EP4676771A1

EP4676771A1 - A charging inlet assembly for a vehicle

Info

Publication number: EP4676771A1
Application number: EP24766636.5A
Authority: EP
Inventors: Padmasubash Sivagaminanthan; Dipanjan MAZUMDAR; Datta RAJARAM SAGARE; Lohit Vishwanath Patil
Original assignee: TVS Motor Co Ltd
Current assignee: TVS Motor Co Ltd
Priority date: 2023-03-05
Filing date: 2024-02-15
Publication date: 2026-01-14
Also published as: WO2024184910A1

Abstract

The present subject matter discloses a charging inlet assembly (100) for a vehicle. The charging inlet assembly (100) includes an inner part (104), an outer part (102), said outer part (102) being hingedly attached to said vehicle, and said outer part (102) being capable of at least one of opening and closing said charging inlet assembly (100) for charging said vehicle, and a terminal (106). Herein, the wherein the terminal (106) is configured to include at least one or more electrical connectors (110). The proposed subject matter enables the charging inlet assembly to be compatible with chargers of all kinds of charging inlet manufacturers, allowing the vehicle to be charged at any charging outlet without having to carry the particular charging cable.

Description

TITLE OF INVENTION

A CHARGING INLET ASSEMBLY FOR A VEHICLE

TECHNICAL FIELD

[0001] The present invention generally relates to charging of electric vehicles and, more particularly to a charging inlet assembly used for charging of electric vehicles.

BACKGROUND

[0002] With a growing popularity of electric vehicles, the need for charging stations increases, and so does the total power available for each charging port, and in case of multiple ports, their total power consumption.

[0003] Although electric mobilities are now commercialized, problems need to be resolved while using the electric vehicles when it comes to two-wheeler electric vehicles. Such problems will increase because of the less package area, and to maintain less weight. Since, these electric vehicles have batteries as a power source which requires large area at vehicle level and electric vehicles charging stations level, it leads to high investment for implementing such electric vehicles charging stations. Charging stations or household charging system are mostly used to regain the power in electric vehicles.

[0004] Existing electric vehicle charging systems, particularly for two-wheelers suffers from the problems of slow charging, non-standardized charging connectors, size and weight of the connectors and open exposure of vehicle side connector etc.

[0005] Charging stations with a plurality of charge ports are known. One way of implementing a plurality of charge ports can be by using an AC/DC converter followed by a DC bus where the charge ports are connected to. However, in such an arrangement, multiple vehicles cannot be charged simultaneously, because each vehicle can have a different inlet voltage. To be able to charge electric vehicles simultaneously DC/DC converters are placed before each charging port, which can increase the cost of the multipart charging station. BRIEF DESCRIPTION OF DRAWINGS

[0006] The detailed description is described with reference to the accompanying figures, which is related to a two-wheeled vehicle being one embodiment of the present subject matter. However, the present subject matter is not limited to the depicted embodiment(s). In the figures, the same or similar numbers are used throughout to reference features and components.

[0007] Fig. 1 illustrates an exploded view of a charging inlet assembly for a vehicle, in accordance with an embodiment of the present subject matter.

[0008] Fig. 2 illustrates a section view of the charging inlet assembly at a charging condition, in accordance with the embodiment depicted in Fig 1.

[0009] Fig. 3 illustrates a top perspective view of the charging inlet assembly in a closed condition, in accordance with an embodiment of the present subject matter.

[00010] Fig. 4 illustrates a top perspective view of the charging inlet assembly in an open condition, in accordance with an embodiment of the present subject matter.

DETAILED DESCRIPTION

[00011] Various features and embodiments of the present subject matter here will be discernible from the following further description thereof, set out hereunder.

[00012] Electric vehicles need a charging port to charge the on-board batteries. Charging inputs could be AC or DC or combo current system. The connector available in vehicle to charge is known as vehicle inlet and the connector that comes along with charging station is known as charging gun. Both AC/DC connectors get engaged during charging. When both connectors are not in use, then they shall be covered to have protection against unwanted exposer. Hinged cap or rubber caps are being used to protect open contacts. Addition to hinged cap or rubber cap, a body panel is being to cover it. This additional covering is required to give aesthetic look as well as to protect unwanted access by unauthorized persons. These contacts can be damaged or misused by unauthorized persons. If proper protection measures are not taken inside the vehicle, then charging contact are prone for shock. So, it is important to provide key lock or some other lock for body panel.

[00013] There are several types of charging connectors for vehicles like Type I, Type II, CCS, CHADEMO, GB/T etc. based on the requirements such as current, charging timing, size, standard used by countries. Type I connectors are preferable in countries where single phase AC or DC and separate bigger connector shall be used for combo system. Type II connectors are preferable in countries where three phase AC or high current DC with separate connectors are used. And combo connector shall be used for both AC and DC. And CHADEMO, GB/T connectors are customized to use in the Japan and China respectively.

[00014] Standard connectors are interchangeable irrespective of different manufacturers. So those kind of charging connectors can be used in different charging stations even four-wheeler automotive stations also and private stations. However, it leads to increase the usage of electric vehicle in addition to that it can reduce the cost on charging station implementation.

[00015] The combo connector is used to connect both AC and DC supply to charge the batteries based on the change in requirements as slow and fast charging with respect to the customer need. So, the inlet connector requires to accept either AC or DC supply while charging. [00016] Majorly charging inlets are protected by two layers on four wheelers from direct exposure to outside. It would be one as inlet cover which gives protection for terminals alone and another one as metallic cap which is used to cover the whole inlet setup and replicate the outer panel style profile of vehicle body. Because of the size and weight addition on inlet connector, this types of covers and cap aren’t capable of being adopted in the two-wheeler.

[00017] Typically, charging vehicle inlets are mainly on the vehicle outer body and is exposed to outside. Hence, there are chances of water ingression inside the connectors. Sometimes, such water is acidic in nature which leads to failures like erosion corrosion and short-circuit. And it should be critical when charging carried out. So that the connector needs to be protected from the water at both conditions like either charging or not in use.

[00018] Further the connectors need to be covered to protect them from environmental and other external factors when not in use. Also, when in use, dust and water can leak in, which will damage the charger. Therefore, it becomes necessary to protect the connectors from such damage. [00019] Commonly the inlet caps or made of rubber and then one more separate body panel is giving a rigid protection where locking is happening. Otherwise, small snap is used for the lock with primary cap alone. Two different caps may not be given in these cases because of its size constrains. The above-mentioned arrangements cannot be suited in the two-wheeler. Snap lock protection may be used for two-wheeler application whereas snap can be operated by anyone and anywhere which may lead to unauthorized usage.

[00020] Thus, there arises a need for a charging inlet assembly for a vehicle which is capable of working with both AC and DC type charging systems, such that it is retrofittable in nature, which can be used by any manufacturer, to eliminate the problem of carrying separate charging cable for AC or DC systems, and other shortcomings and disadvantages as mentioned above.

[00021] Thus, it is an objective of the present subject matter to provide a retrofittable charging inlet assembly for a vehicle which is capable of working with both AC and DC type charging systems, which can be used by any manufacturer, to eliminate the problem of carrying separate charging cable for AC or DC systems.

[00022] It is yet another objective of the present subject matter to protects the electrical charging systems particularly the connectors from dust, water and other harmful particles while charging as the charger will be sealed.

[00023] It is another objective of the present subject matter to prevent unauthorized access to the charging inlet assembly. [00024] The present subject matter along with all the accompanying embodiments and their other advantages would be described in greater detail in conjunction with the figures in the following paragraphs.

[00025] The present subject matter discloses a charging inlet assembly for a vehicle having an inner part, an outer part and a terminal. Herein, the outer part is hingedly attached to the vehicle, and the outer part is capable of at least one of opening and closing said charging inlet assembly for charging the vehicle. Further, the terminal is configured to include at least one or more electrical connectors. The at least one or more electrical connectors is capable of allowing charging at least one of an AC connector and a DC connector through a charging gun.

[00026] In an embodiment, the outer part is configured to match the contours of the vehicle exterior during the outer part being in a closed condition.

[00027] In yet another embodiment, the outer part includes a first seal being mounted on an inner portion of the outer part.

[00028] In another embodiment, the charging inlet assembly includes a locking system comprising a latch and a pre-compressed spring.

[00029] In an embodiment, the locking system is actuated by a key.

[00030] In yet another embodiment, the latch is positioned in an upper part of said charging inlet assembly.

[00031] In another embodiment, the actuation of the locking system enables actuation of a control cable. Herein, the control cable is capable of retracting said latch against said precompressed spring to attain an open condition of the outer part.

[00032] In yet another embodiment, the locking system pushes said latch against said precompressed spring to attain a closed condition of the outer part.

[00033] In yet another embodiment, the latch is retrieved to an original position to rest on the outer part based on the outer part being in said closed condition. [00034] In another embodiment, a second seal is positioned between the inner part and an upper part.

[00035] The present subject matter is further described with reference to accompanying figures. It should be noted that the description and figures merely illustrate principles of the present subject matter. Various arrangements may be devised that, although not explicitly described or shown herein, encompass the principles of the present subject matter. Moreover, all statements herein reciting principles, aspects, and examples of the present subject matter, as well as specific examples thereof, are intended to encompass equivalents thereof.

[00036] The charging inlet assembly may be implemented in any two-wheeled vehicle. However, for the purpose of explanation and by no limitation, the traction control system, and corresponding additional advantages and features are described through the following embodiments. Arrows wherever provided on top right corner of the figure represent direction with respect to vehicle. Arrow F represents forward direction, arrow R represents rearward direction, arrow UW represents upward direction and arrow DW represents downward direction.

[00037] The aforesaid and other advantages of the present subject matter would be described in greater detail in conjunction with the figures in the following description.

[00038] Fig. 1 illustrates an exploded view of a charging inlet assembly for a vehicle, in accordance with an embodiment of the present subject matter. Fig. 2 illustrates a section view of the charging inlet assembly at a charging condition, in accordance with the embodiment depicted in Fig 1. Fig. 1 and Fig. 2 have been explained together for brevity purposes. Typically, a circuit of electric vehicle includes a 230V AC being supplied to an on- board charger (OBC) through a charging gun (not shown) and a charging inlet assembly (100). Before start of supply, a cable control box (not shown) reads the vehicle connections. A vehicle control unit (VCU) (not shown) responds for each information request sent by the cable control box (not shown). The VCU (not shown) can be powered by an additional battery or a traction battery. Once protocols are stablished between VCU & cable control box, the 230V AC supply is available to OBC (not shown). OBC (not shown) turns this AC power into DC power. The DC power pass through a control relay (not shown) before it reaches battery terminals. These control relays (not shown) are again controlled by VCU (not shown). Once battery (not shown) charging is over, VCU (not shown) instructs control cable box (not shown) to stop the further AC supply. The charging inlet assembly (100) for a vehicle comprises an inner part (104), an outer part (102), said outer part (102) being hingedly attached to said vehicle, and said outer part (102) being capable of at least one of opening and closing said charging inlet assembly (100) for charging said vehicle, and a terminal (106); wherein said terminal (106) being configured to include at least one or more electrical connectors (110), said at least one or more electrical connectors (110) being capable of allowing charging at least one of an AC connector and a DC connector through a charging gun (202). Herein, in an embodiment, the outer part (102) is configured to match the contours of said vehicle exterior during said outer part (102) being in a closed condition.

[00039] The charging inlet assembly (100) has proper sealing while in use and not in use against water ingress. The outer part (102) has a first rubber seal (115) in it which is to avoid the water ingress through outer side of the charging inlet assembly (100) to terminal (106) at closed condition. As shown in Fig.l the first seal (115) is mounted on an inner portion of the outer part (102). Further, as shown in Fig. 1, a second seal (130) is positioned between the inner part (104) and an upper part (120). Said first seal (115) and said second seal (130) restricts the water ingress from lateral side to centre when the charging inlet assembly (100) is in a closed condition. The first seal (115) is also used to avoid the water ingress while charging take place. It is sealing the opening area between the charging inlet assembly (100) and the charging gun (202) at mating condition in which the water ingress protection given for the charging inlet assembly (100) while charging also. [00040] Fig. 3 illustrates a top perspective view of the charging inlet assembly in a closed condition, in accordance with an embodiment of the present subject matter. Fig. 4 illustrates a top perspective view of the charging inlet assembly in an open condition, in accordance with an embodiment of the present subject matter. Fig. 3 and Fig. 4 have been explained together for brevity purposes.

The charging inlet assembly (100) has an outer part (102) to close the terminal exposure when the charging inlet assembly (100) is not in use. The outer part (102) is connected along with the inner part (104) of the charging inlet assembly (100) with a hinged joint. The outer part (102) is controlled by a locking system (125). The locking system (125) includes a latch (140) and a precompressed spring (145). The latch (140) is used to engage the outer part (102) at a closed condition. The lock system (125) is used for opening and closing the outer part (102) through a key (not shown). Herein, the latch (140) is positioned in the upper part (120) of the charging inlet assembly (100). When the latch (140) is disengaged using the lock system (125), it automatically opens the outer part (102) by prestressed force kept in the pre-compressed spring (145) at an outer part (102) hinge point. The actuation of said locking system (125) enables actuation of a control cable (135), said control cable (135) being capable of retracting said latch (140) against said precompressed spring (145) to attain an open condition of said outer part (102). After usage of charging inlet assembly (100), the outer part (102) is closed manually and pushed against the precompressed spring (145) force and gets engaged with the latch (140) for locking the outer part (102). The latch (140) is retrieved to an original position to rest on the outer part (102) based on the outer part (102) being in closed condition.

[00041] The outer part (102) is operated up to 112° of opening which is restricted by a stopper (not shown) provided in an upper part (120) to avoid the fouling of opened outer part (102) with nearby parts while opening. When the outer part (102) is unlocked, it is opened by the precompressed spring (145) action in which a damper (not shown) at the hinge is used for the gradual opening. It avoids the sudden impact on stopper and other nearby parts. The damper (not shown) is controlling the opening speed of the outer part (102) by having frictional force between the two interfering parts in it.

[00042] Thus, the proposed subject matter enables the charging inlet assembly to be compatible with chargers of all kinds of charging inlet manufacturers, allowing the vehicle to be charged at any charging outlet without having to carry the particular charging cable.

[00043] The proposed subject matter can be used as combo connector for both single phase AC and high current DC as per two-wheeler requirement with the same size of Type II AC connector. The charging inlet assembly is smaller in size, and terminals can be arranged in more effectively when compared to existing connectors.

[00044] The charging inlet assembly is designed in such a manner that it is compatible with standard dimensions (IEC62196-3) which can be interchangeable with other manufacturer’s charging gun, leading to increased usage of vehicles with this connector. Therefore, the problem of non-standard connector can be avoided.

[00045] It further protects the electrical charging systems particularly the connectors from dust, water and other harmful particles while charging as the charger will be sealed. Moreover, the cap lock prevents unauthorized access to the charging inlet assembly. Further, the sealing means on the cap prevents dust and water when the cap is shut.

[00046] While certain features of the claimed subject matter have been illustrated and described herein, many modifications, substitutions, changes, and equivalents will now occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes that fall within the true spirit of the claimed subject matter. List of reference signs:

100 charging inlet assembly

102 outer part

104 inner part 106 terminal

110 electrical connectors

115 first seal

120 upper part

125 locking system 130 second seal

135 control cable

140 latch

145 pre-compressed spring

202 charging gun

Claims

Claims:

1. A charging inlet assembly (100) for a vehicle, said charging inlet assembly (100) comprising: an inner part (104), an outer part (102), said outer part (102) being hingedly attached to said vehicle, and said outer part (102) being capable of at least one of opening and closing said charging inlet assembly (100) for charging said vehicle, and a terminal (106); wherein said terminal (106) being configured to include at least one or more electrical connectors (110), said at least one or more electrical connectors (110) being capable of allowing charging at least one of an AC connector and a DC connector through a charging gun (202).

2. The charging inlet assembly (100) as claimed in claim 1, wherein said outer part (102) being configured to match the contours of said vehicle exterior during said outer part (102) being in a closed condition.

3. The charging inlet assembly (100) as claimed in claim 1, wherein said outer part (102) includes a first seal (115), said first seal (115) being mounted on an inner portion of said outer part (102).

4. The charging inlet assembly (100) as claimed in claim 1, wherein said charging inlet assembly (100) includes a locking system (125), said locking system (125) comprising a latch (140) and pre-compressed spring (145).

5. The charging inlet assembly (100) as claimed in claim 4, wherein said locking system (125) being actuated by a key.

6. The charging inlet assembly (100) as claimed in claim 4, wherein said latch (140) being positioned in an upper part (120) of said charging inlet assembly (100).

7. The charging inlet assembly (100) as claimed in claim 4, wherein actuation of said locking system (125) enables actuation of a control cable (135), said control cable (135) being capable of retracting said latch (140) against said pre-compressed spring (145) to attain an open condition of said outer part (102).

8. The charging inlet assembly (100) as claimed in claim 7, wherein said locking system (125) pushes said latch (140) against said pre-compressed spring (145) to attain a closed condition of said outer part (102).

9. The charging inlet assembly (100) as claimed in claim 8, wherein said latch (140) being retrieved to an original position to rest on said outer part (102) based on said outer part (102) being in said closed condition.

10. The charging inlet assembly (100) as claimed in claim 1, wherein a second seal (130) being positioned between said inner part (104) and an upper part (120).