High-voltage socket module for a vehicle

Abstract

A high-voltage socket module for use in a ground vehicle, comprising: a housing, the housing comprising: one or more vehicle mountings, an operating power connection, a printed circuit board (PCB) electrically connected to the operating power connection, an HVPO circuit comprising one or more high-voltage conductive traces on the printed circuit board, at least one high-voltage socket electrically connected to the one or more high-voltage conductive traces, and a circuit breaker located between the operating power connection and the at least one high-voltage socket.

Description

REFERENCE TO RELATED REGISTRATIONS

[0001] This application relates to and claims the earlier filing dates and priorities of: U.S. Provisional Patent Application No. 63 / 500,596, entitled “High Voltage Power Connector with Fault Detection”, filed on May 6, 2023, by Charles Nzeylmana and Eduardo Bonilla; and U.S. Provisional Patent Application No. 63 / 554,142, entitled “HIGH VOLTAGE SOCKET MODULE FOR A VEHICLE”, filed on February 15, 2024, by Le LaPlant and Eduardo Bonilla, the disclosures of which are incorporated herein by reference in their entirety. BACKGROUND. Field of invention

[0002] The present invention relates to electrical sockets in vehicles, in particular electrical sockets in a vehicle that are connected to a vehicle electrical system. II. Background of the invention

[0003] Electrical sockets for supplying power to electrical appliances are widely known. Sockets in homes and buildings are usually protected by a circuit breaker and / or a residual current device (RCD). A RCD can open a circuit in the event of a ground fault.

[0004] Earth fault systems have been disclosed in various publications, including: US4200897, JPH0870503A, US5544003, US5587864, US5757598, US2004001292(A1) and US2005259371 (A1), the disclosures of which are incorporated herein by reference in their entirety.

[0005] US4200897, published on April 29, 1980, entitled "GROUND LEAKAGE CURRENT INTERRUPTER" by Robert Dawley, describes a ground fault current interrupter circuit that can be used with a power source and electrical equipment on a construction site.

[0006] JPH0870503A, published on 12.03.1996, entitled “GROUND FAULT DETECTOR CIRCUIT FOR ELECTRIC CAR” by Toshihiko Sugiura et al., describes a ground fault detector circuit for an electric vehicle equipped with a DC high-voltage power supply.

[0007] US5544003, published on August 6, 1996, entitled "PORTABLE ELECTRICAL DISTRIBUTION PANEL" by Joe Vaughan, describes a portable electrical distribution panel with earth fault protection.

[0008] US5587864, published on December 24, 1996, entitled "SHORT CIRCUIT AND GROUND FAULT PROTECTION FOR AN ELECTRICAL SYSTEM" by Allan Gale, generally describes a ground fault detection system that detects unintended current flows between a live conductor and earth, as well as between two live conductors.

[0009] US5757598, published on May 26, 1998, entitled “GROUND FAULT CIRCUIT INTERRUPTER” by Victor Aromin, discloses a residual current circuit breaker (GFCI) that interrupts the flow of current through a pair of conductors extending between a power source and a load.

[0010] US2004001292(A1), published on 01.01.2004, entitled “MOBILE ELECTRIC POWER SUPPLY SYSTEM WITH DEACTIVATABLE GFCI PROTECTION” by Richard Vanderkolk et al., describes a mobile system for supplying an electrical load with alternating current, which includes a residual current circuit breaker.

[0011] US2005259371(A1), filed on May 21, 2004 and published on November 24, 2005, entitled DIFFERENTIAL CURRENT DETECTION by Christopher Henze et al., describes a fault detection circuit for hybrid and electric vehicles that detects a difference between a source current and a return current.

[0012] US2006097673 (A1), published on May 11, 2006, entitled “AC POWER SUPPLYING APPARATUS FOR VEHICLES” by Jae-Beom Jun, describes an AC power supply device for vehicles with a DC-AC inverter.

[0013] Although there are various publications describing socket systems with circuit protection, modern circuit protection devices for electrical building systems do not offer an adequate solution for vehicle systems, and the devices currently used in vehicle systems have a number of shortcomings.

[0014] Therefore, there is a need for an improved onboard power supply system for automotive, ground, and / or vehicle applications that can supply high-voltage power to consumer devices in a vehicle in a more efficient, cost-effective, safer, more convenient, or more reliable manner. There is also a need for a high-voltage outlet for automotive applications that meets the demanding requirements of the automotive environment, provides additional protection for electrical circuits, facilitates fault detection in multi-outlet applications, is more convenient or user-friendly, and / or can detect low battery voltage faults. Furthermore, there is a need for high-voltage outlets for automotive applications that offer improved load protection for both single and multi-outlet configurations. SUMMARY

[0015] This document discloses a high-voltage power outlet module (HVPO) that can supply power to user devices from a vehicle power source in a more efficient, safer, more cost-effective, more convenient, improved and / or more reliable manner.

[0016] This reveals an AC power outlet module that can protect circuits and loads for both single and multiple outlets.

[0017] This document discloses a high-voltage power outlet module (HVPO) with fault detection that can supply power to user devices from a vehicle power source in an efficient, safer, more cost-effective, improved, or more reliable manner.

[0018] This reveals a socket module that can supply consumer devices in an automotive environment with high-voltage current from a vehicle.

[0019] Here, a socket module is revealed that can detect errors for both single and multiple sockets.

[0020] This discloses a socket module with fault detection that can be operated with low battery voltage. This discloses a socket module in which the control module used for high-voltage insulation detection is powered by a vehicle battery (e.g., of type 12 V DC).

[0021] This discloses a socket module with a residual current device (GFCI) powered by a vehicle battery (e.g., of type 12 V DC). This discloses a socket module with a residual current device (GFCI) that can be digitally reset.

[0022] This document discloses a high-voltage power outlet module (HVPO) with over-temperature protection, which can supply power to user devices via a vehicle power source.

[0023] This document discloses a socket module with a removable fuse. The socket module can advantageously be configured as a high-voltage socket module with one or more fuses. In certain embodiments, multiple sockets can be fused independently of one another or by a pair of sockets. In certain embodiments, an AC or DC socket can interrupt the current flow within the HVPO module when the current exceeds the fuse's rated current. The fuse can protect a connected external device or load from excessive current. In certain embodiments where a vehicle network fails, a fuse can still protect an external load.

[0024] Various exemplary embodiments provide HVPO modules containing a housing with one, two, three, four, or more sockets. The sockets can have a rated voltage of 120 V and / or 240 V, or 200 V to 240 V. The housing can have one or more vehicle mounting points for attaching it to a vehicle.The enclosure may, in various or individual ways, carry one, several, or all of the following elements: a vehicle power connector, a printed circuit board (PCB), an electronic control unit, a high-power outlet, an AC outlet, a DC outlet, a USB port, a voltage regulator, a voltage detector, an overcurrent protection device, a residual current device (GFCI), a fault detector, a fuse, a GFCI tester, a shutdown relay, an electronic brake, a light-emitting diode (LED), a magnetic sensor, an electromagnetic sensor, a socket cover, an activation sensor, a display, a communication module, a voltage sensor, a current sensor, a power interrupter, a switch, a reset button, a circuit tester, a circuit insulation tester, a circuit tester, a temperature sensor, a secondary power connector, conductors, and / or conductor traces.

[0025] The socket module may include a temperature sensor. The temperature sensor may be integrated into the module and provide a measurement adjacent to the HVPO circuit. A temperature sensor may be located on a circuit board, near a socket contact, or adjacent to the HVPO circuit. The temperature measurement system may be connected to a communication module configured to transmit temperature data to one or more other HVPO components, modules, or vehicle systems outside the HVPO module.

[0026] The power output module can include an E-breaker. An E-breaker can be used as a circuit breaker, employing an integrated electrical circuit to detect overcurrent and cut off the power supply. The system can be reset electronically or via a mechanical button or switch.

[0027] The power output module can advantageously be configured as a high-voltage socket module for ground vehicles, including motor vehicles, light and / or heavy trucks.

[0028] For a better understanding of the claimed invention, reference is now made to the attached drawings and the detailed description of the preferred embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] The accompanying drawings, which form part of this description, illustrate various embodiments that may be used together, alone or in part to explain or illustrate the principles of the device(s) described herein and in the entire description and claims. Fig. Figure 1 is a perspective view of a socket module, which is explained in more detail in the description. Fig. 2 is an exploded view of the in Fig. 1 shown socket module. Fig. Figure 3 is a block diagram of an embodiment of a socket module, which is explained in more detail in the description. Fig. Figure 4 is a block diagram of an embodiment of a socket module, which is explained in more detail in the description. Fig. Figure 5 is an environmental view of an embodiment of a socket module with a fuse. Fig. Figure 6 is a perspective view of an embodiment of a component of a socket module with a fuse. Fig. Figure 7 is an environmental view of an embodiment of a component of a socket module with a fuse in and out of a slide. Fig. Figure 8 is a system block diagram of a component of a socket module with temperature sensing. Fig. Figure 9 is a thermal imaging map of a component of a socket module with temperature measurement. Fig. Figure 10 is an exploded view of an embodiment of a socket module, which is explained in more detail in the description. DETAILED DESCRIPTION OF PREFERRED EXECUTION FORMS

[0030] This description discloses a high-voltage power outlet module (HVPO). Certain embodiments of the power outlet module are particularly useful for on-board power supply applications in vehicles, including ground vehicles, automobiles, trucks, electric vehicles, hybrid vehicles, and others. The power outlet module may include some or all of the described components, depending on the application and independent of the examples shown in the figures. The power output module can advantageously be used as part of the on-board power distribution to a user or consumer device. The power output module may also be equipped with circuit protection, overcurrent protection, overtemperature protection, current fault detection, and / or a high-voltage supply. In certain configurations, an HVPO module with a residual current device (GFCI) is provided. The GFCI on the HVPO may be fully automated during switching on and off.The GFCI can be set each time the vehicle key is detected, supply mode is activated, the vehicle is started, or service mode is activated. The GFCI can be reset each time the vehicle is switched off. The GFCI can be designed to support multiple inrush currents and backup currents. The GFCI at the HVPO can be automatically controlled by the vehicle (e.g., by the inverter). The GFCI at 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 also operate when the vehicle is isolated from earth. The GFCI can be grounded to a frame or chassis.

[0031] The socket module may have an enclosure. An enclosure may be used to house or enclose associated electronic and electrical components, including conductors, connectors, and sockets. The enclosure may protect internal components and / or isolate the internal components and / or the electricity from the socket users. The enclosure may house any combination of one or more of the following: a vehicle electrical connector, a printed circuit board (PCB), a high-voltage socket, and one or more sockets. The enclosure may also house a fault detection system and / or a power interruption system. Fault detection and / or power interruption may take place within the enclosure. Packaging the electronic and electrical components around and within the enclosure may enable a small form factor. A small form factor is particularly advantageous when space for vehicle components is limited.The form factor can allow for a housing front of 70 mm in height and 70 mm in width, or less. The packaging can also enable tighter stacking tolerances for system components. Furthermore, packaging system components within a housing can reduce variability during circuit testing and fault detection.

[0032] The enclosure can accommodate one or more outlets. The outlet module can have one, two, three, four, or more outlets. The outlets can conform to NEMA or CEE7 standards for AC plugs and sockets. The outlets can be configured in any suitable configuration. The outlets can be configured as double, single, or any other arrangement. The module can include a combination of a single outlet and a pair of outlets, with the single outlet and the paired outlets having separate or combined circuit breaker protection. The outlets can have different voltage ratings, for example, 120 V and 240 V. The outlets can also be configured with suitable receptacles. Suitable receptacles include female sockets or holes.Female conductive receptacles can be configured to accept two-, three-, or four-prong plugs. The female receptacles can also be configured according to the type of electrical device, its intended use, or its power rating. Suitable shapes include, but are not limited to, flat, round, U-shaped, L-shaped, T-shaped, or combinations thereof. The receptacles can be uniformly sized or vary in size, or may be equipped with a locking mechanism to accommodate available uses and / or polarized electrical devices, household appliances, or tools.

[0033] The socket(s) can supply single-phase or multi-phase current, true sine wave AC, modified sine wave AC, modified pulsed square wave AC, direct current, or any other desired waveform. One or more sockets can be high-power sockets. A high-voltage AC socket is one rated for 100 VAC or more at 50 Hz to 60 Hz at 90 °C and 5 amps or more. The sockets can be rated for 100 VAC, 110 VAC, 120 VAC, 220 VAC, 240 VAC, 600 VAC, or more. The sockets can be equipped with components designed to withstand high voltages, rated currents, and heat generation. A DC high-voltage socket is a socket designed for a rated power of 100 VDC or more at 90 °C and 5 amps or more.The socket(s) can be rated for a voltage of 1000 VDC or higher. The socket(s) can be rated for a current of >5, 10, 15, 20, 30, 35, 40, 45, or 50 amps or higher. The socket(s) can be rated for a current of 10, 15, 20, 30, 35, 40, 45, or 50 amps or lower. A high-performance socket module can be configured for its intended use, e.g., in the vehicle, center console, dashboard, armrest, passenger compartment, trunk, storage compartment, outside the vehicle, or on the bed of a pickup truck.

[0034] The sockets can be protected by one or more covers. These covers can cover each socket individually, all sockets together, or a combination of individual and grouped sockets. The sockets can be equipped with a childproof or tamper-proof safety device. Tamper protection can be achieved with a sliding socket cover.

[0035] The power supply to the sockets can be provided by any suitable power source. For clarity, the power source supplying the socket(s) is referred to as the operating current. A vehicle's operating current can be provided in any suitable way. This can include an inverter, traction batteries, auxiliary batteries, an additional battery, or any other suitable device. The operating circuit may have a plug that can be connected to a plug on a vehicle power source. The plugs may be detachable. A detachable mating plug allows for easy installation, a secure connection, and / or the possibility of maintenance and replacement.The operating circuit may further include one or more switches, sensors, relays, circuit breakers, rectifiers, power conditioners, filters, voltage regulators, transformers or other electrical components that are useful or desirable for the transmission, conditioning or interruption of current from a vehicle power source to a socket or to the module itself.

[0036] The operating power supply can be routed to the module via one or more power lines. The power line can be a connecting cable or a wiring harness with a vehicle power connector. The operating power line can be mechanically secured to the housing. The operating power line can be electrically connected to the module or the circuit board. The power supply by the system can include current from the supply power line being routed to a connector on the circuit board, to conductive traces on the circuit board, past one or more sensors, through one or more circuit breakers, and to one or more sockets.

[0037] The module may include fault detection. A fault detection system comprises one or more of the following elements: hardware, software, electrical components, and / or electronic components configured to detect current flowing along an unintended path. Fault detection may include a GFCI sensor coupled to a control unit such as an MCU. The GFCI sensor may include a GFCI transformer in the HVPO circuit. Fault detection may be achieved by detecting a threshold deviation between the conductor currents flowing through the hot and neutral conductors or through the positive and negative conductors. Fault detection may be implemented on a printed circuit board (PCB). Fault detection may be based on the current flowing in the conductive traces on a PCB.

[0038] The module can include a threshold-based fault detection test. This fault detection test can be implemented digitally using the MCU. Fault detection can occur during flow symmetry. Circuit-break fault detection can disconnect the operating voltage if flow symmetry exceeds a predefined threshold; for example, a 15- or 20-ampere outlet might have an unbalance threshold of 4 mA to 6 mA. The module can include circuit insulation testing. It can also include a temperature sensing system, temperature monitoring, and / or over-temperature protection. Temperature monitoring can be implemented by any suitable means. The temperature measurement can be adjustable and calibrated.Temperature sensing can be provided by a temperature sensor or sensor component connected to a control unit comprising one or more processors. Examples of control units include a microprocessor, a microcontroller, a programmable logic controller (PLC), and a microcontroller unit (MCU). Over-temperature protection can be provided using a threshold stored in the control unit or another storage device. An example of a temperature sensor component is a thyristor coupled to a control unit. Temperature sensing can be provided at any suitable location. It can be implemented at the outlet, the socket(s), the terminal(s), on the circuit board, or at other suitable locations.Temperature measurement can be performed at one or more terminals supported by the printed circuit board (PCB), on one or more traces, or on the PCB itself. Temperature measurement may also include an ambient temperature sensor that is thermally isolated from the terminal's thermal zone and / or an overtemperature sensor. Test circuits, insulation tests, and current and overvoltage tests can be used to verify the proper functioning of the operating circuit. If the circuit fails, the operating power supply can be interrupted in any suitable manner. Suitable interruptions of the operating power supply may be provided on the PCB, within the module, or at the vehicle's power source.

[0039] An integrated interruption of the operating power supply can be provided by an electronic switch, fuse, electronic brake, relay, circuit breaker, or other suitable circuit interrupting device. The operating power supply interruption can be connected to the operating circuit. For automotive applications, the relay, fuse, manual breaker, or electronic brake can be of automotive quality. The operating power supply can be interrupted via a vehicle communication network. Vehicle communication networks include LIN, CAN, serial networks, and others. The interruption of the vehicle power source can be achieved by switching off an inverter, opening a circuit leading to the module, or by another suitable current-interrupting device capable of interrupting the power supply to the socket module.Once a fault condition or test error is resolved, the operating circuit can be reset. The reset can be performed digitally via the control unit, directly to an electronic switch, a relay, via the vehicle network to the power source, manually with a switch, or by another circuit reset mechanism. The circuit breaker can be fully automated during power-on and power-off. The power source availability can be set each time the vehicle is started or the vehicle utility mode is activated. The power source availability can be reset each time the vehicle is switched off. The power source availability can be modeled to support multiple inrush currents and backup currents. The power source availability for the socket can be automatically controlled by the vehicle (e.g., via an inverter).

[0040] The module may have one or more mounting points for attaching the module to a vehicle, such as vehicle mounts. The vehicle mount may be supported by the housing. The vehicle mount may be integrated into the housing or provided by another suitable configuration. Suitable vehicle mounts include one or more of the following components: brackets, connectors, screws, bolts, clamps, snap fasteners, supports, through holes, pockets, anchors, flanges, bearings, adhesives, bonded joints, welds, or other suitable joining mechanisms or combinations thereof.

[0041] The module may include a second power connector, "module power," to supply power to one or more module components. The module power can supply power to the control unit, an MCU, and / or one or more sensor components, relays, communication modules, switches, LEDs, displays, transformers, voltage regulators, or other PCB components.

[0042] The module power supply can be provided from a different source than the operating power supply. The module power supply can be provided from a source with a lower voltage than the operating power supply. The module power supply can be routed to the chassis via a pigtail or a cable harness with a connector. The module power supply can be provided from a vehicle battery source, such as a 12-volt, 24-volt, or 48-volt battery. The module's input power can be regulated to any suitable voltage potential appropriate for the various components, including sensors, control units, MCUs, ICs, or other electronic components. Suitable voltage regulation can be provided with a voltage regulator IC or a circuit of 12 V, 9 V, 5 V, 3.5 V, etc.

[0043] The printed circuit board (PCB) can contain one or more control units, microcontrollers, microprocessors, integrated circuits (IC chips), or application-specific integrated circuits (ASIC chips). If a microcontroller is used, it can contain one or more CPUs (processor cores), memory, and / or programmable input / output peripherals. The control unit can provide onboard computing, data storage, and / or communication services for one or more tests, including fault detection, overvoltage protection, overcurrent protection, undervoltage failure, circuit isolation, power, temperature, voltage, current, circuit breaker, shutdown, power consumption, comparisons, calculations, humidity, and others. The control unit can also be used to store tests, test conditions, thresholds, tables, and / or alarm values.The control unit can be used to send data or information to the vehicle network, a circuit breaker, or a module display.

[0044] The printed circuit board (PCB) may include conductive traces for conducting 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: operating current, module current, board components, sensors, switches, relays, voltage regulators, signals, MCU input / output ports, transformers, active electrical components, passive electrical components, connectors, or other board components. The control unit can monitor signals from one or more of its input / output ports (I / O ports) from any of the onboard sensors and output data in response to the signals through one or more I / O ports. The one or more conductive traces may be used for system testing and / or fault detection. The one or more conductive traces may be heavy-duty conductive traces.A printed circuit board with heavy conductor tracks is a printed circuit board with a total mass of more than 28 grams.

[0045] The module may contain one or more fuses. The fuse has a locking mechanism. The fuse may have at least two leads for contacting a fuse holder or socket with a locking mechanism located between them. The fuse may be replaceable. A replaceable fuse is a fuse that is independent of a fuse holder and can be removed from it without cutting the fuse connection or damaging other material. The module may have a fuse holder or socket designed to accommodate a fuse. The fuse may be seated in the fuse holder with a friction fit between the leads of the fuse holder. The fuse may be accessible on the HVPO module. An accessible fuse is a fuse that can be serviced without significant disassembly of the power module.

[0046] The safety mechanism can be any suitable device for opening the circuit that can create an open circuit in an overcurrent situation. The safety mechanism can be designed for operation in an automotive environment with an applied high-voltage AC supply. Suitable safety mechanisms include metals that can sufficiently open the circuit within a predetermined range of applied currents and voltages within a specific time period. This time period can be sufficient to protect circuits under the operating conditions found in an automotive environment. When selecting a suitable material, the intended applications and the potential for current transmission, performance profile, safety delay, arcing, and plasma formation during operation and in the event of an overcurrent can be considered.Suitable fuse mechanisms can include a fusible material that creates an interruption by creating a gap between the fuse's conductors. Suitable fusible materials include metals that can provide a sufficiently large gap at a predetermined range of currents and voltages applied within a time period to open the circuit, damaging the component within a specified overcurrent range.

[0047] Fuses can be provided in any suitable form. Suitable forms may include blade fuses, ferrule fuses, cartridge fuses, post fuses, and others. A blade fuse is a fuse type with two or more conductors and a locking mechanism located between them, which typically electrically connects the flat parts. The flat parts may be blades. Blades may be conductors that have one dimension significantly narrower than another. The fuse may be supported by a carriage. The carriage may hold a replaceable fuse and retractably support it around the module. The carriage may provide a device for holding, accessing, and removing the fuse from a power module.

[0048] The module can have one or more vehicle interfaces. Interfaces can include a vehicle network interface, a vehicle battery interface, a module power interface, a service power interface, and a high-voltage interface. The interfaces can be provided by one or more connectors. The connectors can be located on the printed circuit board, the adapter board, or another suitable component location.

[0049] With reference to the Fig. Figure 1-2 shows an exemplary socket module 102, provided according to the teachings of this disclosure, which includes several optional systems and components. The socket module 102 has a housing 104, a module wiring harness 114, an operating power cable 110, a printed circuit board 152, a control unit (not shown), a communication module (not shown), a power interface 154, and a socket strip 150. The housing 104 comprises several parts, including the socket strip 150 and a rear cover 140. The several parts of the housing can be held together by one or more connectors. As shown, the housing is held together by several fasteners or screws 158. The housing 104 contains the electrical components 142 and the electronic components 144. The housing 104 has several mountings 108a, 108b, 108c, 108d for attaching the module to a vehicle.The housing also features several AC sockets (124, 126, 128, 130) and DC sockets (132, 134). As shown, the AC sockets (124, 126, 128, 130) are designed for high-voltage operation and configured as double sockets. The sockets can be arranged in pairs or individually.

[0050] The socket module 102 has a module wiring harness 114. The module wiring harness 114 is supported by the housing 104. As shown, the module wiring harness 114 is routed through the rear cover 140 of the housing 104. The module wiring harness 114 has conductors protected by a sheath and a connector connected to the conductors. The connector is configured to mate with a vehicle wiring harness and connect to a vehicle power supply. The wiring harness also has one or more conductors for hardwired communication with the vehicle network. The module wiring harness 114 can supply module power to the control unit, the MCU, and / or one or more sensor components, relays, communication modules, switches, LEDs, indicators, transformers, voltage regulators, power distribution boards, or other PCB components.The module's power supply can be provided by a source other than the operating power source or the operating power cable 110. The vehicle power source can be a battery or another suitable power source.

[0051] The socket module 102 has a power supply cable 110. The power supply cable 110 is supported by the housing 104. As shown, the power supply cable 110 passes through the rear cover 140 of the housing 104. The power supply cable 110 has conductors protected by a sheath 118, with a connector 112 attached to the conductors. The connector 112 is configured to connect to a power supply plug of a vehicle power supply cable or wiring harness. The vehicle power supply can be a battery, an inverter, or another suitable power source. One or more service power cables can provide the power source for the sockets. If both AC and DC high-power sockets are used, the power supply can be provided by different power cables and / or different power sources.

[0052] For example, as shown, one end of the supply cable 110 is connected to the circuit board 152. The circuit board 152 has a connector 122 for receiving the electrical connection of the supply cable.

[0053] The 152 printed circuit board features a heavy-duty conductive trace connected to the board's power connector. This heavy-duty conductive trace is sized for the intended power application, such as high-power outlets. Heavy-duty traces on the board can have a mass exceeding one ounce. The traces are configured to carry current along the board, past sensors, a switch, a circuit breaker, an electrical interface, and to one or more outlets. Separate traces and / or branched traces can be used for one, multiple, or all of the outlets.

[0054] Module 102 includes, as shown in the example, an electrical interface module 154. The electrical interface module 154 provides a connector / terminal holder to distribute power from the printed circuit board 152 to the specified socket or power strip 150. The electrical interface module 154 has a variety of interface conductors 156 for electrical connection to a variety of PCB power distribution interfaces or terminals 148a, 148b, 148c, 148d. The power interface conductors 156 are, in turn, electrically connected to the sockets of the power strip 150.

[0055] The power interface 154 supports one or more optical fibers 138. One optical fiber can provide an indicator 138a for the module 102, the circuit board 144, the power interface 154, or the power strip 150. The indicator 138a can signal the status of the power module 100, including power-on state, status, faults, or error codes.

[0056] The socket module 102 has a power strip or front panel 150. The power strip 150 has an on / off switch 136. The on / off switch 136 can be used to activate the supply voltage for the sockets, an interface, or the circuit board. The power strip also has an indicator 138b. The socket indicator can be provided via a light guide on the power interface. The indicator 138b can signal the status of the power output module 100, including the power supply status, faults, and / or error codes.

[0057] As shown, the socket module 102 has a cover 106 connected to the housing 104. As configured in this example, the cover 106 protects the sockets, the switch 136, and the indicator 138a when closed. The cover 106 can also be used to display the module's electrical rating or other warning information, such as AC 120 V, 20 A, and max. 2.4 kW. The cover can be configured with a sensor 146 or a switch. The sensor or switch can be used to warn when the cover 106 is moved or opened. The sensor 146 can be used to activate or deactivate the power supply to the power strip 150 or the power interface 154 when the cover is moved. The sensor 146 can be a magnetic or Hall-effect sensor. The sensor 146 can transmit the position or movement of the cover to the module control unit.

[0058] Fig. Figure 10 shows an alternative embodiment of a current output module 1000, which incorporates some, most, or all of the features described in Fig. It can contain the two elements shown, where identical elements are of the same type. As in Fig. As shown in Figure 10, the socket module comprises a 240 V plug or socket 1002, a pair of 120 V plugs 104, a circuit breaker and / or reset switch 1006, and a fuse assembly 1008. The fuse assembly, circuit breaker, and plug are integrated into the module and arranged within the front panel housing as shown, protected by a cover 1010. The cover, switch, circuit breaker, or other mechanical, electrical, or electronic devices can provide a tamper-proof power supply. A tamper-proof power supply can help reduce the risk of young children accessing high voltage.

[0059] With reference to the Fig. 3a and Fig. Figure 3b shows block diagrams 300 and 301 of exemplary embodiments of a high-power outlet module 302, 303, which includes several optional systems, components, and a system boundary. The modules comprise a printed circuit board with a control unit 306. While the components of the Module I block diagram can be configured in a single module, the components can be arranged on one or more printed circuit boards. The power connection modules 302, 303 can be particularly useful for AC high-voltage outlets or DC high-voltage outlets with current fault detection.

[0060] Modules 302 and 303 comprise one or more vehicle interfaces. As shown, the vehicle interfaces include a service power interface 330, a vehicle battery or power module interface 332, and a vehicle network module with a network interface 340. Vehicle interfaces can include any combination of electrical components, including power cables, conductors, wiring harnesses, connectors, or any other suitable interface connection. Vehicle interfaces can be provided by one or more connectors on one or more printed circuit boards.

[0061] Network communication between the module 302 or the control unit 306 and a vehicle can be provided by any suitable means, including a network communication module or an IC connected to an MCU. The network communication module 320 can have a vehicle network interface connected to the vehicle network 340. The communication protocol can be any suitable protocol, including CAN, LIN, TCP / IP, optical, serial, wireless, or any other suitable network communication method.

[0062] The 330 operating power interface is connected to a high-voltage AC power source. The 330 operating power interface supplies power from the vehicle to the sockets, such as the service power line. The service power line may include a connector attached to the hot (H), live (L), or active conductor and a neutral (N) conductor for AC service.

[0063] As shown, the module features voltage detection and overcurrent protection 334. The voltage detection and overcurrent protection 334 can be provided by any suitable means. As shown, the voltage detection and overcurrent protection are measured on the supply current line within the module 302 and can also be measured on the hot line. The data can be acquired by a control unit 306. The current and voltage data can then be processed by an MCU to interrupt the power supply, display the system status, or report to the vehicle network.

[0064] The module's power interface 332 can be connected to a vehicle battery. The module may include a voltage regulation circuit or a voltage regulator 326, which is electrically connected to the module's power interface. The voltage regulator 326 can regulate the battery voltage to a voltage suitable for powering the MCU or other components, for example, 12 volts, 9 volts, 5 volts, 3.3 volts, etc.

[0065] The module may include a circuit insulation test 310. The module may include a GFCI detection or sensing 312. GFCI detection may be provided by a GFCI transformer. As in Fig. As shown in Figure 3b, the module can also include a GFCI test module 314. The test module can include current fault generation and detection.

[0066] The module may include a shutdown mechanism 316. The shutdown mechanism 316 can be provided by opening the supply circuit or interrupting the module's power supply. A power supply interruption can occur when a current symmetry is detected that exceeds a predefined threshold. For example, a shutdown relay can be enabled or disabled by an MCU on a 15- or 20-ampere supply line when a threshold symmetry of 4 mA to 6 mA is detected. Fig. Figure 4 shows a series of interruptions in the supply voltage 400, which are in the modules such as 302 or 303 in 316 of Fig. 3a and Fig. 3b can be integrated. Shutdown mechanisms include fuses 402, single switches 404 or double switches 406, relays 404 and E-breakers 408.

[0067] The module can include a temperature measurement, one or more temperature sensors, and / or an overtemperature protection device 318. The overtemperature protection device 318 can be in thermal contact with the socket 308, at a current interface, on the circuit board, next to the conductor tracks, or at another suitable location(s). The thermal contact can be made using thermally conductive materials such as metals, copper, aluminum, thermally conductive polymers, and others. The temperature measurement can be performed by a thermistor attached to the terminal area of ​​the AC thermistor. The temperature value of the AC output can be transmitted via LIN or another protocol.

[0068] Fault detection (324), overvoltage detection, undervoltage detection, insulation testing (310), overcurrent protection, and temperature measurement can be used to test whether the power supply circuit is functioning properly or is overloaded. If a test or check fails, the power supply can be interrupted.

[0069] The supply voltage can be interrupted in any suitable manner, including opening the circuit, disconnecting the power supply at the interface, and disconnecting the power supply at the source. A suitable supply voltage interruption can be provided on the printed circuit board or integrated into the power module. Onboard supply interruption can be achieved by a disconnect relay connected in the supply voltage circuit. Onboard power interruption can be achieved by an electrical breaker or an electronic breaker with integrated current sensing connected in the supply circuit. For automotive applications, the relay or electrical breaker can be of automotive grade. The vehicle power supply can also be interrupted at the socket by a fuse.The vehicle's power supply can be interrupted at the source via a vehicle communication network. This interruption can be achieved by switching off an inverter, opening a circuit, or using any other suitable power interruption device designed to cut off the power supply to the socket module. Once a fault condition or test failure is resolved, the power supply circuit can be reset. Reset can be performed digitally by the control unit, directly at an electronic switch, a relay, via the vehicle network to the power source, manually, or by another circuit reset mechanism.

[0070] A digital power reset can be performed by any suitable means. A module with a module power supply separate from the main power source can enable the power supply of an MCU or other control unit, sensors, and network communication even when the main power line or outlets are not powered. Among other things, the module control unit and sensors can continue to operate to determine if the fault or overload condition has been resolved.

[0071] With reference to Fig. Figure 5 shows an exemplary power output module 500. The output module 500 can include one or more of the optional systems, modules, and / or components disclosed in the description. The module 500 has a housing 502. The housing 502 has, as shown, several parts, including a front panel 504 and a rear cover 506. The several parts of the housing can be held together by one or more connectors. As shown, the housing is held together by several press fits. The housing 502 carries the electrical and electronic components of the module 500. The housing 502 has one or more mountings 508 for attaching the module to a vehicle, e.g., vehicle mounts. The housing also carries at least one high-voltage socket 510 for a high-voltage power supply. As shown, the module has a removable fuse 512.A 512 fuse can be designed for a single overload or be resettable. A removable fuse is a fuse that is independent of the housing or fuse holder and can be removed from the housing or fuse holder without cutting the fuse holder or otherwise damaging the material.

[0072] Module 500 is shown with at least one indicator or indicator light 514. An indicator can be provided by any suitable means, including a light guide connected to an LED, a transmitter, a processor, and / or a circuit board. An indicator can provide information about the module, the circuit board, the power strip, the sockets, and / or the plugs. For example, an indicator light can signal to the user the status of the socket module, including the power supply status, status, any fault, open circuit, or error codes on the front panel. The indicator can also function when the power supply to the socket plugs has been interrupted.

[0073] With reference to the Fig. 6 and Fig. Figure 7 shows an HVPO module (600) comprising a housing 602, a circuit board 604, a fuse holder 606, and a fuse assembly 608. The fuse assembly is supported by the housing 602 and is removable from the fuse holder to establish an electrical connection on the module. As shown, the fuse assembly 608 includes a fuse 610 and a slide 612. A fuse assembly with a movable slide allows for the removal and insertion of a fuse into the fuse holder. As illustrated, for example, by the arrow and finger gesture in the drawing, the fuse assembly can be easily lifted off the module output side.

[0074] The fuse holder can be made of a flexible or elastic conductive material to accommodate the fuse contacts with an interference fit. The fuse holder is mounted on the circuit board 604 and is aligned with the conductive trace to form a circuit when functional and an open circuit when the fuse is removed or blown. The fuse assembly can be adapted for use with any HVPO module and is particularly suitable for use in an HVPO module as described in this document, including those described in the Fig. 1, Fig. 2, Fig. 5 and Fig. 10 shown.

[0075] As in Fig. As shown in Figure 7, the fuse can be removed from the slide. And although the shape and design of the fuse may vary, as shown, the fuse is a blade fuse with two flat conductors 614, 616 for contacting corresponding contacts on the fuse holder.

[0076] In Fig. Figure 8 below shows a block diagram of an overtemperature protection system. The overtemperature protection system 800 comprises a processor 802 and a temperature sensor 804, which are integrated into an HVPO module. As shown, the overtemperature 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 for LIN, CAN, serial, Ethernet, Wi-Fi, Bluetooth®, or another suitable communication or data transmission protocol. The temperature sensor can be placed at any suitable location. Suitable locations include, for example, in thermal contact with one or more outputs, the conductive traces, the output terminals, and the circuit board. As shown in Fig. As shown in Figure 2, the temperature sensor 160 is located in the module next to the circuit board 152, the conductive traces and the output terminals.

[0077] Fig. Figure 9 shows a thermal image 900 of an HVPO module, a printed circuit board 902 with a conductive trace 904 for the supply voltage to one or more high-voltage outputs. Thermal zones are depicted, including a local heating zone 906, a medium heating zone 908, and an ambient temperature zone 910, which is generally located outside of or isolated from the local and medium heating zones. A local heating zone is a zone in which temperature measurements of the supply system can be performed to reliably (>99%) prevent system failures or damage. Overtemperature detection can therefore be provided in any thermal zone, but preferably in a local heating zone that is thermally distinct from the ambient temperature zone. QUOTES INCLUDED IN THE DESCRIPTION

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

[0000] US 63 / 500,596

[0001] US 63 / 554,142

[0001] US 4200897 [0004, 0005] JPH0870503 [0004, 0006] US 5544003 [0004, 0007] US 5587864 [0004, 0008] US 5757598 [0004, 0009] US 2004001292(A1 [0004, 0010] US 2005259371 (A1 [0004, 0011] US 2006097673 (A1

[0012]

Claims

[1] A high-voltage socket module for use in a ground vehicle, comprising: a housing, wherein the housing carries the following: one or more vehicle mountings, an operating power connection, a printed circuit board (PCB) electrically connected to the operating power connection, an HVPO circuit comprising one or more high-voltage conductive traces on the printed circuit board, at least one high-voltage socket electrically connected to the one or more high-voltage conductive traces, and a circuit breaker located between the operating power connection and the at least one high-voltage socket. [2] The high-voltage socket module according to claim 1, further comprising a temperature sensor next to the HVPO circuit, a microprocessor configured to monitor temperature data from the temperature sensor, a fuse arranged in series with the high-voltage conductive track, and an earth fault current breaker coupled to the at least one high-voltage socket. [3] The socket module according to claim 1, further comprising a temperature sensor which is located next to the HVPO circuit and configured to detect overtemperatures, and a communication module which is configured to transmit temperature data to one or more other components. [4] The socket module according to claim 1, further comprising a residual current circuit breaker arranged between the operating current connection and the at least one high-power socket. [5] The socket module according to claim 1, further comprising a fuse arranged in series with the conductor tracks. [6] The socket module according to claim 1, further comprising a microprocessor designed to monitor module states and to activate the circuit breaker upon detection of a state. [7] The socket module according to claim 1, further comprising a thermistor which is in thermal over-temperature detection contact with the HVPO circuit. [8] The socket module according to claim 1, further comprising an ambient temperature sensor which is supported by the housing. [9] The socket module according to claim 1, wherein the high-voltage conductive track weighs more than 28 grams and is designed to carry more than 5 A. [10] The socket module according to claim 1, wherein the circuit board comprises a vehicle network communication module designed to send module data to one or more other components. [11] The socket module according to claim 1, wherein the circuit board has a microprocessor configured to check the module state, interrupt the power supply to one or more outlets in a given state, continue to check the state and reset the one or more outlets when the given state changes. [12] The socket module according to claim 1, comprising at least one high-voltage socket designed for an alternating voltage of 100 VAC or more. [13] The socket module according to claim 1, further comprising a microprocessor connected to a sensor and configured to detect circuit faults. [14] The socket module according to claim 1, comprising at least three high-voltage sockets, one single socket and at least one set of paired sockets, wherein the single socket and the paired sockets have separate residual current protection. [15] The socket module according to claim 1, wherein the circuit board is configured to check for faults, interrupt the power supply to the one or more sockets upon fault detection, continue to check for faults and digitally reset the one or more sockets upon correction of the fault. [16] The socket module according to claim 1, wherein the circuit board comprises one or more of the following elements: a voltage detection circuit, an overcurrent protection circuit, a relay for switching off the supply voltage, a communication module, a voltage sensor, a current sensor, a current interruption circuit, a switch, a circuit test circuit, a circuit insulation testing and inspection device, a temperature sensor, an overtemperature protection circuit, one or more LEDs, a socket cover, a cover detection circuit, a plug detection circuit, or a modular power connector. [17] The socket module according to claim 1, wherein the circuit board is equipped with an earth fault detection and, upon detection of an earth fault or an earthed neutral conductor, a fault is detected and a signal is sent to a microprocessor which in turn interrupts the supply voltage to the power connection, to the power interface or to the power strip. [18] The socket module according to claim 5, wherein the fuse is supported by a removable slide. [19] The socket module according to claim 1, which further comprises a printed circuit board, wherein the printed circuit board has a heavy conductor in electrical connection between the supply power connection and the high-voltage socket, wherein the printed circuit board has a fuse, wherein the fuse is detachably connected to the conductive conductor. [20] The socket module according to claim 1, wherein the circuit breaker comprises an E-breaker arranged in series with the conductor track. [21] A socket module for use in a vehicle, comprising: a housing, wherein the housing supports one or more vehicle fixings; a power supply connection supported by the housing; a printed circuit board (PCB) connected to the power supply connection; and one or more conductive traces on the PCB electrically connected to the power supply connection; at least one high-voltage socket electrically connected to the one or more conductive traces; and a residual current device (RCD) arranged between the power supply connection and the at least one high-voltage socket. [22] Socket module for use in a vehicle, comprising: a housing, wherein the housing carries one or more vehicle mountings; a power supply connection; a printed circuit board (PCB) connected to the power supply connection; one or more conductive traces on the PCB electrically connected to the power supply connection; at least one high-voltage socket with 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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