GB2606010A

GB2606010A - A charging inlet and a plug connector incorporating a heating system

Info

Publication number: GB2606010A
Application number: GB2105743.5A
Authority: GB
Inventors: Schäfer Christian; Pütz Tim
Original assignee: Aptiv Technologies Ltd
Current assignee: Aptiv Technologies Ltd
Priority date: 2021-04-22
Filing date: 2021-04-22
Publication date: 2022-10-26
Also published as: GB202105743D0

Abstract

A charging inlet 200 and a plug connector 300 for an electric vehicle (EV) incorporate a respective heating system. The EV may be connected to a charging station via a charging cable 400 having, at each end, a plug connector that cooperates with corresponding charging inlets of the EV and the charging station. The charging inlet has an inlet housing 203 with an inlet power terminal portion 201 that cooperates with a corresponding connector terminal portion 303 of the plug connector for the supply of electrical power to the EV. Each of the charging inlet and the plug connector include a heating system 600 with at least one heating element 610 which, when operated by a respective control module, is configured to heat one or more heat zones of the respective inlet housing and connector housing to a target temperature above a water freezing point. Each heating system may include a set of temperature sensors 620 integrated into the respective inlet housing and connector housing for monitoring one or more temperature parameters. One or more heat temperature sensors 620a monitor the temperature of the heat zones and at least one ambient temperature sensor 620b monitors ambient temperature.

Description

A charging inlet and a plug connector incorporating a heating system Field The present application relates in general to charging systems for charging electric vehicles, and more in particular, to a charging inlet of an electric vehicle and/or a charging station and a plug connector of a charging cable incorporating a heating system.

Background

Electric vehicles (EV) such as battery electric vehicles (BEV) or plug-in hybrid vehicles (PHEV) are charged conductively using a cord-set that connects the vehicle with a charging pole or a wall-box of a charging station. The vehicle is provided with a charging inlet, also referred to as a charge plug socket, located behind a flap in the vehicle's chassis. The charging inlet is configured to be coupled with a plug connector, also referred to as a coupler, of a charging cable during charging in a female-to-male arrangement. For example, the charging inlet may be provided with a cavity configured for receiving an engaging portion of the plug connector. During charging, the flap is opened, either manually by the user or electronically by the control unit of the vehicle, and the user inserts a plug connector, also referred to as a coupler, into the charging inlet. During charging, the plug connector is locked to the charging inlet to ensure constant electrical contact between the contact terminals of the plug connector and the contact terminal of the charging inlet, thereby avoiding the generation of electrical arcs.

During charging, and with the flap of the charging inlet open, water and snow enter the charging inlet. Even if the flap is provided with a cover to protect the connection between the plug connector and the charging inlet, wind can bring humidity, water, and snow into the charging inlet cavities. In general, the charging inlet is provided with a sloping inner surface to allow water to drain from the charging inlet cavity. As the connection interface between the charging inlet and plug connector is not sealed during charging, water or snow may settle between the corresponding coupling surfaces. During cold weather condition, where the temperature drops below a water freezing point, the water droplets at the coupling surfaces would freeze, causing the plug connector to become stuck with the charging inlet. Water droplets may further settle in the locking mechanism of the charging inlet, which under cold weather conditions, may inhibit the operation of the locking mechanism and prevent decoupling of the plug connector from the charging inlet. As a result, in cold weather conditions, the user may have to apply excessive force to disconnect the plug connector from the charging inlet, which depending on the thickness of the ice and/or the force exerted, may damage the charging inlet and/or the plug connector and compromise the safety of the user.

Therefore, there is a need to provide a system that overcomes the problems associated with charging an electric vehicle in cold weather conditions.

Summary

It is an aim of the present disclosure to provide a system for safely disconnecting the plug connector from a charging inlet during cold weather condition.

According to a first aspect of the present disclosure, a charging inlet is provided, which is configured to cooperate with a plug connector of a charging cable connected to a power source for charging an electric vehicle, the charging inlet comprising: an inlet housing comprising an inlet power terminal portion configured to cooperate with a corresponding connector terminal portion of the plug connector for the supply of electrical power to the electric vehicle; wherein the inlet housing comprises a heating system comprising at least one heating element, which when operated by an inlet control module, is configured to configured to heat one or more heat zones of the inlet housing to a target temperature above a water freezing point.

The heating system of the charging inlet is configured to be operated by an inlet control module to heat the interface between the charging inlet and the plug connector to melt ice already formed or prevent ice from forming during charging.

The heating system comprises at least one heating element, which is operated by the inlet control module to generate sufficient heat at desired locations of the charging inlet. The charging inlet may be part of an electric vehicle (EV) and/or a charge station, e.g. a home charge station, public charging poles or stations, and the like. The inlet control module operating the heating system of the charging inlet may be provided as an independent unit or as part of a central control unit of the charging vehicle or the charging station. Furthermore, the inlet control module may be part of the heating system. The inlet control unit is configured to operate the heating eleement to generate a desired amount of heat for raising the temperature of the inlet housing above a water freezing point, e.g. above 0 degrees Celsius. Raising the inlet housing temperature above a water freezing point prevents the formation of ice between the coupling surfaces of the charging inlet and the plug connector and/or the locking mechanism. As such, the plug connector can be safely disconnected from the charging inlet at cold weather conditions when the ambient temperature drops below 0 degrees Celsius. The inlet control module may be configured to supply a fixed voltage or current to the heating system from a power source. Furthermore, the inlet control unit may be configured to adjust the heat generated by the heating system, e.g. by adjusting the supply of voltage or current, or by adjusting the duration that the at least one heating element is operated, and the like. For example, the inlet control module may be configured to adjust the operation of the heating element based on external trigger signals, e.g. a user pressing a button on the dashboard of the electric vehicle to increase the heat generated, a trigger signal generated based on the reading of one or more temperature sensors, and the like.

According to embodiments of the present disclosure, the inlet housing comprises an inlet collar at least partially surrounding the inlet power terminal portion, the inlet collar comprising a connector receiving portion configured for receiving a corresponding inlet engaging portion (302b) of the plug connector. According to embodiments of the present disclosure, the least one heating element (610) is provided around the inlet collar (204) such that the heat generated is at least distributed around the connector receiving portion (207).

The at least one heating element may be provided around an inlet collar of the inlet housing such that the heat generated is distributed to a connector receiving portion configured to receive a corresponding inlet engaging portion of the plug connector. As such, when the plug connector is coupled to the charging inlet, the heating element is configured to at least heat corresponding coupling surfaces of the connector receiving portion and inlet engaging portion.

According to embodiments of the first aspect of the present disclosure, the at least one heating element is configured to generate, in response to a supply of voltage or current from a power source controlled by the inlet control module, an amount of heat for heating the one or more heat zones of the inlet collar. The heating element of the heating system may be a resistive heating element, but other types of heating elements may be used. For example, one or more resistance heating wires may be provided in the inlet housing, which may be controlled independently by the inlet housing to adjust the amount of heat generated and/ or selectively heat different areas of the inlet housing and the locking mechanism. The voltage or current applied to the heating element may be supplied from different sources, e.g. from a battery such as the battery of the electric vehicle, from the charging supply network, e.g. AC or DC, from the control signal of a charging inlet in a wall box of a charging station e.g. Control Pilot (CP) or Proximity Pilot (PP), or from any other suitable power source.

According to embodiments of the first aspect of the present disclosure, the heating system comprises a set of temperature sensors for monitoring one or more temperature parameters, the set of temperature sensors being communicatively coupled to the inlet control module. For example, the temperature sensors may comprise any one or combination of: positive or negative temperature Coefficient, PTC or NTC, sensors, Resistance Temperature Detector (RTD) sensors, thermocouples, Semiconductor-based temperature sensors, and the like. The set of temperature sensors may comprise at least one ambient temperature sensor configured for monitoring the ambient temperature. The control module may be configured to activate the heating system based on the ambient temperature being within a threshold ambient temperature value. For example, in the case of the ambient temperature being at or below a certain temperature threshold, e.g. below 1 degree Celsius, the inlet control module is configured to activate the heating system to heat the inlet housing. The inlet control module may be configured to increase the amount of heat generated in proportion to the ambient temperature. For example, as the ambient temperature drops, the amount of voltage/current applied to the heating system may be proportionally increased so that more heat is generated by the heating system. The inlet control unit may adjust the supply of voltage or current to the heating system in accordance with a Look-up-Table (LUT) indicating the voltage or current to be supplied for different ambient temperatures. The inlet control unit may further take into account the heat generated at the power terminal pins of the charging inlet and plug connector during charging. As such, the heating system may be activated only when certain conditions are met, e.g. ambient temperature at or below a threshold temperature. Furthermore, the inlet control module may adjust the operation of the heating element based on the type of power source used to supply the voltage/current to the heating system. For example, if the electrical power is provided by a battery, the inlet control module may reduce the electrical power supplied to the heating element. It should be noted that the temperature sensors are entirely optional, and as previously described, the inlet control module may be configured to supply a fixed voltage to the heating system.

According to embodiments of the first aspect of the present disclosure, the set of temperature sensors comprises one or more heat temperature sensors configured for monitoring the temperature at one or more locations on the inlet housing The heating system is configured to be operated by the inlet control unit based on information received from at least a set of temperature sensors. For example, the inlet control module may switch on the heating system in response to the ambient temperature being within a range from a temperature threshold value, e.g. at or below 3 degrees Celsius. Furthermore, based on the ambient temperature, the inlet control module may dynamically adjust the operation of the heating system in proportion to the ambient temperature. For example, if the ambient temperature drops to a very low temperature, e.g. -10 degrees Celsius, the heating system may increase the voltage supplied to the heating element and/or switch on additional heating elements to increase the temperature generated at the heat zones. In this way, the operation of the heating system is dynamically adjusted based on the environmental conditions, thereby ensuring the safe disconnection of the plug connector from the charging inlet even at very low temperatures, e.g. -40 degrees Celsius.

According to embodiments of the first aspect of the present disclosure, the operation of the heating element is configured to be adjusted by the inlet control module, based on the temperature detected by the heat temperature sensors, so that the inlet housing is maintained at the target temperature.

The operation of the heating system may be adjusted to maintain the target temperature by the inlet control unit, either dynamically based on the temperature information received by the temperature sensor(s) or, without having temperature sensor(s) available in the control loop, statically based on a defined duration of operating time or the supply of fixed current or voltage. For example, the operation of the heating system may be adjusted based on the temperature sensors monitoring the temperature at the heat zones and/or the ambient temperature sensors. The target temperature may be preselected or adjusted according to the environmental conditions. For example, the target temperature may define a maximum surface temperature for the charging inlet, e.g. 70 degrees Celsius. The target temperature may be predefined so to ensure the safety of the user and the reliability of materials. For example, the target surface temperature of the charging inlet may be set so that it is safe for the user to touch the surface of the charging inlet.

According to embodiments of the first aspect of the present disclosure, the heating elements and the set of temperature sensors are integrated in the inlet housing.

The heating element and the temperature sensors of the heating system are integrated into the inlet housing, e.g. via a moulding technique such as overmolding, injection moulding, and the like. For example, the heating element may be provided around the inlet collar of the inlet housing near an internal wall of the connector receiving portion. The temperature sensors may be positioned at different locations around the inlet housing. The ambient sensors may be provided at locations that are not affected by the heating generated by the heating element, e.g. at an outer surface of the inlet housing positioned at a distance from the heat zones or at another location. In the case of more than one ambient temperature sensor, the ambient temperature may be calculated as an average temperature based on the measurements of the ambient sensors. The ambient sensors may also be based at another pad of the electric vehicle (EV) or the charging station, e.g. may be part of the inlet control module.

According to embodiments of the first aspect of the present disclosure, the target temperature of inlet housing may be between 2.0 to 70.0 degrees Celsius. For example, the target temperature may be measured as the average surface temperature of the inlet housing and/or the charging inlet. In general, the target temperature should be sufficient to melt ice, even in very cold conditions, as previously mentioned, and safe for the user so as to prevent injuries.

According to embodiments of the first aspect of the present disclosure, the inlet housing comprises a locking mechanism configured to cooperate with a corresponding locking member of the plug connector to releasably secure the plug connector to the charging inlet during charging. The locking member of the plug connector may comprise one or more openings in the engaging inlet portion, which are configured to cooperate with corresponding engagement elements of a locking mechanism of the charging inlet so as to releasably secure the plug connector to the charging inlet. The locking mechanism of the charging inlet may be activated in a manner known to the skilled person in the ad, e.g. by the inlet control unit and/or the central control unit, in response to receiving an indication that charging of the electric vehicle has begun According to a second aspect of the present disclosure, a plug connector of a charging cable is provided, which is configured to cooperate with a charging inlet for charging an electric vehicle, the charging cable being connected at one end 30 to a power source, the plug connector comprising: a connector housing comprising a connector power terminal portion configured to cooperate with a corresponding inlet power terminal portion of a charging inlet for the supply of electrical power to the electric vehicle; wherein the connector housing comprises a heating system comprising at least one heating element, which when operated by a connector control module, is configured to heat one or more heat zones of the connector housing to a target temperature above a water freezing point. According to embodiments of the second aspect of the present disclosure, the connector housing comprises a connector collar comprising an inlet engaging portion configured to cooperate with a corresponding connector receiving portion of the charging inlet.

According to embodiments of the second aspect of the present disclosure, the at least one heating element is provided around the connector collar such that the heat generated is at least distributed around the inlet engaging portion.

The plug connector of a charging cable may be provided with the heating system operating in the same manner as the heating system of the charging inlet. For example, a charging cable may be provided at one or both ends with a plug connector that incorporates a heating system for melting ice or preventing ice from forming at the interface regions between the charging inlet and the plug connector electric vehicle. The heating system comprises at least one heating element. In the plug connector, the at least one heating element may be provided at the inlet collar of the plug connector. For example, the at least one heating element may be provided around an inlet engaging portion configured to cooperate with a corresponding connector receiving portion of a charging inlet. Furthermore, the at least one heating element may be provided around an inner and/or outer collar portion of the connector collar. In general, one or more heating elements may be provided in one or more locations of the connector collar, e.g. at the inlet engaging portion, inner portion, and outer portion. The heating system of the plug connector is operated by a connector control module, which may be part of the heating system and provided as a standalone module on the plug connector. The connector control module may be part of the In Cable-Control and Protection Device (IC-CPD). The plug connector of the second aspect may be used in combination with the charging inlet of the first aspect for charging an electric vehicle. In this case, the connector control module and/or the inlet control module may select to operate only one of the heating systems or to operate both heating systems simultaneously. The corresponding heating systems of the charging inlet and the plug connector may be controlled independently or in combination by the corresponding control modules, e.g. the inlet control module and connector control module. For example, in some cases, such as freezing temperatures, it may be beneficial to activate the heating systems of the charging inlet and the plug connector simultaneously.

In general, the heating system incorporated in the plug connector is substantially the same as the heating system of the charging inlet of the first aspect. Furthermore, the connector control module is configured to operate the heating system of the plug connector in substantially the same manner as the operation of the heating system of the charging inlet by the inlet control module.

According to embodiments of the second aspect of the present disclosure, the at least one heating element is configured to generate, in response to a supply of voltage or current from a power source controlled by the connector control module, an amount of heat for heating the one or more heat zones of the connector housing. Similar to the heating system of the charging inlet of the first aspect, the heating element of the heating system may be a resistive heating element, but other types of heating elements may be used. The heating elements are substantially the same and configured to be operated in the same manner as described previously with reference to the heating system of the charging inlet.

According to embodiments of the second aspect of the present disclosure, the heating system comprises a set of temperature sensors for monitoring one or more temperature parameters, the set of temperature sensors being communicatively coupled to the connector control module. The temperature sensors are the same as the ones previously indicated for the charging inlet of the first aspect.

According to embodiments of the second aspect of the present disclosure, the set of temperature sensors comprises at least one ambient temperature sensor configured for monitoring the ambient temperature. For example, and similar to the first aspect, the heating system is configured to be operated by the connector control module in response to the ambient temperature being within a threshold ambient temperature value, e.g. 3 degrees Celsius. The connector control module is configured to use the temperature measurements of the ambient sensors to operate the heating system in a similar manner to that described above, with reference to the operation of the heating system of the charging inlet.

According to embodiments of the second aspect of the present disclosure, the set of temperature sensors comprises one or more heat temperature sensors configured for monitoring the temperature of the one or more heat zones.

According to embodiments of the second aspect of the present disclosure, the operation of the heating element is configured to be adjusted by the connector control module, based on the temperature monitored by the heat temperature sensors, so as to maintain the heat zones at the target temperature. The connector control module is configured to use the measurements taken by the heat temperature sensors to operate the heating system in a similar manner to that described above, with reference to the operation of the heating system of the charging inlet.

According to embodiments of the second aspect of the present disclosure, the heating element and the set of temperature sensors are integrated into the connector housing. For example, and similar to the charging inlet of the first aspect, the one or more heating elements and the sensors may be integrated at different locations in the connector housing, e.g. using a moulding technique such as overmolding, injection moulding, and the like.

According to embodiments of the second aspect of the present disclosure, the target temperature is between 2.0 to 70.0 degrees Celsius. For example, and similar to the first aspect of the present disclosure, the target temperature may be measured as the average surface temperature of the connector housing, e.g. at the locations of the collar and the engaging portion. The target temperature should be sufficient to melt ice, even in very cold conditions, as previously mentioned, and safe for the user so as to prevent injuries.

According to embodiments of the second aspect of the present disclosure, the connector housing comprises one or more locking members configured to cooperate with a locking mechanism of the charging inlet to releasably secure the plug connector to the charging inlet during charging. The locking members of the plug connector may comprise one or more openings in the inlet engaging portion, which are configured to cooperate with corresponding engagement elements of a locking mechanism of the charging inlet so as to releasably secure the plug connector to the charging inlet. The locking mechanism of the charging inlet may be activated in a manner known to the skilled person in the art, e.g. by the inlet control unit and/or the central control unit, in response to receiving an indication that charging of the electric vehicle has begun.

According to a further aspect of the present disclosure, an electric vehicle and/or a charging station is provided comprising: a charging inlet according to embodiments of the first aspect, configured to be coupled with a plug connector of a charging cable for charging the electric vehicle.

According to yet another aspect of the present disclosure, a charging cable is provided for connecting an electric vehicle to a charging station during charging, the charging cable comprising: at least one plug connector according to embodiments of the second aspect.

According to embodiments of the present disclosure, the charging cable may be adapted for use in any one of the following charging modes: - Mode 1, whereby the charging cable is provided at one end with a plug connector configured to cooperate with a charging inlet of an electric vehicle, and a socket plug at the other end that is configured to be connected to a domestic power socket, e.g. AC; - Mode 2, similar to a mode 1 charging cable, whereby the safety functions and the communication between vehicle and charging port are provided via an In -Cable -Control and Protection Device (IC-CPD) equipment.

- Mode 3, whereby the charging cable is provided at both ends with a plug connector. The mode 3 charging cable is used to connect at one end to a charging inlet of a charging station or pole and at the other end to a charging inlet of the electric vehicle; -Mode 4, whereby the charging cable is part of a charging station and provided at one end with a plug connector that is to be connected to the charging inlet of the electric vehicle. Mode 4 charging cables may accommodate both AC and DC power connections.

According to a further aspect of the present disclosure, a method is provided for operating a heating system for heating one or more heat zone of a charging inlet according to embodiments of the first aspect and/or a plug connector according to the embodiments of the second aspect, the method comprising: receiving, at a control module, temperature information obtained by one or more temperature sensors, the temperature information associated with one or more temperature parameters of the charging inlet and/or the plug connector; determining, at the control module, if the temperature parameters are within a corresponding threshold value range; and wherein, in response to at least one of the temperature parameters being within the corresponding temperature range, activating one or more heating elements of a corresponding heating system for heating one or more heat zones of the charging inlet and/or the plug connector to a target temperature above a water freezing point.

Brief Description Of The Drawings

The following drawings are provided as an example to explain further and describe various aspects of the present disclosure: Figure 1 shows an exemplified arrangement for charging an electric vehicle in accordance with a mode 3 charging configuration according to embodiments of the present disclosure.

Figures 2 to 4 show an example of a charging inlet according to embodiments of the present disclosure.

Figure 5 shows an example of a heating system according to embodiments of the present disclosure.

Figures 6 and 7 show an example of a plug connector according to embodiments of the present disclosure.

Figure 8 shows an example of the incorporation of the heating system of Figure 4 to the plug connector according to embodiments of the present disclosure.

Figure 9 shows an exemplified method for operating the heating system of Figure 4 for a charging inlet or a plug connector according to embodiments of the present disclosure.

Detailed Description Of The Drawings

The following discussion provides many exemplary embodiments of the inventive subject matter. Although each embodiment represents a single combination of inventive elements, the inventive subject matter is considered to include all possible combinations of the disclosed elements. Thus, if one embodiment comprises elements A, B, and C, and a second embodiment comprises elements B and D, then the inventive subject matter is also considered to include other remaining combinations of A, B, C, or D, even if not explicitly disclosed.

For simplicity and clarity of illustration, reference numerals may be repeated among the Figures to indicate corresponding or analogous elements. Numerous details are set forth to provide an understanding of the examples described herein. The examples may be practised without these details. In other instances, well-known methods, procedures, and components are not described in detail to avoid obscuring the examples described. The description is not to be considered as limited to the scope of the examples described herein.

Figure 1 shows an exemplified arrangement for charging an electric vehicle (EV) 100 in a mode 3 charging configuration according to embodiments of the present disclosure. In a mode 3 charging configuration, the EV 100 is connected to the charging station 500 via a charging cable 400 provided at each end with a plug connector 300 configured to cooperate with corresponding charging inlets 200 of the electric vehicle 100 and the charging station 500. To charge the electric vehicle 100, the user plugs one of the plug connectors 300 to the charging inlet on the electric vehicle 100 and the other plug connector to the charging station 500, which is configured to supply the power. The charging station 500 may be arranged as a wall box at a house, a charging poll at a public space, or in any other desired configuration. The charging cable 400 is adapted according to the charging mode. For example, in mode 1 or 2, the charging cable 400 is configured so that one end is plugged directly into a household plug, while in mode 4, the charging cable 400 may be part of the charging station 500. In general, at least one end of the charging cable 400 is provided with a plug connector 300 configured to cooperate with a charging inlet 200 of the electric vehicle 100 and/or the charging station 500. The charging inlet 200 of an EV 100 and/or a charging station 500 is configured to receive the plug connector 300 in a female-to-male arrangement. The charging inlet 200 may further be provided with a locking mechanism configured to secure the plug connector 300 during the charging of the EV 100. The charging inlet 200 and the plug connector 300 may take any desired form and shape to accommodate the local power supply and charging regulations of a geographic region.

Figures 2 to 4 show an example of a charging inlet 200 according to embodiments of the present disclosure. Figure 2 is an exploded view and Figure 3 and 4 are an assembled view. The charging inlet 200 depicted is known as a Combined Charging System (CCS) inlet for AC and DC charging. Although the present disclosure will be described using as an example the CCS charging inlet, it is also applicable to the other charging inlet types known in the art, such as type 1, type 2, and the like. In general, a charging inlet comprises a power terminal portion 201 comprising at least one set of contact terminal 202, which is mounted to an inlet housing 203. As shown in Figures 2 and 3, a CCS charging inlet 200 supports both Alternative Current (AC) and Direct Current (DC) charging and thus is provided with corresponding contact terminals 202a and 202b. The inlet housing 203 comprises a collar 204 having an internal wall 206, which is configured to surround the set of contact terminals 202a, 202b. As shown in Figure 3, a gap is defined between the internal wall 206 of the collar 204 and the set of contact terminals 202a, 202b, forming a cavity defining a connector receiving portion 207 configured for receiving a connector engaging portion 302 of the plug connector 300. The charging inlet 200 may further be provided with a cover 208 for covering one of the second set of contact terminal 202b, as shown in Figure 3. The cover 208 is secured via a latching mechanism comprising a latching member 212 configured to interact with a latching receiving member 205 of the collar 204. The charging inlet 200 may be provided with a flap to cover the terminal contacts 202 of the power terminal portion 201, so as to prevent water and humidity to enter into the charging inlet 200 when not in use. As shown in Figures 2 to 4 the charging inlet 200 is provided with a heating system 600 comprising at least one heating element 610, at least one heat temperature sensor 620a, and at least one ambient temperature sensor 620a. The heating element 610 and the temperature sensors 620a and 620b may be integrated into the charging inlet housing 203, e.g. via overmolding or another suitable method.

The heating elements 610 may be provided at desired locations on the inlet housing 203, e.g. around the collar 204, so that the heat generated is evenly distributed around the connector receiving portion 207. The connector receiving portion 207 of the charging inlet 200 is provided with sloping surfaces to drain the water in the charging inlet. The heat temperature sensors 620a and the ambient temperature sensors 620b may be positioned at different locations on the charging inlet housing 203, as shown in Figures 2 to 4. A control module 700 may be used to adjust the supply of voltage or current to the heating element 610, based for example on the temperature readings received from the temperature sensors 620a and 620b, a shown in Figure 5. For example, the inlet control module 700 may increase the temperature at the interface points between the charging inlet 200 and the plug connector 300 in proportion to the ambient temperature. As such, disconnecting the plug connector 300 from a charging inlet 200 is safely performed even at very cold weather conditions, e.g. below -30 degrees Celsius or even lower. The heat generated by the heating element must be within acceptable temperature limits to ensure the safety of the user and prevent damage to the components.

Figure 5 shows an example of the heating system 600 incorporated in the charging inlet of Figures 2 to 4 according to embodiments of the present disclosure. As previously discussed, the heating system 600 comprises one or more heating elements 610 configured to generate an amount of heat in response to a voltage or current being applied. The heating elements 610 may be in the form of resistive heating wires or another equivalent element configured for generating heating in response to the supply of electrical power. The heating system 600 may be provided with a set of temperature sensors 620 for measuring temperature parameters such as the temperature generated at a heat zone and/or the ambient temperature. The set of temperature sensors 620 comprises one or more heat temperature sensors (HS1-n) 610a configured to measure the temperature at a heat zone, and one or more ambient temperature sensors (AS1-n) 620b. The heating system 600 is provided with a control module 700, which is configured to operate the at least one heating element 610, based on the information received from the temperature sensors 620 or temperature signal(s) provided by a communication/bus interface from the car or charging station. For example, the control module 600 may activate the heating system 600 based on an ambient sensor 620b, indicating that the ambient temperature is below a certain temperature threshold, e.g. 3 degrees Celsius. The control module 700 is configured to supply a voltage to the one or more heating elements 610 so that an amount of heat is generated at the desired region. The control module 700 is configured to adjust the operation of the heating element 610, based on the temperature measured by the temperature sensors 620a, so that the temperature at the desired regions is maintained within a target value, e.g. at 70 degrees Celsius or less. The control module 700 may be provided as a separate unit or as part of another module, e.g. the central control unit of an electric vehicle 100, a charging station 500, an In Cable -Control and Protection Device (IC-CPD), and the like. The voltage or current supplied to at least one heating element 610 may be provided from different sources, such as the on-board power network of the electric vehicle, the charging supply network itself, e.g. AC or DC, and the like.

The heating system 600 of Figure 5 can be applied equally to a plug connector 300 of a charging cable 400 according to embodiments of the present disclosure. Figures 6 to 8 shows a plug connector 300 connected to a charging cable 400 according to embodiments of the present disclosure. The charging cable 400 may be adapted for use in any one of the charging modes described above, e.g. mode 1, mode 2, mode 3, or mode 4. In general, the plug connector 300 comprises a connector housing 301 provided with a connector power terminal portion 303 comprising at least one set of contact terminals 304 configured to be coupled with corresponding contact terminals 202 of a charging inlet 200 for the supply of electrical power to the electric vehicle 100. The connector housing 301 is provided with a collar 302, which comprises an inlet collar portion 302a, an external collar portion 302c, and an inlet engaging portion 302b. The inlet engaging portion 302b is configured to be inserted into the connector receiving portion 207 of a corresponding charging inlet 200 during charging of the electric vehicle 100, as previously described with reference to Figures 1 to 5. The inlet engaging portion 302b may further be provided with one or more locking members 305 configured to cooperate with a locking mechanism of the charging inlet 200 to secure the plug connector 300 to the charging inlet 200 during charging. As shown in Figure 7, and similar to the charging inlet 200, the heating system 600 may be integrated into the connector housing 301 of the plug connector 300. For example, the heating elements 610 may be integrated at the connector collar 302. For example, one or more heating elements 610 may be provided at the inner collar portion 302a, the inlet engaging portion 302b, the external collar portion 30c, or in any other suitable location. As such, when the plug connector 300 is connected to the charging inlet 200, a sufficient amount of heat is generated to melt the ice between the contact surfaces of the charging inlet 200 and the plug connector 200. The heat temperature sensors 620a and the ambient temperature sensors 602b may be placed at different locations on the connector housing 301, as shown in Figure 8. For example, the heat temperature sensors 620a may be placed at different locations on the connector collar 302, e.g. at the inlet engaging portion 302b, the inner collar portion 302a, the external collar portion 302b. The ambient sensors 620b may be placed at different locations on the connector housing 301 or in another part of the charging system. For example, the ambient temperature sensors may be provided at the IC-CPD device, the control unit of the charging station or the electric vehicle, and the like. In general, the heating system 600 is operated by the connector control module 700 in a similar manner to that previously discussed with reference to the charging inlet of Figure 5.

Figure 9 shows an exemplified method 800 for operating the heating system 600 of a charging inlet 200, such as the one shown in Figure 5, or a plug connector 300, such as the one shown in Figures 7 and 8, according to embodiments of the present disclosure. At step 801, temperature information is received at the control module 700 from the temperature sensors 602 e.g. the temperature sensors 602a and/or the ambient sensors 602b. The temperature information associated with one or more temperature parameters of the charging inlet 200 and/or plug connector 300 such as heat zone temperature, ambient temperature, average surface temperature, and the like. The control module 700, at step 802, is configured to process the temperature information to determine, at step 803, if the temperature parameters are within a corresponding temperature value range. At step 804, the control module 700 is configured, in response to at least one temperature parameter being within a corresponding temperature range, to activate one or more heating elements 610 of a corresponding heating system 600 so as to heat one or corresponding heat zones of the charging inlet 200 and/or the plug connector 300 to a target temperature above a water freezing point.

While the heating system of the present disclosure has been described in terms of the preferred embodiments thereof, it is not intended to be so limited, but rather only to the extent set forth in the claims that follow.

Claims

Claims 1. A charging inlet (200) configured to cooperate with a plug connector (300) of a charging cable connected to a power source for charging an electric vehicle (100), the charging inlet (200) comprising: an inlet housing (203) comprising an inlet power terminal portion (201) configured to cooperate with a corresponding connector terminal portion (303) of the plug connector (300) for the supply of electrical power to the electric vehicle (100); wherein the inlet housing (203) comprises a heating system (600) comprising at least one heating element, which when operated by an inlet control module (700), is configured to heat one or more heat zones of the inlet housing (203) to a target temperature above a water freezing point.
2. The charging inlet (200) of claim 1, wherein the inlet housing (201) comprises an inlet collar (204) at least partially surrounding the inlet power terminal portion (201), the inlet collar (204) comprising a connector receiving portion (207) configured for receiving a corresponding inlet engaging portion (302b) of the plug connector (300).
3. The charging inlet (200) of claim 2, wherein the least one heating element (610) is provided around the inlet collar (204) such that the heat generated is at least distributed around the connector receiving portion (207).
4. The charging inlet (200) of any one of claims 1 to 3, wherein the at least one heating element (610) is configured, in response to a supply of voltage or current from a power source controlled by the inlet control module (700), to generate an amount of heat for heating the one or more heat zones of the inlet housing (203).
5. The charging inlet (200) of any one of the preceding claims, wherein the heating system (600) comprises a set of temperature sensors (620) for monitoring one or more temperature parameters, the set of temperature sensors (620) being communicatively coupled to the inlet control module.
6. The charging inlet (200) of claim 5, wherein the set of temperature sensors (620) comprises at least one ambient temperature sensor (620b) configured for monitoring the ambient temperature.
7. The charging inlet (200) of claim 6, wherein the heating system (600) is configured to be operated by the inlet control module (700) in response to the ambient temperature being within a threshold ambient temperature value.
8. The charging inlet (200) of any one of claims 5 to 7, wherein the set of temperature sensors (620) comprises one or more heat temperature sensors (620a) configured for monitoring the temperature at one or more locations on the inlet housing (203).
9. The charging inlet (200) of claim 8, wherein the operation of the heating element (610) is configured to be adjusted by the inlet control module (700), based on the temperature detected the heat temperature sensors (620a), so as to maintain the inlet housing (203) at the target temperature.
10. The charging inlet (200) of any one of the preceding claims, wherein the heating element (610) and the set of temperature sensors (620) are integrated into the inlet housing (203).
11. The charging inlet (200) of any one of the preceding claims, wherein the target temperature is between 2.0 to 70.0 degrees Celsius.
12. The charging inlet (200) of any one of the preceding claims, wherein the 30 temperature sensors (620) comprise any one or a combination of positive or negative temperature coefficient, FTC or NTC, sensors, Resistance Temperature Detector (RTD) sensors, thermocouples, and Semiconductor-based temperature sensors.
13. The charging inlet (200) of any one of the preceding claims, wherein the inlet 5 housing (203) comprises a locking mechanism configured to cooperate with a corresponding locking member of the plug connector (300) to releasably secure the plug connector (300) to the charging inlet (200) during charging.
14. A plug connector (300) of a charging cable (400) configured to cooperate with a charging inlet (200) for charging an electric vehicle (100), the charging cable (400) being connected at one end to a power source, the plug connector (300) comprising: a connector housing (301) comprising a connector power terminal portion (303) configured to cooperate with a corresponding inlet power terminal portion (201) of a charging inlet (200) for the supply of electrical power to the electric vehicle (100); wherein the connector housing (301) comprises a heating system (600) comprising at least one heating element (610), which when operated by a connector control module (700), is configured to heat one or more heat zones of 20 the connector housing(301) to a target temperature above a water freezing point.
15. The plug connector (300) of claim 14, wherein the connector housing (301) comprises a connector collar (302) comprising an inlet engaging portion (302b) configured to cooperate with a corresponding connector receiving portion (207) of the charging inlet (200).
16. The plug connector (300) of claim 15, wherein the at least one heating element (610) is provided around the connector collar (302) such that the heat generated is at least distributed around the inlet engaging portion (302b).
17. The plug connector (300) any one of claims 14 to 16, wherein the at least one heating element (610) is configured to generate, in response to a supply of voltage or current from a power source controlled by the connector control module (700), an amount of heat for heating the one or more heat zones of the connector housing (302).
18. The plug connector (300) of any one of the preceding claims, wherein the heating system (600) comprises a set of temperature sensors (620) for monitoring one or more temperature parameters, the set of temperature sensors (620) being communicatively coupled to the connector control module (700).
19. The plug connector (700) of claim 18, wherein the set of temperature sensors comprises at least one ambient temperature sensor (620b) configured for monitoring the ambient temperature.
20. The plug connector (300) of claim 19, wherein the heating system (600) is configured to be operated by the connector control module (700) in response to the ambient temperature being within a threshold ambient temperature value.
21. The plug connector (300) of any one of claims 18 to 20, wherein the set of temperature sensors (620) comprises one or more heat temperature sensors 20 (620a) configured for monitoring the temperature of the one or more heat zones.
22. The plug connector (300) of claim 21, wherein the operation of the heating element (610) is configured to be adjusted by the connector control module (700), based on the temperature monitored by the heat temperature sensors (620a), so as to maintain the heat zones at the target temperature.
23. The plug connector (300) charging inlet of any one of claims 14 to 22, wherein the heating element (610) and the set of temperature sensors (620) are integrated into the connector housing (301).
24. The plug connector (300) of any one of claims 14 to 23, wherein the target temperature is between 2.0 to 70.0 degrees Celsius.
25. The plug connector (300) of any one of claims 14 to 24, wherein the temperature sensors comprise any one or combination of positive or negative temperature coefficient, FTC or NTC, sensors, Resistance Temperature Detector 5 (RTD) sensors, thermocouples, Semiconductor-based temperature sensors
26. The plug connector (300) of any one of claims 14 to 25, wherein the connector housing (301) comprises a locking member (305) configured to cooperate with a locking mechanism of the charging inlet (200) to releasably secure the plug connector (300) to the charging inlet (200) during charging.
27. An electric vehicle (100) and/or a charging station (500) comprising: a charging inlet (200) according to any one of claims 1 to 13 configured to be coupled with a plug connector (300) of a charging cable (400) for charging the electric vehicle (100).
28. A charging cable (400) for connecting an electric vehicle (100) to a charging station (500) during charging, the charging cable comprising: at least one plug connector (300) according to any one of claims 14 to 26. 20
29. A method for operating a heating system (600) for heating one or more heat zones of a charging inlet (200) according to any one of claims 1 to 13 and/or a plug connector (300) according to any one of claims 14 to 26, the method comprising: receiving, at a control module (700), temperature information obtained by one or more temperature sensors (602a, 602b), the temperature information associated with one or more temperature parameters of the charging inlet and/or the plug connector; determining, at the control module (700), if the temperature parameters are within a corresponding threshold value range; and wherein, in response to at least one of the temperature parameters being within the corresponding temperature range, activating one or more heating elements (610) of a corresponding heating system (600) for heating one or more heat zones of the charging inlet (200) and/or the plug connector (300) to a target temperature above a water freezing point.