ES1299367U - Electric vehicle charging plug with seals (Machine-translation by Google Translate, not legally binding) - Google Patents

Abstract

An electric vehicle plug (100; 500; 1100), comprising: two or more pins (106; 108) comprising at least one line pin and one neutral pin; a land; a face plate (102; 502; 1102) including an outer surface (103) and a plurality of raised parts (202) and lowered parts (205) formed on an inner surface, and some of the raised parts partly form grooves (104 ; 1206) through which extend at least two of the two or more legs (106; 108), and one or more of the raised parts (202) that form a support (506; 1000; 1112); positioned on an inwardly facing surface of the faceplate (102; 502; 1102), where the faceplate fills the through hole (300) of each pin; at least one temperature sensor for monitoring the inside temperature of the line pin, the neutral pin, or both the line pin and the neutral pin; and a housing (224; 506; 1104) for holding at least one temperature sensor adjacent to the bracket and adjacent to the line pin, the neutral pin, or both the line pin and the neutral pin; a data cable (118) connected to at least one temperature sensor and configured to transmit temperature data to a controller that is not part of and is physically separate from the socket (100; 500; 1100); and an outer surface of the front plate (102; 502; 1102); characterized in that it contains first seals (112) formed around the two or more pins and placed on the inward facing surface of the front plate, The first seals are supported by ridges (302) formed within the slots (104) and are configured to fill any opening between the two or more lugs and the faceplate; second seals (116; 1204) formed around the two or more lugs and configured to cover the first seals (112) with a material sufficient to protect the first seals from the associated heat and pressure and a third seal injection molded into the Form of an inner mold (110) that covers at least the second seals and the recessed portions of the front plate and an outer overmold (130) that covers the inner mold (110). (Machine-translation by Google Translate, not legally binding)

Description

DESCRIPTION

Electric vehicle charging plug with seals

technical field

The present description relates to an electrical connector, and more particularly to an electric vehicle charging plug with seals.

Background

Electrical outlets are commonly used to supply power to electrical appliances such as electric toasters and kettles and electric vehicle charging devices, some of which draw more current than other powered devices. Conventional electrical outlets typically do not include protection mechanisms for higher current draw applications that can cause the outlets to overheat, melt, or burn. As a result, conventional electrical outlets can be damaged and cause unsafe conditions. However, adding protection mechanisms increases the possibility that when electrical plugs are exposed to humid environments, moisture can enter the plug, damage the protection mechanisms, and cause additional damage and unsafe conditions. Therefore, there is a need to improve the plugs of electric vehicles and, in particular, with respect to the seals used therein.

Explanation of the invention

According to one aspect of the present disclosure, there is provided an electric vehicle charging socket comprising at least one temperature sensor for monitoring the interior temperature of the electric vehicle socket. The electric vehicle charging plug further comprises a data cable that transmits temperature data to a physically separate controller. The electric vehicle charging plug further comprises a housing or support for receiving at least one temperature sensor, wherein the housing or support can be embedded within an interior mold of the electric vehicle plug. A first seal may seal a junction between at least one pin and a faceplate or bridge plate. A second seal can seal both a joint between the at least one temple and a front plate or bridge plate as well as the joints between it and the inner mould. A third seal provided by the interior mold seals the entire interior of the electric vehicle plug.

In one embodiment, the first seal may be formed by a combination of epoxy, gaskets, sealing oils, sealing greases, and/or cold melt adhesive formed around a pin or between a pin/blade joint and a ring. or separate lid. In one embodiment, the second seal may be formed by the separate ring or cap and sheet tops that press the ring or cap onto the first seal. In one embodiment, the second seal may be formed by the separate ring or cap.

In one embodiment, the at least one temperature sensor may be provided by an integrated circuit temperature sensor on a printed circuit board assembly ("PCBA") housed within a PCBA package. In one embodiment, the at least one temperature sensor may be provided by thermistors housed within highly thermally conductive ceramic housings positioned around and near the tops of the blades.

The embodiments also include methods for assembling the plugs described in this document. In one aspect, a method for assembling an electric vehicle plug includes forming a face plate including an outer surface and a plurality of raised portions and lower portions formed on an inner surface, some of the raised portions partially forming grooves through which which two or more tabs extend, and one or more of the raised portions form a bracket positioned on an inwardly facing surface of the faceplate; inserting the two or more pins into two or more slots between the slots, the two or more pins comprising a line pin and a neutral pin, each pin including a through hole extending through a central portion of the pin and it is filled with the front plate; inserting at least one temperature sensor into a sensor housing, the at least one temperature sensor configured to monitor a temperature inside the line pin, the neutral pin, or both the line pin and the neutral pin; placing the sensor housing in the bracket, the sensor bracket is configured to hold at least one temperature sensor adjacent to the bracket and adjacent to the line pin, the neutral pin, or both the line pin and the neutral pin; forming first seals around each of the two or more tabs and inwardly facing surface of the faceplate, the first seals being supported by ridges formed within the grooves; forming second seals around each of the two or more lugs and covering the first seals with a material sufficient to protect the first seals from the pressure and heat associated with an injection molded third seal in the form of an inner mold covering in at least the second seals and the lowered parts of the faceplate; connect a data cable to at least one temperature sensor, the data cable configured to transmit temperature data temperature to a controller that it is not a part of and is physically separate from the plug; and covering the inner mold and an outer surface of the face plate with an outer mold.

Brief description of the drawings

The embodiments of the present description will be described in more detail below with reference to the attached drawings, in which:

Figure 1 illustrates an exploded perspective view of a charging socket for electric vehicles according to one embodiment of the present disclosure;

Figure 2 illustrates an exploded perspective view of the components of the bridge of the Figure 1 embodiment;

Figure 3 is a cross-sectional view of the components of the bridge of Figure 1;

Figure 4 illustrates another perspective view of the components of the bridge of Figure 1 when fully assembled;

Figure 5 illustrates an exploded perspective view of a charging plug for electric vehicles according to one embodiment of the present disclosure;

Figure 6 illustrates a perspective view of the components of the bridge of the embodiment of Figure 5 when fully assembled;

Figure 7 illustrates an exploded perspective view of the components of the bridge of Figure 6;

Figure 8 is a cross-sectional view of the components of the bridge of Figure 5;

Figure 9 illustrates a perspective view of an inner side of the components of the bridge of Figure 6;

Figure 10 illustrates a perspective view of the inner side of the bridge of Figure 9 without the sensor supports;

Figure 11 illustrates a perspective view of the bridge components of one embodiment; Figure 12 illustrates an exploded view of the components of Figure 11;

Figure 13 illustrates a detail perspective view of a second seal in accordance with one embodiment;

Figure 14 is a cross-sectional view of the components of the bridge of Figure 11;

Figure 15 illustrates a perspective view of the electric vehicle charging plug of Figure 1, Figure 5 and/or Figure 11 when an inner mold is applied in accordance with the embodiment of the present disclosure;

Figure 16 illustrates a perspective view of the electric vehicle charging plug of Figure 1, Figure 5 and/or Figure 11 when an overmold is applied in accordance with the embodiment of the present disclosure;

Figure 17A illustrates a perspective view of a first set of plugs whose configurations are standardized in a first set of countries;

Figure 17B illustrates a perspective view of a second set of plugs whose configurations are standardized in a second set of countries;

Figure 17C illustrates a perspective view of a third set of plugs whose configurations are standardized in a third set of countries;

Figure 17D illustrates a perspective view of a fourth set of plugs whose configurations are standardized in a fourth set of countries; and

Figure 17E illustrates a perspective view of a fifth set of plugs whose configurations are standardized in a fifth set of countries.

Figures 18 to 31 represent embodiments of the present description that can be used in Denmark and that will be described in more detail below with reference to the attached drawings:

Figure 18 illustrates an exploded perspective view of an electric vehicle charging plug in accordance with one embodiment of the present disclosure;

Figure 19 illustrates an exploded perspective view of the components of the bridge of the embodiment of Figure 18;

Figure 20 is a cross-sectional view of the components of the bridge of Figure 19;

Figure 21 illustrates an exploded perspective view of an electric vehicle charging plug in accordance with one embodiment of the present disclosure;

Figure 22 illustrates a perspective view of the components of the bridge of the embodiment of Figure 21 when fully assembled;

Figure 23 illustrates an exploded perspective view of the components of the bridge of Figure 21;

Figure 24 is a cross-sectional view of the components of the bridge of Figure 21;

Figure 25 illustrates a perspective view of an inner side of the components of the bridge of Figure 22;

Figure 26 illustrates a perspective view of the inner side of the bridge of Figure 22 without the sensor supports;

Figure 27 illustrates a perspective view of the bridge components of one embodiment;

Figure 28 illustrates an exploded view of the components of Figure 27;

Figure 29 is a cross-sectional view of the components of the bridge of Figure 27;

Figure 30 illustrates a perspective view of the electric vehicle charging plug of Figure 18, Figure 21 and/or Figure 27 when an inner mold is applied in accordance with the embodiment of the present disclosure; and

Figure 31 illustrates a perspective view of the electric vehicle charging plug of Figure 18, Figure 21 and/or Figure 27 when an overmold is applied in accordance with the embodiment of the present disclosure.

Figures 32 to 45 represent embodiments of the present disclosure that may be used in parts of Europe and will be described in more detail below with reference to the accompanying drawings:

Figure 32 illustrates an exploded perspective view of an electric vehicle charging plug in accordance with one embodiment of the present disclosure;

Figure 33 illustrates an exploded perspective view of the components of the bridge of the embodiment of Figure 32;

Figure 34 is a cross-sectional view of the components of the bridge of Figure 33;

Figure 35 illustrates a perspective view of the components of the bridge of Figure 33 when fully assembled;

Figure 36 illustrates an exploded perspective view of a charging plug for electric vehicles in accordance with one embodiment of the present disclosure;

Figure 37 illustrates an exploded perspective view of the components of the bridge of the embodiment of Figure 36;

Figure 38 is a cross-sectional view of the components of the bridge of Figure 36;

Figure 39 illustrates a perspective view of the components of the bridge of Figure 36 when fully assembled;

Figure 40 illustrates a perspective view of an inner side of the components of the bridge of Figure 36;

Figure 41 illustrates a perspective view of the bridge components of one embodiment;

Figure 42 illustrates an exploded view of the components of Figure 41;

Figure 43 is a cross-sectional view of the components of the bridge of Figure 41;

Figure 44 illustrates a perspective view of the electric vehicle charging plug of Figures 32, 36 and/or 41 when an inner mold is applied in accordance with the embodiment of the present disclosure; and

Figure 45 illustrates a perspective view of the electric vehicle charging plug of Figures 32, 36 and/or 41 when an overmold is applied in accordance with the embodiment of the present disclosure.

Detailed description

The present disclosure describes an improved electric vehicle charging plug that is capable of accurately monitoring the plug's temperature and transmitting temperature data to an off-plug controller that can cut power to the plug if the plug overheats. Once the electrical outlet temperature exceeds a predetermined threshold, the controller can automatically cut an electrical circuit to prevent damaging the electrical outlet and creating unsafe conditions. Since electric vehicle plugs may be exposed to outdoor environmental conditions, including heavy mist, fog, heavy rain, driving rain, snow, etc., additional sealing components are required to ensure that moisture cannot enter the plug. and cause a short or to disable temperature sensing devices.

Although the embodiments represent a three-prong electric vehicle plug for connection to a power outlet, it should be understood that the present description is not limited to just this type of plug. Any type of EV charging plug can benefit from the same enhancements described in this document, including those with only two pins and those with more than three pins on a main plug, such as any of the plugs shown in Figures 17A. , 17B, 17C, 17D and 17E. The present disclosure may also improve plugs for connecting to a vehicle socket, such as SAE J1772, IEC Type 2, TESLA and CHADeMO, and electric vehicle plugs with pins in multiple plug components, including SAE J1772 CCS and IEC Type 2 CCS. The electrical plugs of the present description can also be used for plugs of any voltage standard, as well as plugs that support two or more voltage standards. Electrical plugs can be of any shape, size and type, such as type A and CN and suitable for any voltage.

When referring to items illustrated in each of the figures, the numbered label corresponding to each item will begin with a number corresponding to the figure in which it is first discussed and best illustrated. For example, if an element is first discussed with reference to Figure 1, the label for the element will follow the format 1NN, and when an element discussed first with reference to Figure 2 is referenced, the element label will follow the format 2NN etc

Figure 1 illustrates an exploded perspective view of one embodiment of an electric vehicle charging plug (100) according to a first embodiment. The electric vehicle charging plug (100) includes a face plate (102) within which a number of slots (104) sufficient to correspond to the pins (106) and (108) of the electric vehicle charging plug are formed. (100). The pins 106 and 108 may be round pins or blades depending on the plug type and may be formed from any suitable material such as brass. While blades or blade pins are referred to as line, neutral, and ground pins, depending on the plug standard of a particular country, all pins may be round, all pins may be round. be foil temples or some combination of round temples and foil temples. The faceplate (102) may be made of any suitable material, including Polypropylene ("PP"), Polybutylene Terephthalate ("PBT"), and Polycarbonate ("PC"). Each of the slots (104) in the faceplate (102) can be uniquely shaped to snugly match the shape of the portion of the pins (106) and (108) that insert into the slots (104).

Referring to Figures 2-4, the slots (104) may be formed within an inward-facing side or surface of the faceplate (102). One side or outer surface (103) of the faceplate (102) would face the socket (not shown) to which the electric vehicle charging plug (100) would be connected during an ignition cycle. Each of the slots (104) may be formed by raised areas or portions (202) of the faceplate (102) to form a central opening (200) with facing interior walls that mate with each tab (106) or tab ( 108). Inward facing walls may be configured to be slightly larger than the circumference of the corresponding tabs (106) or (108) so that the tab fits perfectly within the central opening (200) of the slots (104). The legs (106) and (108) can be placed in the mold (not shown) used to form the faceplate (102) so that the material used to form the faceplate (102) flows into the through holes (300). ) on each pin. This can hold the tabs (106) and (108) in place during use and therefore the through holes (300) can act as a fixing element and prevent movement of the tabs relative to the faceplate. (102). In the embodiments, the through holes (300) cannot be used because space limitations associated with the plug design require the pins to be crimped out of the faceplate and then assembled to the faceplate. As a result, the design of the temples can be different, such as including raised rings or recessed reliefs around the temples that mate with the faceplate material and prevent the temples from moving relative to the faceplate once assembled. The raised portions (202) of the faceplate (102) can include a series of ridged areas (204) and recessed areas (205) and create a series of low portions that form nooks and crannies within the faceplate (102) that they can be filled with the material of the inner mold (110), when the inner mold is formed, as described later in this document. Filling the nooks and crannies of the faceplate (102) with the inner mold (110) forms a third seal (the first and second seals will be described below) inside the electric vehicle charging socket (100) against moisture.

The seals (112) can be a gasket, epoxy, sealing oils, sealing greases, cold melt adhesive or a combination of these that are placed around other sealed portions of the legs (106) and (108) as a first seal. against moisture and other materials, such as dust and sand, entering the electric vehicle charging socket (100). The seal (112) may be an O-ring type gasket that fits snugly around the lugs (106) and (108) to ensure good sealing engagement with the faceplate (102) material. The seals (112) may be supported by a ridge (302) formed within the groove (104) of the tab (106; 108). Seal (112) may be formed of any suitable material, including Epoxy, Cold Fusion, Sealing Oils, Sealing Grease, Nitril, Neoprene, Ethylene Propylene, Silicone, Fluorocarbon, and PTFE, that have good adhesion to metal or plastic surfaces. . The seal (112) can be configured to have any suitable shape to fit the pins (106; 108) and faceplate material (102) and form a first moisture-tight seal.

The seals (112) may have a shape that matches the shape of the ridge (302) formed within the slots (104) of the tabs (106; 108). Certain temples or sheets may have raised metal rings (not shown) around the temple into which seals (112) may be placed or include backs (220) and other components (not shown) that extend along the perimeter. of the rounded part of the temple and require the slots. (104), flanges (302) and stamps to have different shapes. In such a case, the shape of the seal (112) may take the shape of a cylinder, a three-dimensional rectangle, a polygon or an irregular shape depending on the shape and size of the ridge (302) of the corresponding groove (104).

In some embodiments, a tab may form a lip that supports a seal (112) instead of, or in addition to, a lip (302) formed in the faceplate (102) material. For example, a lip formed in the faceplate material (102) can support a pin lip, and the pin lip can support the seal (112). In this example, the rim of the faceplate material directly supports the pin, while the rim of the faceplate material indirectly supports the seal (112) through the pin.

A plastic cover or cap (116), made of PP, PBT, PC or other suitable material, can be placed on top of each seal (112) within each groove (104), as shown in Figure 3. The shape of the plastic cap (116) can be a cylinder, a three-dimensional rectangle, a polygon or an irregular shape depending on the shape and size of the ridge (302) of the corresponding slot (104) to match the shape of the epoxy, cold melt adhesive, sealing oils, sealing greases, and/or gasket (112). If the tab includes rings or other components, the cap (116) may rest on the top ring of two metal rings or other components. The inner mold (110) can be formed from the same material as the plastic cover (116) and face plate (102). Using the same material for the face plate (102), the cover (116) and the inner mold (110) ensures a very good bonding performance between those components, which helps to further seal the electric vehicle charging plug ( 100) as described later in this document.

The inner mold (110) can be injection molded during the manufacturing of the electric vehicle charging plug (100). While the molten plastic of the inner mold is injected in a liquid state, the cover ring (116) and face plate (102) can be in a solid state so that the cover (116) and face plate (102) are covered by the plastic of the inner mold (110). The plastic of the inner mold (110) can be injected at a sufficiently high pressure and a sufficiently high temperature necessary to guarantee that the plastic material Inner mold casting (110) completely fills all nooks and crannies of the faceplate (102) and other interior components of the electric vehicle charging plug (100). By filling the nooks and crannies of the faceplate (102) and covering other interior components of the electric vehicle charging socket (100), including the cap (116), the interior mold (110) can form the third seal between the cap (116) and the pins (106; 108) and/or the blades. The cap (116) may be shaped sufficiently to cover any epoxy, cold melt adhesive, sealing oils, sealing greases, or gasket that might otherwise be exposed. Shaped enough to cover all of the epoxy, cold melt adhesive, sealing oils, sealing greases, or gasket and may be thick enough to ensure that all exposed seal material of the epoxy, cold melt adhesive, sealing oils , sealing greases, or gasket (112) is covered. The cap (116) can also have a sufficient height, that is, high enough, to form an insulating and/or protective cover for the seal (112) that prevents the seal (112) from completely melting during plastic injection. of the inner mold (110). Therefore, the cap (116) can form a second seal of the electric vehicle charging plug (100).

The faceplate (102) may further include a backing (220) formed of the faceplate material that is configured to support a printed circuit board assembly ("PCBA") (304), which is housed within a housing. package, also called PCBA package (224). The encapsulation housing (224) may be formed of PP, PBT or PC and shaped to hold the PCBA (304), which may include an integrated circuit temperature sensor. To protect the PCBA (304) from the heat and pressure of the internal injected mold, the PCBA (304) can be covered with a protective potting compound within the potting housing (224). The potting compound can be a resin, such as polyamide and polyolefin thermoplastics that use low pressure molding and a short processing molding cycle. In one embodiment, the filler compound can be Henkel LOCTITE TECHNOMELT PA6208 or OM646 (formerly called MACROMELT), or an epoxy resin, polyurethane, or silicone compound.

The PCBA IC temperature sensor (304) may be configured to transmit analog or digital signals including temperature data via data wires (118) to a controller (not shown) that is not a party to and is physically separate from the PCBA. from the electric vehicle charging socket (100). The data cables (118) may be wrapped in a shield to filter electrical noise in order to accurately capture and transmit temperature data. The controller may be part of a power system to which a cable is connected, such as the cable (120), from the electric vehicle charging socket (100) and which supplies voltage and current to the charging plug of the electric vehicle (100). The end of the cable (120) within the inner mold (110) may include a metal clip (122) to secure the cable (120) within the inner mold (110). When the temperature data provided by the PCBA (304) indicates that the temperature inside the electric vehicle charging socket (100) has exceeded a temperature threshold, the controller can cause the power system to stop providing voltage and current to the electric vehicle. electric vehicle charging plug (100).

The complete physical separation of the controller from the electric vehicle charging plug (100) is an important safety feature of the present disclosure. Some existing plug and cord systems locate a controller separate from the plug, but somewhere on the cord that is close to the plug. If a short circuit occurs within the plug and the controller is close enough to the plug to be damaged as a result, the controller may not be able to prevent the power system from continuing to supply voltage and current. This can be especially problematic with some EV plugs that operate with a voltage rating higher than the standard 110.

The Line, Neutral, and Ground wires (124), along with the Data wires (118), can be housed inside the cable (120) and placed near the pins (106; 108) and PCBA (304), moment wherein they are separated from each other to connect to their respective electric vehicle charging plug component (100). The cable (120) may extend through an opening (118) in the inner mold (110). Both the inner mold (110) and overmold (130) include grip notches (132) on each side of the inner mold and overmold (130) to allow a user of the electric vehicle charging plug (100) to improve their grip on the plug when in use. The overmold may be formed from thermoplastic elastomer ("TPE") or thermoplastic polyurethane ("TPU") or other suitable material. An upper part of the overmold can be configured to have a flexible part (134). The cable sheath (120) can also be formed from TPE or TPU or other suitable material, resulting in good bonding performance with overmolding of the same material.

The sealing system of the EV charging socket (100) and the methods described in this document comply with the IP67 waterproof rating, which means that the EV charging socket is 100% protected against solid objects such as dust and sand, and has been tested to work for at least 30 minutes under 15cm to 1m of water. The method and sealing system of the charging plug of the electric vehicle (100) described herein also meets higher waterproof ratings up to IPX9K waterproof rating, which means that the electric vehicle charging plug withstands high-pressure, high-temperature sprays at close range .

The figures from Figure 5 to Figure 10 illustrate the embodiment of the electric vehicle charging plug (500), which is similar to the embodiment described above and includes most of the same components, but includes thermistors instead of a PCBA ( 304), housings for the thermistors, and a slightly different faceplate (502). Negative Temperature Coefficient ("NTC") or Positive Temperature Coefficient ("PTC") thermistors (504), a type of resistor whose resistance decreases or increases as temperature increases, may be housed in a housing (506) surrounding the top of each temple (106; 108). The housing (506) can be made of ceramic and can act as a housing for thermistors (504). The ceramic can be a highly thermally conductive ceramic, such as aluminum nitride, silicon carbide, and aluminum oxide. Other heat conductive ceramics include beryllium oxide and boron nitride, among others. A highly thermally conductive ceramic material can be used to aid in the detection of heat by the thermistors (504). The housing (506) couples the thermistors (504) to a corresponding pin (106) or (108) to ensure that heat generated by the pin is efficiently transferred to the thermistor (504). If a high thermal conductivity ceramic was not used, when the inner mold was injected, the plastic material of the inner mold can form an insulating barrier between the pin and the thermistor (504). The use of the ceramic housing (506) ensures that the inner mold (110) does not form an insulating barrier between the pin and the thermistor (504). The ceramic housing can also be electrically insulating, helping to ensure that the charging plug can pass high voltage test requirements.

A data cable (118) can be connected to each thermistor (504) and configured to transmit analog signals including temperature data to a controller (not shown) that is not part of and physically separate from the electric vehicle plug, as shown. explained earlier in this document. When temperature data provided by the thermistor (504) indicates that the temperature inside the electric vehicle charging socket (500) has exceeded a temperature threshold, the controller can cause the power system to reduce current or stop supplying voltage and current.

The Line, Neutral, and Ground wires (124), along with the Data wires (118), can be housed inside the cable jacket (120) until they are close to the pins and thermistors (504), at which point they are separated from each other to connect to their respective electric vehicle charging plug component (500).

As further illustrated in Figures 6-10, the faceplate (502) may include brackets (1000) that are configured to mate with each housing (506) and hold the housing in position relative to the top of the corresponding pin. . The supports (1000) can have the shape that is illustrated in more detail in Figure 10. As shown in Figures 8 and 9, the housing (506) can rest partially or totally on the corresponding cover (116) to help hold the cover (116) in position, and can also partially rest on the upper surface of the support (1000). The height of the supports (1000) is slightly greater than the height of the raised part (202) to create an opening (800) under each housing (506). The opening (800) can serve as a gap and crack, as explained above, which can be filled with the inner mold (110) material as a result of pressurization during inner mold formation, which serves to hold all inner components. in place and forming a third seal of the electric vehicle charging plug (500).

Figure 11 illustrates an embodiment of an electric vehicle charging plug (1100) similar to the embodiments depicted in Figure 1 and Figure 5. The charging plug (1100) includes a faceplate (1102), a single bracket, or housing (1104) and a single thermistor (1106). The housing (1104) may be formed from a ceramic material. The ceramic material can be a highly thermally conductive ceramic, such as aluminum nitride, silicon carbide, and aluminum oxide. Other heat conductive ceramics include beryllium oxide and boron nitride, among others. A highly thermally conductive ceramic material can aid in the detection of heat by the thermistor (1106). The housing (1104) can couple the thermistor (1106) to the pins (1108) and (1110), which can be the line and neutral pins, to ensure that the heat generated by the pins is efficiently transferred to the thermistor (1106). ). The ceramic housing can also be electrically insulating, helping to ensure that the charging plug can pass high voltage test requirements.

The thermistor 1106 may be a negative temperature coefficient ("NTC") or a positive temperature coefficient ("PTC") thermistor. Thermistor 1106 can be positioned between pins 1108 and 1110 in a central position so that it is equally spaced from both pins. Housing (1104) can surround both tabs (1108) and (1110) and be held in place by brackets (1112) formed on the inside of faceplate (1102). The Figure 12 provides more details of the faceplate (1102), as well as the first (1202) and second (1204) seals, as described earlier in this document. Figure 13 provides additional detail regarding the second plastic seals or rings (1204). A plurality of interference crush ribs (1302) may be formed around the perimeter of each plastic ring (1204). Although four crush ribs (1302) are shown in Figure 13, a larger or smaller number may be used. The crush ribs (1302) are very thin and are configured to crush and deform when they fit into the grooves (1206) of the faceplate (1102) to help secure the plastic ring of the second seal (1204) within the groove. (1206). Crushing ribs (1302) may also be used on the plastic cap rings (116) of the embodiments of Figures 1 and Figure 5. Figure 14 provides a cross-sectional view of the embodiment of Figure 11 at left. Figure 12.

Figure 15 illustrates the electric vehicle charging plug (100) or (500) fully assembled with only the inner mold (110) exposed and the cable (120). Figure 16 illustrates the electric vehicle charging plug (100) or (500) fully assembled with only the overmold (130) exposed, the flexible part (134) and the cable (120).

The sealing system of the electric vehicle charging socket (500) and the methods described in this document comply with the IP67 waterproof rating, which means that the electric vehicle charging socket is 100% protected against solid objects such as dust. and sand, and has been tested to work for at least 30 minutes under 15cm to 1m of water. The EV Charging Plug (500) sealing system and methods described in this document also meet higher waterproof ratings up to IPX9K waterproof rating, which means the EV Charging Plug resists sprays at high pressure and high temperature at close range.

As noted above, while electric vehicle charging plugs (100), (500) and (1100) are described in terms of having a ground pin and reed pins for line and neutral, this is only for the particular standard plug type illustrated in Figures 1-16, corresponding, for example, to a standard plug in China, Australia, or Argentina. Plugs in other countries and for different voltages have different pin configurations and grounding Figure 17A illustrates a first set (1700) of plugs that are standard in various other countries. For example, the plug (1702) is a standard NEMA 5-15 plug in the United States, the Philippines, and Vietnam. The plug (1702) It has foil pins for line and neutral and one pin for ground. The plug (1704) is standard for Europe, Korea and Indonesia and has only two pins for line and neutral, but no ground pin. Instead, the plug (1704) includes a set of side contacts (1703) to provide a ground connection when plugged into a German plug and a ground tube (1705) to provide a ground connection when plugged into a German plug. a French plug. The plug (1706) has horizontally oriented neutral and line blade pins, while ground is also a vertically oriented blade, which can be used, for example, in the UK. The plug (1708) has three bladed pins for line, neutral and ground, with the line and neutral pins at 45 degree angles to the ground pin, which can be used, for example, in Argentina.

Figure 17B illustrates a perspective view of a second set of plugs (1710) that are standard in other countries, including plug (1712) in Japan, plug (1714) in Brazil, plug (1716) in China (similar to plug (1708) but with the ground pin on top when plugged in instead of bottom), and plug (1718) in Australia. Figure 17C illustrates a perspective view of a third set of plugs (1720) that are standard in other countries, including plug (1722) in South Africa, plug (1726) in Switzerland, and plug (1728) in Thailand. The plug (1724) is an International Electrotechnical Commission (IEC) plug for 200-250 volts that is used in many different countries. The 32 amp version is commonly used to power stationary campers and moored boats, while the 16 amp version is commonly used to power caravans/touring vehicles and tents.

Figure 17D illustrates a perspective view of a fourth set of plugs (1730), including the plug (1732) in Taiwan, the plug (1734) in Chile and Italy, the plug (1736) in Israel, and the plug (1738). ) in Denmark. Figure 17E illustrates a perspective view of a fifth set of plugs (1740), including plug (1742) in India, plug (1744), a NEMA 14-3 plug in the United States, plug (1746) , a TT 30 plug in the United States and the plug (1748), a NEMA 14-50 plug also in the United States.

Figures 18 to 31 represent aspects of plugs that can be used in Denmark, where element numbers matching the elements of plugs depicted in Figures 1-16 for China can serve a similar function, even though incorporated in a somewhat different physical form. Such elements of similar function are described above with respect to Figures 1-16. Other elements represented in Figures 18 to 31 may be functionally different from the elements of the previous figures, and some of those elements of different functions are described below.

Figure 20 is a cross-sectional view of the components of the bridge of Figure 18. The recessed relief (2020) is a relief along the surface of a lug on the faceplate (102). The recessed relief (2020) can be filled with material from the face plate (102). An inner surface of the faceplate (102) that forms a slot (104) for a corresponding pin can support the corresponding pin in the recessed relief (2020) and can act to prevent movement of the corresponding pin with respect to the face plate (102). front plate (102).

The pin ridges (2022) may be ridges formed on a corresponding pin at a location within the corresponding slot of the pin (104). A flange of the tab (2022) may function to support a seal (112). In some embodiments, the pin lip (2022) may be positioned in an adjacent slot lip (302) formed of faceplate material such that the pin lip (2022) and its adjacent slot lip (302) they can be combined to form a large combined lip for jointly supporting a seal (112).

Figures 32 to 45 represent aspects of plugs that may be used in some parts of Europe, where item numbers matching the item numbers on plugs depicted in Figures 1-16 for China may serve a similar function while materializing. in a somewhat different physical form. Such elements of similar function are described above with respect to Figures 1-16. Other elements depicted in Figures 32 to 45 may be functionally different from the elements in the previous figures, and some of those elements with different functions are described below.

Figure 34 is a cross-sectional view of the components of the bridge of Figure 32. The recessed relief (3420) is a relief along the surface of a lug on the faceplate (102). The recessed relief (3420) can be filled with material from the face plate (102). An inner surface of the faceplate (102) that forms a slot (104) for a mating pin can support the mating pin in the recessed relief (3420) and can act to prevent movement of the mating pin relative to the faceplate (102). front plate (102).

The tab ridges (3422) may be ridges formed on a corresponding tab at a location within the tab corresponding slot (104). A flange of the pin (3422) may function to support a seal (112). In some embodiments, the pin flange (3422) may be positioned in an adjacent slot flange (302) formed of faceplate material such that the pin flange (3422) and its adjacent slot flange (302) they can be combined to form a large combined lip for jointly supporting a seal (112).

It will be appreciated that the sealing systems and methods discussed herein are not limited to the embodiments depicted, and other sealing systems and methods may be applied to form a seal and/or bond between various plug elements, eg, lugs, bridge, wires. , cable tubes, cable insulation, housings and thermistors. While certain embodiments have been described, these embodiments have been presented by way of example only and are not intended to limit the scope of the inventions described herein. For example, depending on various types of plugs, the number of temperature sensors, such as thermistors, built into an electrical plug, the configuration of the housing containing the temperature sensors, and the process for assembling the electrical plug may vary without departing from the spirit of the present revelation. In fact, the present disclosure described herein can be carried out in a variety of other ways; furthermore, various omissions, substitutions, and changes in the form of the embodiments described herein may be made without departing from the spirit of the inventions described herein. The appended claims and their equivalents are intended to cover those forms or modifications that would fall within the scope and spirit of some of the inventions described in this document.

Claims (12)

1§.- An electric vehicle plug (100; 500; 1100), comprising: two or more pins (106; 108) that include at least one line pin and one neutral pin; a land; a face plate (102; 502; 1102) including an outer surface (103) and a plurality of raised parts (202) and lowered parts (205) formed on an inner surface, and some of the raised parts partly form grooves (104 ; 1206) through which extend at least two of the two or more legs (106; 108), and one or more of the raised parts (202) that form a support (506; 1000; 1112); positioned on an inwardly facing surface of the faceplate (102; 502; 1102), where the faceplate fills the through hole (300) of each pin; at least one temperature sensor for monitoring the inside temperature of the line pin, the neutral pin, or both the line pin and the neutral pin; and a housing (224; 506; 1104) for holding at least one temperature sensor adjacent to the bracket and adjacent to the line pin, the neutral pin, or both the line pin and the neutral pin; a data cable (118) connected to at least one temperature sensor and configured to transmit temperature data to a controller that is not part of and is physically separate from the socket (100; 500; 1100); and an outer surface of the front plate (102; 502; 1102); characterized in that it contains first seals (112) formed around the two or more lugs and positioned on the inward facing surface of the faceplate, the first seals are supported by ridges (302) formed within the grooves (104) and are configured to fill any opening between the two or more temples and the faceplate; second seals (116; 1204) formed around the two or more lugs and configured to cover the first seals (112) with a material sufficient to protect the first seals from the associated heat and pressure and a third seal injection molded into the shape of an inner mold (110) that covers at least the second seals and the recessed parts of the front plate and an outer overmold (130) that covers the inner mold (110) 2§.- The electric vehicle plug of claim 1, characterized in that the first seals (112) are formed by one or more epoxy, cold fusion, sealing oils, sealing greases, Nnitrile, neoprene, ethylene propylene, silicone, fluorocarbon and PTFE. 3§.- The electric vehicle plug of claim 1, characterized in that the material of the second seals (116; 1204) and the material of the front plate (102; 502; 1102) and the third seals or interior mold (110 ) are chosen from polypropylene, polybutylene terephthalate and polycarbonate. 4-.- The plug for electric vehicle of claim 1, characterized in that the first seals (112) and the second seals (116; 1204) have shapes that coincide with the shapes of the corresponding ridges (302). 5-.- The electric vehicle plug of claim 1, characterized in that the two or more pins (106; 108) are one of two or more round pins or two or more sheets. 6-.- The electric vehicle plug of claim 1, characterized in that at least one temperature sensor is an integrated circuit temperature sensor mounted on a printed circuit board assembly (304). 7-.- The electric vehicle plug of claim 6, characterized in that the housing is an encapsulation housing (224) configured to hold the printed circuit board assembly (304) and cover the printed circuit board assembly with a potting compound to protect the PCB assembly from the pressure and heat associated with the injection molded third seal. 8-.- The electric vehicle plug of claim 1, characterized in that the at least one temperature sensor includes a first sensor and a second sensor, the housing includes a first housing (506) to hold the first sensor (504) and a second housing (506) for holding the second sensor (504), and the holder includes a first holder (1000) and a second holder (1000), the first holder being positioned adjacent to the dial pin by the first holder and the second housing is placed next to the neutral pin by the second support. 9-.- The electric vehicle plug of claim 8, characterized in that the first sensor (504) and the second sensor (504) are a negative temperature coefficient thermistor or a positive temperature coefficient thermistor, and wherein the The first housing and the second housing are made of heat-conducting ceramic. 10-.- The electric vehicle plug of claim 1, characterized in that the ground connection is a ground connection pin (106; 108), a ground connection plate, a set of side contacts or a connection tube to Earth. 11-.- The electric vehicle plug of claim 1, characterized in that the second seals (116; 1204) include one or more ribs (1302) located around a periphery of the second seals and configured to crush and deform within the grooves and secure the second seals. 12§.- The electric vehicle plug of claim 1, characterized in that at least one pin (106; 108) includes a through hole (300) that extends through a central part of the pin, and the material that forms the faceplate fills the through hole.