. The fuse assembly with the movable bracket allows the fuse to be removed and inserted into the fuse socket. For example, as shown by the arrow and finger gesture in the figure, the fuse assembly can be easily lifted from the module on the socket panel.

[0091] The fuse holder may include a flexible or resilient conductive material for receiving fuse contacts with an interference fit. The fuse holder is shown located on a PCB 604 and arranged in series with conductive traces to form a circuit when functional and an open circuit when the fuse is removed or blown. The fuse assembly is suitable for use with any HVPO module and is particularly suitable for the HVPO modules described in this specification, including... Figure 1 , Figure 2 , Figure 5 and Figure 10 Those shown.

[0092] like Figure 7 As shown, the fuse can be removed from the bracket. Although fuse dimensions and designs may vary, as shown, the fuse is one of a blade fuse with two blade conductors 614, 616 for contacting the corresponding contacts on the fuse holder.

[0093] Now for reference Figure 8 The diagram at 800 shows a block diagram of an over-temperature protection system. The over-temperature protection system 800 includes a processor 802 and a temperature sensor 804 integrated with the HVPO module. The over-temperature protection system 800 also includes a communication module 806. The communication module 806 can be connected to one or more nodes 808. The communication module can be configured with LIN, CAN, serial, Ethernet, Wi-Fi, Bluetooth®, or other suitable communication or data transmission protocols. The temperature sensor can be placed in any suitable location. Suitable locations include thermal contact with one or more sockets, conductive traces, socket terminals, and PCBs. Figure 2 As shown, the temperature sensor 160 is located in a module adjacent to the PCB 152, conductive traces, and socket terminals.

[0094] Figure 9 A thermal image 900 of the HVPO module is depicted. The PCB 902 has conductive traces 904 for supplying power to one or more high-voltage power sockets. The thermal zones shown include a near-hot zone 906, a medium-hot zone 908, and an ambient temperature zone 910, which is typically outside or isolated from the near-hot and medium-hot zones. The near-hot zone is the area where temperature measurement of the power supply system can reliably prevent (>99%) system failures or damage. Therefore, over-temperature sensing can be provided in any thermal zone, but is preferably in the near-hot zone that is thermally separated from the ambient temperature zone.

Claims

1. A high-voltage power socket module for vehicles, characterized in that, The high-voltage power socket module includes: A housing that supports one or more vehicle connectors; Power supply connection; A printed circuit board electrically connected to the power supply connection; HVPO circuitry includes one or more conductive traces disposed on the printed circuit board; At least one AC high-voltage power socket electrically connected to the one or more conductive traces; and A circuit interrupter is installed between the power supply connection and at least one high-power socket.

2. The high-voltage power socket module according to claim 1, characterized in that, It also includes a temperature sensor adjacent to the HVPO circuit, a microprocessor configured to monitor temperature data from the temperature sensor, a fuse connected in series with the conductive trace, and a ground fault circuit interrupter coupled to the at least one high-power socket.

3. The high-voltage power socket module according to claim 1, characterized in that, It also includes a temperature sensor located adjacent to the HVPO circuit and configured for over-temperature sensing, and a communication module configured to broadcast temperature data to one or more other components.

4. The high-voltage power socket module according to claim 1, characterized in that, It also includes a ground fault circuit interrupter disposed between the power supply connection and the at least one high-power socket.

5. The high-voltage power socket module according to claim 1, characterized in that, It also includes a fuse connected in series with the conductive trace.

6. The high-voltage power socket module according to claim 1, characterized in that, It also includes a thermistor that is in thermal contact with the HVPO circuit and is used for over-temperature sensing.

7. The high-voltage power socket module according to claim 1, characterized in that, It also includes an ambient temperature sensor supported by the housing.

8. The high-voltage power socket module according to claim 1, characterized in that, The conductive traces weigh more than 28 grams and are suitable for carrying currents exceeding 5A.

9. The high-voltage power socket module according to claim 1, characterized in that, The printed circuit board has a vehicle network communication module configured to broadcast module data to one or more other components.

10. The high-voltage power socket module according to claim 1, characterized in that, The printed circuit board has a microprocessor configured to poll module status conditions, interrupt the power supply to one or more sockets when a specified status condition is met, continue polling the status conditions, and reset the one or more sockets when the specified status condition changes.

11. The high-voltage power socket module according to claim 1, characterized in that, Includes at least one high-voltage power outlet suitable for 100V AC or higher.

12. The high-voltage power socket module according to claim 1, characterized in that, It includes at least three high-power sockets, one single socket and at least one set of paired sockets, wherein the single socket and the paired sockets have separate ground fault circuit interrupter protection.

13. The high-voltage power socket module according to claim 1, characterized in that, The printed circuit board is configured to poll for faults, interrupt power to the one or more sockets during fault detection, continue polling for faults, and digitally reset the one or more sockets when the fault is cleared.

14. The high-voltage power socket module according to claim 1, characterized in that, The printed circuit board has one or more of the following: voltage detector, overcurrent protector, power-off relay, communication module, voltage sensor, current sensor, power interruption, switch, circuit test, circuit isolation check and test, temperature sensor, over-temperature protection, one or more LEDs, socket cover, cover plate detection, plug detection, or modular power connector.

15. The high-voltage power socket module according to claim 1, characterized in that, The printed circuit board is adapted to detect ground faults, and when a ground fault or ground neutral condition is detected, it senses the fault detection and sends a signal to a microprocessor, which then cuts off the power supply to the power socket, power interface, or socket panel.

16. The high-voltage power socket module according to claim 5, characterized in that, The fuse is supported by a removable bracket.

17. The high-voltage power socket module according to claim 1, characterized in that, It also includes a printed circuit board having heavy-duty conductive traces electrically connected between the power supply connection and the high-voltage power socket, and the printed circuit board having a fuse wherein the fuse is detachably connected to the heavy-duty conductive traces.

18. The high-voltage power socket module according to claim 1, characterized in that, The circuit interrupter includes an electronic circuit breaker connected in series with the conductive trace.

19. A high-voltage power socket module for a vehicle, characterized in that, The high-voltage power socket module includes: A housing that supports one or more vehicle connectors; The power supply connection is supported by the housing; The printed circuit board connected to the power supply connection; and One or more conductive traces are disposed on the printed circuit board and electrically connected to the power supply connection. At least one AC high-voltage power socket electrically connected to the one or more conductive traces; And a ground fault circuit interrupter disposed between the power supply connection and the at least one AC high-voltage power socket.

20. A high-voltage power socket module for vehicles, characterized in that, The high-voltage power socket module includes: A housing that supports one or more vehicle connectors; Power supply connection; A printed circuit board connected to the power supply connection; One or more conductive traces are disposed on the printed circuit board and electrically connected to the power supply connection. At least one AC high-voltage power socket having one or more terminals electrically connected to the one or more conductive traces; And a temperature sensor adjacent to the one or more conductive traces.

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