Charging terminal for charging inlet assembly of vehicle

Abstract

To provide a charging inlet assembly which enables easy replacement of a finger protection cap.SOLUTION: A charging inlet assembly includes a charging inlet housing having a front part and a rear part. The charging inlet housing has a terminal channel between the front part and the rear part. The charging inlet assembly includes a charging terminal which is received by the corresponding terminal channel and held by the charging inlet housing. The charging terminal has a fitting end and an end edge. The end edge is configured to be electrically coupled to a corresponding power cable. The fitting end includes a pin 272 configured to be connected to a charging plug. The pin extends to a distal end 274. The charging inlet assembly includes a terminal cap 300 coupled to the corresponding pin. The terminal cap is produced from a dielectric material. The terminal cap is coupled to the distal end by a screw.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] This application claims the benefit of U.S. Application No. 63 / 644,582, entitled "CHARGING TERMINAL FOR A CHARGING INLET ASSEMBLY OF A VEHICLE," filed May 9, 2024, and U.S. Application No. 63 / 522,484, entitled "SERVICEABLE / ARC-SAFE FINGER PROTECTION CAP," filed June 22, 2023, the subject matter of which is incorporated by reference in its entirety herein.

[0002] The subject matter herein relates generally to vehicle charging systems. [Background technology]

[0003] A charging inlet assembly is used to charge a vehicle, such as for charging a battery system of an electric vehicle (EV) or hybrid electric vehicle (HEV). The charging inlet assembly includes charging terminals carried by a housing of the charging inlet assembly. The charging terminals include finger protection caps on the ends of the charging terminals to prevent inadvertent contact with the charging terminals. However, the finger protection caps are susceptible to damage, such as from arcing during charging. Repairing or replacing the finger protection caps is difficult and typically requires removing the entire charging inlet assembly to replace the charging terminals. Additionally, the finger protection caps can inadvertently become dislodged from the charging terminals and become caught in the charging plug. Summary of the Invention [Problem to be solved by the invention]

[0004] There remains a need for an improved charging inlet assembly. [Means for solving the problem]

[0005] In one embodiment, a charging inlet assembly is provided, the charging inlet assembly including a charging inlet housing having a front portion and a rear portion. The charging inlet housing has a terminal channel between the front portion and the rear portion. The charging inlet assembly includes a charging terminal received in a corresponding terminal channel and retained in the charging inlet housing. The charging terminal has a mating end and a termination. The termination is configured to electrically couple to a corresponding power cable. The mating end includes a pin configured to connect to a charging plug. The pin extends to a distal end. The charging inlet assembly includes a terminal cap coupled to the corresponding pin. The terminal cap is fabricated from a dielectric material. The terminal cap is threadably coupled to the distal end.

[0006] The invention will now be described, by way of example only, with reference to the accompanying drawings in which: [Brief description of the drawings]

[0007] [Figure 1] FIG. 2 is a front perspective view of a charging inlet assembly in accordance with an exemplary embodiment. [Diagram 2] FIG. 2 is a rear perspective view of a charging inlet assembly in accordance with an exemplary embodiment. [Diagram 3] FIG. 2 is an exploded view of a DC charging terminal in accordance with an exemplary embodiment. [Figure 4] FIG. 1 is an assembly view of a DC charging terminal in accordance with an exemplary embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0008] FIG 1 is a front perspective view of a charging inlet assembly 100 according to an exemplary embodiment. FIG 2 is a rear perspective view of a charging inlet assembly 100 according to an exemplary embodiment. Charging inlet assembly 100 includes an AC charging module 102 and a DC charging module 104 according to an exemplary embodiment.

[0009] Charging inlet assembly 100 is used as a charging inlet for a vehicle, such as an electric vehicle (EV) or a hybrid electric vehicle (HEV). Charging inlet assembly 100 is configured for mating reception with a charging connector (not shown). In an exemplary embodiment, charging inlet assembly 100 is configured to mate with various charging connectors, such as a DC fast charging connector (e.g., an SAE combo CCS charging connector) and an AC charging connector (e.g., an SAE J1772 charging connector). Charging inlet assembly 100 may be a charging connector associated with the North American Charging System (NACS), such as an SAE J3400 charging connector.

[0010] Charging inlet assembly 100 includes a housing 110 configured to be mounted to a vehicle. Housing 110 holds AC charging module 102 and DC charging module 104 for mating with a charging connector. In various embodiments, components of AC charging module 102 and / or components of DC charging module 104 are removable from housing 110. For example, charging modules 102, 104 may be coupled to housing 110 using latches, fasteners, clips, or other fastening means. The charging modules 102, 104 may be removable from the housing 110 to separate the components of the charging modules 102, 104 (e.g., charging pins, cables, circuit boards, etc.) from the housing 110, such as for purposes of repair and / or replacement of the charging module components or other components of the charging inlet assembly 100.

[0011] In the exemplary embodiment, housing 110 includes an AC section 112 that receives AC charging module 102 and a DC section 114 that receives DC charging module 104. AC section 112 is configured to mate with an AC charging connector or the AC section of a charging connector. DC section 114 is configured to mate with a DC charging connector or the DC section of a charging connector. AC section 112 includes an AC terminal channel 116. DC section 114 includes a DC terminal channel 118.

[0012] The AC charging module 102 includes an AC terminal 120 at the AC 112 portion. The AC terminal 120 is held in the housing 110. The AC terminal 120 is received in a corresponding AC terminal channel 116. The AC terminal 120 is configured to mate with a charging connector. In the embodiment shown in FIG. 1, five AC terminals 120 are provided, including a first AC charging terminal 120a, a second AC charging terminal 120b, a ground terminal 120c, a proximity terminal 120d, and a pilot terminal 120e. Optionally, the AC terminals 120 may be terminals of different sizes. In an exemplary embodiment, the AC terminal 120 includes a pin at a mating end of the AC terminal 120. An AC cable 122 is terminated to the AC terminal 120 and extends from the charging inlet assembly 100 to another component of the vehicle, such as a battery system of the vehicle. In various embodiments, the AC cable 122 may extend straight away from the AC charging module 102 and the housing 110. In various other embodiments, the AC cable 122 may extend at a 90° angle (e.g., a right angle) or other angle away from the AC charging module 102 and the housing 110.

[0013] In an exemplary embodiment, AC portion 112 of charging inlet assembly 100 defines a low-voltage connector configured to mate with a low-voltage portion of a charging connector. The low-voltage connector (e.g., AC terminals 120 and AC cable 122) is configured to mate with other components in a system, such as a battery power distribution unit, to control charging of the vehicle. The low-voltage connector may send and receive signals related to charging, such as a status of connection, a status of charging, a voltage of charging, etc. The low-voltage connector may be a socket connector configured to receive a charging plug. A seal may be provided at the interface of the low-voltage connector.

[0014] The DC charging module 104 comprises a DC charging port 126 at a front portion of the housing 110 configured to mate with a charging plug, a DC terminal module 200 at a rear portion of the housing 110, and a DC cable assembly 220 configured to removably couple to the DC terminal module 200. The DC terminal module 200 comprises a DC housing 210, one or more DC terminals 240, and one or more cover assemblies 230 coupled to the DC housing 210 to cover the DC terminals 240. The DC housing 210 is coupled to the rear portion of the inlet housing 110. The DC terminals 240 extend through the inlet housing 110 to a front portion of the inlet housing 110 where the DC charging port 126 is located, for mating with a charging connector. The DC cable assembly 220 includes a DC power cable 222 that is electrically coupled to a corresponding DC terminal 240.

[0015] During assembly, the DC terminal 240 is placed in the DC section 114. The DC terminal 240 is placed in the housing 110 at the location of the DC charging port 126. The DC terminal 240 is received in the corresponding DC terminal channel 118. The DC terminal 240 is configured to mate with the charging connector. In the embodiment shown in FIG. 1, two DC terminals 240 are provided. In an exemplary embodiment, the DC terminal 240 includes a pin at a mating end of the DC terminal 240. The DC power cable 222 extends from the charging inlet assembly 100 to another component of the vehicle, such as the vehicle's battery system. In various embodiments, the DC power cable 222 may extend 90 degrees (e.g., a right angle) or at other angles away from the DC terminal module 200.

[0016] In an exemplary embodiment, DC portion 114 of charging inlet assembly 100 defines a high-voltage connector configured to couple to a high-voltage portion of a charging connector. The high-voltage connector (e.g., DC terminals 240 and DC power cable 222) is configured to couple to other components in a system, such as a vehicle battery and / or a battery power distribution unit. The high-voltage connector is used for fast charging of the battery. The high-voltage connector may be a socket connector configured to receive a charging plug. A seal may be provided at the interface of the high-voltage connector.

[0017] Inlet housing 110 includes a front portion 130 and a rear portion 132. Front portion 130 of housing 110 faces outward and is the side that faces an operator connecting a charging connector. Rear portion 132 faces the interior of the vehicle and is generally not accessible without removing housing 110 from the vehicle. Housing 110 includes a panel 134 on front portion 130. In an exemplary embodiment, an AC socket 136 is formed on panel 134 at AC portion 112 and a DC socket 138 is formed on panel 134 at DC portion 114. AC socket 136 includes a space around AC terminal 120 that receives a charging connector. During charging, an AC charging connector is inserted into AC socket 136 to electrically connect to AC terminal 120. The DC socket 138 includes a space around the DC terminals 240 that receive a charging connector. The DC charging connector is configured to be plugged into the DC socket 138. During charging, the DC charging connector is plugged into the DC socket 138 and electrically connects to the DC terminals 240. The panel 134 may surround the AC socket 136 and the DC socket 138 at the front portion 130.

[0018] In the exemplary embodiment, housing 110 includes a mounting flange 140 ( FIG. 1 ) coupled to panel 134 at front portion 130. Mounting flange 140 includes mounting tabs 142 that are used to mount housing 110 to a vehicle. Mounting tabs 142 have openings 144 that receive fasteners (not shown) for securing charging inlet assembly 100 to the vehicle. Other types of mounting mechanisms may be used to secure charging inlet assembly 100 to the vehicle. Housing 110 and / or the mounting flange may include seals for sealing charging inlet assembly 100 to the vehicle.

[0019] In various embodiments, charging inlet assembly 100 may include a terminal cover (not shown) on a front portion of housing 110 to cover portions of housing 110, such as DC portion 114 and / or AC portion 112. Housing 110 may also include one or more rear covers on a rear portion of housing 110 to close access to the rear portion of housing 110. The covers may be clipped or latched to a main portion of housing 110 using clips, latches, or the like. In alternative embodiments, other types of fastening mechanisms, such as fasteners, may be used.

[0020] Figure 3 is an exploded view of DC charging terminal 240 according to an exemplary embodiment. Figure 4 is an assembled view of DC charging terminal 240 according to an exemplary embodiment. AC charging terminal 120 (shown in Figure 1) may be similar to DC charging terminal 240 and may include similar components.

[0021] Charging terminal 240 includes a terminal body 242 extending between a front portion 244 and a rear portion 246. Charging terminal 240 includes a mounting portion 250 configured to secure to a terminal channel 118, such as inlet housing 110 and / or DC housing 210 (shown in FIG. 2 ). Charging terminal 240 includes a termination portion 260 at rear portion 246 configured to be terminated to DC power cable 222. Charging terminal 240 includes a mating portion 270 at front portion 244 configured to connect to a corresponding charging socket of a charging plug.

[0022] Charging terminal 240 includes a cylindrical portion. For example, mounting portion 250 may be a cylindrical portion. In an exemplary embodiment, mounting portion 250 includes a terminal seal 252 configured to be sealed between charging terminal 240 and housing 110. Terminal seal 252 extends circumferentially about mounting portion 250. In an exemplary embodiment, mounting portion 250 includes a groove 254 extending circumferentially about mounting portion 250. Groove 254 is configured to receive a fastening element, such as a latch, to secure charging terminal 240 to housing 110. Mounting portion 250 includes one or more flanges 256.

[0023] In the exemplary embodiment, charging terminal 240 includes a post 262 at rear portion 246. Termination portion 260 includes a terminal bus bar 264 coupled to post 262. Terminal bus bar 264 may be secured to post 262 by welding. In other embodiments, terminal bus bar 264 is secured to post 262 using fasteners, such as screw fasteners. Terminal bus bar 264 may be secured to post 262 by a compression connection. In other embodiments, terminal bus bar 264 may be integral with mounting portion 250 of charging terminal 240 rather than being a separate component coupled thereto. Terminal bus bar 264 is configured to electrically connect to power cable 222. For example, power cable 222 may be welded to pads 266 of terminal bus bar 264. In alternative embodiments, terminal bus bar 264 may be crimped to power cable 222 or secured to power cable 222 using a bolted connection.

[0024] The mating portion 270 extends forward from the mounting portion 250. In the exemplary embodiment, the mounting portion 270 includes a pin 272 that extends to a distal end 274. The pin 272 is cylindrical. The pin 272 has an outer surface 276 configured to engage with a charging socket of a charging plug. In the exemplary embodiment, at least a portion of the pin 272 is hollow. For example, the pin 272 includes a threaded hole 280 at the distal end 274. The threaded hole 280 includes an internal thread 282.

[0025] In an exemplary embodiment, charging terminal 240 includes a terminal cap 300 that is threadably coupled to distal end 274 of pin 272. Terminal cap 300 is coupled to distal end 274 by rotating terminal cap 300 in a tightening direction. Terminal cap 300 is fabricated from a dielectric material. Terminal cap 300 covers distal end 274 of pin 272. Terminal cap 300 is a finger protection cap used to prevent contact with pin 272. Terminal cap 300 is removable from pin 272 by rotating terminal cap 300 in an unclamping or loosening direction.

[0026] In an exemplary embodiment, terminal cap 300 is manufactured from a plastic material. For example, terminal cap 300 may be a molded part. In various embodiments, the material may be a polyethylene plastic. In various embodiments, the plastic material may be a high temperature plastic material to avoid melting due to arcing. For example, the material may be a polytetrafluoroethylene (PTFE) plastic having a melting temperature of over 300° C. Optionally, the material may include a ceramic filler to increase the melting temperature of the part. In other embodiments, terminal cap 300 is manufactured from a ceramic material and has a high melting temperature. The ceramic material may have a melting temperature of over 2000° C. The high melting temperature avoids damage or melting due to arcing between the charging terminals.

[0027] In an exemplary embodiment, the terminal cap 300 includes a tip 310 and a threaded shaft 312 extending from the tip 310. The tip 310 includes a head 314 of the terminal cap 300. An end of the head 314 may be tapered, such as to guide mating with a socket terminal of a charging plug. In an exemplary embodiment, the head 314 includes a drive element 316 configured to be engaged by a tool to rotate the terminal cap 300 to tighten or loosen the terminal cap 300 on the pin 272. In the embodiment shown in FIGS. 3 and 4, the drive element 316 is a hexagonal opening configured to receive a hexagonal drive tool. In alternative embodiments, other types of drive elements may be used. The threaded shaft 312 includes threads 318 along the threaded shaft 312. The threads 318 are configured to engage with the threads 282 of the female threads 280 to secure the terminal cap 300 to the pin 272.

Claims

1. A charging inlet assembly (100), comprising: The charging inlet assembly (100) comprises: - a charging inlet housing (110) having a front portion (130) and a rear portion (132) with a terminal channel (116, 118) between said front portion and said rear portion; a charging terminal (120) received in a corresponding terminal channel and retained in the charging inlet housing, the charging terminal having a mating end and a terminal end configured to electrically couple to a corresponding power cable (222), the mating end including a pin (272) configured to connect to a charging plug and extending to a distal end (274); a terminal cap (300) coupled to the corresponding pin, the terminal cap being fabricated from a dielectric material and threadedly coupled to the distal end; Equipped with A charging inlet assembly (100).

2. The distal end (274) has a threaded hole (280); The terminal cap (300) is screwed into the screw hole. The charging inlet assembly (100) of claim 1.

3. Each terminal cap (300) includes a tip portion (310) and a threaded shaft (312) extending from the tip portion; The screw shaft is threadedly coupled to the corresponding pin (272). The charging inlet assembly (100) of claim 1.

4. Each terminal cap (300) is manufactured from a plastic material. The charging inlet assembly (100) of claim 1.

5. Each terminal cap (300) is made of a ceramic material. The charging inlet assembly (100) of claim 1.

6. Each terminal cap (300) is fabricated from a dielectric material capable of withstanding arcing. The charging inlet assembly (100) of claim 1.

7. Each terminal cap (300) includes a drive element (316) configured to be engaged by a tool used to rotate said terminal cap to threadably couple said terminal cap to said pin (272). The charging inlet assembly (100) of claim 1.

8. The terminal cap (300) includes a forward portion forward of the distal end (274) and a rearward portion rearward of the distal end. The charging inlet assembly (100) of claim 1.

9. The terminal cap (300) has an outer portion that is on the outside of the pin (272) and an inner portion that is on the inside of the pin. The charging inlet assembly (100) of claim 1.

10. A charging terminal (120) for a charging inlet assembly (100), comprising: The charging terminal is a terminal body (242) extending between a front portion (244) and a rear portion (246), the terminal body having an attachment portion (250) configured to secure to a terminal channel (116, 118) of the charging inlet assembly; a termination (260) at the rear, said termination being configured to be terminated to a power cable (222); and - a mating portion (270) at the front, the mating portion comprising a pin (272) configured to connect to a charging socket of a charging plug, the pin having a distal end (274); a terminal cap (300) threadably coupled to the distal end of the pin and fabricated from a dielectric material; Equipped with Charging terminal (120).

11. The distal end (274) includes a threaded hole (280); The terminal cap (300) is screwed into the screw hole. The charging terminal (120) of claim 10.

12. The terminal cap (300) includes a tip portion (310) and a threaded shaft (312) extending from the tip portion, The screw shaft is threadedly coupled to the pin (272). The charging terminal (120) of claim 10.

13. The terminal cap (300) is made of a plastic material. The charging terminal (120) of claim 10.

14. The terminal cap (300) is made of a ceramic material. The charging terminal (120) of claim 10.

15. The terminal cap (300) is made of a dielectric material that can withstand arcing. The charging terminal (120) of claim 10.

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