Charging terminal for a vehicle's charging inlet arrangement

Abstract

A charging inlet assembly (100) comprises a charging inlet housing (110) having a front (130) and a rear (132). The charging inlet housing has terminal channels (116, 118) between the front and rear. The charging inlet assembly includes charging terminals (120) that are received in the corresponding terminal channels and held in the charging inlet housing. The charging terminals have connecting ends and termination ends. The terminals are configured to be electrically connected to the corresponding power cables (222). The connecting ends include studs (272) configured to connect to a charging plug. The studs extend to distal ends (274). The charging inlet assembly includes terminal caps (300) that are connected to the corresponding studs. The terminal caps are made of a dielectric material. The terminal caps are threaded to the distal ends.

Description

[0001] This application claims priority to U.S. Application Nos. 63 / 644,582, filed May 9, 2024, entitled "CHARGING TERMINAL FOR A CHARGING INLET ASSEMBLY OF A VEHICLE" and 63 / 522,484, filed June 22, 2023, entitled "SERVICEABLE / ARC-SAFE FINGER PROTECTION CAP," the subject matter of which is incorporated herein by reference in its entirety.

[0002] The subject matter discussed here generally concerns vehicle charging systems.

[0003] Charging inlet assemblies are used for charging vehicles, such as charging the battery system of an electric vehicle (EV) or a hybrid electric vehicle (HEV). The charging inlet assembly includes charging terminals held by a charging inlet assembly housing. The charging terminals include finger protection caps on the ends of the charging terminals to prevent accidental contact with the charging terminal. However, the finger protection caps are susceptible to damage, for example, from electric shock during charging. Repairing or replacing the finger protection cap is difficult and typically requires removing the entire charging inlet assembly to replace the charging terminal. Furthermore, the finger protection caps can accidentally pop off the charging terminal and become lodged in the charging connector.

[0004] There is still a need for an improved charge inlet arrangement.

[0005] In one embodiment, a charging inlet assembly is provided that includes a charging inlet housing having a front and a rear. The charging inlet housing has terminal channels between the front and rear. The charging inlet assembly includes charging terminals received in the corresponding terminal channels and retained within the charging inlet housing. The charging terminals have terminal ends and termination ends. The terminals are configured to be electrically connected to the corresponding power cables. The terminal ends include studs configured to be connected to a charging plug. The studs extend to the distal ends. The charging inlet assembly includes terminal caps connected to the corresponding studs. The terminal caps are made of a dielectric material. The terminal caps are threadably connected to the distal ends.

[0006] The invention will now be described by way of example with reference to the accompanying figures, in which: Fig. 1 is a front perspective view of a charge inlet assembly in accordance with an exemplary embodiment. Fig. 2 is a rear perspective view of the charge inlet assembly in accordance with an exemplary embodiment. Fig. 3 is an exploded view of the DC charging terminal according to an exemplary embodiment. Fig. 4 is an assembled view of the DC charging terminal according to an exemplary embodiment.

[0007] Fig. 1 is a front perspective view of a charge inlet assembly 100 in accordance with an exemplary embodiment. Fig. Figure 2 is a rear perspective view of the charging inlet assembly 100 in accordance with an exemplary embodiment. The charging inlet assembly 100 includes an AC charging module 102 and a DC charging module 104 in an exemplary embodiment.

[0008] The charging inlet assembly 100 is used as a charging inlet for a vehicle, such as an electric vehicle (EV) or hybrid electric vehicle (HEV). The charging inlet assembly 100 is configured to be connected to a connector (not shown). In an exemplary embodiment, the charging inlet assembly 100 is configured to mate with various types of charging connectors, such as a DC fast charging connector (e.g., the SAE Combo CCS charging connector) in addition to AC charging connectors (e.g., the SAE J1772 charging connector). The charging inlet assembly 100 may be charging connectors connected to the North American Charging System (NACS), such as SAE J3400 charging connectors.

[0009] The charging inlet assembly 100 includes a housing 110 configured for installation in the vehicle. The housing 110 accommodates the AC charging module 102 and the DC charging module 104, which are connected to the connector. In various embodiments, the components of the AC charging module 102 and / or the DC charging module 104 are removable from the housing 110. For example, the charging modules 102, 104 can be connected to the housing 110 with latches, fasteners, clips, or other securing means. The charging modules 102, 104 can be removed from the housing 110 to separate components of the charging modules 102, 104 (e.g., bolts, cables, circuit boards, and the like) from the housing 110, for example, to repair and / or replace the components of the charging module or other components of the charging inlet assembly 100.

[0010] In an exemplary embodiment, the housing 110 includes an AC section 112 that houses the AC charging module 102 and a DC section 114 that houses the DC charging module 104. The AC section 112 is configured to be connected to an AC charging connector or an AC section of the charging connector. The DC section 114 is configured to be connected to a DC charging connector or a DC section of the charging connector. The AC section 112 includes AC terminal channels 116. The DC section 114 includes DC terminal channels 118.

[0011] The AC charging module 102 includes AC terminals 120 in the AC section 112. The AC terminals 120 are housed in the housing 110. The AC terminals 120 are received in corresponding AC terminal channels 116. The AC terminals 120 are configured to be connected to the charging terminal. In the illustrated embodiment, five AC terminals 120 are provided, including a first AC charging terminal 120a, a second AC charging terminal 120b, a ground terminal 120c, a proximity terminal 120d, and a pilot terminal 120e. Optionally, the AC terminals 120 can be different sized terminals. In one exemplary embodiment, the AC terminals 120 include studs on the connection ends of the AC terminals 120.AC power cables 122 are connected to the AC terminals 120 and extend from the charging inlet assembly 100 to another component of the vehicle, such as the vehicle's battery system. In various embodiments, the AC power cables 122 may extend straight away from the AC charging module 102 and the housing 110. In other embodiments, the AC power cables 122 may extend from the AC charging module 102 and the housing 110 at a 90° angle (e.g., at a right angle) or at other angles.

[0012] In an exemplary embodiment, the AC portion 112 of the charging inlet assembly 100 defines a low-voltage terminal configured to connect to the low-voltage portion of the charging ports. The low-voltage terminal (e.g., the AC terminals 120 and the AC cables 122) is configured to couple to other components in the system, such as a battery distribution unit, to control the charging of the vehicle. The low-voltage terminal can send / receive signals related to the charging process, such as connection status, charging status, charging voltage, and the like. The low-voltage terminal can be a socket configured to receive the charging plug. Seals can be provided at the interface of the low-voltage terminal.

[0013] The DC charging module 104 includes a DC charging receptacle 126 at the front of the housing 110 configured to mate with the charging plug, a DC terminal assembly 200 at the rear of the housing 110, and a DC terminal assembly 220 configured to be removably connected to the DC terminal module 200. The DC terminal module 200 includes a DC housing 210, one or more DC terminals 240, and one or more cover assemblies 230 connected to the DC housing 210 to cover the DC terminals 240. The DC housing 210 is connected to the rear of the inlet housing 110. The DC terminals 240 pass through the inlet housing 110 to the front of the inlet housing 110 at the DC charging socket 126 to connect to the charging plug.The DC cable assembly 220 includes DC cables 222 that are electrically connected to the corresponding DC terminals 240.

[0014] When assembled, the DC terminals 240 are disposed in the DC section 114. The DC terminals 240 are disposed in the housing 110 at the DC charging receptacle 126. The DC terminals 240 are received in corresponding DC terminal channels 118. The DC terminals 240 are configured to be connected to the charging terminal. In the illustrated embodiment, two DC terminals 240 are provided. In an exemplary embodiment, the DC terminals 240 include studs at the connection ends of the DC terminals 240. The DC cables 222 extend from the charging inlet assembly 100 to another component of the vehicle, such as the vehicle's battery system. In various embodiments, the DC cables 222 may extend away from the DC terminal module 200 at a 90° angle (e.g., at a right angle) or at other angles.

[0015] In an exemplary embodiment, the DC section 114 of the charging inlet assembly 100 defines a high-voltage connector configured to couple to the high-voltage portion of the charging port. The high-voltage connector (e.g., the DC terminals 240 and the DC cables 222) is configured to connect to other components in the system, such as the battery and / or the vehicle's battery distribution unit. The high-voltage connector is used to quickly charge the battery. The high-voltage connector may be a socket designed to receive the charging connector. Seals may be provided at the high-voltage connector interface.

[0016] The inlet housing 110 includes a front 130 and a rear 132. The front 130 of the housing 110 faces outward and is used by the operator to connect the charging port. The rear 132 faces the interior of the vehicle and is generally inaccessible without removing the housing 110 from the vehicle. The housing 110 includes a panel 134 on the front 130. In an exemplary embodiment, an AC receptacle 136 is formed in the panel 134 at the AC section 112 and a DC receptacle 138 is formed in the panel 134 at the DC section 114. The AC receptacle 136 includes a space around the AC terminals 120 that receives the connector for charging. During charging, the AC charging plug is inserted into the AC receptacle 136 to electrically connect to the AC terminals 120.The DC charging socket 138 includes a space around the DC terminals 240 that accommodate the charging connector. The DC charging connector is configured to be plugged into the DC socket 138. During charging, the DC charging connector is plugged into the DC socket 138 to electrically connect the DC terminals 240. The panel 134 may surround the AC socket 136 and the DC socket 138 at the front 130.

[0017] In an exemplary embodiment, the housing 110 includes a mounting flange 140 ( Fig. 1) connected to the panel 134 at the front 130. The mounting flange 140 includes mounting tabs 142 for securing the housing 110 to the vehicle. The mounting tabs 142 have openings 144 that receive fasteners (not shown) for securing the charge inlet assembly 100 to the vehicle. Other types of fasteners may also be used to secure the charge inlet assembly 100 to the vehicle. The housing 110 and / or the mounting flange may include a gasket to seal the charge inlet assembly 100 to the vehicle.

[0018] In various embodiments, the charging inlet assembly 100 may include a terminal cover (not shown) on the front of the housing 110 to cover portions of the housing 110, such as the DC power section 114 and / or the AC power section 112. The housing 110 may include one or more rear covers on the rear of the housing 110 to close access to the rear of the housing 110. The cover(s) may be clipped or locked to the main body of the housing 110, for example, with clips or latches. In alternative embodiments, other types of securing elements, such as fasteners, may also be used.

[0019] Fig. 3 is an exploded view of the DC charging terminal 240 according to an exemplary embodiment. Fig. Figure 4 is an assembled view of the DC charging terminal 240 according to an exemplary embodiment. The AC charging terminal 120 (shown in Fig. 1) may be constructed similarly to the DC charging terminal 240 and include similar components.

[0020] The charging terminal 240 includes a terminal body 242 extending between a front side 244 and a rear side 246. The terminal 240 includes a mounting portion 250 configured to be secured in the terminal channel 118, for example, in the inlet housing 110 and / or the DC housing 210 (shown in Fig.2). The charging terminal 240 includes a termination portion 260 on the rear side 246, which is configured to connect to the DC power cable 222. The charging terminal 240 includes a coupling portion 270 on the front side 244, which is configured to connect to the corresponding socket of the charging plug.

[0021] The charging terminal 240 includes cylindrical portions. For example, the mounting portion 250 may be a cylindrical portion. In an exemplary embodiment, the mounting portion 250 includes a terminal seal 252 configured to seal between the charging terminal 240 and the housing 110. The terminal seal 252 extends circumferentially around the mounting portion 250. In an exemplary embodiment, the mounting portion 250 includes a groove 254 extending circumferentially around the mounting portion 250. The groove 254 is configured to receive a latch or other securing element to secure the charging terminal 240 within the housing 110. The mounting portion 250 includes one or more flanges 256.

[0022] In an exemplary embodiment, the charging terminal 240 includes a post 262 on the rear side 246. The termination portion 260 includes a terminal bus bar 264 connected to the post 262. The terminal bus bar 264 may be secured to the post 262 by welding. In other embodiments, the terminal bus bar 264 is secured to the post 262 with a fastener, such as a thread. The terminal bus bar 264 may be connected to the post 262 by a compressed connection. In other embodiments, the terminal bus bar 264 may be an integral part of the mounting portion 250 of the charging terminal 240, rather than being a separate and discrete component connected thereto. The terminal bus bar 264 is configured to be electrically connected to the power cable 222.For example, the power cable 222 may be welded to a pad 266 of the terminal bus bar 264. In alternative embodiments, the terminal bus bar 264 may be crimped to the power cable 222 or connected to the power cable 222 by means of a screw connection.

[0023] The coupling portion 270 extends forward from the mounting portion 250. In an exemplary embodiment, the coupling portion 270 includes a stud 272 that extends to a distal end 274. The stud 272 is cylindrical. The stud 272 has an outer surface 276 configured to engage the socket of the charging plug. In an exemplary embodiment, at least a portion of the stud 272 is hollow. For example, the stud 272 includes a threaded bore 280 at the distal end 274. The threaded bore 280 includes an internal thread 282.

[0024] In an exemplary embodiment, the charging terminal 240 includes a terminal cap 300 threadedly connected to the distal end 274 of the stud 272. The terminal cap 300 is connected to the distal end 274 by rotating the terminal cap 300 in a tightening direction. The terminal cap 300 is made of a dielectric material. The terminal cap 300 covers the distal end 274 of the stud 272. The terminal cap 300 is a finger protection cap that serves to prevent contact with the stud 272. The terminal cap 300 is removable from the stud 272 by rotating the terminal cap 300 in a direction to loosen or loosen it.

[0025] In an exemplary embodiment, the terminal cap 300 is made of a plastic material. For example, the terminal cap 300 may be a molded part. In various embodiments, the material may be a polyethylene plastic. In various embodiments, the plastic material may be a high-temperature plastic material to avoid melting due to electrical arcing. For example, the material may be a polytetrafluoroethylene (PTFE) plastic, which has a melting temperature above 300°C. Optionally, the material may also include ceramic fillers to increase the melting temperature of the part. In other embodiments, the terminal cap 300 is made of a ceramic material and has a high melting temperature. The ceramic material may have a melting temperature above 2000°C.The high melting temperature prevents damage or melting due to arcing between the charging terminals.

[0026] In an exemplary embodiment, the terminal cap 300 includes a tip 310 and a threaded shaft 312 extending from the tip 310. The tip 310 includes a head 314 of the terminal cap 300. One end of the head 314 may be tapered, for example, to guide the socket of the charging plug with the terminal. In an exemplary embodiment, the head 314 includes a drive member 316 configured to be engaged with a tool to rotate the terminal cap 300 to tighten or loosen the terminal cap 300 relative to the bolt 272. In the illustrated embodiment, the drive member 316 is a hex opening configured to receive a hex drive tool. In alternative embodiments, other types of drive members may be used. The threaded shaft 312 includes threads 318 along the threaded shaft 312.The threads 318 are configured to engage the threads 282 of the threaded bore 280 to secure the terminal cap 300 to the bolt 272. QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] US 63 / 644,582

[0001] WO 63 / 522,484

[0001]

Claims

[1] A charging inlet assembly (100) comprising: a charge inlet housing (110) having a front side (130) and a rear side (132), the charge inlet housing having terminal channels (116, 118) between the front side and the rear side; Charging terminals (120) received in the respective terminal channels and held in the charging inlet housing, the charging terminals having terminal ends and termination ends, the termination ends being configured to be electrically connected to respective power cables (222), the terminal ends comprising studs (272) configured to be connected to a charging plug, the studs extending to distal ends (274); and Terminal caps (300) connected to the corresponding bolts, the terminal caps being made of a dielectric material and the terminal caps being threadably connected to the distal ends. [2] The charge inlet assembly (100) of claim 1, wherein the distal ends (274) have threaded bores (280) and the terminal caps (300) are threadably connected to the threaded bores. [3] The charge inlet assembly (100) of claim 1, wherein each terminal cap (300) includes a tip (310) and a threaded shaft (312) extending from the tip, the threaded shaft being threadably connected to the corresponding stud (272). [4] The charging inlet assembly (100) of claim 1, wherein each terminal cap (300) is made of a plastic material. [5] The charge inlet assembly (100) of claim 1, wherein each terminal cap (300) is made of a ceramic material. [6] The charging inlet assembly (100) of claim 1, wherein each terminal cap (300) is made of a dielectric material capable of withstanding electrical arcs. [7] The charge inlet assembly (100) of claim 1, wherein each terminal cap (300) includes a drive member (316) configured to be engaged by a tool used to rotate the terminal cap to threadably connect the terminal cap to the bolt (272). [8] The charging inlet assembly (100) of claim 1, wherein the terminal cap (300) includes a front portion forward of the distal end (274) and a rear portion rearward of the distal end. [9] The charge inlet assembly (100) of claim 1, wherein the terminal cap (300) includes an outer portion outside the bolt (272) and an inner portion inside the bolt. [10] Charging terminal (120) for a charging inlet assembly (100), the charging terminal comprising: a terminal body (242) extending between a front side (244) and a rear side (246), the terminal body including a mounting portion (250) configured to be secured in a terminal channel (116, 118) of the loading inlet assembly; a termination section (260) on the rear side, the termination section being configured to be connectable to a power cable (222); a coupling portion (270) on the front side, the coupling portion comprising a bolt (272) configured to connect to a socket of a charging plug, the bolt having a distal end (274); and a terminal cap (300) threadably connected to the distal end of the bolt, the terminal cap being made of a dielectric material. [11] The charging terminal (120) of claim 10, wherein the distal end (274) includes a threaded bore (280) and the terminal cap (300) is threadably connected to the threaded bore. [12] The charging terminal (120) of claim 10, wherein the terminal cap (300) includes a tip (310) and a threaded shaft (312) extending from the tip, the threaded shaft being threadably connected to the bolt (272). [13] The charging terminal (120) of claim 10, wherein the terminal cap (300) is made of a plastic material. [14] The charging terminal (120) of claim 10, wherein the terminal cap (300) is made of a ceramic material. [15] The charging terminal (120) of claim 10, wherein the terminal cap (300) is made of a dielectric material capable of withstanding electrical arcs.

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