Power input connector assembly

Abstract

Power input connector assembly (100) for an electric vehicle charging station (200), the power input connector assembly (100) comprising a residual current device (110) configured to be arranged to a printed circuit board (300), a support module (120) and wire terminal block module (130), wherein the support module (120) being configured to enable direct connection of connection members (140a-b) to the wire terminal block module (130) and the printed circuit card (300).

Description

[0001] Power input connector assembly

[0002] The disclosed embodiments relate to a power input connector assembly for an electric vehicle charging station.

[0003] The disclosed embodiments relate especially to a power input connector assembly for an electric vehicle charging station including a residual current device.

[0004] Background

[0005] With the green shift ongoing there has been a considerable increase in electric vehicles, wherein this brings along a requirement for charging stations both at home and at work, as well as fast chargers. There exist a number of different solutions and types of chargers and charging stations. Lately, there has also been an increasing focus on safety of such chargers and charging stations, especially for home and work charging stations that are not fast chargers.

[0006] One of the requirements is that the home and work charging stations should have a residual current device (RCDs) to protect against risks for electric shock and fires. The RCD will, when detecting a leakage of electrical current to ground, be activated and cut off the electrical power supplied to a specific fuse.

[0007] There have been proposed different methods for detecting the residual current in the mentioned charging stations. One method is to measure residual current by passing power input phases through the RCD sensor or by integrating the RCD sensor in the input connector(s). Examples of these solutions are, among others, described in WO 2020167141 Al, NO 347622, DE 102015002704 Al and EP 4279325 Al.

[0008] The main disadvantages of the mentioned prior art solutions are that they involve many components and are cumbersome to assemble, due to they are requiring a separate distribution circuit board to connect connectors running from wire terminals via the RCD to the printed circuit board (PCB).

[0009] The prior art solutions further suffer from problems in meeting the requirements for creepage and clearance. Many of the prior art solutions further suffer from not meeting the requirements for dust and water tightness, requiring that the outer encapsulation / housing meet the Ingress Protection (IP) requirements, resulting in problems with internal cooling of the electric vehicle charging station.

[0010] Another disadvantage with some of the prior art solutions is that they make use of a physical turn switch to set the correct fuse size that is connected to the electric vehicle charging station. This requires physical access to the printed circuit board and constitutes a potential risk for water and / or dust penetration.

[0011] There is thus a need for a power input connector assembly for an electric vehicle charging station solving the issues of the prior art solutions.

[0012] Summary

[0013] The disclosed embodiments provide a power input connector assembly for an electric vehicle charging station.

[0014] Provided herein is a power input connector assembly for an electric vehicle charging station including residual current device (RCD).

[0015] Provided herein is a power input connector assembly for an electric vehicle charging station that meets the requirements for creepage and clearance.

[0016] Also provided herein is a power input connector assembly for an electric vehicle charging station having few parts.

[0017] Also provided herein is a power input connector assembly for an electric vehicle charging station being easy to assemble.

[0018] Also provided herein is a power input connector assembly for an electric vehicle charging station having minimal size.

[0019] Also provided herein is a power input connector assembly for an electric vehicle charging station having low total power loss due to few parts in the current carrying path. Also provided herein is a power input connector assembly for an electric vehicle charging station not requiring a separate printed circuit board (PCB) for connecting connection members transferring the current through the RCD.

[0020] Also provided herein is a power input connector assembly for an electric vehicle charging station that is not suffering from derating, resulting in that the charging current must be reduced due to increased temperature, by comprising a dustproof sealing according to IP54 that is required to meet the requirements of OVCIII (over voltage category III).

[0021] Also provided herein is a power input connector assembly for an electric vehicle charging station that is cheaper to produce and assemble compared to prior art solutions.

[0022] Provided herein is a power input connector assembly for an electric vehicle charging station maintaining the interior encapsulation / barrier, by that the internal encapsulation is provided with a touch switch or button for testing of the RCD ground fault protection.

[0023] Also provided herein is a power input connector assembly for an electric vehicle charging station maintaining the interior encapsulation / barrier, by that the internal encapsulation is provided with a touch switch for setting the fuse size.

[0024] Provided herein is a power input connector assembly for an electric vehicle charging station maintaining the interior encapsulation / barrier, by that the internal encapsulation is provided with a touch switch configured to test the RCD ground fault protection and setting of the fuse size.

[0025] Also provided herein is a power input connector assembly for an electric vehicle charging station comprising a display configured to indicate that a test of the RCD ground fault protection is being performed.

[0026] Provided herein is a power input connector assembly for an electric vehicle charging station wherein the PCB is configured to show the set fuse size of the electric vehicle charging station.

[0027] Also provided herein is a power input connector assembly for an electric vehicle charging station that meets the demands of IEC EN62955, where all the electric phases are mechanically disconnected at the same time at a ground fault, and wherein the distance of the terminals in disconnected distance is larger than 3 mm. Also provided herein is a power input connector assembly for an electric vehicle charging station enabling automated detection of breach in protective earthed neutral (PEN) conductor and neutral connector (P).

[0028] The invention

[0029] A power input connector assembly for an electric vehicle charging station is defined by the technical features of claim 1. Preferable features of the power input terminal module are described in the dependent claims.

[0030] The main components of an electric vehicle charging station is a power output connection assembly (PICA) and a power output connector assembly (POCA) arranged in a housing, wherein the PICA is arranged to a power supply and the POCA is arranged to a connector enabling connection to an electric vehicle for charging. The electric vehicle charging station further comprises electronics for controlling the electric vehicle charging station, such as a printed circuit board (PCB), communication means, etc., and wherein the components are arranged in a housing for attachment of the electric vehicle charging station to a support structure, such that the only accessible component is the connector for connecting the charging cable. These components are well known for a skilled person and needs no further detailed description herein.

[0031] The present invention is related to a PICA for such an electric vehicle charging station.

[0032] The inventive embodiments of the present invention provide a PICA for an electric charging station that meets the requirements of creepage and clearance.

[0033] The inventive embodiments of the present invention provide a PICA for an electric charging station removing the need for a separate distribution circuit board for connection of connection members running from wire terminals of a wire terminal block module via a residual current device to the PCB.

[0034] In accordance with the present invention, the PICA comprises a residual current device (RCD) configured to be arranged to a printed circuit board (PCB) of the electric vehicle charging station by a lower side thereof.

[0035] The PICA according to the present invention further comprises a support module arranged to the upper side of the RCD and a wire terminal block module arranged to the other side of the support module. In accordance with one embodiment of PICA, the support module comprising a base and a leg protruding downwards from the base, wherein the leg is configured to accommodate and position connection members in a through hole of the RCD, and wherein distal lower parts of the leg extend through holes in the PCB with a gap / spacing therebetween, and protrude a length at the other side of the PCB.

[0036] In accordance with the present invention, the respective connection member at one side is electrically connected directly to a respective wire terminal of the wire terminal block module and at the opposite side is directly connected to the PCB.

[0037] According to one embodiment of PICA according to the present invention, the support module comprises a separate leg protruding downwards from the base for a ground connection member. The leg positions the ground connection member outside the RCD.

[0038] In accordance with one embodiment of the PICA according to the present invention, the connection members are mainly L-shaped.

[0039] According to one embodiment of the PICA according to the present invention, the base and legs of the support module are provided with respective recesses and tracks aligned and configured to receive and accommodate the respective L-shaped connection members.

[0040] In accordance with one embodiment of the PICA according to the present invention, the support module comprises locking devices associated with the respective track and the L-shaped connections members are provided with at least one corresponding locking recess or slot for mutual engagement retaining the L-shaped connection members to the support module.

[0041] According to one embodiment of the PICA according to the present invention, the wire terminals of the wire terminal block module are provided with one or more connectors at lower side facing the connection members, and the connection members are at facing sides provided with at least one corresponding connection slot for connection of the respective connection members and wire terminals directly.

[0042] In accordance with one embodiment of the PICA according to the present invention, the base of the support module is provided with an upwards protruding flange configured for engagement with a corresponding flange or wall of an interior encapsulation of the electric vehicle charging station to provide a dustproof interior sealing. According to a further embodiment of the PICA according to the present invention, the interior encapsulation is provided with at least one touch switch or button enabling, remote of the printed circuit board, testing of residual current device ground fault protection and / or setting of electric vehicle charging station fuse size, while maintaining the dust and water tightness of the interior encapsulation.

[0043] In accordance with a further embodiment of the PICA according to the present invention, the interior encapsulation is provided with a display configured to indicate that the test of the residual current device ground fault protection is being performed, while maintaining the dust and water tightness of the interior encapsulation.

[0044] According to a further embodiment of the PICA according to the present invention, the printed circuit board is provided with a display configured to show the set fuse size of the electric vehicle charging station.

[0045] By the present invention is provided a PICA for electric vehicle charging stations that meets the requirement for creepage and clearance. By the PICA according to the present invention, the electric vehicle charging station meets the demands of IEC EN62955, where all the electric phases are mechanically disconnected at the same time at a ground fault, and wherein the distance of the terminals in disconnected distance is larger than 3 mm.

[0046] The present invention provides a PICA that has few parts and thus contributes to the electric vehicle charging station being easy to assemble, having minimal size (do not require separate distribution PCB) as well as will be cheaper both to manufacture and assemble compared to prior art solutions.

[0047] By the present invention is provided a PICA that results in lower total power loss in the electric vehicle charging station due to few parts in the current carrying path, hereunder not requiring a separate distribution PCB.

[0048] The present invention further provides a solution that meets the requirements of dustproof sealing (IP54) of over voltage category III, resulting in that the electric vehicle charging device will not suffer from derating due to high temperature resulting in that the charging current will have to be reduced. This also enables the electric vehicle charging station to include ventilating devices.

[0049] By the present invention is provided a solution where one does not need physical access to the PCB for setting the correct fuse size, thus maintaining the dust and water tightness intact. Moreover, by the present invention is provided a power input connector assembly for an electric vehicle charging station enabling the electric vehicle charging station to have a test button for performing testing of the RCD ground fault protection, while maintaining the dust and water tightness of the interior encapsulation.

[0050] Further preferable features and advantageous details of the present invention will appear from the following example description, claims and attached drawings.

[0051] Example

[0052] The present invention will below be described in further detail with reference to the attached drawings, where:

[0053] Fig. la is a principle drawing of a power input connector assembly according to one embodiment of the present invention, seen inclined from a front side,

[0054] Fig. lb is a principle drawing of the power input connector assembly in Fig. la seen inclined from rear side,

[0055] Fig. 2 is a principle drawing of a residual current device according to the present invention,

[0056] Fig. 3a-b are principle drawings of a support module according to the present invention seen inclined from above and below,

[0057] Fig. 3c-d are principle drawings of the support module in Fig. 3a-b with connection members accommodated therein,

[0058] Fig. 4 is a principle drawing showing further details of the connection members according to the present invention,

[0059] Fig. 5 is a cross-sectional side view showing further details of the power input connector assembly according to the present invention,

[0060] Fig. 6 is a principle drawing showing the power input connection assembly with the PCB from the underside showing further details of the present invention,

[0061] Fig. 7 is a principle drawing of a wire terminal block module according to the present invention seen from the underside, and Fig. 8a-c are examples of an electric vehicle charging station with a power input connection assembly according to the present invention, wherein Fig. 8b-c show the vehicle charging station with the front part removed.

[0062] Reference is now made to Fig. la-b showing principle drawings of a power input connector assembly (PICA) 100 according to the present invention seen inclined from the front side and rear side, which PICA 100 is suitable for use in an electric vehicle charging station 200, see Fig. 8a-c. The PICA 100 according to the present invention comprises as main components a residual current device (RCD) 110, a support module 120 and a wire terminal block module 130.

[0063] According to the present invention, the RCD 110 is arranged on and connected to a main power printed circuit board (PCB) 300 of the electric vehicle charger station 200 via connections 111, see Fig. lb, 5 and 6. The RCD 110, which is known perse, see also Fig. 2, is formed by a housing 112 with a residual current sensor 113 enclosing a through hole 114 adapted for accommodating connection members 140a-b, further described below. The housing 112 is further provided with a fixation flange 115 provided with fixation holes 116 for arrangement of the support module 120 to the RCD 110. The mentioned connections 111 are usually arranged at the lower side of the RCD 110, i.e. the side facing the PCB 300 for connection thereto.

[0064] Reference is now made to 3a-d showing principle drawings of a support module 120 according to the present invention, wherein Fig. 3a-b show the support module 120 without connection members 140a-b accommodated therein and Fig. 3c-d show corresponding figures to Fig. 3a-b wherein the connection members 140a-b are accommodated therein.

[0065] The support module 120 is formed by a base 121 and a leg 122 protruding downwards from the base 121, thus forming a mainly T-shaped body The mentioned leg 122 is adapted to be accommodated in the mentioned through hole 114 of the RCD 110 and has a length longer than the total height of the RCD 110 and PCB 300, while the upper (horizontal) base 121 exhibits a size and shape corresponding to the size and shape of the upper part of the housing 112 of the RCD 110 for contact and engagement therewith. The base 121 is further provided with an upwards protruding flange 123 extending in a shape at least large enough to receive and accommodate the wire terminal block module 130. The mentioned flange 123 extends with a height configured to be in engagement with an interior encapsulation 250 (see Fig. 5 and 8b) of the electric vehicle charging station 200 to provide a dustproof sealing IP54, which is required to meet the requirements of OVCIII (over voltage category III), to protect the circuit board 300 and other electrical components interior the electric vehicle charging station 200. In the shown embodiment, the mentioned flange 123 is a double walled flange wherein the gap between the walls of the flange 123 is configured to receive and accommodate a corresponding flange or wall 251 of the interior encapsulation 250, see Fig. 5, for mutual engagement and thus sealing therebetween. To further improve the sealing, a gasket or similar (not shown) can be arranged in the gap of mentioned flange 123 to increase the dustproof properties of the sealing. In this manner, the interior of the electric vehicle charging station 200 is dustproof, resulting in that the dustproof requirements of the exterior encapsulation of the electric vehicle charging station 200 are reduced, enabling the use of ventilation features (not shown) in the electric vehicle charging station 200 and preventing derating of the vehicle charging station 200 due to too high temperatures resulting in that the current must be reduced.

[0066] The base 121 is further provided with corresponding attachment means 124 adapted for alignment with the fixation holes 116 of the RCD 110 when the support module 120 is arranged to the RCD 110, wherein attachment means, such as screws 117 (Fig. lb) or similar, can be inserted for fixation of the support module 120 to the RCD 110. In the shown embodiment, the attachment means 124 is a threaded hole.

[0067] Accordingly, the leg 122 of the support module 120 is adapted to be received and accommodated in the through hole 114 so that the lower distal ends 125 thereof is extending through corresponding through holes 301 of the PCB 300, see Fig. 6.

[0068] The support module 120 is further provided with a separate leg 128 protruding downwards from the base 121 at a distant part of the base 121, i.e. with a distance from the leg 122, wherein the leg 128 is configured for receiving and accommodating a ground (GND) connection member 140b, further described below. In the shown embodiment, the leg 128 is protruding downwards from a corner of the base 121.

[0069] In accordance with one embodiment of the present invention, the PICA 100 it comprises the use of L-shaped (high-power) connection members 140a-b, as shown in Fig. 4, wherein the connection member 140b is the ground (GND) connection member and the connection members 140a are LI, L2, L3 and N, wherein the connection members 140a-b are configured for connection to the PCB 300, further described below. In accordance with the present invention, the base 121 is further provided with respective recesses 126 for receiving and accommodating bases / foot of the respective L-shaped connection members 140a-b, and the legs 122, 128 are provided with associated (aligned) tracks or recesses 127 for receiving and accommodating the respective legs of the L-shaped connection members 140a-b. In this manner the L-shaped connection members 140a-b are accommodated, separated / isolated and retained in the support module 120 with the required distances and clearance therebetween.

[0070] The mentioned L-shaped connection members 140a-b have a length that is some longer than the legs 122 and 128 of the support module 120 for connection with the PCB 300. To meet the requirements of creepage, the PCB 300 is provided with through holes 301 (Fig. 6) for receiving distal lower parts 125 of the leg 122 with a spacing / gap, positioning the distal lower parts 125 of the leg 122 under the PCB 300, ensuring that there is no physical contact between the support module 120 and PCB 300. According to the present invention, the mentioned distal lower parts 125 protrude a length under / beyond the PCB 300 that is longer than the connection members 140a to ensure that the PICA 100 according to the present invention meets the requirements for creepage. In accordance with the shown embodiment of the support module 120, the distal lower parts 125 are L-shaped and forms physical barriers between the (hot) connection members 140a.

[0071] The mentioned tracks 127 and recesses 126 thus retain the respective L-shaped connection members 140a-b with the base thereof positioned in the base 121 of the support module 120 and the leg thereof positioned in the legs 122 and 128 of the support module 120. For ensuring that the L-shaped connection members 140a-b remain in the respective tracks 127 and recesses 126 of the support module 120, the respective tracks 127 are provided with a retaining biasing locking device 129 adapted to be received in a corresponding locking recess or slot 141 in the leg of the L-shaped connection members 140a-b. In this manner the respective L-shaped connection member 140a-b is detachably secured to the respective track 127 and recesses 126 of the support module 120 by the biasing locking device 129.

[0072] According to the present invention, the distal lower ends of the mentioned L-shaped connection members 140a-b are received in corresponding through receiving holes 302 in the PCB 300, see Fig. 5 and 6, such that the distal lower ends protrude through the PCB 300 and are at the lower or upper side of the PCB 300 connected to corresponding connectors (not shown) of the PCB 300, e.g. by press-fit or soldering or a combination of these techniques.

[0073] In accordance with the present invention, the support module 120 is attached to the RCD 110 and the combined support module 120 and RCD 110 is next arranged to the PCB 300, wherein the PCB 300, support module 120 and RCD 110 are detachably secured to each other by attachment means 150, such as a screw, see Fig. 6, extending through an attachment hole (not shown) in the PCB 300 and into a threaded hole (not shown) in the leg 122 of the support module 120. The wire terminal block module 130 of the PICA 100 according to the present invention comprises wire terminals 131a-b for the respective connection member 140a-b, wherein the terminal 131b is a ground terminal and the terminals 131a are for LI, L2, L3 and N. In accordance with the present invention, the wire terminals 131a-b are provided with one or more connectors 132 (see Fig. 5 and 7) at lower side facing the respective L-shaped connection member 140a-b for attachment and electrical connection to the respective L-shaped members 140a-b via connection slots 142 (see Fig. 4) arranged in the facing side of the L-shaped connection member 140a-b. The terminals 131a-b are further provided with a lock and release mechanism 133 (see Fig. la, 7) for fixing electric wires (not shown) of a power source (not shown) to the connectors 132.

[0074] Reference is no made to Fig. 8a-c showing examples of a vehicle charging station 200 suitable for making use of the PICA 100 according to the present invention. The shown vehicle charging station 200 comprises a housing formed by a front part 210 and rear part 220, detachable from each other. The electric vehicle charging station 200 further comprises the PICA 100 according to the present invention and a power output connector assembly (POCA) 230 arranged to the rear part 220 as shown in Fig. 8b., wherein the PICA 100 is arranged to a power supply (not shown) and the POCA 230 is arranged to a connector 240 (shown with a lid 241 in Fig. 8b) enabling connection to an electric vehicle for charging. The electric vehicle charging station 200 further comprises electronics for controlling the electric vehicle charging station 200, such as a printed circuit board (PCB) 300 as discussed above, communication means (not shown), etc., and wherein the components are arranged in the housing formed by the parts 210, 220 for attachment of the electric vehicle charging station 200 to a support structure (not shown), such that the only accessible component is the connector 240 for connecting the charging cable.

[0075] As can be seen from Fig. 8b and 5, the interior encapsulation 250 provides a dustproof sealed interior environment for components of the electric vehicle charging station 200.

[0076] Reference is now made to Fig. 8c showing a further embodiment the interior encapsulation 250, wherein the interior encapsulation 250 is provided with at least one touch switch or button 260, such as capacitance, resistance or piezoelectric, integrated to maintain the dust and water tightness of the interior encapsulation 250. In the shown embodiment, a test of the RCD ground fault protection can be activated by pressing the mentioned switch or button 260 a pre-set time, such as e.g., but not limited to 3-5 seconds. The mentioned interior encapsulation 250 in accordance with a further embodiment comprises a display 261, such as an LCD, LED or similar, integrated to maintain the dust and water tightness of the interior encapsulation 250 and configured to indicate that the test of the RCD ground fault protection is being performed. In accordance with the present invention, the interior encapsulation 250 is partly or entirely transparent. The interior encapsulation 250 is preferably at least transparent in areas with displays 310 or indicators of the PCB 300.

[0077] According to a further embodiment of the present invention, the same touch switch or button 260 is configured for setting the fuse size of the electric vehicle charging station 200, wherein the fuse size is shown on a display 310 of the PCB 300, viewable through the transparent, at least parts thereof, interior encapsulation 250. In an alternative embodiment, the interior encapsulation 250 is provided with a separate touch switch or button 260 for setting the fuse size.

[0078] The mentioned fuse size will typically be set by pushing the touch switch or button 260 enabling toggling between pre-set fuse sizes. In this manner, the electric vehicle charging station 200 can be set up without the use of applications on a phone or other communication means, as well as without danger of breaking the barrier of the interior encapsulation 250.

Claims

Claims1. Power input connector assembly (100) for an electric vehicle charging station (200), the power input connector assembly (100) comprising a residual current device (110) configured to be arranged to a printed circuit board (300) of the electric vehicle charging station (200) by a lower side thereof, a support module (120) arranged to the upper side of the residual current device (110) and a wire terminal block module (130) arranged to the other side of the support module (120), wherein the support module (120) comprising a base (121) and a leg (122) protruding downwards from the base (121), wherein the leg (122) is configured to accommodate and position connection members (140a) in a through hole (114) of the residual current device (110), and wherein distal lower parts (125) of the leg (122) extend through holes (301) in the printed circuit board (300) with a gap therebetween, and protrude a length at the other side of the printed circuit board (300), and comprising a separate leg (128) protruding downwards from the base (121) for a ground connection member (140b), wherein the connection members (140a-b) are mainly L-shaped, wherein the respective connection member (140a-b) at one side is electrically connected directly to a respective wire terminal (131a-b) of the wire terminal block module (130) and at the opposite side is directly connected to the printed circuit board (300), wherein the base (121) and legs (122, 128) of the support module (120) are provided with respective recesses (126) and tracks (127) aligned and configured to receive and accommodate the respective L-shaped connection members (140a-b), and wherein the support module (120) comprises locking devices (129) associated with the respective track (127) and the L-shaped connections members (140a-b) are provided with at least one corresponding locking recess or slot (141) for mutual engagement retaining the L-shaped connection members (140a-b) to the support module (120).

2. Power input connector assembly (100) according to claim 1, wherein the wire terminals (131a-b) of the wire terminal block module (130) are provided with one or more connectors (132) at lower side facing the connection members (140a-b), and the connection members (140a-b) are at facing sides provided with at least one corresponding connection slot (142) for connection of the respective connection members (140a-b) and wire terminals (131a-b) directly.

3. Power input connector assembly (100) according to any preceding claim, wherein the base (121) of the support module (120) is provided with an upwards protruding flange (123) configured forengagement with a corresponding flange or wall (251) of an interior encapsulation (250) of the electric vehicle charging station (200) to provide a dustproof interior sealing.

4. Power input connector assembly (100) according to claim 3, wherein the interior encapsulation (250) being provided with at least one touch switch or button (260) enabling, remote of the printed circuit board (300), testing of residual current device (110) ground fault protection and / or setting of electric vehicle charging station (200) fuse size, while maintaining the dust and water tightness of the interior encapsulation (250).

5. Power input connector assembly (100) according to claim 4, wherein the interior encapsulation (250) is provided with a display (261) configured to indicate that the test of the residual current device (110) ground fault protection is being performed, while maintaining the dust and water tightness of the interior encapsulation (250).

6. Power input connector assembly (100) according to claim 4, wherein the printed circuit board (300) is provided with a display (310) configured to show the set fuse size of the electric vehicle charging station (200).

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