LIGHTING MODULE FOR THE CHARGING PORT OF AN ELECTRIC VEHICLE

Abstract

Charging connection module (34) for an electric vehicle (EV) (10), the module (34) comprising: a charging connector body (36) having a first side (38), an opposite second side (40) and an interface (42) for attachment to a body of the EV (10); a socket (44) attached to the first side (38) of the charging connector body (36) and configured to receive a charging plug (46); an electrical connector (50) attached to the second side (40) of the charging port body (36), in electrical communication with the receptacle (44), and configured to engage an electrical system (24) including a battery of the EV (10); a channel (52) defined by the first side (38) of the charging connector body (36); and a cassette (54) configured to slidably engage the channel (52), the cassette (54) comprising: a cassette body (56) defining an access opening (60) configured to facilitate access of the charging plug (46) to the socket (44) after the cassette (54) has been inserted into and seated in the channel (52); and a lighting element (62) disposed on the cartridge body (56) and configured to illuminate the socket (44); wherein the cassette body (56) is defined by an outer circumference, wherein the cassette body (56) defines a projection (58) disposed on at least a portion of the outer circumference, and wherein the projection (58) is configured to slidably engage the channel (52); wherein the first side (38) of the charging port body (36) has a lip (38A) configured to overlap at least a portion of the projection (58) after the cassette (54) has been inserted into and seated in the channel (52).

Description

INTRODUCTION

[0001] The present disclosure relates to a lighting module for a charging port of an electric vehicle.

[0002] An electric vehicle, also called an EV, uses one or more electric motors or traction motors for propulsion. An electric vehicle can be powered by electricity from external sources via a collector system or be equipped with a battery, solar panels, or an electric generator to convert fuel into electricity.

[0003] A plug-in electric vehicle (PEV) is a motor vehicle that contains a rechargeable battery pack that can be charged from an external power source, such as a socket, while the electricity stored in the battery pack powers the wheels or contributes to propulsion. A PEV is a subcategory of electric vehicles that includes all-electric or battery-electric vehicles (BEVs), plug-in hybrid electric vehicles (PHEVs), and electric vehicle conversions of hybrid electric vehicles and conventional internal combustion engine vehicles. A hybrid electric vehicle (HEV) combines a conventional (usually fossil-fuel-powered) powertrain with some form of electric propulsion.

[0004] Electric vehicles are typically charged using conventional charging sockets or at dedicated charging stations. This process typically takes a considerable amount of time, but can also be completed overnight and often provides a charge sufficient for normal daily use. Electric vehicle users can plug their car into the socket while at work and leave it charging throughout the day to increase the potential range and eliminate range anxiety.

[0005] DE 10 2012 101 491 A1 describes a lighting unit with a lighting function section and a light-guiding element. The lighting function section comprises a light source and a light-transmitting housing. The light source is formed by multiple types of LEDs with different emission colors. The light-guiding element is formed using a synthetic resin material that is light-transmitting. The light-guiding element has a light-incident section, a light-emitting section provided at a charging port of a housing, and an intermediate section connecting the light-incident section to the light-emitting section. When the light-emitting section emits light with the guided light, the light-emitting section can be made to appear as if it were illuminating the charging port of the housing.JP 2020 - 13 643 A describes a light guide body that can indicate the position of an object to be installed using a small number of light sources and can also illuminate its interior.

[0006] DE 10 2012 211 048 A1 describes a charging device for charging a charge storage device. The device comprises a coupling device for coupling a plug for charging the charge storage device, a light guide for illuminating the coupling device and / or for indicating the charge level of the charge storage device, and a light source for coupling light into the light guide. The light guide can be used to provide search illumination and display the charge level of the charge storage device.

[0007] JP 2013 - 233 054 A describes a power receiving device with a lighting function. An LED serving as a light source for input illumination is housed in a body, and a light guide portion receives the light emitted by the LED and guides the light to one side of a housing.

[0008] DE 11 2017 004 519 T5 describes a vehicle lighting device. This device includes first light-emitting sections arranged near a boundary portion between a body and a cover via notch fields formed on the upper and lower edges of the cover; and second light-emitting sections arranged on the inside of the cover. When the cover is unlocked during operation, the first light-emitting sections are turned on. When the cover is pressed to open the cover during operation, the first light-emitting sections are turned off. When the cover is opened, the second light-emitting sections are turned on to illuminate the power supply terminals.

[0009] US 2018 / 0 216 973 A1 describes a light ring assembly that provides bright, uniform, and homogeneous illumination and can be used for numerous automotive and non-vehicle lighting applications. It comprises a housing, a circuit board with a number of individual light sources, a light ring, and a lens. Light emitted by the light sources enters an optical input surface on a bottom side of the light ring, is reflected within the body of the light ring to mix and disperse more widely, and then exits through an optical output surface on a top side of the light ring. DESCRIPTION

[0010] According to the invention, a charging connector module for an electric vehicle (EV) comprises a charging connector body having a first side, an opposite second side, and an interface for mounting to a body of the EV. The charging connector module also has a receptacle attached to the first side of the charging connector body and configured to receive a charging plug. The charging connector module additionally has an electrical connector attached to the second side of the charging connector body, in electrical communication with the receptacle, and configured to engage an electrical system including a battery of the electric vehicle. The charging connector module additionally has a channel defined by the first side of the charging connector body. The charging connector module further includes a cassette configured to slidably engage the channel.The cassette includes a cassette body defining an access opening configured to facilitate access of the charging plug to the receptacle after the cassette is inserted and seated within the channel. The cassette also includes a light-emitting element disposed on the cassette body and configured to illuminate the receptacle.

[0011] The charging port body and the cassette may have complementary locking features configured to maintain engagement of the cassette with the channel.

[0012] According to the invention, the cartridge body is defined by an outer periphery. The cartridge body defines a projection located on at least a portion of the outer periphery. The projection is configured to slidably engage the channel.

[0013] The luminous element may form at least part of the projection.

[0014] According to the invention, the first side of the charging port body has a lip configured to overlap at least a portion of the projection after the cassette has been inserted into and seated within the channel.

[0015] The light-emitting element may be configured to establish an electrical connection with and receive electrical power from the electrical system of the EV after the cassette is inserted into and seated within the channel.

[0016] The lighting element can surround the access opening.

[0017] Alternatively, the access opening may be defined by an inner perimeter, and the luminous element may cover a portion of the inner perimeter of the access opening.

[0018] The lighting element may comprise a translucent cover and at least one light-emitting diode (LED), as well as a light guide connected to the at least one LED. In such an embodiment, each of the at least one LED and the light guide may be housed within the cover.

[0019] The charging port module can contain multiple LEDs, each projecting a different light color.

[0020] An electric vehicle having an EV body, a traction motor configured to generate EV drive torque, an EV electrical system having a rechargeable battery configured to generate electric current to operate the traction motor, and the charging port module described above is also disclosed.

[0021] The above features and advantages, as well as other features and advantages of the present disclosure, will be readily apparent from the following detailed description of the embodiment(s) and the best mode(s) for carrying out the described disclosure when considered in conjunction with the accompanying drawings and the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a schematic perspective view of an electric vehicle using a charging port module according to the disclosure. Fig. 2 is a schematic perspective exploded side view of the Fig. 1, which in particular shows a lighting cassette according to the disclosure. Fig. 3 is a schematic front view of the Fig. 1 and Fig. 2, which particularly shows an embodiment of the lighting cassette and a horizontally pivotable charging port door according to the disclosure. Fig. 4 is a schematic perspective rear view of the Fig. 1 and Fig. 2 illustrated charging connector module according to the disclosure. Fig. 5 is a schematic perspective exploded rear view of the Fig. 1 and Fig. 2 illustrated charging connector module according to the disclosure. Fig. 6 is a schematic partial cross-sectional view of the Fig. 5 illustrated charging connector module according to the disclosure. Fig. Figure 7 is a schematic perspective view of another embodiment of the Fig. 2 shown lighting cassette according to the disclosure. Fig. Figure 8 is a schematic front view of the Fig. 1 and Fig. 2, which in particular shows a vertically pivotable charging port door according to the disclosure. DETAILED DESCRIPTION

[0022] Referring to Fig. 1, an electric vehicle (EV) 10 having an EV body 10A is illustrated. The vehicle 10 may be, but is not limited to, a commercial vehicle, an industrial vehicle, a passenger vehicle, an aircraft, a watercraft, a train, or the like. It is also contemplated that the EV 10 may be a mobile platform, such as an aircraft, an all-terrain vehicle (ATV), a boat, a personal mobility device, a robot, and the like, to fulfill the purposes of this disclosure. As illustrated, the EV 10 includes a powertrain 12. The powertrain 12 includes a power source 14 configured to produce a power source torque T (in Fig. 1) for propelling the EV 10 via driven wheels 16 relative to a road surface 18. The power source 14 is shown as an electric motor generator or traction motor. As shown in Fig. As shown in Figure 1, the powertrain 12 may also include an additional power source 20, such as an internal combustion engine. Power sources 14 and 20 may cooperate to propel the electric vehicle 10.

[0023] As shown, the EV 10 additionally includes a programmable electronic controller 22 and an EV electrical system 24. The electrical system 24 is connected to the power sources 14 and 20, the electronic controller 22, and other vehicle systems via a high-voltage bus 24A. As shown in Fig. 2, the electrical system 24 includes a battery module 26 having one or more rechargeable energy storage cells or batteries 28. The battery module 26 is configured to generate electrical power to drive the traction motor 14 and supply electrical energy to the power source 20. The electronic controller 22 may be programmed to control the drivetrain 12 and the electrical system 24 to produce a predetermined torque T of the power source, as well as various other vehicle systems, such as lighting, infotainment, and heating, ventilation, and air conditioning (HVAC).

[0024] In particular, the electronic controller 22 may be configured as a vehicle body controller or as a central processing unit (CPU) programmed to control various systems and functions of the vehicle 10. To this end, the electronic controller 22 includes a processor and an accessible, non-transferable memory in which, for example, instructions for operating the powertrain 12 and the electrical system 24 are programmed. The memory may be a suitable writable medium involved in providing computer-readable data or process instructions. Such writable medium may take many forms, including, but not limited to, non-volatile media and volatile media. Non-volatile media for the electronic controller 22 may be, for example, optical or magnetic hard drives and other permanent storage. The volatile media may include, for example,a dynamic random access memory (DRAM), which can represent main memory.

[0025] Operating instructions may be transmitted over one or more transmission media, including coaxial cable, copper wire, and fiber optic cable, including the wires comprising a system bus coupled to a computer processor, or over a wireless connection. The memory of the electronic controller 22 may also comprise a flexible disk, a hard disk, magnetic tape, other magnetic medium, a CD-ROM, a DVD, another optical medium, etc. The electronic controller 22 may be configured or equipped with other necessary computer hardware, such as a high-speed clock, necessary analog-to-digital (A / D) and / or digital-to-analog (D / A) circuitry, input / output (I / O) circuitry and devices, and suitable signal conditioning and / or buffering circuitry.Algorithms required or accessible by the electronic controller 22 may be stored in memory and executed automatically to provide the required functionality of the powertrain 12 and the electrical system 24.

[0026] The electronic controller 22 may be specifically configured, i.e., programmed, to detect a request 30 to charge the battery module 26. The request 30 to charge the battery(ies) 28 may be the result of determining that the state of charge (SOC) of the battery module has fallen below a predetermined SOC. The electronic controller 22 would then command a specific charge rate 32 of the battery(ies) 28 by setting a value of the charge current I flowing into the battery module 26 in response to the detected request 30. The EV 10 additionally includes a charge port module 34. As shown in Fig. 2, the charging connector module 34 comprises a charging connector body 36 having a first side 38 and a second side 40. The charging connector module 34 also comprises an interface 42 (in the Fig. 2 and Fig. 4) arranged on the second side 40 for attachment to the EV body 10A, such as clips for firmly securing the charging connector module 34 to a body panel of the EV body. The charging connector module 34 additionally includes a connector or socket 44 (in Fig. 3) attached to the first side 38 of the charging connector body 36. The socket 44 is configured to receive a charging plug 46 (in Fig. 1) which is connected to an external power source 48, such as a charging station, and thereby receives the charging current I for charging the battery(ies) 28 of the EV 10.

[0027] As in Fig. 2, the charge port module 34 also includes an electrical connector 50 attached to the second side 40 of the charge port body 36. The electrical connector 50 is in electrical communication with the receptacle 44 and is configured to be connected to the vehicle's electrical system 24. The charge port module 34 additionally includes a locating track or channel 52 defined by the first side 38 of the charge port body 36. The channel 52 defines a pocket 52A. As shown, the charge port module 34 further includes a cassette 54 configured to slidably engage, i.e., be connected to, and slide with respect to, the channel 52. The sliding engagement of the cassette 54 relative to the charge port body 36 is in Fig. 2 by a double arrow 55. The cassette 54 comprises a cassette body 56 which is defined by an outer circumference P ois defined.

[0028] With further reference to Fig. 2, the cassette body 56 may define a projection 58. The projection 58 may be formed on at least a portion of the outer circumference P o of the cassette body 56. The projection 58 may be arranged on the outer circumference P o be arranged on at least two sides of the cassette body 56. In a particular embodiment, the projection 58 can be arranged on three sides of the cassette body 56, for example on the sides 56-1, 56-2 and 56-3, as in Fig. 5. The projection 58 is specifically configured to slidably engage the channel 52 to mate the cartridge 54 with the charging connector body 36. In other words, the projection 58 is designed and constructed to fit into the channel 52 and slide along it until the cartridge 54 is fully seated within a pocket 52A formed by the channel within the charging connector body 36.

[0029] The first side 38 of the charge connector body 36 may have a lip 38A configured to overlap at least a portion of the projection 58 after the cassette 54 has been inserted into and seated within the channel 52. The lip 38A is configured to cover a seam 39 between the first side 38 of the charge connector body 36 and the cassette body 56 when the cassette 54 is seated within the channel 52. The cassette body 56 also defines an access opening 60 (in Fig. 5), which has an inner circumference P i The access opening 60 is configured to facilitate access of the charging plug 46 to the receptacle 44 after the cassette has been inserted into and fully seated within the channel 52. The cassette 54 also includes a light-emitting element 62 disposed proximate the access opening 60.

[0030] As shown, the luminous element 62 is arranged on the cartridge body 56 and is configured to illuminate, ie, project light onto, the socket 44. The luminous element 62 may form at least a portion of the projection 58. As shown in Fig. 6, the one in Fig. 5, the luminous element 62 extends into the projection 58. The luminous element 62 may be a substantially continuous element surrounding the access opening 60, as shown in FIGS. Fig. 2, Fig. 7 and Fig. 8. Alternatively, the light element 62, as shown in Fig. 3, a certain part of the inner circumference P i the access opening 60. In particular, the luminous element 62 may be a compact element formed integrally with the cassette body 56 and positioned to direct a light beam directly onto the socket 44 (in Fig. 3) when the cassette 54 is inserted into the charging connector body 36.

[0031] The light-emitting element 62 may be configured to connect to and receive the electrical current I from the electrical system 24 of the EV 10 after the cassette 54 has been inserted into and seated within the channel 52. The light-emitting element 62 may include a light-transmitting cover 64 and a combination of fiber optic elements, such as at least one light-emitting diode (LED) 66A and a light guide 66B in communication therewith (shown in Fig. 7). As shown, each LED 66A and each light guide 66B may be housed within the cover 64. When multiple LEDs 66A are used in the light-emitting element 62, each of the LEDs 66A may selectively project a different color of light into the light guide 66B. Selective activation of certain LEDs 66A may be commanded by the vehicle operator via an in-vehicle user interface (not shown) or automatically controlled by the electronic controller 22. In other words, the charge port module 34 with multiple LEDs 66A may enable individually selected or "customizable" lighting.

[0032] For example, the electronic controller 22 may be programmed to activate a particular color LED 66A in correlation with a particular vehicle, such as the vehicle 10 in which the charging port module 34 is installed. Accordingly, different vehicles or vehicle lines may be configured to accommodate the charging port module 34 with multiple LEDs 66A, with each vehicle utilizing a different color illumination of its respective receptacle 44. The electronic controller 22 may also be programmed to activate a particular light indication via the light-emitting element 62, such as flashing patterns, repeating lighting patterns with varying intensities or colors. Such different patterns may be used, for example, during charging of the battery module 26 to alert the vehicle operator of an reached SOC.A warning message 68 can be programmed into the electronic control 22 either by the vehicle manufacturer or by the vehicle user and can indicate, for example, a full charge, a 50% charge or a different SOC.

[0033] As in Fig. 2, the charging connector body 36 and the cassette 54 may have complementary, corresponding locking features 70A and 70B (in Fig. 2). The locking features 70A, 70B are configured to fix and maintain the position of the cassette 54 relative to the charging connector body 36, i.e., to maintain the engagement of the cassette in the channel 52. The locking feature 70A may, for example, be configured as receptacle(s) that are part of the charging connector body 36 (shown in Fig. 2), while the locking feature 70B may be configured as tab(s) that are part of the cassette body 56 (shown in Fig. 2 and Fig. 7). Alternatively, the specific arrangement of the locking features 70A, 70B may be reversed, such that, for example, the tab(s) are part of the charge port body 36 and the receptacle(s) are part of the cassette 54 (not shown). The locking features 70A, 70B may enable removal and replacement of the cassette 54 as needed. The cassette body 56 may include a handle portion 72 specifically configured to allow the cassette to be grasped by the vehicle user or a technician for removal from the charge port module 34.

[0034] As in Fig. 3 and Fig. 8, the charging connector module 34 also includes a charging connector door 74. The charging connector door 74 may be connected to the housing of the charging connector 36 via a hinge 76 and configured to be positioned either substantially in a horizontal plane X (in Fig. 3), ie to one side of the bushing 44, or falls substantially in a vertical plane Y downwards below the bushing (in Fig. 8). The charging port door 74 is configured to selectively cover and permit access to the receptacle 44. The charging port module 34 may include a mechanical, electromechanical, or electromagnetic locking mechanism 78 configured to selectively maintain the closure of the charging port door 74 and unlock when access to the receptacle 44 is required. The electronic controller 22 may be programmed to activate the lighting element 62 in response to the opening of the door 74, e.g., upon triggering the locking mechanism 78, to timely initiate illumination of the receptacle 44.

[0035] The detailed description and the drawings or figures are supporting and descriptive of the disclosure, but the scope of the disclosure is defined solely by the claims. While some of the best modes and other embodiments for carrying out the claimed disclosure have been described in detail, various alternative designs and embodiments exist for carrying out the disclosure defined in the appended claims. Moreover, the embodiments illustrated in the drawings or the features of various embodiments recited in this description are not necessarily intended to be independent embodiments.Rather, it is possible that each of the features described in one of the embodiments may be combined with one or more other desired features of other embodiments, resulting in other embodiments not described in words or by reference to the drawings. Accordingly, such other embodiments fall within the scope of the appended claims.

Claims

[1] Charging port module (34) for an electric vehicle (EV) (10), wherein the module (34) comprises: a charging connector body (36) with a first side (38), an opposite second side (40) and an interface (42) for attachment to a body of the EV (10); a socket (44) which is attached to the first side (38) of the charging port body (36) and is configured to receive a charging plug (46); an electrical connector (50) which is attached to the second side (40) of the charging terminal body (36), is in electrical connection with the socket (44) and is configured to engage with an electrical system (24) which includes a battery of the EV (10); a channel (52) defined by the first side (38) of the charging terminal body (36); and a cassette (54) configured to engage smoothly in the channel (52), the cassette (54) comprising: a cassette body (56) defining an access opening (60) configured to facilitate access of the charging plug (46) to the socket (44) after the cassette (54) has been inserted into and is seated in the channel (52); and a light element (62) which is arranged on the cassette body (56) and configured to illuminate the socket (44); wherein the cassette body (56) is defined by an outer circumference, wherein the cassette body (56) defines a projection (58) which is arranged on at least one section of the outer circumference, and wherein the projection (58) is configured to engage slidably in the channel (52); wherein the first side (38) of the charging connector body (36) has a lip (38A) configured to overlap at least part of the projection (58) after the cassette (54) has been inserted into and is seated in the channel (52). [2] Charging port module (34) according to claim 1, wherein the charging port body (36) and the cassette (54) have complementary locking features configured to maintain the engagement of the cassette (54) with the channel (52). [3] Charging port module (34) according to claim 1, wherein the light element (62) forms at least a part of the projection (58). [4] Charging port module (34) according to claim 1, wherein the light element (62) is configured to establish an electrical connection with the electrical system (24) of the EV (10) and to receive electrical current from it after the cassette (54) has been inserted into and is seated in the channel (52). [5] Charging port module (34) according to claim 1, wherein the light element (62) surrounds the access opening (60). [6] Charging port module (34) according to claim 1, wherein the access opening (60) is defined by an inner circumference, and wherein the light element (62) covers a section of the inner circumference of the access opening (60). [7] Charging port module (34) according to claim 1, wherein the light element (62) comprises a translucent cover (64) and at least one light-emitting diode (LED) (66A) and a light guide (66B) in conjunction with the at least one LED (66A), and wherein each of the at least one LED (66A) and of the light guide (66B) are housed within the cover (64). [8] Charging port module (34) according to claim 7, wherein the at least one LED (66A) comprises several LEDs (66A) each projecting a different color of light.

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