Housing cover and charging inlet

Abstract

The present invention provides a housing cover and a charging inlet that can improve the ease of assembly of the housing cover to the housing. [Solution] The housing cover of one embodiment is a housing cover that is attached to an opening in the housing of a charging inlet that opens toward one side in a first direction, and comprises a pair of opposing sides that face each other in a second direction intersecting the first direction, and a connecting side that connects the ends of the pair of opposing sides in a third direction intersecting the first and second directions, wherein the connecting side is more flexible than each of the pair of opposing sides, and is fitted into the opening of the housing in a state of elastic deformation caused by displacement that brings the other ends of the pair of opposing sides in the third direction closer together.

Description

Technical Field

[0001] Embodiments of the present invention relate to a housing cover and a charging inlet.

Background Art

[0002] Conventionally, connectors installed in vehicles such as electric vehicles and plug-in hybrid vehicles have been proposed to supply (charge) power from outside the vehicle to the batteries mounted on the vehicles (see, for example, Patent Document 1). This type of connector is generally also called a charging inlet.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] A charging inlet has a power supply connector (counterpart component) detachable from one side in a first direction. A region in the housing of the charging inlet that avoids the terminal holding portion is an opening that opens toward one side in the first direction. It is conceivable to attach a housing cover so as to close this opening.

[0005] One embodiment is to provide a housing cover and a charging inlet that can improve the assemblability of the housing cover to the housing.

Means for Solving the Problems

[0006] A housing cover in one embodiment is a housing cover attached to an opening in the housing of a charging inlet that opens toward one side in a first direction, and comprises a pair of opposing sides that face each other in a second direction intersecting the first direction, and a connecting side that connects the ends of the pair of opposing sides in a third direction intersecting the first and second directions, wherein the connecting side is more flexible than each of the pair of opposing sides, and is fitted and attached into the opening of the housing in a state of elastic deformation caused by displacement that brings the other ends of the pair of opposing sides in the third direction closer together. [Effects of the Invention]

[0007] According to one embodiment, it is possible to provide a housing cover and a charging inlet that can improve the ease of assembling the housing cover to the housing. [Brief explanation of the drawing]

[0008] [Figure 1] A perspective view of the charging inlet and housing cover of the embodiment. [Figure 2] A perspective view of the housing cover of the embodiment, seen from a different direction than in Figure 1. [Figure 3A] Front view of the housing cover of the embodiment before elastic deformation. [Figure 3B] A front view of the housing cover of the embodiment in an elastically deformed state. [Figure 3C] Enlarged view of section C in Figure 3B. [Modes for carrying out the invention]

[0009] The embodiments will be described below with reference to the drawings. In the following description, components having the same or similar functions will be denoted by the same reference numerals. Duplication of these components may be omitted. Note that the components described below do not limit the scope of the embodiments.

[0010] In this disclosure, terms are defined as follows: “Connection” may include electrical connections, not just mechanical ones. That is, “Connection” may include cases where two elements to be connected are directly connected, not just cases where two elements to be connected are connected with another element in between. “Accommodation” may include cases where only a part of a part is accommodated, not just cases where the rest of the part protrudes. “Facing” means that the virtual projections of two objects overlap when viewed from a particular direction. That is, “Facing” may include cases where two objects face each other with another member present between them, not just cases where two objects face each other. “Parallel,” “orthogonal,” or “same” may include cases where they are “approximately parallel,” “approximately orthogonal,” or “approximately the same,” respectively.

[0011] In this disclosure, the arrow X in the figure represents the front-to-back direction, the arrow Y represents the left-to-right direction, and the arrow Z represents the up-to-down direction. In the embodiment, the mating direction (insertion / removal direction) between the charging inlet 1 and the power supply connector (not shown) is described as the front-to-back direction. In this disclosure, the power supply connector side is considered the front and the charging inlet 1 side is considered the rear in the front-to-back direction. The power supply connector is mated and connected to the charging inlet 1 by moving from front to rear, and removed by moving in the opposite direction. Left and right in the left-to-right direction refer to left and right when facing forward. In the embodiment, the first connector part 3 and the second connector part 4, which will be described later, are arranged side by side in the vertical direction. The first connector part 3 is located above the second connector part 4.

[0012] In the following, when the X and Y directions are not distinguished, they may be referred to as the "horizontal direction." In the following, this embodiment will be described using the case where the X direction is the "front-back direction," the Y direction is the "left-right direction," and the Z direction is the "up-down direction" as an example. In the following, the +X direction will be referred to as "forward," the -X direction as "backward," the +Y direction as "left," the -Y direction as "right," the +Z direction as "upward," and the -Z direction as "downward." However, these expressions do not limit the direction of gravity of the charging inlet 1 (the installation orientation of the charging inlet 1).

[0013] (First Embodiment) <1. Configuration of the charging inlet> Figure 1 is a perspective view of the charging inlet 1 of the first embodiment. The charging inlet 1 is an in-vehicle component. The charging inlet 1 is a connector that is mounted on the body of a vehicle equipped with a battery, such as an electric vehicle (EV) or a plug-in hybrid electric vehicle (PHEV). When charging the vehicle's battery, a power supply connector (not shown) from a power supply device (not shown) is fitted into the charging inlet 1. With this power supply connector fitted into the charging inlet 1, power is supplied from the power supply device to the vehicle and the battery is charged.

[0014] The charging inlet 1 according to this embodiment has a first connector portion 3 and a second connector portion 4. Multiple signal terminals and power terminals are attached to these first connector portion 3 and second connector portion 4 from the -X direction. For example, multiple signal terminals connected to signal lines and multiple power terminals connected to power lines are inserted into and attached to the first connector portion 3. For example, a pair of power terminals connected to power lines are inserted into and attached to the second connector portion 4. The charging inlet 1 comprises a housing 10 and a housing cover 40.

[0015] <2. Housing Configuration> The housing 10 comprises a front housing 20 and a rear housing (not shown) connected to the rear of the front housing 20. The front housing 20 is molded from synthetic resin. The front housing 20 comprises an inner peripheral wall portion 21, an AC socket 25a, a DC socket 25b, an outer peripheral wall portion 22, and a mounting flange 24. The front housing 20 is provided symmetrically with respect to a central plane C1 (see Figure 3A) located in the center of the overall width and perpendicular to the Y direction.

[0016] The inner peripheral wall portion 21 is formed in a cylindrical shape extending in the X direction. An internal space 21a that opens in the +X direction is formed in the region surrounded by the inner peripheral wall portion 21. The internal space 21a is partitioned by the inner peripheral surface of the inner peripheral wall portion 21. A power supply connector (not shown) inserted from the +X direction is fitted into the internal space 21a. In the present embodiment, two inner peripheral wall portions 21 are provided side by side in the vertical direction (Z direction).

[0017] A cylindrical AC socket 25a extending in the X direction is disposed at a portion surrounded by the upper (+Z direction side) inner peripheral wall portion 21. Signal terminals and power terminals (not shown) are inserted and held in the AC socket 25a from the -X direction. Only one AC socket 25a is disposed on the upper inner peripheral wall portion 21. The upper inner peripheral wall portion 21 is formed in a cylindrical shape along the outer peripheral surface of the AC socket 25a. The upper inner peripheral wall portion 21, the AC socket 25a, the signal terminals, and the power terminals constitute the first connector portion 3.

[0018] A pair of cylindrical DC sockets 25b extending in the X direction are disposed at a portion surrounded by the lower (-Z direction side) inner peripheral wall portion 21. Power terminals are inserted and held in each DC socket 25b from the -X direction. Each power terminal is a charging terminal through which a charging current flows. The pair of DC sockets 25b are arranged side by side in the Y direction. An elliptical inner peripheral wall portion 21 that is long in the Y direction when viewed from the X direction is formed so as to surround the arrangement portions of the pair of DC sockets 25b from the outer peripheral side. By inserting a power supply connector into the lower inner peripheral wall portion 21, the power supply connector is connected to the pair of power terminals. The lower inner peripheral wall portion 21, the DC sockets 25b, and the pair of power terminals constitute the second connector portion 4.

[0019] The upper inner peripheral wall portion 21 and the lower inner peripheral wall portion 21 are connected to each other in the Z direction. The lower end portion of the upper inner peripheral wall portion 21 and the upper end portion of the lower inner peripheral wall portion 21 are each cut out so as to form a gap 21b in the Y direction. By connecting the lower end portion of the upper inner peripheral wall portion 21 and the upper end portion of the lower inner peripheral wall portion 21 to each other in the Z direction, the internal space 21a of the upper inner peripheral wall portion 21 and the internal space 21a of the lower inner peripheral wall portion 21 communicate with each other through the gap 21b.

[0020] The outer peripheral wall portion 22 is provided so as to surround the arrangement portions of the upper and lower two inner peripheral wall portions 21 from the outer peripheral side. The outer peripheral wall portion 22 is formed in a cylindrical shape extending in the X direction. The outer peripheral wall portion 22 forms the outer shape of the portion of the front housing 20 excluding the mounting flange 24. The outer peripheral wall portion 22 has a rectangular shape that is long in the vertical direction and chamfered at the four corners in an arc shape when viewed from the X direction. The +X direction end portion of the front housing 20 (including the +X direction end portions of the outer peripheral wall portion 22 and the upper and lower inner peripheral wall portions 21) is formed along a plane orthogonal to the X direction.

[0021] The outer peripheral wall portion 22 includes an upper surface portion 22a extending in the Y direction, a pair of left and right upper arc portions 22b respectively connected to both left and right sides of the upper surface portion 22a, a pair of left and right side surface portions 22c connected to the lower sides of the left and right upper arc portions 22b, a pair of left and right lower arc portions 22d connected to the lower sides of the left and right side surface portions 22c, and a lower surface portion 22e spanning between the left and right inner ends of the left and right lower arc portions 22d. The lower arc portion 22d is formed in an arc shape with a smaller curvature than the upper arc portion 22b and is arranged so as to be located more inward in the left and right direction toward the lower side. The left and right side surface portions 22c extend in the vertical direction parallel to each other.

[0022] Between the upper surface portion 22a and the upper inner peripheral wall portion 21, a pair of upper vertical wall portions 23 are formed that extend once in the +Z direction and then bend inward in the left and right directions from both left and right sides of the inner peripheral wall portion 21 toward both left and right sides of the upper surface portion 22a. Above the inner peripheral wall portion 21, a trapezoidal space is formed that is surrounded by the upper surface portion 22a and the left and right upper vertical wall portions 23 when viewed from the X direction.

[0023] Hereinafter, on both the left and right sides of the front housing 20, the wall portion formed by the upper vertical wall portion 23, the side portion of the upper inner peripheral wall portion 21, and the side portion of the lower inner peripheral wall portion 21 in a continuous manner will be referred to as the corrugated wall portion 26. In the upper and lower intermediate portions of the left and right corrugated wall portions 26, a recess 26a is formed that is recessed toward the space between the upper and lower inner peripheral wall portions 21.

[0024] Furthermore, the wall portion formed by the continuous formation of an upper arc portion 22b, a side portion 22c, and a lower arc portion 22d on both the left and right sides of the front housing 20 is referred to as the outer wall portion 27. A vertically elongated side space 28 is formed between the outer wall portion 27 and the corrugated wall portion 26. The portion enclosed by the +X ends of the outer wall portion 27 and the corrugated wall portion 26 is a side opening 28a that opens the side space 28 toward the +X direction. Including the left and right side openings 28a, an opening 29 is formed in the front housing 20 that opens toward the +X direction.

[0025] The mounting flange 24 protrudes further outward from the outer peripheral wall portion 22 when viewed from the X direction. The mounting flange 24 has bolt holes 24a on the left and right sides of the upper and lower parts of the outer peripheral wall portion 22 when viewed from the X direction. The charging inlet 1 is attached to the vehicle body by inserting mounting bolts (not shown) through these bolt holes 24a and screwing and tightening each mounting bolt into the screw holes (not shown) on the vehicle body side. A rear housing (not shown) protrudes from the rear of the mounting flange 24 and guides power lines and the like into the vehicle body.

[0026] <3. Housing Cover Configuration> As shown in Figure 1, the housing cover 40 is attached to the opening 29 in the front housing 20 of the charging inlet 1 that opens in the +X direction. Referring to Figures 2 and 3A, the housing cover 40 comprises a pair of opposing sides 41 that face each other in the Y direction, and a connecting side 47 that connects the upper ends 41b of the pair of opposing sides 41 in the Z direction. The housing cover 40 is a one-piece molded product made of insulating resin. The housing cover 40 is provided symmetrically with respect to the central plane C1. Reference numeral 41c in the figures indicates the lower end of each opposing side 41.

[0027] Each opposing side portion 41 is provided with a cover plate portion 42 that, when viewed from the X direction, has a shape that overlaps with the side space 28 and the opening 28a. The cover plate portion 42 is flat along a plane perpendicular to the X direction. An inner wall portion 43 extends from the side edge of the cover plate portion 42 on the left-right inner side (the side closer to the center plane C1) along the X direction. An outer wall portion 44 extends from the side edge of the cover plate portion 42 on the left-right outer side (the side further from the center plane C1) along the X direction. Each opposing side portion 41 has a U-shaped cross-section that opens to the rear, formed by the cover plate portion 42 that forms the front wall and the inner wall portion 43 and outer wall portion 44 that form the left-right inner and outer walls. Each opposing side portion 41 has the aforementioned U-shaped (in other words, bowl-shaped) cross-section and extends in the Z direction. Behind the lower end of the cover plate portion 42, a lower end wall portion 45 is formed that faces the rectangular parallelepiped-shaped lower surface portion 22e from the left and right outer sides. Each opposing side portion 41 is not limited to a bowl shape with a partially open cross-section, but may also be a hollow shape with a closed cross-section.

[0028] The inner wall portion 43 is formed to follow the left-right outer surface of the corrugated wall portion 26 of the front housing 20. The outer wall portion 44 is formed to follow the left-right inner surface of the outer wall portion 27 of the front housing 20. Elastic pieces 44a are formed at multiple locations on the top and bottom of the outer wall portion 44, which engage with locking claws (not shown) formed on the inner surface of the outer wall portion 27 when the housing cover 40 is attached to the front housing 20. At the bottom of the inner wall portion 43, a notch 43a is formed in the inner circumferential wall portion 21 to avoid interference with the outer wall portion 44, as the left-right width of each opposing side portion 41 narrows on the left and right outer sides of the lower inner circumferential wall portion 21. A projection 41a is formed in the upper and lower middle portion of the inner wall portion 43, which is inserted into a recess 26a formed in the upper and lower middle portion of the corrugated wall portion 26 of the front housing 20.

[0029] The connecting edge portion 47 has a narrower cross-sectional shape than the cross-sectional shape in the Z direction of each opposing edge portion 41 (the U-shaped cross-sectional shape described above) and extends in the Y direction. The connecting edge portion 47 is more flexible than each opposing edge portion 41 (especially easily bends along a plane perpendicular to the X direction), making it easier for the elastic deformation described later to occur when attaching the housing cover 40 to the front housing 20. The connecting edge portion 47 has a solid cross-sectional shape, in contrast to the hollow cross-section of each opposing edge portion 41. The connecting edge portion 47 is formed to be flush with the cover plate portion 42 (to form a part of the cover plate portion 42). The phrase "more flexible than each opposing edge portion 41" means, for example, that its second moment of area is smaller than that of each opposing edge portion 41. If each opposing edge portion 41 and the connecting edge portion 47 are made of different materials, the elastic moduli of each material may be different.

[0030] Figure 3A is a front view of the housing cover 40 as a standalone unit, viewed from the X direction, with no external force acting on it. As shown in Figure 3A, in its standalone state, the housing cover 40 has its left and right opposing sides 41 on the lower sides that are open outward in the left-right direction. The line 21c in the figure shows the inner surfaces of the left and right side portions 22c when the housing cover 40 and the front housing 20 are superimposed. In Figure 3A, the outer surfaces of the left and right opposing sides 41 are inclined so that the lower side is positioned further outward in the left-right direction relative to the inner surfaces of the left and right side portions 22c which are parallel in the vertical direction.

[0031] The line T1 in the figure indicates the lower surface of the upper portion 22a of the front housing 20. In Figure 3A, the upper edge of the connecting edge 47 (corresponding to the upper end of the housing cover 40) is slightly curved downwards with respect to the straight line T1 which is parallel to the left-right direction (the connecting edge 47 in this case is shown by a dashed line in Figure 3C).

[0032] Figure 3B is a front view from the X direction showing the housing cover 40 attached to the opening 29 of the front housing 20. As shown in Figure 3B, the housing cover 40 is fitted into the opening 29 of the front housing 20 in a state where it is elastically deformed so that the lower ends 41c of the pair of opposing sides 41 are brought closer together in the Y direction. Once fitted into the opening 29 of the front housing 20, the housing cover 40 is pressed against the inner surface of the opening 29 (the inner surface of the outer wall portion 27) by a force that tries to restore it to its state before elastic deformation (a force that tries to open the lower ends 41c of the pair of opposing sides 41 apart from each other). This configuration suppresses rattling of the housing cover 40 and ensures a stable mounting state.

[0033] The deformation that brings the lower ends 41c of a pair of opposing sides 41 closer together is achieved by the bending of the connecting side 47, which is more flexible than each of the opposing sides 41. In its individual state, the connecting side 47 has a downwardly convex curved shape, but as the pair of opposing sides 41 move closer together, it deforms to bulge upward. In Figures 3B and 3C, the connecting side 47 deforms so that, for example, its upper edge becomes parallel to (or overlaps with) the straight line T1. The connecting side 47 after elastic deformation (shown as a solid line in the figure) is displaced upward by a dimension D1 compared to the connecting side 47 before elastic deformation (shown as a dashed line in the figure).

[0034] By utilizing the deformation of this connecting edge portion 47, for example, if the connecting edge portion 47 is fitted into the opening 29, it becomes possible to press the connecting edge portion 47 against the upper inner surface of the opening 29, thereby further stabilizing the mounting state of the housing cover 40.

[0035] <4. Action and Effects> One embodiment of the housing cover 40 is a housing cover 40 that is attached to an opening 29 in the front housing 20 of the charging inlet 1 that opens toward one side in a first direction (front side in the front-rear direction), and comprises a pair of opposing sides 41 that face each other in a second direction (left-right direction) that intersects with the first direction, and a connecting side 47 that connects the ends (upper ends 41b) of the pair of opposing sides 41 in a third direction (up-down direction) that intersects with the first and second directions. The connecting side 47 is more flexible than each of the pair of opposing sides 41, and is fitted into the opening 29 of the front housing 20 in a state of elastic deformation that causes it to bulge upward due to displacement that brings the other ends (lower ends 41c) of the pair of opposing sides 41 in the third direction closer together.

[0036] In this configuration, the housing cover 40 is fitted into the opening 29 of the front housing 20 in a deflected state with the pair of opposing sides 41 displaced to bring them closer together. The force that causes the housing cover 40 to return to its state before elastic deformation (the force that causes the pair of opposing sides 41 to open away from each other) presses the pair of opposing sides 41 against the inner surface of the opening 29. This configuration allows for sufficient clearance in the opening 29 to mount the housing cover 40, while also stabilizing the mounting state of the housing cover 40 after it has been installed.

[0037] Furthermore, when the pair of opposing sides 41 are displaced to bring them closer together, the connecting side 47, which is more flexible than each of the pair of opposing sides 41, curves to bulge outwards in one direction (upwards, outside the region sandwiched between the pair of opposing sides 41). In this embodiment, the connecting side 47, which had a concave upper surface before elastic deformation, curves to become flat or convex after elastic deformation. With this configuration, if the connecting side 47 is fitted into the opening 29, the housing cover 40 can be pressed against the inner surface of the opening 29 at three points, including the connecting side 47 and the pair of opposing sides 41. This configuration makes the mounting state of the housing cover 40 even more stable.

[0038] In the housing cover 40 described above, each of the pair of opposing sides 41 has a hollow or bowl-shaped cross-section and extends in the vertical direction, while the connecting side 47 has a solid cross-section that is narrower than each of the opposing sides 41 and extends in the horizontal direction. With this configuration, by making each opposing side portion 41 hollow or bowl-shaped in cross-section, it is possible to suppress weight increase while ensuring the rigidity of each opposing side portion 41. By making the connecting side portion 47 thinner in cross-section than each opposing side portion 41, it is possible to easily and compactly form the connecting side portion 47, which is more flexible than each opposing side portion 41. By making the connecting side portion 47 solid in cross-section, buckling of the flexible connecting side portion 47 can be suppressed.

[0039] The charging inlet 1 of this embodiment comprises a front housing 20 that holds terminals, and a housing cover 40 that is attached to an opening 29 in the front housing 20 that opens toward one side in a first direction. With this configuration, the housing cover 40 provides sufficient clearance in the opening 29 of the housing for mounting the housing cover 40, while also stabilizing its mounting state after installation.

[0040] The configuration in the above embodiment is just one example of the present invention, and various modifications are possible without departing from the spirit of the invention, such as replacing the components of the embodiment with well-known components. [Explanation of symbols]

[0041] 1. Charging inlet 20 Front Housing (Housing) 29 Opening 40 Housing Cover 41 Opposite sides 47 Connecting edge 41b Upper end (one end in the third direction) 41c Lower end (the other end in the third direction)

Claims

1. A housing cover that is attached to an opening in the housing of a charging inlet that opens toward one side in a first direction, It comprises a pair of opposing sides facing each other in a second direction intersecting the first direction, and a connecting side connecting the ends of the pair of opposing sides in a third direction intersecting the first and second directions, The connecting edge is more flexible than each of the pair of opposing edges. A housing cover that is fitted and installed into the opening of the housing in a state of elastic deformation caused by displacement that brings the other ends of the pair of opposing sides in the third direction closer together.

2. The housing cover according to claim 1, wherein the connecting edge is elastically deformed so as to be displaced to one side in the third direction by displacement that brings the other ends of the pair of opposing edges in the third direction closer together, and is fitted and installed into the opening of the housing.

3. Each of the pair of opposing sides has a hollow or bowl-shaped cross-section and extends in the third direction. The housing cover according to claim 1 or 2, wherein the connecting edge portion has a cross-sectional shape narrower than each of the pair of opposing edges and extends in the second direction.

4. The housing cover according to claim 3, wherein the connecting edge portion has a solid cross-sectional shape and extends in the second direction.

5. A charging inlet comprising a housing that holds terminals, and a housing cover attached to an opening in the housing that opens toward one side in a first direction, The housing cover comprises a pair of opposing sides facing each other in a second direction intersecting the first direction, and a connecting side connecting the ends of the pair of opposing sides in a third direction intersecting the first and second directions, The connecting edge is more flexible than each of the pair of opposing edges. The housing cover is fitted and installed into the opening of the housing in a state of elastic deformation caused by displacement that brings the other ends of the pair of opposing sides in the third direction closer together, and is a charging inlet.

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