DE102013215188A1 - Socket component for charging opening of electric car, has fuse retainer defining fuse cavity, and wire secured at proximate end of terminal and comprising direct inline fuse attached to proximate end and arranged in retainer - Google Patents

Abstract

The component (10) has a connector socket formed around one of apertures and defining a terminal cavity. A fuse retainer is extended from a base along a direction, and defines a fuse cavity. Proximal end of a terminal is arranged in the connector socket and distal end extends from the base along another direction, within an outer socket (32) for connecting with another terminal. A wire is secured at the proximate end of the terminal and arranged in the retainer, and comprises a direct inline fuse attached to the proximate end of the terminal. An independent claim is also included for a method for assembling a wire harness at a socket component for charging access of a vehicle.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application claims U.S. Provisional Patent Application No. 61 / 678,787 filed Aug. 2, 2012, the disclosure of which is incorporated by reference in its entirety.

TECHNICAL AREA

The present disclosure relates to a vehicle-mounted jack assembly for a charging access that connects a charging cable connector for receiving electrical energy from an external power source, and more particularly to a vehicle charging port with integrated fuses that is submersible.

BACKGROUND

Vehicle drawer access includes jack assemblies for connecting a charging cable from an external power source to a vehicle wiring harness that is directly or indirectly connected to a vehicle battery. Among other circuits, the interface between the charging cable and the receptacle assembly connects the vehicle battery to the electrical network that uses AC power wires to allow charging of the battery. The jack assembly may include an internal printed circuit board (PCB) to connect wires from the wiring harness to plug-in terminals or pins that mate with corresponding terminals in the charging cable connector. To provide over-current protection on the vehicle side, the vehicle wiring harness may include fuses connected to the AC wiring of the wire harness. The fuses help protect vehicle wiring for long-term unattended charging. The fuses are typically connected behind the charging access to the AC power lines. For some applications, the fuses in the printed circuit board are integrated with the charging port.

The charging socket is exposed to harsh automotive environments (eg, water, salt, hot and cold temperatures, sunlight, etc.), especially when the vehicle is being driven, and must be sealed to protect high voltage internal circuits from contamination. Since the high voltage circuits require substantial isolation between ground, neutral and phase lines, any internal circuit design on the charging socket must include a complete seal against the surrounding environment. The printed circuit board is a flat plane with little to no insulation of the components. The use of printed circuit boards or other circuit design with circuit traces (eg, a system of bus bars, flexible circuit, or the like) requires that the insulator applied during the manufacturing process (eg, contoured coating, potting materials, etc.) be used. free of micropollutants. If water gets into the jack assembly, the inner circuitry on the pins provides a leakage path for water that potentially creates shorts across the printed circuit board. In fact, under high voltage conditions, the presence of moisture can bridge the short distances between circuit traces and create high resistance short circuit conditions.

Furthermore, during charging, the fuses heat up and cool off when charging is completed. The variation of the fuse temperature creates a thermal stress on the fuse carriers (eg, the printed circuit board, the bus bar system, or the flexible circuit) and the insulating potting material, which creates potential separation of the materials and potential leakage paths.

SUMMARY

One or more embodiments of the present disclosure are directed to a receptacle assembly for vehicle charging access. The bushing assembly may include a base for mounting to a vehicle trim, the base having a first side facing in a first direction, a second side facing in a second direction opposite to the first direction, and through-going openings for receiving Includes connections. The jack assembly may further include an outer socket extending from the base in the first direction to receive a charging cable connector. At least one receptacle may extend from the base in the second direction. The connection socket may be formed around one of the openings and define a connection cavity. At least one fuse receptacle may extend from the base in the second direction and define a fuse cavity. The jack assembly may include at least one terminal having a proximal end disposed in the receptacle and a distal end extending from the base in the first direction within the outer receptacle for connection to a mating terminal. A wire may be attached to the proximal end of the connector. The wire may have an in-line attached directly to it. Include fuse, which may be arranged in the fuse holder.

In one or more embodiments, the in-line fuse may include a lead directly connected to the proximal end of the lead. Alternatively, the wire may include a first wire portion and a second wire portion which are separated by the in-line fuse. The in-line fuse may include a first lead attached to the first wire portion and a second lead attached to the second wire portion. The second wire section can connect the in-line fuse to the proximal end of the connector. The jack assembly can connect the at least one port and the in-line fuse directly to a vehicle wiring harness without an internal printed circuit board, bus bar, or flexible circuit.

A fuse cover may include the in-line fuse in the fuse holder. The female assembly may have wire channels formed in the second side to guide the wire from the female connector to a wire harness. Further, an inner sleeve may extend from the base in the second direction and receive a plurality of wires from the wire harness. The inner socket can define an internal cavity within which the socket, fuse holder and wire channels are located.

One or more additional embodiments of the present disclosure are directed to a socket assembly for a vehicle charging access having a flange for mounting to a vehicle trim panel and a base having a first side facing in a first direction, a second side facing into a first side facing the first direction opposite second direction, and having continuously formed openings for receiving terminals. An outer socket may extend from the base in the first direction to receive a charging cable connector. An inner sleeve may extend from the base in the second direction to receive a plurality of wires from a wire harness. The inner sleeve may define an inner cavity having at least one connector socket formed around one of the apertures and at least one fuse holder. Both the connector socket and the fuse holder can extend from the base in the second direction. The inner socket may include wire channels to guide a wire from the socket to the fuse holder and from the fuse holder to a wire aperture.

The fuse holder may include a circumferential wall that defines a fuse cavity to receive an in-line fuse. The peripheral wall may have a pair of grooves for receiving a pair of fuse lines. Each groove may be at opposite ends of the fuse holder.

The jack assembly may include at least one terminal having a proximal end disposed in the receptacle and a distal end extending from the base in the first direction within the outer receptacle for connection to a mating terminal. A wire comprising a first wire section and a second wire section may be attached to the proximal end of the terminal. An inline fuse disposed in the fuse holder may separate the first wire portion from the second wire portion. The in-line fuse may include a first lead attached to the first wire portion and a second lead attached to the second wire portion. A fuse cover may include the in-line fuse in the fuse holder. The inner sleeve may be filled with potting material and overmoulded with the potting material to form a cover that encloses the inner sleeve.

Alternatively, the receptacle assembly may include at least one terminal having a proximal end disposed in the receptacle and a distal end extending from the base in the first direction within the outer receptacle for connection to a mating terminal. An inline fuse can be located in the fuse holder. The in-line fuse can have a first line and a second line. The second lead may be attached directly to the proximal end of the lead. A wire may be attached directly to the first lead and routed through the wire channels to the wire lead. A fuse cover may enclose the fuse in the fuse holder. The inner sleeve may be filled with potting material and overmoulded with the potting material to form a cover that encloses the inner sleeve.

One or more additional embodiments of the present disclosure are directed to a method of mounting a wire harness to a receptacle assembly for vehicle charging access. The method may include providing the jack assembly having a base with a first side turned in a first direction, a second side turned in a second direction opposite the first direction, and a plurality of openings there are formed through. The jack assembly can be a fuse holder which extends from the base in the second direction. The wire harness may include a plurality of wires, each wire having a terminal attached to a first end of the wire. At least one wire may include an inline fuse attached directly thereto. The method may further include inserting a second end of each wire through one of the openings and passing at least the wire comprising the in-line fuse through the wire channels formed on the second side of the base so that the in-line fuse is received by the fuse holder becomes.

The method may also include placing a fuse cover over the inline fuse that it encloses in the fuse holder. The method may also include attaching the second end of each wire to a connector for connecting the wire harness to the vehicle harness. Further, the female assembly may include an inner sleeve extending from the base in the second direction. The inner sleeve may define an internal cavity within which the fuse holder, apertures and wire channels are located. The method may further include: inserting potting material into the inner socket over the fuse holder and the plurality of wires, and molding the potting material to the socket assembly, around the terminals, the in-line fuse and the plurality of wires close to the second side of the base to fix.

BRIEF DESCRIPTION OF THE DRAWINGS

1 FIG. 10 is a schematic view of a jack assembly according to one or more embodiments of the present disclosure mounted on a vehicle and shown connected to a charging cable; FIG.

2 FIG. 3 is a front perspective view of an exemplary jack assembly according to one or more embodiments of the present disclosure;

3 is a perspective, exploded side view of the female assembly 2 in accordance with one or more embodiments of the present disclosure;

4 is a perspective rear view of the female assembly 2 without electrical components in accordance with one or more embodiments of the present disclosure;

5 is a perspective rear view of the female assembly 2 electrical components according to one or more embodiments of the present disclosure;

6 is another perspective rear view of the jack assembly 2 after casting, in accordance with one or more embodiments of the present disclosure; and

7 FIG. 10 is a close exploded view of a connector showing a connection to a fuse according to one or more embodiments of the present disclosure. FIG.

DETAILED DESCRIPTION

In the following detailed description, reference is made to the accompanying drawings, which form a part hereof. In the drawings, similar symbols typically indicate similar components unless the context dictates otherwise. The illustrative embodiments described in the detailed description, drawings, and claims are not intended to be limiting. Other embodiments may be used and other changes may be made without departing from the spirit and scope of the subject matter presented herein. It is readily apparent that the aspects of the present disclosure, as generally described and illustrated in the figures herein, are interchanged, interchanged, set forth in a wide variety of different configurations, all of which are expressly contemplated and constitute part of this disclosure. combined and constructed.

Referring to the 1 is a socket assembly 10 in accordance with one or more embodiments of the present disclosure. The socket assembly 10 is on a vehicle 12 mounted and provides a charging access to the vehicle for receiving electrical energy. The socket assembly 10 connects a charging cable connector 14 with a vehicle wiring harness 16 , The charging cable connector 14 can come from an external power supply 18 to provide electrical energy. The vehicle wiring harness 16 can with one in the vehicle 12 mounted on-board charger (OBC) 20 be connected. The integrated charger 20 in turn, with an energy storage device 22 , such as a battery, for storing the electrical energy by charging the energy storage device. The integrated charger 20 the vehicle side, the process of charging the energy storage device 22 enable and manage.

Referring to the 1 - 6 , can the socket assembly 10 One Base 24 and one flange 26 for mounting on the vehicle 12 exhibit. The base 24 can be a first page 28 moving in a first direction away from the vehicle 12 turned, and a second page 30 include facing in a direction opposite to the second direction, toward the vehicle interior, facing. 2 shows a front view of the female assembly 10 , The base 24 may be disposed over an opening (not shown) in an outer panel of the vehicle 12 is molded into it. The flange 26 can, as shown, from the base 24 extend to the outside. The flange 26 Can be mounted on the vehicle 12 be contoured. The socket assembly 10 may further be an outer socket 32 for receiving the charging cable connector 14 include. The outer socket 32 can be different from the base 24 in the first direction away from the vehicle 12 extend. In one or more embodiments, the jack assembly 10 a lid (not shown) pivotally connected to an outer surface of the jack assembly 10 connected and over a distal end 34 the outer socket 32 is arranged to the outer socket 32 seal. In one or more additional embodiments, the lid may be pivotally connected to another vehicle surface while still above the distal end 34 the outer socket 32 is arranged. Although in 1 is shown that the outer panel is disposed on an outer surface of the vehicle body, the outer panel may be so embedded that the entire outer sleeve 32 or at least a portion thereof is disposed inwardly from the outer surface of the vehicle.

The socket assembly 10 can through her own wire harness 36 on the vehicle wiring harness 16 be attached. The wire harness 36 can be a plurality of individual wires 38 include in 3 are shown. A connection 40 may be at a first end 42 every wire 38 be attached. A number of openings 44 can through the base 24 be formed through the terminals 40 take. Every connection 40 can have a proximal end 46 and a distal end 48 (which in the 3 and 7 are shown). The proximal end 46 every connection 40 can on the wire 38 be attached and from one of the openings 44 be included in the base 24 are formed. The distal end 48 every connection 40 can be outside the base 24 in the first direction within the outer socket 32 extend. In this way, the distal end 48 every connection 40 be formed with a mating connector (not shown) of the charging cable connector 14 to be connected.

The interface between the socket assembly 10 and the charging cable connector 14 can be determined in an effort to standardize the connection for the entire electric vehicle industry. For example, the Society of Automotive Engineers ("SAE") in the SAE J1772 , which is hereby incorporated by reference, establishes such an interface. According to one or more embodiments, the interface between the jack assembly 10 and the charging cable connector 14 five plug connections 40 ("Pins"). The interface specified in the SAL J1772 consists of five circuits that correspond to the following functions: AC line 1 (L1), AC line 2 (L2, N), Chassis ground, Control Pilot, and Proximity Detection. However, the jack assembly is 10 not limited by this SAE specification and can be used for applications that commit other interface requirements.

Referring to the 3 and 7 may be the proximal end 46 of the connection 40 on the wire 38 by mechanical means such as crimping. Once the wires are attached to the connectors, a second end can be attached 50 every wire 38 through the openings 44 be introduced after passing through the outer socket 32 from the first page 28 was fed. Every connection 40 may have features for attachment to the socket assembly 10 include. According to one or more embodiments, circumferential barbs may be used 52 circulating from one between the proximal end 46 and the distal end 48 intermediate section of the connection 40 extend. The barbs 52 can be about the inner diameter of the openings 44 in the base 24 extend to a press fit between the port 40 and the base 24 provide. This press fit helps with the connections 40 in the socket assembly 10 to keep. An end stop 54 can also be in between the barbs 52 and the distal end 48 intermediate section of the connection 40 be educated. The end stop 54 can be radial over the barbs 52 extend out to the base 24 to touch and an insertion depth of the connection 40 to restrict.

Each AC line wire can have an inline fuse 56 include that directly with the wire 38 connected is. The inline backup 56 can along the wire 38 at a location near the terminal 40 be arranged so that they pass through the socket assembly 10 can be added and thus integrated into the vehicle loading access. The fuses protect all the downstream wiring (ie between the fuses and the integrated charger and / or battery). Thus, the integration of the power line fuses at the charging access - where the power is taken, rather than continue downstream in the vehicle wiring harness 16 - provide optimal overcurrent protection.

According to one or more embodiments, the inline fuse 56 the wire 38 divide in two, taking the wire 38 in a first wire section 58 and a second wire section 60 Splits. The fuse 56 can be a fuse 62 and a pair of leads 64 include. A first line 64a can with the first wire section 58 be electrically connected and a second line 64b can with the second wire section 60 be electrically connected. The second wire section 60 can the inline backup 56 with the connection 40 connect. The first wire section 58 can with the vehicle wiring harness 16 get connected. The wires 64 can by a welding process, such as resistance welding or ultrasonic welding, to the wire 38 be attached, although other forms of attachment in question. The wire 38 can be a heat shrink material 66 which is provided over exposed wire lines after welding.

According to one or more additional embodiments, the inline fuse 56 directly to the connection 40 be connected as in 7 is clarified. In this way, the second line 64b the first end 42 of the wire 38 form and go directly to the proximal end 46 of the connection 40 by mechanical means such as crimping. The first line 64a can on the wire 38 be attached as described above.

The 4 - 6 show a rear view of the socket assembly 10 , As shown, the bushing assembly 10 Furthermore, an inner socket 68 include. The inner socket 68 can be different from the base 24 in the second direction to the interior of the vehicle 12 to extend. The inner socket 68 can have an internal cavity 70 for receiving the plurality of wires 38 define that at the terminals 40 attached and through the openings 44 from the first page 28 were fed. Inside the inner cavity 70 can the socket assembly 10 Furthermore, a plurality of connection sockets 72 for storing the connections 40 include. The connection sockets 72 can also differ from the base 24 in the second direction to the interior of the vehicle 12 to extend. Each connection socket 72 can be around one of the openings 44 and generally coaxial therewith. Each connection socket 72 can have a connection cavity 74 for receiving the proximal end 46 one of the connections 40 define.

The socket assembly 10 can also at least one fuse holder 76 for storing inline fuses 56 exhibit. The fuse holder 76 can also be inside the inner cavity 70 the inner socket 68 arranged and also from the base 24 in the second direction to the interior of the vehicle 12 to extend. The fuse holder 76 can be a wraparound wall 78 include a fuse cavity 80 defined to an inline backup 56 take. In particular, the fuse holder 76 a bracket 82 or a similar bearing feature within the fuse cavity 80 include to the fuse body 62 take. A pair of grooves 84 can in the surrounding wall 78 be formed, each at substantially opposite ends of the fuse holder 76 to the wires 64 the fuse 56 take. The holder 82 and the grooves 84 can also help with the backup 56 to be fixed during assembly.

The inner socket 68 can have a number of wire channels 86 include to the individual wires 38 from the connection sockets 72 to a wire passage 88 to lead, where to the wire harness 36 can be shaped. Any AC power line, the inline fuse 56 includes, can through the wire channels 86 from the connection socket 72 to the fuse holder 76 and then to the wire passage 88 be guided. As shown, the wire harness can 36 a connector 90 for mating with another connector (not shown) attached to the vehicle wiring harness 16 is attached, include. Once the wires 38 in the inner socket 68 can be positioned, the second end 50 every wire 38 on the connector 90 be attached in a known manner.

Furthermore, the electrical components within the inner socket 68 (eg the wires 38 , the inline fuses 56 and the proximal end 46 the connections 40 ) by a molded thermoplastic material 92 by means of a potting process ( 6 ) are encapsulated. The molded potting material 92 can help to insulate and seal the electrical components against moisture and mechanical damage. Accordingly, the potting material 92 in the inner socket 68 be entered via the electrical components. Next, the female assembly 10 be placed in a mold so that the potting material 92 is molded to the female assembly, which is a cover 94 forms the inner socket 68 includes. The wire channels 86 , the connection sockets 72 and the backup shots 76 in the inner socket 68 are formed, together with the potting material 92 for insulation between the individual wire circuits.

According to one or more embodiments, the fuse holder 76 a fuse cover 96 have over the fuse 56 can be placed during assembly before the inner socket 68 with the potting material 92 is overmoulded, as in 5 is shown. By taking the fuse 56 within the fuse holder 76 includes, the fuse cover 96 an air gap around the fuse 56 provide and maintain to prevent the potting material 92 how a heat sink works. Although only a fuse cover 96 for clarification purposes in 5 Shown is a fuse cover with each fuse holder 76 be used.

The fuses 56 in a wire with the wires 38 Integrating and isolating any wire circuit can provide better performance in water immersion tests and in real-life conditions where the vehicle 12 may be exposed to excessive moisture than to connect all circuits to a printed circuit board, busbar or flexible circuit. In particular, shorts across a printed circuit board created by water leakage paths on the pins can be eliminated. Furthermore, the internal circuitry of the jack assembly is unaffected by potential manufacturing contaminants that are common in printed circuit board manufacturing.

While embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the subject matter presented herein. Furthermore, the features of various embodiments may be combined to form further embodiments of the present disclosure.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited non-patent literature

• SAE J1772 [0026]

Claims (20)

A socket assembly for vehicle charging access, comprising: a base for mounting to a vehicle trim panel, the base having a first side turned in a first direction, a second side turned in a second direction opposite to the first direction, and through-hole openings for receiving terminals; an outer socket extending from the base in the first direction to receive a charging cable connector; at least one receptacle extending from the base in the second direction, the receptacle formed around one of the apertures and defining a terminal cavity; at least one fuse receptacle extending from the base in the second direction, the fuse receptacle defining a fuse cavity; at least one terminal having a proximal end disposed in the receptacle and a distal end extending from the base in the first direction within the outer receptacle for connection to a mating terminal; and a wire attached to the proximal end of the terminal, the wire including an in-line fuse directly attached thereto, the in-line fuse being disposed in the fuse receptacle. The jack assembly of claim 1, wherein the in-line fuse comprises a lead directly connected to the proximal end of the terminal. The jack assembly of claim 1, wherein the wire comprises a first wire portion and a second wire portion separated by the in-line fuse, the in-line fuse having a first wire attached to the first wire portion and a second wire attached to the second wire portion wherein the second wire section connects the in-line fuse to the proximal end of the terminal. The jack assembly of claim 1, wherein the jack assembly directly connects the at least one port and the in-line fuse to a vehicle wiring harness without an internal printed circuit board, bus bar, or flexible circuit. The jack assembly of claim 1, further comprising a fuse cover that encloses the in-line fuse in the fuse holder. The jack assembly of claim 1, further comprising wire channels formed in the second side to route the wire from the receptacle to a wire harness. The receptacle assembly of claim 6, further comprising an inner socket extending from the base in the second direction receiving a plurality of wires from the wire harness, the inner socket defining an interior cavity within which the receptacle, the fuse receptacle and the wire channels are located. A socket assembly for vehicle charging access, comprising: a flange for mounting to a vehicle trim panel; a base having a first side turned in a first direction, a second side turned in a second direction opposite to the first direction, and through-hole openings for receiving terminals; an outer socket extending from the base in the first direction to receive a charging cable connector; and an inner socket extending from the base in the second direction for receiving a plurality of wires from the wire harness, the inner socket defining an inner cavity having at least one receptacle formed around one of the apertures and at least one fuse receptacle, wherein both the receptacle and the fuse receptacle extend from the base in the second direction, the inner receptacle comprising wire channels for routing a wire from the receptacle to the fuse receptacle and from the fuse receptacle to a wire passage. The receptacle assembly of claim 8, wherein the fuse receptacle comprises a circumferential wall defining a fuse cavity for receiving an in-line fuse, the peripheral wall having a pair of grooves for receiving a pair of fuse lines, each groove located at opposite ends of the fuse receptacle. The receptacle assembly of claim 8, further comprising: at least one terminal having a proximal end disposed in the receptacle and a distal end extending from the base in the first direction within the outer receptacle for connection to a mating terminal; a wire comprising a first wire portion and a second wire portion, the second wire portion being attached to the proximal end of the terminal; and an in-line fuse disposed in the fuse holder and separating the first wire portion from the second wire portion, the inline fuse comprising a first wire attached to the first wire portion and a second wire attached to the second wire portion. The receptacle assembly of claim 10, further comprising a fuse cover that encloses the in-line fuse in the fuse receptacle. The female assembly of claim 10, wherein the inner sleeve is filled with potting material and overmolded with the potting material to form a cover that encloses the inner sleeve. The jack assembly of claim 8, further comprising: at least one terminal having a proximal end disposed in the receptacle and a distal end extending from the base in the first direction within the outer receptacle for connection to a mating terminal; an in-line fuse disposed in the fuse holder and having a first line and a second line, the second line being attached directly to the proximal end of the terminal; and a wire that is attached directly to the first lead and routed through the wire channels to the wire lead. The receptacle assembly of claim 13, further comprising a fuse cover that encloses the in-line fuse in the fuse receptacle. The jack assembly of claim 13, wherein the inner sleeve is filled with potting material and overmolded with the potting material to form a cover that encloses the inner sleeve. A method of mounting a wire harness to a receptacle assembly for vehicle charging access, the method comprising: Providing the jack assembly having a base having a first side facing in a first direction, a second side facing in a second direction opposite to the first direction, and a plurality of openings formed therethrough the jack assembly has a fuse holder extending from the base in the second direction; Providing the wire harness which comprises a plurality of wires, each wire having a terminal attached to a first end of the wire, at least one wire including an in-line fuse directly attached thereto; Inserting a second end of each wire through one of the openings; and Passing at least the wire comprising the in-line fuse through the wire channels formed on the second side of the base so that the in-line fuse is received by the fuse holder. The method of claim 16, further comprising: Place a fuse cover over the in-line fuse that it encloses in the fuse holder. The method of claim 16, further comprising: Attaching the second end of each wire to a connector for connecting the wire harness to the vehicle harness. The method of claim 16, wherein the receptacle assembly further comprises an inner sleeve extending from the base in the second direction, the inner sleeve defining an internal cavity within which the fuse receptacle, apertures and the wire channels are located. The method of claim 19, further comprising: Introducing potting material into the inner socket via the fuse holder and the plurality of wires; and Molding the potting material to the jack assembly to secure the terminals, the inline fuse and the plurality of wires close to the second side of the base.

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