ELECTRIC VEHICLE CHARGING PLUGGAGE WITH SEALS

Abstract

The invention relates to an electric vehicle charging plug comprising at least one temperature sensor for monitoring the internal temperature of the plug. The electric vehicle charging plug further comprises a data cable transmitting temperature data to a physically separate control device. The electric vehicle charging plug also includes a housing or support for receiving the at least one temperature sensor, the housing being able to be integrated into an internal mold of the plug. A first seal provides a junction between the at least one pin / blade and a faceplate or bridge plate. A second seal provides a junction between the at least one pin / blade and a faceplate or bridge plate, as well as the internal mold. A third seal provided by the internal mold seals the entire interior of the electric vehicle plug.

Description

Title of the invention: ELECTRIC VEHICLE CHARGING PLUG WITH SEALS Technical field

[0001] The present invention relates to an electrical connector, and more particularly to an electric vehicle charging plug with seals.

[0002] CONTEXT

[0003] Electrical plugs are commonly used to power electrical appliances, such as toasters and electric kettles and electric vehicle charging devices, some of which draw more current than other electrical devices. Conventional electrical plugs generally do not include protective mechanisms for higher current draw applications, which can result in the plugs overheating, melting, or burning. As a result, conventional electrical plugs can become damaged and can cause hazardous conditions. However, the addition of protective mechanisms increases the risk that, when electrical plugs are exposed to wet environments, moisture can penetrate the plug, damage the protective mechanisms, and cause further damage and hazardous conditions.There is therefore a need for improvements to electric vehicle plugs, particularly with regard to the seals used in them.

[0004] SUMMARY

[0005] According to one aspect of the present invention, there is provided an electric vehicle charging plug that includes at least one temperature sensor for monitoring an internal temperature of the electric vehicle plug. The electric vehicle charging plug further includes a data cable that transmits temperature data to a physically separate controller. The electric vehicle charging plug further includes a supporting housing or holder for receiving the at least one temperature sensor, the housing / holder being embeddable in an internal mold of the electric vehicle plug. A first seal may seal a junction between the at least one pin / blade and a faceplate or bridge plate. A second seal may seal both a junction between the at least one pin / blade and a faceplate or bridge plate and junctions between it and the internal mold.A third gasket provided by the internal mold seals the entire interior of the electric vehicle plug.

[0006] In one embodiment, the first seal may be a combination of epoxy, gaskets, sealing oils, sealing greases and / or adhesive. cold fusion formed around a pin or between a junction between the pin and a separate ring or cap. In one embodiment, the second seal may be formed by the separate ring or cap and the upper blade portions pressing the ring or cap onto the first seal. In one embodiment, the second seal may be formed by the separate ring or cap.

[0007] In one embodiment, the at least one temperature sensor may be provided by an integrated circuit temperature sensor on a printed circuit board assembly ("PCB A") housed in a PCB A potting. In one embodiment, the at least one temperature sensor may be provided by thermistors housed in highly thermally conductive ceramic packages positioned around and proximate the upper portions of the blades.

[0008] Embodiments also include methods of assembling the plugs described herein. In one aspect, a method of assembling an electric vehicle plug includes forming a faceplate including an outer surface and a plurality of raised portions and lowered portions formed on an inner surface, some of the raised portions partially forming slots through which two or more prongs are extended, and one or more of the raised portions forming a bracket positioned on an inwardly facing surface of the faceplate; inserting the two or more prongs into two or more of the slots, the two or more prongs including a live prong and a neutral prong, each prong including a through hole that extends through a central portion of the prong and is filled by the faceplate;inserting at least one temperature sensor into a sensor housing, the at least one temperature sensor configured to monitor an internal temperature of either the live pin, the neutral pin, or both the live pin and the neutral pin; positioning the sensor housing on the holder, the sensor holder configured to hold the at least one temperature sensor adjacent to the holder and adjacent to either the live pin, the neutral pin, or both the live pin and the neutral pin; forming first seals around each of the two or more pins and the inwardly facing surface of the faceplate, the first seals being supported by flanges formed within the slots;forming the second seals around each of the two or more pins and covering the first seals with a material in a manner sufficient to protect the first seals from pressure and heat associated with a third injection-molded seal in the form of an internal mold that covers at least the second seals and the lowered portions of the faceplate; connecting a data cable to the at least one temperature sensor, the data cable being configured to transmit temperature data to a control device that does not; not part of the plug and is physically separate therefrom; and covering the inner mold and an outer surface of the faceplate with an outer mold. Brief description of the drawings

[0009] Embodiments of the present invention will be described in more detail below with reference to the accompanying drawings, in which:

[0010] [Fig.l] illustrates an exploded perspective view of an electric vehicle charging plug according to one embodiment of the present invention;

[0011] [Fig.2] illustrates an exploded perspective view of the bridge components of the embodiment of [Fig.l];

[0012] [Fig.3] is a cross-sectional view of the bridge components of [Fig.l];

[0013] [Fig.4] illustrates another perspective view of the bridge components of [Fig.l] when fully assembled;

[0014] [Fig.5] illustrates an exploded perspective view of an electric vehicle charging plug according to one embodiment of the present invention;

[0015] [Fig.6] illustrates a perspective view of the bridge components of the embodiment of [Fig.5] when fully assembled;

[0016] [Fig.7] illustrates an exploded perspective view of the bridge components of [Fig.6]

[0017] [Fig.8] is a cross-sectional view of the bridge components of [Fig.5];

[0018] [Fig.9] illustrates a perspective view of an interior side of the bridge components of [Fig.6];

[0019] [Fig. 10] illustrates a perspective view of the inner side of the bridge of [Fig.9] without the sensor holders;

[0020] [Fig.l 1] illustrates a perspective view of the bridge components of one embodiment;

[0021] [Fig. 12] illustrates an exploded view of the components of [Fig. 11];

[0022] [Fig. 13] illustrates a perspective view of the details of a second joint according to a embodiment;

[0023] [Fig. 14] is a cross-sectional view of the bridge components of [Fig. 11];

[0024] [Fig. 15] illustrates a perspective view of the electric vehicle charging plug of [Fig.l], [Fig.5] and / or [Fig. 11] when an internal mold is applied according to the embodiment of the present invention;

[0025] [Fig. 16] illustrates a perspective view of the electric vehicle charging plug of [Fig. 1], [Fig. 5] and / or [Fig. 11] when an overmold is applied according to the embodiment of the present invention;

[0026] [Fig.17A] illustrates a perspective view of a first set of plugs whose configurations are standardized in a first set of countries;

[0027] [Fig.l7B] illustrates a perspective view of a second set of plugs whose configurations are standardized in a second set of countries;

[0028] [Fig.l7C] illustrates a perspective view of a third set of plugs whose configurations are standardized in a third set of countries;

[0029] [Fig.l7D] illustrates a perspective view of a fourth set of plugs whose configurations are standardized in a fourth set of countries; and

[0030] [Fig.l7E] illustrates a perspective view of a fifth set of plugs whose configurations are standardized in a fifth set of countries.

[0031] [Fig.18] to [Fig.31] illustrate embodiments of the present invention which may be used in Denmark and which will be described in more detail below with reference to the accompanying drawings:

[0032] [Fig. 18] illustrates an exploded perspective view of an electric vehicle charging plug according to one embodiment of the present invention;

[0033] [Fig. 19] illustrates an exploded perspective view of the bridge components of the embodiment of [Fig. 18];

[0034] [Fig.20] is a cross-sectional view of the bridge components of [Fig.19];

[0035] [Fig.21] illustrates an exploded perspective view of a vehicle charging plug electrical according to an embodiment of the present invention;

[0036] [Fig.22] illustrates a perspective view of the bridge components of the embodiment of [Fig.21] when fully assembled;

[0037] [Fig.23] illustrates an exploded perspective view of the bridge components of [Fig.21];

[0038] [Fig.24] is a cross-sectional view of the bridge components of [Fig.21];

[0039] [Fig.25] illustrates a perspective view of an interior side of the bridge components of [Fig.22];

[0040] [Fig.26] illustrates a perspective view of the inner side of the bridge of [Fig.22] without the sensor holders;

[0041] [Fig.27] illustrates a perspective view of the bridge components of one embodiment;

[0042] [Fig.28] illustrates an exploded view of the components of [Fig.27];

[0043] [Fig.29] is a cross-sectional view of the bridge components of [Fig.27];

[0044] [Fig.30] illustrates a perspective view of the electric vehicle charging plug of [Fig. 18], [Fig. 21] and / or [Fig. 27] when an internal mold is applied according to the embodiment of the present invention; and

[0045] [Fig.31] illustrates a perspective view of the electric vehicle charging plug of [Fig.18], [Fig.21] and / or [Fig.27] when an overmold is applied according to the embodiment of the present invention.

[0046] [Fig.32] to [Fig.45] illustrate embodiments of the present invention which may be used in certain parts of Europe and which will be described in more detail hereinafter with reference to the accompanying drawings:

[0047] [Fig.32] illustrates an exploded perspective view of an electric vehicle charging plug according to one embodiment of the present invention;

[0048] [Fig.33] illustrates an exploded perspective view of the bridge components of the embodiment of [Fig.32];

[0049] [Fig.34] is a cross-sectional view of the bridge components of [Fig.33];

[0050] [Fig.35] illustrates a perspective view of the bridge components of [Fig.33] when fully assembled;

[0051] [Fig.36] illustrates an exploded perspective view of an electric vehicle charging plug according to one embodiment of the present invention;

[0052] [Fig.37] illustrates an exploded perspective view of the bridge components of the embodiment of [Fig.36];

[0053] [Fig.38] is a cross-sectional view of the bridge components of [Fig.36];

[0054] [Fig.39] illustrates a perspective view of the bridge components of [Fig.36] when fully assembled;

[0055] [Fig.40] illustrates a perspective view of an interior side of the bridge components of [Fig.36];

[0056] [Fig.41] illustrates a perspective view of the bridge components of one embodiment;

[0057] [Fig.42] illustrates an exploded view of the components of [Fig.41];

[0058] [Fig.43] is a cross-sectional view of the bridge components of [Fig.41];

[0059] [Fig.44] illustrates a perspective view of the electric vehicle charging plug of [Fig.32], [Fig.36] and / or [Fig.41] when an internal mold is applied according to the embodiment of the present invention; and

[0060] [Fig.45] illustrates a perspective view of the electric vehicle charging plug of [Fig.32], [Fig.36] and / or [Fig.41] when an overmold is applied according to the embodiment of the present invention.

[0061] DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

[0062] The present invention describes an improved electric vehicle charging plug that is capable of accurately monitoring the temperature of the plug and transmitting temperature data to a controller outside the plug that can cut off power to the plug if the plug overheats. Once the temperature of the electrical plug exceeds a predetermined threshold, the controller can automatically cut off an electrical circuit to prevent damage to the electrical plug and the creation of unsafe conditions. Since electric vehicle plugs may be exposed to outdoor environmental conditions, including heavy mist, fog, heavy rain, pouring rain, snow, etc., additional sealing components are required to ensure that moisture cannot penetrate the plug and cause a short circuit or disable the temperature sensing devices.

[0063] Although embodiments describe a three-prong electric vehicle plug for connection to a power outlet, it should be understood that the present invention is not limited to this type of plug. Any type of electric vehicle charging plug may benefit from the same improvements described herein, including those with only two prongs and those with more than three prongs in a main plug, such as any of the plugs shown in Figures 17A, 17B, 17C, 17D, and 17E. The present invention may also improve plugs for connection to a vehicle's outlet, such as SAE J1772, IEC Type 2, TESLA, and CHADeMO, and electric vehicle plugs with prongs in multiple plug components, including SAE J1772 CCS and IEC Type 2 CCS.The electrical plugs of the present invention can also be used for plugs of any voltage standard as well as for plugs supporting two or more voltage standards. The electrical plugs can be of any shape, size and type, such as types A and CN and suitable for any voltage.

[0064] When referencing elements illustrated in each of the figures, the numbered label corresponding to each element will begin with a number corresponding to the figure in which it is first described and best illustrated. For example, if an element is first described with reference to [Fig. 1], the element label will follow the format 1NN, and when an element first described is referred to with reference to [Fig. 2], the element label will follow the format 2NN, etc.

[0065] [Fig.l] illustrates an exploded perspective view of one embodiment of an electric vehicle charging plug 100 according to a first embodiment. The electric vehicle charging plug 100 includes a faceplate 102 having formed therein a sufficient number of slots 104 to correspond to the pins 106 and 108 of the electric vehicle charging plug 100. The pins 106 and 108 may be blades or round pins depending on the plug type and may be made of any suitable material, such as brass. Although reference is made to blades or blade pins with respect to live, neutral, and ground pins, depending on the plug standard for a particular country, all pins may be round, all pins may be blade pins, or a combination of round and blade pins.The faceplate 102 may be made of any suitable material, including polypropylene (“PP”), polybutylene terephthalate (“PBT”), and polycarbonate (“PC”). Each of the slots 104 of the faceplate 102 may have . a unique shape to perfectly match the shape of the portion of pins 106 and 108 that are inserted into slots 104.

[0066] With reference to Figures 2-4, the slots 104 may be formed within an inwardly facing side or surface of the faceplate 102. An outwardly facing side or surface 103 of the faceplate 102 would face the power outlet (not shown) to which the electric vehicle charging plug 100 would be connected during a power-up cycle. Each of the slots 104 may be formed by raised areas or portions 202 of the faceplate so as to form a central opening 200 with inwardly facing walls that mate with each pin 106 or pin 108. The inwardly facing walls may be configured to be slightly larger than the circumference of the corresponding pins 106 or 108 such that the pin fits snugly into the central opening 200 of the slots 104.The pins 106 and 108 may be positioned in the mold (not shown) that is used to form the faceplate 102 such that the material used to form the faceplate 102 flows into the through holes 300 in each pin. This may hold the pins 106 and 108 in place during use and, therefore, the through holes 300 may act as a fastener and prevent movement of the pins relative to the faceplate 102. In embodiments, the through holes 300 cannot be used because space limitations associated with the plug design require that the pins be crimped to the outside of the faceplate and then assembled into the faceplate.The design of the pins may be different accordingly, such as including raised rings or recessed reliefs around the pins that engage the faceplate material and prevent the pins from moving relative to the faceplate once assembled. The raised portions 202 of the faceplate 102 may include a number of raised areas 204 and recessed areas 205 and create a number of lowered portions that form nooks and crannies within the faceplate 102 that may be filled by the material of the internal mold 110, when the internal mold is formed, as described in more detail herein. Filling the nooks and crannies of the faceplate 102 with the internal mold 110 forms a third seal (the first and second seals will be described below) of the interior of the electric vehicle charging plug 100 against moisture.

[0067] The seals 112 may be a gasket, epoxy, sealing oils, sealing greases, cold melt adhesive, or a combination thereof that are positioned around other sealed portions of the pins 106 and 108 as a first seal against moisture and other materials, such as dust and sand, entering the electric vehicle charging plug 100. The seal 112 may be an O-ring type seal that fits snugly around the pins 106 and 108 to ensure good sealing engagement with the material of the faceplate 102. The seals 112 may be supported by a flange 302 formed within the slot 104 of the pin 106 / 108. The seal 112 may be made of any suitable material, including epoxy, cold melt adhesive, sealing oils, sealing grease, nitrile, neoprene, ethylene propylene, silicone, fluorocarbon, and PTFE, which has good adhesion to metal or plastic surfaces. The seals 112 may be configured to have any suitable shape to engage the pins 106 / 108 and the material of the faceplate 102 and form a first moisture-tight seal.

[0068] The seals 112 may be formed in a shape that corresponds to the shape of the rim 302 formed in the slots 104 of the pins 106 / 108. Some pins or blades may have raised metal rings (not shown) around the pin in which the seals 112 may be positioned or include shoulders and other components (not shown) that extend along the perimeter of the rounded portion of the pin and require the slots 104, rims 302, and seals to have different shapes. In such a case, the shape of the seal 112 may be formed as a cylinder, a three-dimensional rectangle, a polygon, or an irregular shape depending on the shape and size of the rim 302 of the corresponding slot 104.

[0069] In some embodiments, a pin may form a flange that supports a seal 112 instead of or in addition to a flange 302 formed in the material of the faceplate 102. For example, a flange formed in the material of the faceplate 102 may support a pin flange, and the pin flange may support the seal 112. In this example, the flange in the faceplate material directly supports the pin, while the flange in the faceplate material indirectly supports the seal 112 via the pin.

[0070] A plastic cap 116, made of PP, PBT, PC, or other suitable material, may be positioned over each seal 112 within each slot 104, as shown in [Fig. 3]. The shape of the plastic cap 116 may be a cylinder, a three-dimensional rectangle, a polygon, or an irregular shape depending on the shape and size of the rim 302 of the corresponding slot 104 so that it matches the shape of the epoxy, cold melt adhesive, sealing oils, sealing greases, and / or the seal 112. If the spindle includes rings or other components, the cap 116 may rest on top of the upper ring of two metal rings or other components. The internal mold 110 may be made of the same material as the plastic cap 116 and the faceplate 102. Using the same material for the faceplate 102, the cap 116 and the internal mold 110 ensures very good bonding performance between these components, which helps to further seal the electric vehicle charging plug 100 as described in more detail herein.

[0071] The inner mold 110 may be injection molded during the manufacture of the electric vehicle charging plug 100. While the molten plastic of the inner mold is injected in a liquid state, the ring 116 and the faceplate 102 may be in a solid state such that the cap 116 and the faceplate 102 are covered by the plastic of the inner mold 110. The plastic of the inner mold 110 may be injected under a sufficiently high pressure and at a sufficiently high temperature necessary to ensure that the molten plastic material of the inner mold 110 completely fills all the nooks and crannies of the faceplate 102 and other internal components of the electric vehicle charging plug 100.By filling the nooks and crannies of the faceplate 102 and covering other internal components of the electric vehicle charging plug 100, including the cap 116, the internal mold 110 may form the third seal between the cap 116 and the pins 106 and blades 108. The cap 116 may have a shape sufficient to cover all of the epoxy, cold melt adhesive, sealing oils, sealing greases, or a gasket that might otherwise be exposed. The shape sufficient to cover all of the epoxy, cold melt adhesive, sealing oils, sealing greases, or gasket may have a thickness that ensures that all of the epoxy, cold melt adhesive, sealing oils, sealing greases, or exposed gasket material 112 is covered.The cap 116 may also have sufficient height, i.e. high enough, to form an insulating and / or protective cover for the seal 112 which prevents the seal 112 from being completely melted during the injection of the plastic from the internal mold 110. The cap 116 may therefore form a second seal of the electric vehicle charging plug 100.

[0072] The faceplate 102 may further include a carrier 220 formed in the faceplate material that is configured to hold a printed circuit board assembly (“PCB A”) 304, which is housed in a potting housing, also referred to as a PCB A potting housing 224. The potting housing 224 may be made of PP, PBT, or PC and be formed to hold the PCBA 304, which may include an integrated circuit temperature sensor. In order to protect the PCBA 304 from the heat and pressure of the internal injection mold, the PCBA 304 may be coated with a protective potting compound within the potting housing 224. The potting compound may be a resin, such as polyamide and polyolefin thermoplastics that utilize low-pressure molding and a short process molding cycle. In one embodiment, the potting compound may be Henkel LOCTITE TECHNOMELT PA6208 or OM646 (formerly marketed as MACROMELT), or an epoxy resin, polyurethane, or silicone compound.

[0073] The integrated circuit temperature sensor of the PCBA 304 may be configured to transmit analog or digital signals including temperature data via data cables 118 to a controller (not shown) that is not part of and physically separate from the electric vehicle charging plug 100. The data cables 118 may be encased by a shield to filter out electrical noise so as to accurately capture and transmit the temperature data.The controller may be part of a power system to which a cable, such as the cable 120 of the electric vehicle charging plug 100, is connected and which supplies voltage and current to the electric vehicle charging plug 100. The end of the cable 120 within the internal mold 110 may include a metal clip 122 for securing the cable 120 within the internal mold 110. When temperature data provided by the PCBA 304 indicates that the temperature within the electric vehicle charging plug 100 has exceeded a temperature threshold, the controller may cause the power system to stop supplying voltage and current to the electric vehicle charging plug 100.

[0074] The complete physical separation of the control device from the electric vehicle charging plug 100 is an important safety feature of the present invention. Some existing plug and cable systems place a control device separate from the plug, but somewhere on the cable that is close to the plug. If a short circuit occurs in the plug and the control device is close enough to the plug to be damaged, the control device may not be able to prevent the power system from continuing to provide voltage and current. This can be particularly problematic with some electric vehicle plugs that operate at a voltage rating higher than the 110 standard.

[0075] The live, neutral, and ground cables 124, as well as the data cables 118, may be housed within the cable 120 and positioned proximate the pins 106 / 108 and the PCBA 304, at which point they are separated from each other for connection to their respective component of the electric vehicle charging plug 100. The cable 120 may extend through an opening 118 of the inner mold 110. The inner mold 110 and the overmold 130 include gripping notches 132 on either side of the inner mold and the overmold 130 to allow a user of the electric vehicle charging plug 100 to improve their grip on the plug during use. The overmold may be made of thermoplastic elastomer (“TPE”). ") or thermoplastic polyurethane ("TPU") or other suitable material. An upper portion of the overmold may be configured to have a flexible portion 134. The cable jacket 120 may also be made of TPE or TPU or other suitable material, resulting in good bonding performance with the overmold of the same material.

[0076] The sealing system and method of the electric vehicle charging plug 100 described herein meet the waterproof rating of IP67, which means that the electric vehicle charging plug is fully protected against solid objects such as dust and sand, and has been tested to operate for at least 30 minutes under 15 cm to 1 m of water. The sealing system and method of the electric vehicle charging plug 100 described herein also meet higher waterproof ratings up to the waterproof rating of IPX9K, which means that the electric vehicle charging plug is resistant to high-pressure and high-temperature sprays at close range.

[0077] [Fig. 5] through [Fig. 10] illustrate the embodiment of the electric vehicle charging plug 500, which is similar to the embodiment described above and includes most of the same components, but includes thermistors instead of a PCB A 304, housings for the thermistors, and a slightly different faceplate 502. Negative temperature coefficient (“NTC”) or positive temperature coefficient (“PTC”) thermistors 504, a type of resistor whose resistance decreases or increases as temperature increases, may be positioned in a housing 506 that surrounds the top of each pin 106 / 108. The housing 506 may be ceramic and may serve as a housing for the thermistors 504. The ceramic may be a highly thermally conductive ceramic, such as aluminum nitride, silicon carbide, and aluminum oxide.Other thermally conductive ceramics include beryllium oxide and boron nitride, among others. A highly thermally conductive ceramic material may be used to facilitate heat sensing by the thermistors 504. The housing 506 couples the thermistors 504 to a corresponding pin 160 / 108 to ensure that heat generated by the pin is efficiently transferred to the thermistor 504. If a highly thermally conductive ceramic was not used, when the inner mold was injected, the plastic material of the inner mold may form an insulating barrier between the pin and the thermistor 504. The use of the ceramic housing 506 ensures that the inner mold 110 does not form an insulating barrier between the pin and the thermistor 504. The ceramic housing may also be electrically insulating, thereby ensuring that the charging plug is capable of passing high voltage testing requirements.

[0078] A data cable 118 may be connected to each thermistor 504 and configured to transmit analog signals including temperature data to a controller (not shown) that is not part of and is physically separate from the electric vehicle plug, as previously explained herein. When the temperature data provided by the thermistor 504 indicates that the temperature within the electric vehicle charging plug 500 has exceeded a temperature threshold, the controller may cause the power system to reduce current or stop providing voltage and current.

[0079] The live, neutral, and ground cables 124, as well as the data cables 118, may be housed within the cable jacket 120 until they are close to the pins and thermistors 504, at which point they are separated from each other for connection to their respective component of the electric vehicle charging plug 500.

[0080] As further illustrated in Figures 6-10, the faceplate 502 may include brackets 1000 that are configured to mate with each bracket 506 and hold the bracket in position relative to the top of the corresponding pin. The brackets 1000 may have the shape illustrated in more detail in [Fig. 10]. As shown in Figures 8 and 9, the bracket 506 may rest partially or entirely on the corresponding cap 116 to help hold the cap 116 in position, and may also rest partially on the top surface of the bracket 1000. The height of the brackets 1000 is slightly greater than the height of the raised portion 204 so as to create an opening 800 under each bracket 516.The opening 800 may serve as a nook and cranny as explained above which may be filled with the material of the internal mold 110 following pressurization during the formation of the internal mold, which serves to hold all internal components in place and which forms a third seal of the electric vehicle charging plug 500.

[0081] [Fig. 11] illustrates an embodiment of an electric vehicle charging plug 1100 similar to the embodiments shown in [Fig. 1] and [Fig. 5]. The charging plug 1100 includes a faceplate 1102, a single support or housing 1104, and a single thermistor 1106. The housing 1104 may be made of a ceramic material. The ceramic material may be a highly thermally conductive ceramic, such as aluminum nitride, silicon carbide, and aluminum oxide. Other thermally conductive ceramics include beryllium oxide and boron nitride, among others. A highly thermally conductive ceramic material may assist in heat detection by the thermistor 1106. The package 1104 may couple the thermistor 1106 to pins 1108 and 1110, which may be the live and neutral pins, to ensure that the heat generated by the pins is efficiently transferred to the 1106 thermistor. The ceramic case can also be electrically insulating, which helps ensure that the charging plug is able to pass high voltage test requirements.

[0082] The thermistor 1106 may be a negative temperature coefficient (“NTC”) or positive temperature coefficient (“PTC”) thermistor. The thermistor 1106 may be positioned between pins 1108 and 1110 in a central position such that it is equidistant from both pins. The housing 1104 may surround both pins 1108 and 1110 and be held in position by brackets 1112 formed on the inner side of the faceplate 1102. [Fig. 12] provides further details of the faceplate 1102, as well as the first seals 1202 and the second seals 1204, as previously described herein. [Fig. 13] provides additional details regarding the second seals or plastic rings 1204. A plurality of interference crush ribs 1302 may be formed around the perimeter of each plastic ring 1204. Although four crush ribs 1302 are shown in [Fig.13], a smaller or larger number may be used. The crush ribs 1302 are very thin and are configured to be crushed and deformed when inserted into the slots 1206 of the faceplate 1102 so as to help secure the plastic ring 1204 in the slot 1206. Crushing ribs 1302 may be used on the plastic rings 116 of the embodiments of Figures 1 and 5 as well. [Fig. 14] provides a cross-sectional view of the embodiment of [Fig.l 1] to [Fig.12].

[0083] [Fig. 15] illustrates the fully assembled 100 / 500 electric vehicle charging plug with only the exposed inner mold 110 and cable 120. [Fig. 16] illustrates the fully assembled 100 / 500 electric vehicle charging plug with only the exposed overmold 130, flexible portion 134, and cable 120.

[0084] The sealing system and method of the electric vehicle charging plug 500 described herein meet the waterproof rating of IP67, which means that the electric vehicle charging plug is fully protected against solid objects such as dust and sand, and has been tested to operate for at least 30 minutes under 15 cm to 1 m of water. The sealing system and method of the electric vehicle charging plug 500 described herein also meet higher waterproof ratings up to the waterproof rating of IPX9K, which means that the electric vehicle charging plug is resistant to high-pressure and high-temperature sprays at close range.

[0085] As indicated above, although the 100 / 500 / 1100 electric vehicle charging plugs are described in terms of a pin for ground and blade pins for live and neutral, this is only for the particular standard plug type that is illustrated in Figures 1 to 16, which corresponds for example to a standard plug in China, Australia, or Argentina. Plugs in other countries and for different voltages have different pin and ground configurations. [Fig. 17A] illustrates a first set 1700 of plugs that are standard in several other countries. For example, plug 1702 is a standard NEMA 5-15 plug in the United States, the Philippines, and Vietnam. Plug 1702 has blade prongs for live and neutral and one prong for ground. Plug 1704 is standard for Europe, Korea, and Indonesia and has only two prongs for live and neutral, but no prong for ground. Instead, plug 1704 includes a set of side contacts 1703 intended to provide grounding when plugged into a German socket / outlet and a grounding tube 1705 intended to provide grounding when plugged into a French socket / outlet.The 1706 plug has live and neutral blade pins oriented to be parallel to the horizon while the ground is also a blade oriented to be vertical to the horizon, which can be used, for example, in the UK. The 1708 plug has three blade pins for live, neutral and ground, with the live and neutral pins lying at 45 degree angles to the ground pin, which can be used, for example, in Argentina.

[0086] [Fig.l7B] illustrates a perspective view of a second set of 1710 plugs that are standard in other countries, including the 1712 plug in Japan, the 1714 plug in Brazil, the 1716 plug in China (similar to the 1708 plug but with the ground pin on top when plugged in rather than underneath), and the 1718 plug in Australia. [Fig.l7C] illustrates a perspective view of a third set of 1720 plugs that are standard in other countries, including the 1722 plug in South Africa, the 1726 plug in Switzerland, and the 1728 plug in Thailand. The 1724 plug is an International Electrotechnical Commission (IEC) plug for 200-250 volts that is used in several different countries. The 32 amp version is commonly used to power static RVs and moored boats, while the 16 amp version is commonly used to power caravans / touring vehicles and tents.

[0087] [Fig.l7D] illustrates a perspective view of a fourth set of 1730 plugs, including plug 1732 in Taiwan, plug 1734 in Chile and Italy, plug 1736 in Israel, and plug 1738 in Denmark. [Fig.l7E] illustrates a perspective view of a fifth set of 1740 plugs, including plug 1742 in India, plug 1744, a NEMA 14-3 plug in the United States, plug 1746, a TT 30 plug in the United States, and plug 1748, a NEMA 14-50 plug also in the United States.

[0088] Figures 18 to 31 depict aspects of plugs that may be used in Denmark, in which element numbers that correspond to the elements of the plugs shown in Figures 1 to 16 for China may serve a function similar while being incorporated into a somewhat different physical form. Such functionally similar elements are described above with respect to Figures 1-16. Other elements shown in Figures 18-31 may be functionally different from the elements of the earlier figures, and some of these functionally different elements are described below.

[0089] [Fig. 20] is a cross-sectional view of the bridge components of [Fig. 18]. The recessed relief 2020 is a relief along a surface of a pin at the faceplate 102. The recessed relief 2020 may be filled with the material of the faceplate 102. An interior surface of the faceplate 102 forming a slot 104 for a corresponding pin may provide support for the corresponding pin at the recessed relief 2020 and may act to prevent movement of the corresponding pin relative to the faceplate 102.

[0090] The pin flanges 2022 may be flanges formed in a corresponding pin at a location within the corresponding slot 104 of the pin. A pin flange 2022 may function to support a seal 112. In some embodiments, the pin flange 2022 may be positioned at a neighboring slot flange 302 made of a faceplate material such that the pin flange 2022 and its neighboring slot flange 302 may combine to form a large combined flange to jointly support a seal 112.

[0091] Figures 32-45 depict plug aspects that may be used in some parts of Europe, in which element numbers that correspond to the elements of the plugs shown in Figures 1-16 for China may perform a similar function while being incorporated into a somewhat different physical form. Such similarly functional elements are described above with respect to Figures 1-16. Other elements shown in Figures 32-45 may be functionally different from the elements of the prior figures, and some of these different-functional elements are described below.

[0092] [Fig. 34] is a cross-sectional view of the bridge components of [Fig. 32]. The recessed relief 3420 is a relief along a surface of a pin at the faceplate 102. The recessed relief 3420 may be filled with the material of the faceplate 102. An interior surface of the faceplate 102 forming a slot 104 for a corresponding pin may provide support for the corresponding pin at the recessed relief 3420 and may act to prevent movement of the corresponding pin relative to the faceplate 102.

[0093] The pin flanges 3422 may be flanges formed in a corresponding pin at a location within the corresponding slot 104 of the pin. A pin flange 3422 may function to support a seal 112. In some embodiments, the pin flange 3422 may be positioned at a neighboring slot flange 302 made of a faceplate material such that the pin flange 3422 and its neighboring slot flange 302 may combine to form a large combined flange to jointly support a seal 112.

[0094] It will be understood that the sealing systems and methods described herein are not limited to the embodiments shown, and other such sealing systems and methods may be applied to form a seal and / or attachment between various elements of the plug, e.g., pins, a bridge, cables, cable tubes, wire insulation, a housing, and thermistors. While certain embodiments have been described, these embodiments have been presented by way of example only and are not intended to limit the scope of the inventions described herein. For example, depending on the different types of plugs, the number of temperature sensors, such as thermistors, integrated into an electrical plug, the configuration of the housing containing the temperature sensors, and the process of assembling the electrical plug may vary without departing from the spirit of the present invention.Indeed, the present invention described herein may be embodied in a variety of other forms; further, various omissions, substitutions, and modifications of the form of the embodiments described herein may be made without departing from the spirit of the inventions described herein. The appended claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of some of the inventions described herein.

Claims

1. Claims Electric vehicle sheet, including: two or more pins comprising at least one live pin and one neutral pin, each pin comprising a through hole extending through a central portion of the corresponding pin; a mass; a faceplate comprising an outer surface and a plurality of raised portions and lowered portions formed on an inner surface, some of the raised portions partially forming slots through which at least two or more pins extend, and one or more of the raised portions forming a bracket positioned on an inwardly facing surface of the faceplate, a faceplate forming material filling the through hole of each pin when the faceplate has been formed; at least one temperature sensor for monitoring an internal temperature of the live pin, the neutral pin, or both the live pin and the neutral pin; a carrier bracket for holding the at least one temperature sensor adjacent to the bracket and adjacent to either the live pin, the neutral pin, or both the live pin and the neutral pin; first gaskets formed around the two or more pins and positioned on the inwardly facing surface of the faceplate, the first gaskets being supported by flanges formed in the slots and configured to fill any openings between the two or more pins and the faceplate; second seals formed around the two or more pins and configured to cover the first seals with a material sufficient to protect the first seals from pressure and heat associated with a third seal injection molded in the form of an internal mold that covers at least the second seals and the lowered portions of the faceplate; a data cable connected to the at least one temperature sensor and configured to transmit temperature data to a control device that is not part of the plug and is physically separate therefrom; and an outer mold covering the inner mold and an outer surface of the faceplate.

2. An electric vehicle plug according to claim 1, wherein the first seals are made of epoxy and / or cold melt adhesive and / or sealing oils and / or sealing greases and / or nitrile and / or neoprene and / or ethylene propylene and / or silicone and / or fluorocarbon and / or PTFE.

3. An electric vehicle plug according to claim 1, wherein the material of the second seals and a material of the faceplate and the third seals are selected from polypropylene, polybutylene terephthalate and polycarbonate.

4. An electric vehicle plug according to claim 1, wherein the first seals and the second seals have shapes that correspond to the shapes of the corresponding flanges.

5. An electric vehicle plug according to claim 1, wherein the two or more pins are round pins or blades.

6. An electric vehicle plug according to claim 1, wherein the at least one temperature sensor is an integrated circuit temperature sensor mounted on a printed circuit board assembly.

7. The electric vehicle plug of claim 6, wherein the carrier is a potting housing configured to contain the printed circuit board assembly and cover the printed circuit board assembly with a potting compound to protect the printed circuit board assembly from pressure and heat associated with the third injection molded seal.

8. The electric vehicle plug of claim 1, wherein the at least one temperature sensor comprises a first sensor and a second sensor, the carrier bracket comprises a first carrier bracket for holding the first sensor and a second carrier bracket for holding the second sensor, and the bracket comprises a first bracket and a second bracket, wherein the first carrier bracket is positioned adjacent to the live pin by the first bracket and the second carrier bracket is positioned adjacent to the neutral pin by the second bracket.

9. An electric vehicle plug according to claim 8, wherein the first sensor and the second sensor are a negative temperature coefficient thermistor or a negative temperature coefficient thermistor. positive temperature, and the first carrier support and the second carrier support being a thermally conductive ceramic.

10. An electric vehicle plug according to claim 1, wherein the ground is a ground pin, a ground blade, a set of side contacts or a ground tube.

11. The electric vehicle plug of claim 1, wherein the second seals comprise one or more ribs located around a periphery of the second seals and configured to crush and deform into the slots and secure the second seals.

12. A method of assembling an electric vehicle plug, comprising: positioning two or more pins in a faceplate mold, the two or more pins including a live pin and a neutral pin, each pin including a through hole that extends through a central portion of the pin; forming a faceplate in the faceplate mold such that faceplate-forming material flows through holes in each pin upon formation of the faceplate, the faceplate including an outer surface and a plurality of raised portions and lowered portions formed on an inner surface, some of the raised portions partially forming slots through which the two or more pins extend, and one or more of the raised portions forming a bracket positioned on an inwardly facing surface of the faceplate;inserting at least one temperature sensor into a sensor holder bracket, the at least one temperature sensor being configured to monitor an internal temperature of either the live pin, the neutral pin, or both the live pin and the neutral pin; positioning the sensor holder bracket on the bracket, the sensor holder bracket being configured to hold the at least one temperature sensor adjacent to the bracket and adjacent to either the live pin, the neutral pin, or both the live pin and the neutral pin; forming first seals around each of the two or more pins and the inwardly facing surface of the faceplate, the first seals being supported by flanges formed within the slots; forming the second seals around each of the two or more pins and covering the first seals with a material in a manner sufficient to protect the first seals from pressure and heat associated with a third seal injection molded in the form of an internal mold that covers at least the second seals and the lowered portions of the faceplate; connecting a data cable to the at least one temperature sensor, the data cable configured to transmit temperature data to a control device that is not part of the plug and is physically separate therefrom; and covering the internal mold and an outer surface of the faceplate with an external mold.

13. A method according to claim 12, wherein the first seals are made of epoxy and / or cold melt adhesive and / or sealing oils and / or sealing greases and / or nitrile and / or neoprene and / or ethylene propylene and / or silicone and / or fluorocarbon and / or PTFE, and the material of the second seals and a material of the faceplate and the third seals being selected from polypropylene, polybutylene terephthalate and polycarbonate.

14. The method of claim 12, wherein the plurality of raised portions and lowered portions form nooks and crannies in the faceplate that are filled by the third gasket.

15. The method of claim 12, wherein the first seals and the second seals have shapes that correspond to the shapes of the corresponding flanges.

16. The method of claim 12, wherein the at least one temperature sensor is an integrated circuit temperature sensor mounted on a printed circuit board assembly.

17. The method of claim 16, wherein the sensor carrier is a potting housing configured to contain the printed circuit board assembly, further comprising: covering the printed circuit board assembly with a potting compound to protect the printed circuit board assembly from pressure and heat associated with the third injection molded seal.

18. The method of claim 12, wherein the at least one temperature sensor comprises a first sensor and a second sensor, wherein the first sensor and the second sensor are one of a negative temperature coefficient thermistor or a positive temperature coefficient thermistor, the sensor holder carrier comprising a first carrier carrier for holding the first sensor and a second carrier carrier for holding the second sensor, the first carrier carrier and the second carrier carrier being a thermally conductive ceramic, the carrier comprising a first carrier and a second carrier, and wherein positioning the temperature sensor on the carrier comprises positioning the first carrier carrier on the first carrier adjacent the live pin and positioning the second carrier carrier on the second carrier adjacent the neutral pin.

19. The method of claim 12, wherein the second seals comprise one or more ribs located around a periphery of the second seals, and forming the second seals comprises inserting the second seals into the slots so as to crush and deform the one or more ribs.

20. An electric vehicle plug according to claim 1, wherein each through hole extends through a central longitudinal axis of the corresponding pin.

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