Modular electric vehicle charging foundation system

Abstract

A modular electric vehicle charging foundation system 10 which comprises a base structure 12 defining a cabling void, and a raising frame element 16 connected or connectable to an upper portion of the

Description

The present invention relates to a modular electric vehicle charging foundation system for the installation of electric vehicle chargers, as well as to a modular electric vehicle charging system. A method of reducing groundwork requirements for an electric vehicle 5 charger installation site is also provided. Electric vehicle chargers are becoming more commonplace as road furniture as the market for electric vehicles expands. The size of the ducting which brings the cabling to the electric vehicle charger subsurface is large, making it difficult to manoeuvre into position and install. 10 At present, electric vehicle chargers are installed by bolting the electric vehicle charger of choice into a large concrete slab in the ground, with the ducting penetrating through the concrete slab, and being held in place thereby. Since different chargers from different LO manufacturers have different requirements for cabling, having different mounting and CM cabling entry points, this means that to replace the electric vehicle charger with another CXI 15 of a different construction, the entire site must be excavated. This is extremely time-"1” consuming. CO It is an object of the present invention to reduce the civil works required to extract and reinstall a site for electric vehicle charger architecture. According to a first aspect of the invention, there is provided a modular electric vehicle 20 charging foundation system comprising: a base structure defining a cabling void; a raising frame element connected or connectable to an upper portion of the base structure and having an adapter coupling; an electric-vehicle-charger adapter plate having a plate body, a cabling aperture therethrough and a plurality of mounting points on the plate body for onward connection to an electric vehicle charger, the electric-vehicle-charger 25 adapter plate being releasably engagable with the adapter coupling to provide a foundation for an electric vehicle charger once installed; and a blanking cover releasably engagable with the adapter coupling, the electric-vehicle-charger adapter plate and blanking cover being selectably interchangeable; wherein at least part of the plate body extends laterally outwardly from a top of the adaptor coupling relative to an in-use vertical 30 axis, said at least part of the plate body comprising the plurality of mounting points so as to overhang the adaptor coupling. 23 12 25 The present invention is in effect a universal foundation system, specifically but not necessarily exclusively for electric vehicle chargers, which is achieved by the provision of an adapter plate for an electric vehicle charger with a corresponding blanking plate which is selectably interchangeable. This allows the groundworks to be completed to 5 install the subsurface components and blanked off before the charger is itself installed. Any electric vehicle charger can be installed, regardless of fixing points or cable entry points, and extra raising frame elements and base structures can be installed to upgrade the scale of a site with more units very easily. This has many advantages. The installation time is reduced, and all civils works can be 10 completed without prior knowledge of the charger type to be used. The appearance of the site pre-installation is also significantly improved, since there is no unsightly ducting projecting through a concrete slab. The lateral extension of the plate allows for easy access to the mounting points thereof when installing an electric vehicle charger. 15 Preferably, the base structure may be formed from a plurality of interengagable base portions. The ability to alter the dimensions of the base structure is highly useful, since the volume of the cabling void can be dimensioned according to need. The base portions may be stackable on top of one another. 20 Stackable base portions are extremely useful. The base structure can be adjusted in height to suit a bend radius of the cabling, since the cabling for electric vehicle chargers is resistant to flexion. Optionally, the adapter coupling may be formed having a rectilinear profile. Alternatively, the adapter coupling may be formed having a tubular profile. 25 Different above-ground frame sections may be more applicable in particular contexts, so different forms of adapter coupling may have different uses and associated advantages. The electric-vehicle-charger adapter plate may comprise at least one locator which depends from a plate body thereof. 23 12 25 A depending locator of the adapter plate helps to align the adapter plate accordingly, simplifying installation thereof to the raising frame element. Optionally, at least part of the electric-vehicle-adapter plate may extend laterally outwardly from a perimetric flange thereof. 5 It will be appreciated that the use of the substantial base structure ensures that the centre of gravity of the whole system is stable, and thus overhanging of the structure by the adapter plate is possible. Larger chargers can thus be installed on small structure. The raising frame element may include a connection region at the adapter coupling allows access to a fastening means to the electric-vehicle-charger adapter plate. 10 Give that the raising frame element will typically be installed into the ground prior to the installation of the adapter plate itself, it is preferred that the adapter plate be installable without needing to access sub-surface architecture. A dedicated connection region permits such installation. Preferably, the electric-vehicle-charger adapter plate may include an access aperture to 15 permit access therethrough to the connection region. A specific access aperture ensures that the connection region remains accessible, regardless of whether the adapter plate needs to be dimensioned to overlie the connection region due to the dimensions of the electric vehicle charger. According to a second aspect of the invention, there is provided a modular electric 20 vehicle charging system comprising a modular electric vehicle charging foundation system in accordance with the first aspect of the invention, and an electric vehicle charger engagable with the electric vehicle charger adapter plate. Whilst the present invention has been prepared with electric vehicle chargers in mind, 25 the direct interchangeability of an adapter plate and blanking cover at a single raising frame point has not been posited in the art to date. The invention will now be more particularly described, by way of example only, with reference to the accompanying drawings, in which: 23 12 25 Figure 1 shows a perspective representation of a first embodiment of a modular electric vehicle charging foundation system in accordance with the first aspect of the invention, with the system being shown in Figure 1(a) in an exploded condition, and an adapter plate being shown alone in Figure 1(b); 5 Figure 2 shows a side view of the modular electric vehicle charging foundation system of Figure 1 in an installed state; Figure 3 shows a plan view of the modular electric vehicle charging foundation system of Figure 1; Figure 4 shows a cross-sectional representation of the modular electric vehicle 10 charging foundation system of Figure 3 taken along line A-A, with inset Figure 4(i) showing the detail of the connection between the base structure and raising frame element; Figure 5 shows a perspective view of the modular electric vehicle charging foundation system of Figure 1 in use with an indicative electric vehicle charger; 15 Figure 6 shows a perspective representation of the modular electric vehicle charging foundation system of Figure 1 having a blanking cover thereon; Figure 7 shows a perspective view of a second embodiment of a modular electric vehicle charging foundation system in accordance with the first aspect of the invention, inclusive of a blanking cover; 20 Figure 8 shows an exploded perspective view of the modular electric vehicle charging foundation system of Figure 7; Figure 9 shows an exploded perspective representation of the modular electric vehicle charging foundation system of Figure 7, including a second embodiment of adapter plate; 25 Figure 10 shows an exploded perspective representation of the modular electric vehicle charging foundation system of Figure 9 the system being shown in full in Figure 10(a) and the adapter plate being shown in detail in Figure 10(b); Figure 11 shows a cross-sectional representation of the modular electric vehicle charging foundation system of Figure 9, inset Figure 11(a) showing the connection between the blanking cover and raising frame element, and inset Figure 11 (ii) showing the connection between the base structure and raising frame element; Figure 12 shows an exploded perspective representation of the modular electric vehicle charging foundation system of Figure 7 including a third embodiment of adapter 5 plate; and Figure 13 shows an exploded perspective representation of the modular electric vehicle charging foundation system of Figure 7 including a fourth embodiment of adapter plate. Referring to Figure 1, there is indicated a modular electric vehicle charging foundation 10 system, referenced globally at 10. This system 10 is suitable for the purpose of installing electric vehicle chargers in a location in a manner which allows for straightforward upgrade or replacement of the electric vehicle charger. LO As best seen in Figure 1(a), the modular electric vehicle charging foundation system 10 CM comprises a base structure 12, which is here formed as a plurality of modularly CXI 15 engagable sub-surface base portions 14 which stackably engage on top of one another "1” to a desired height. The base structure 12 is in use installed in a trench at a groundworks CO site. The base structure 12 is often informally referred to as a chamber or plinth. CM In this embodiment, the base structure 12 is formed having a square or substantially square footprint, but it will be apparent that an appropriately dimensioned base structure 20 12 will be utilised in the field in a context-dependent manner. The base structure 12 thus defines an appropriate cabling void for receiving electric charging cables, which may be larger, thicker, and / or less flexible than other similar cables for road furniture. The modular electric vehicle charging foundation system 10 further includes a raising frame element 16, which is formed to be receivable directly onto the base structure 12. 25 In practice, the installer will attach the raising frame element to the top base portion 14 during installation before fully assembling the base structure 12. The raising frame element 16 has a perimetric flange 18 which extends to the edge of the top surface of the base structure 12 to form a complete perimetric lid. There is then also an adapter coupling 20, which may or may not be integrally formed with the 30 perimetric flange 18. In the illustrated embodiment of Figure 1(a), the adapter coupling 20 comprises a tubular neck portion 22 extending upwardly from the perimetric flange 18. An aperture 24 through the neck portion 22 is dimensioned to permit access therethrough for electric vehicle charging cables without kinking. 10 CXI CXI 15 CXI 20 25 30 The adapter coupling 20 further includes a top support member 24 which allows for an electric-vehicle-charger adapter plate 26, such as that shown in Figure 1(b), to be fastened thereto. The electric-vehicle-charger adapter plate 26 here has a collar 28 which has a complementary cylindrical shape for being receivably inserted into the neck portion 22, and which defines a cabling aperture 30 therethrough, whilst a plate body 32 of the electric-vehicle-charger adapter plate 26 has a plurality of mounting points 34 for onward connection onto an associated electric vehicle charger. The plate body 32 of the electric-vehicle-charger adapter plate 26 includes an access aperture 36 therein to permit access to a connection region 38 of the adapter coupling 20 when connecting the electric-vehicle-charger adapter plate 26 to the raising frame element 16. The adapter coupling 20 here has a plurality of mounting lugs 40 which extend through the perimetric flange 18, and which, when installed, provide security in the installation medium. This is illustrated as a concrete layer 42 over a compactable aggregate 44, as shown in detail in Figure 2. The subsurface installed structure of the modular electric vehicle charging foundation system 10 can be seen in detail in Figure 2. An incoming cable conduit 50 is provided which enters the cabling void of the base structure 12 underground, typically in the compactable aggregate layer 44. The concrete layer 42 is provided partway up the neck portion 22 of the adapter coupling 20, with a top finishing layer 52 then being provided up to the bottom of the top support member 24, so that the top support member 24 is or is substantially flush with the final top finishing layer 52. This provides a suitable base for an electric-vehicle-charger adapter plate 26 to be selectably mounted thereon. The base structure 12 is further engaged with a sump 54 at the base of the trench in which the base structure 12 has been originally installed, to collect undesirable liquids ingressing into the base structure 12, thereby protecting the electrical cabling. The electric-vehicle-charger adapter plate 26 is then installed on top of the adapter coupling 20 by insertion of the collar 28 into the neck portion 22, which ensures that a consistent passage is provided up through the electric-vehicle-charger adapter plate 26 from the cabling void. The engagement can be best seen in Figure 3, which is the plan view. The electric-vehicle-charger adapter plate 26 is installed such that the access aperture 36 is aligned with the connection region 38 of the adapter coupling 20. The lateral sides 56 of the plate body 32 overhang the adapter coupling 20 so as to leave the mounting points 34 free for 5 engagement with an electric vehicle charger. Figure 4 shows the connection region 38 of the adapter coupling 20 in detail. This is formed as a side port 58 on the side of the neck portion 22, thereby allowing a fastener to be accessed from both inside the collar 28 of the electric-vehicle-charger adapter plate 26 and from inside the side port 58. Releasable engagement of the electric-vehicle-10 charger adapter plate 26 and raising frame element 16 is therefore possible even once the base structure 12 is installed to block access to the cabling void. Inset Figure 4(i) shows a corresponding fastening between the base structure 12 and a base coupling 46 of the raising frame element 16, illustrated as a skirt depending from the adapter coupling 20 and / or perimetric flange 18, which is connected via a screw-threaded fastener 48 LO 15 such as a nut and bolt. CXI It will be appreciated that whilst the raising frame element 16 shown is receivable into the base structure 12, it could easily cap the base structure 12 instead, and therefore the CO base coupling 46 shown is merely illustrative. Similarly, the adapter coupling 20 is shown as projecting above the level of the perimetric flange 18, but in such a scenario, no flange 20 would be necessary. The adapter coupling 20 could also be flush or level with the base coupling 46. Additionally, it may be possible to integrally form the raising frame element 16 with the base structure 12, so that they are permanently connected to one another. A formal base coupling would be unnecessary in such a scenario. An indicative connection between an electric vehicle charger 60 and the electric-vehicle-25 charger adapter plate 26 is shown in Figure 5. The base of the electric vehicle charger 60 may be mounted to the mounting points 34 of the electric-vehicle-charger adapter plate 26, for instance, by access through the cabinet door 62 of the electric vehicle charger 60. By utilising a modular electric vehicle charging foundation system 10, a single electric 30 vehicle charger 60 can be installed at a site. However, the strength of the modular electric vehicle charging foundation system 10 is that the modular engagement between the raising frame element 16 and the electric-vehicle-charger adapter plate 26 allows for the electric-vehicle-charger adapter plate 26 to be demounted and replaced with either a blanking cover 64, such as the circular cap or similar manhole cover which is illustrated in Figure 6, should the removal of the electric vehicle charger 60 be desirable, or with a different electric-vehicle-charger adapter plate suitable for use with a different electric vehicle charger. This advantageously allows for the replacement of different types of 5 electric vehicle charger without needing to perform groundwork. All actions can be undertaken above ground. Figures 7 and 8 show a second embodiment of a modular electric vehicle charging foundation system, referenced globally at 110. Identical or similar features of the embodiment to those disclosed in connection with the first embodiment will be referenced 10 using identical or similar reference numerals, and further detailed description will be omitted for brevity. The base structure 112 is substantially identical to that shown in the first embodiment; however, the raising frame element 116 now has a rectilinear adapter coupling 120, as opposed to the tubular arrangement of the first embodiment. The skirt 146 has a greater 15 length extending into the cabling void, so as to engage with the second base portion 114. The perimetric flange 118 still seats onto the top of the base structure 112. The modular electric vehicle charging foundation system 110 includes a blanking cover 164, such as a standard manhole cover, which is seatable onto the raising frame element 116, and which can be fastened in place via fastening elements engagable through the 20 corresponding receivers 166 of the raising frame element 116. Figures 9 and 10 show the modular electric vehicle charging foundation system 110 with an alternative electric-vehicle-charger adapter plate 126a. The plate body 132a of this electric-vehicle-charger adapter plate 126a has a width W1 which is greater than its length L1, best illustrated in Figure 10(b), with the width W1 being greater than a first 25 dimension of the adapter coupling 120. This allows the mounting points 134 to overhang the adapter coupling 120, as seen in Figure 9. Since the length L1 of the plate body 132a of the electric-vehicle-charger adapter plate 126a is less than that of a second dimension of the adapter coupling 120, and as such, an insertion plate 168 is provided to bridge any void space which would otherwise allow 30 for ingress of water into the base structure 112 from above. This engagement is visible in Figure 11. The electric-vehicle-charger adapter plate 126a includes first and second dependent locators 170 which have much the same purpose as the skirt of the raising frame element 116, that is, to correctly orient and align the electric-vehicle-charger adapter plate 126a in the adapter coupling 120. The locators 170 abuttably engage with the walls of the 5 adapter coupling 120, keeping the electric-vehicle-charger adapter plate 126a aligned. The fasteners 148 which hold the electric-vehicle-charger adapter plate 126a in position on the raising frame element 116 are illustrated in inset Figure 10(i), and these may be provided as screw-threaded fasteners or alternative fastening members, such as worm screws. 10 Figure 12 shows the modular electric vehicle charging foundation system 110 with a further alternative electric-vehicle-charger adapter plate 126b. This electric-vehicle-charger adapter plate 126b has a plate body 132b which has a length L2 which is greater than its width W2, with the length L2 being greater than a second dimension of the adapter coupling 120. This provides a much larger base for a bigger electric vehicle LO 15 charger than that of the previous electric-vehicle-charger adapter plate 126a, and also eliminates the need for an insertion plate. CXI In this embodiment, some of the mounting points 134 are positioned on laterally CO overhanging parts of the plate body 132b, whilst some lie within the area of the aperture 130 of the raising frame element 116. 20 It is preferred, however, that the cabling aperture 130 has the same dimensions across a set of a plurality of electric-vehicle-charger adapter plates 126a, 126b, so that no additional manipulation of the subsurface cables is required when switching between different electric vehicle chargers. Figure 13 shows the modular electric vehicle charging foundation system 110 with a 25 further alternative electric-vehicle-charger adapter plate 126c. This electric-vehiclecharger adapter plate 126c has a plate body 132c which an equal width W3 and length L3. This provides a square base for an electric vehicle charger. It will be apparent that whilst the raising frame elements has been defined as sitting and spanning a single base structure at once, larger base structures are known. It will thus 30 be appreciated that a plurality of different raising frame elements could be attached to a single base structure, to provide a plurality of chargers at a single site. This is intended to fall within the scope of the present invention. Due to the more difficult cabling requirements associated with electric vehicle chargers, which have thick and unwieldy subsurface cabling, the present invention is very suited towards the installation of such systems. However, it will be appreciated that the present invention could be applied to any appropriate road furniture, such as electrical control 5 cabinets, in which case adapter plates which are not directed to electric vehicle chargers could be utilised, either separately, or as modular replacements for the electric-vehicle-charger adapter plates addressed above. The provision of a modular electric vehicle charging foundation system comprising a base structure, a raising frame, and a plurality of different adapter plates enables the 10 selective alteration of an installation site to suit a new electric vehicle charger to be installed, thus creating a true modular electric vehicle charging system. In a preferred embodiment, there is provided a single blanking cover, which allows the system to be capped off once groundworks is complete to permit safe crossing over the site by pedestrians or vehicles, and then an adapter plate which is installed at a later date which LO 15 is bespoke to the electric vehicle charger to be installed. Indeed, this system is readily adaptable to other types of road furniture, including but not limited to traffic light signal CXI boxes, electrical cabinets, and other junction box architecture. 1— CO It is thus possible to provide a method of reducing groundwork requirements for an electric vehicle charger installation site, by installing a base structure in a trench at a 20 desired site for the electric vehicle charger; engaging a raising frame element with an upper portion of the base structure, the raising frame comprising a perimetric flange, a skirt receivable into the cabling void of the base structure and having at least one fastening means for fastening the skirt to the base structure, and an adapter coupling; and then selecting a suitable electric-vehicle-charger adapter plate from a plurality of 25 different electric-vehicle-charger adapter plates each having a cabling aperture therethrough, wherein the selected electric-vehicle-charger adapter plate is releasably engagable with the adapter coupling to provide a foundation for a selected electric vehicle charger. The words ‘comprises / comprising’ and the words ‘having / including’ when used herein 30 with reference to the present invention are used to specify the presence of stated features, integers, steps, or components, but do not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof. It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention which are, for brevity, described in the context of a single embodiment, may also be provided separately or in 5 any suitable sub-combination. The embodiments described above are provided by way of examples only, and various other modifications will be apparent to persons skilled in the field without departing from the scope of the invention as defined herein. 23 12 25

Claims

1. A modular electric vehicle charging foundation system comprising:a base structure defining a cabling void;a raising frame element connected or connectable to an upper portion of the base structure and having an adapter coupling;an electric-vehicle-charger adapter plate having a plate body, a cabling aperture therethrough and a plurality of mounting points on the plate body for onward connection to an electric vehicle charger, the electric-vehicle-charger adapter plate being releasably engagable with the adapter coupling to provide a foundation for an electric vehicle charger once installed; anda blanking cover releasably engagable with the adapter coupling, the electric-vehicle-charger adapter plate and blanking cover being selectably interchangeable;wherein at least part of the plate body extends laterally outwardly from a top of the adaptor coupling relative to an in-use vertical axis, said at least part of the plate body comprising the plurality of mounting points so as to overhang the adaptor coupling.

2. A modular electric vehicle charging foundation system as claimed in claim 1, wherein the base structure is formed from a plurality of interengagable base portions.

3. A modular electric vehicle charging foundation system as claimed in claim 2, wherein the base portions are stackable on top of one another.

4. A modular electric vehicle charging foundation system as claimed in any one of the preceding claims, wherein the adapter coupling is formed having a rectilinear profile.

5. A modular electric vehicle charging foundation system as claimed in any one of claims 1 to 3, wherein the adapter coupling is formed having a tubular profile.

6. A modular electric vehicle charging foundation system as claimed in any one of the preceding claims, wherein the electric-vehicle-charger adapter plate comprises at least one locator which depends from a plate body thereof.23 12 257. A modular electric vehicle charging foundation system as claimed in any one of the preceding claims, wherein at least part of the electric-vehicle-adapter plate extends laterally outwardly from a perimetric flange thereof.

58. A modular electric vehicle charging foundation system as claimed in any one of the preceding claims, wherein the raising frame element includes a connection region at the adapter coupling allows access to a fastening means to the electric-vehicle-charger adapter plate.

109. A modular electric vehicle charging foundation system as claimed in claim 8, wherein the electric-vehicle-charger adapter plate includes an access aperture to permit access therethrough to the connection region.15 10. A modular electric vehicle charging system comprising a modular electric vehicle charging foundation system as claimed in any one of the preceding claims, and an electric vehicle charger engagable with the electric vehicle charger adapter plate.

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