GB2620374A - Electric vehicle charger installation base and method of installation - Google Patents
Electric vehicle charger installation base and method of installation Download PDFInfo
- Publication number
- GB2620374A GB2620374A GB2209480.9A GB202209480A GB2620374A GB 2620374 A GB2620374 A GB 2620374A GB 202209480 A GB202209480 A GB 202209480A GB 2620374 A GB2620374 A GB 2620374A
- Authority
- GB
- United Kingdom
- Prior art keywords
- electric vehicle
- vehicle charger
- outer casing
- cylindrical core
- installation base
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 238000009434 installation Methods 0.000 title claims abstract description 86
- 238000000034 method Methods 0.000 title claims abstract description 33
- 238000004519 manufacturing process Methods 0.000 claims abstract description 6
- 239000000463 material Substances 0.000 claims description 29
- 229920003023 plastic Polymers 0.000 claims description 14
- 239000004033 plastic Substances 0.000 claims description 14
- 239000000758 substrate Substances 0.000 claims description 9
- 238000000465 moulding Methods 0.000 claims description 8
- 239000004570 mortar (masonry) Substances 0.000 claims description 6
- 239000002131 composite material Substances 0.000 claims description 5
- 238000005553 drilling Methods 0.000 claims description 5
- 229910052751 metal Inorganic materials 0.000 claims description 4
- 239000002184 metal Substances 0.000 claims description 4
- 230000005484 gravity Effects 0.000 claims description 3
- 238000009966 trimming Methods 0.000 claims 1
- 239000003981 vehicle Substances 0.000 description 10
- 239000002689 soil Substances 0.000 description 5
- 238000009412 basement excavation Methods 0.000 description 4
- 239000011440 grout Substances 0.000 description 3
- 229910000831 Steel Inorganic materials 0.000 description 2
- 238000004364 calculation method Methods 0.000 description 2
- 239000004567 concrete Substances 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
- 238000002347 injection Methods 0.000 description 2
- 239000007924 injection Substances 0.000 description 2
- 229920000642 polymer Polymers 0.000 description 2
- 239000004576 sand Substances 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- 230000002301 combined effect Effects 0.000 description 1
- 230000002844 continuous effect Effects 0.000 description 1
- 229920001577 copolymer Polymers 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 230000005611 electricity Effects 0.000 description 1
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- 238000011065 in-situ storage Methods 0.000 description 1
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- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 1
- 229910052721 tungsten Inorganic materials 0.000 description 1
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
- B60L53/00—Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles
- B60L53/30—Constructional details of charging stations
- B60L53/31—Charging columns specially adapted for electric vehicles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
- B60L53/00—Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles
- B60L53/10—Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles characterised by the energy transfer between the charging station and the vehicle
- B60L53/14—Conductive energy transfer
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
- H02G3/00—Installations of electric cables or lines or protective tubing therefor in or on buildings, equivalent structures or vehicles
- H02G3/02—Details
- H02G3/04—Protective tubing or conduits, e.g. cable ladders or cable troughs
- H02G3/0493—Service poles
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
- H02G9/00—Installations of electric cables or lines in or on the ground or water
- H02G9/10—Installations of electric cables or lines in or on the ground or water in cable chambers, e.g. in manhole or in handhole
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/60—Other road transportation technologies with climate change mitigation effect
- Y02T10/70—Energy storage systems for electromobility, e.g. batteries
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/60—Other road transportation technologies with climate change mitigation effect
- Y02T10/7072—Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
Landscapes
- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Transportation (AREA)
- Mechanical Engineering (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Charge And Discharge Circuits For Batteries Or The Like (AREA)
Abstract
An electric vehicle charger installation base 1 comprises an inner hollow cylindrical core 2 and an outer casing 3. The inner core has a base, a continuous sidewall, and at least one inlet aperture 4, 5 provided in the continuous sidewall 6. The outer casing has an inner surface in contact with the inner hollow cylindrical core, the outer casing being provided with at least one inlet aperture adapted to communicate with the at least one inlet aperture of the inner cylindrical core. The inner hollow cylindrical core is sized and shaped to receive and retain an electric vehicle charger, and wherein the inner hollow cylindrical core further comprises a locking mechanism adapted to lock an electric vehicle charger into the inner hollow cylindrical core. Methods of manufacturing and installing the electric vehicle charger base are also described.
Description
ELECTRIC VEHICLE CHARGER INSTALLATION BASE AND METHOD OF INSTALLATION
The present invention relates to an electric vehicle charger installation base, a method of manufacture of an electric vehicle charger installation base and a method of installing an electric vehicle charger installation base.
Conventional electric vehicle chargers are typically installed in dedicated parking spaces, such as those in public car parks, work place car parks, motorway service stations and supermarkets. Conventional domestic electric vehicle chargers are typically installed on private driveways or in private garages, since this provides easy access to a domestic electricity supply and any cabling between the charger and an electric vehicle remains entirely on the property. In urban areas or areas where housing is provided without off-street parking however, it is common to find vehicles parked on the road alongside a kerb separating the road from a footway, such as a pavement or sidewalk. For electric vehicles kerbside parking is an issue since it can be difficult to access charging facilities. For exam-ple, charging from an adjacent domestic property would require cabling to be provided from the property to the vehicle, with trailing cables lying across the footway causing a risk of accidents. One solution to this has been to provide electric vehicle charging installations within lamp posts (such as those from UbitricityTM) or by utilising charging posts or sockets that retract into the ground when not in use (such as those from Trojan Energy Ltd). However, unless existing infrastructure is positioned appropriately for use any new installations involve a significant civil works outlay in terms of excavation for charge post foundations and cabling, all within the proximity of domestic dwellings or on busy roads. The present invention aims to address these issues by providing, in a first aspect, an electric vehicle charger installation base, comprising: an inner hollow cylindrical core having a base, a continuous sidewall, and at least one inlet aperture provided in the con-tinuous sidewalk and an outer casing having an inner surface in contact with the inner hollow cylindrical core, the outer casing being provided with at least one inlet aperture adapted to communicate with the at least one inlet aperture of the inner cylindrical core; wherein the inner hollow cylindrical core is sized and shaped to receive and retain an electric vehicle charger, and wherein the inner hollow cylindrical core further comprises a locking mechanism adapted to lock an electric vehicle charger into the inner hollow cylindrical core.
By combining a cylindrical inner core to which an electric vehicle charger can be locked, and a cylindrical outer core that secures the electric vehicle can be fixed within the ground, a simple core drill process can be used to cut the hole required to install the electric vehicle charger installation base, thus reducing or removing the amount excavation, spoil and aggregate and binding material required to install conventional electric vehicle chargers on-street urban area without off-street parking. This process would also offer a high level of repeatability and quality as each foundation would be precisely defined by the drilling tool rather than exhibit the variability of a hand dug/cut hole. Preferably, the outer casing further comprises an outer textured surface. Preferably, the textured surface comprises a plurality of channels.
Preferably, the inner hollow cylindrical core further comprises a cabling duct con-nected with the or each of the at least one inlet apertures, and wherein the cabling duct passes through the outer casing and terminates at the outer textured surface of the outer casing.
Preferably, the locking mechanism comprises an aperture in the base of the inner hollow cylindrical core adapted to receive a locking lug provided on the base of an electric vehicle charger in a first orientation. Alternatively, the locking mechanism comprises an aperture in the continuous sidewall of the inner hollow cylindrical core and a resilient retainer positioned within the aperture.
Preferably, the hollow inner cylindrical core is formed from a plastics material.
The outer casing may be a composite material. Alternatively, the outer casing may com-prise a hollow, flexible receptacle filled with a non-compressible ballast material. Embodiments of the present invention also provide, in a second aspect, a method of manufacturing an electric vehicle charger installation base, comprising: moulding an inner hollow cylindrical core having a base, a continuous sidewall, and at least one inlet aperture provided in the continuous side wall from a plastics material; inserting a cabling duct into the or each of the at least on inlet apertures; and inserting the inner hollow cylindrical core into an outer casing, the outer casing having an inner surface in contact with the inner hollow cylindrical core and an outer textured surface, the outer casing being provided with at least one inlet aperture adapted to communicate with the at least one inlet aperture of the inner cylindrical core.
Preferably, the outer casing is a mouldable material, overmoulded onto the inner hollow cylindrical core, and wherein the method further comprises the step of demoulding the electric vehicle installation base.
Preferably, any excess cabling duct is trimmed away such that it terminates at the outer textured surface of the outer casing. The outer casing may be a hollow, flexible recepta-cle, and method may further comprise the step of: filling the outer casing of the electric vehicle installation base with a non-compressible ballast material. The outer casing may be one of a plastics material or a metal cage.
Embodiments of the present invention also provide, in a third aspect, a method of installing an electric vehicle charger installation base as outlined above, comprising: drill- ing a circular hole in a substrate in which an electric vehicle charger is to be installed to a depth greater than that required to accommodate the electric vehicle charger installation base; securing the electric vehicle charger installation base within the hole; installing ca-bling into the apertures in both the inner hollow cylindrical core and the outer casing; and locking an electric vehicle charger to the electric vehicle charger installation base.
A trench may be cut in the substrate to accommodate cabling.
Mortar may be injected or gravity poured around the outer casing to retain the electric vehicle charging base within the circular hole.
The outer casing may be a hollow, flexible receptacle, and the method may further comprise the step of: filling the outer casing of the electric vehicle installation base with a non-compressible ballast material.
The invention will now be described by way of example only, and with reference to the accompanying drawings, in which: Figure 1 is a first schematic perspective view of an electric vehicle charger installation base in accordance with embodiments of the present invention; Figure 2 is a second schematic perspective view of an electric vehicle charger installation base in accordance with embodiments of the present invention; Figure 3 is a schematic perspective view of the inner hollow cylindrical core of an electric vehicle charger installation base in accordance with embodiments of the present invention; Figure 4 is a schematic base view of the inner hollow cylindrical core of an electric vehicle charger installation base in accordance with embodiments of the present invention; Figure 5 is a schematic perspective view of an electric vehicle charger installed in an elec-tric vehicle charger installation base in accordance with embodiments of the present invention; Figure 6 is a schematic cut-away view of a locking mechanism for an electric vehicle charger installation base in accordance with embodiments of the present invention; Figure 7 is a flowchart of a method of manufacture of an electric vehicle charger installa-tion base in accordance with embodiments of the present invention; and Figure 8 is a flowchart of a method of installation of an electric vehicle charger installation base in accordance with embodiments of the present invention.
The embodiments of the present invention take an alternate approach to utilising existing infrastructure, such as lampposts, or requiring significant excavation or engineer-ing to install on-street electric vehicle chargers in urban areas. The electric vehicle charger is instead installed in an electric vehicle charger installation base having a two-part construction. An inner hollow cylindrical core having a base, a continuous sidewall, and at least one inlet aperture provided in the continuous sidewall is provided, along with an outer casing. The outer casing has an inner surface in contact with the inner hollow cylindrical core, and is provided with at least one inlet aperture adapted to communicate with the at least one inlet aperture of the inner cylindrical core. The inner hollow cylindrical core is sized and shaped to receive and retain the electric vehicle charger. In addi- tion, the inner hollow cylindrical core further comprises a locking mechanism adapted to lock an electric vehicle charger into the inner hollow cylindrical core. Ideally, the electric vehicle charger used is based on a flexible bollard, since this offers appropriate impact behaviour in an urban setting. By adopting a two-part construction for the electric vehi-cle charger installation base, such a flexible bollard will remain in place during impact, and will bend out of the way of a vehicle. This is discussed in more detail below.
Figure 1 is a first schematic perspective view of an electric vehicle charger installation base in accordance with embodiments of the present invention. The electric vehicle charger installation base 1 comprises an inner hollow cylindrical core 2 and an outer cas-ing 3. At least one inlet aperture 4,5 is provided in both the inner hollow cylindrical core 2 and the outer casing 3 to enable cabling to be passed from an electrical supply to the centre of the electric vehicle charger installation socket liar installation into an electric vehicle charger in situ. The electric vehicle charger installation base 1 is in the shape of a hollow cylinder, with the outer casing 3 having a continuous sidewall 6 and a closed base 7.
Figure 2 is a second schematic perspective view of an electric vehicle charger installation base in accordance with embodiments of the present invention. The outer casing 3 is provided with a textured surface comprised of a plurality of channels. This has two purposes: the channels 8a...n on the closed base 7 of the outer casing 3 provide in-creased adhesion to grout compared with a smooth closed base, which creates a more secure fixing of the electric vehicle charger installation base in the footway; and the plurality of channels 9a...n provided on the continuous sidewall 6 of the outer casing 3 enable mortar to be injected along the outside of the electric vehicle charger installation base 1 to secure the electric vehicle charger installation base 1 once positioned within the hole in the footway.
Figure 3 is a schematic perspective view of the inner hollow cylindrical core of an electric vehicle charger installation base in accordance with embodiments of the present invention. The inner hollow cylindrical core 2 has a base 10 and a continuous sidewall 11, and is provided with at least one inlet aperture 12 in the continuous sidewall 11. Three inlet apertures 12a, b, c are illustrated in this example, however the number required will depend on the supply cabling configuration. The inner hollow cylindrical core 2 is sized and shaped to receive and retain an electric vehicle charger, and further comprises a locking mechanism adapted to lock an electric vehicle charger into the inner hollow cylindrical core 2. This is shown in more detail in Figure 4. The inner hollow cylindrical core 2 fur- 3 5 ther comprises a cabling duct 13 connected with the or each of the at least one inlet aper-tures 12a, b, c. The cabling duct 13 passes through the outer casing 3 and terminates at the outer textured surface of the outer casing 3, as shown in Figure 1. The cabling ducts 13 are designed to be smooth passages of minimum bend radius. These guide the stiff and rigid armoured cables that are unable to bend around tight corners. This makes installation easier as the cabling naturally locates to the bottom of the electric vehicle charger when pushed through the cab cabling duct 13, and prevents the need for the stiff cables being wrestled into position.
Figure 4 is a schematic base view of the inner hollow cylindrical core of an electric vehicle charger installation base in accordance with embodiments of the present invention. This illustrates a locking mechanism in accordance with a first embodiment of the present invention. The locking mechanism 14 comprises an aperture 15 in the base 10 of the inner hollow cylindrical core 2, which is adapted to receive a locking lug (not shown) provided on the base of an electric vehicle charger in a first orientation. The aperture 15 is shaped to accommodate a generally rectangular lug, such that when the lug is inserted into the aperture 15 in the correct orientation it drops through aperture 15. The continuous sidewall 11 of the inner hollow cylindrical core 2 is provided with a lip (not shown) that juts out from the base 10 to create a space underneath the base 10 when the electric vehicle charger installation base is in use into which the lug can be rotated. Rotating the lug by a quarter turn prevents withdrawal through the aperture 15, since the lug is retained in place by the base 10. To release the lug, another quarter turn is required to ensure that it is in the correct orientation to be withdrawn through the aperture 15. A locking pin (not shown) may be used to prevent rotation and removal of the electric vehi- 2 0 cle charger by unauthorised persons.
Figure 5 is a schematic perspective view of an electric vehicle charger installed in an electric vehicle charger installation base in accordance with embodiments of the present invention. The electric vehicle charger 16 is a flexible bollard, inserted into the inner hollow cylindrical core 2 of the electric vehicle charger installation base 1. To aid installa-tion, an arrow 17 is provided on the upper surface of the outer casing 3, which indicates the direction of the aperture 15 in the base 10 of the inner hollow cylindrical core 2. This therefore allows the correct alignment of the lug on the base of the electric vehicle charger 16 so that the lug drops through the aperture 15 and the electric vehicle charger 16 can be rotated and locked into position.
Figure 6 is a schematic cut-away view of a locking mechanism for an electric vehi-cle charger installation base in accordance with embodiments of the present invention. Rather than providing a locking mechanism in the base 10 of the inner hollow cylindrical core 2, a locking mechanism 18 is provided on the continuous sidewall 11. This locking mechanism 18 comprises an aperture 19 in the continuous sidewall 11 of the inner hollow cylindrical core 2 and a resilient retainer 20 positioned within the aperture 19. In the ex-ample illustrated, the resilient retainer 20 is a formed steel spring mounted on the continuous sidewall 11 and having a section positioned within the aperture 19 and able to contact the exterior of the electric vehicle charger 16. The spring force applied by the resilient retainer 20 acts to retain the electric vehicle charger 16 in position. A cover 21 is provided over the resilient retainer 20, with an aperture 22 on its upper surface. Once the electric vehicle charger 16 is in place a tool 23 may be inserted through this aperture 22 to depress the resilient retainer 20 thus moving it out of contact with the electric vehi-cle charger 16 in the form of a quick release.
In each of the embodiments above, the inner hollow cylindrical core 2 is formed from a plastics material and the outer casing 3 is formed from a composite material. Suitable plastics materials include injection or rotational mouldable polymers, copolymers and reinforced polymers and resins. Suitable composite materials include con- crete. In alternative embodiments, the outer casing 3 comprises a hollow, flexible recep-tacle. This may be moulded from the same plastics material as the inner hollow cylindrical core 2 in the same moulding process, or moulded separately from either the same material as the inner hollow cylindrical core 2 or an alternative plastics material. Alternatively, the outer casing 3 may be a metal cage, such as a wire cage rather than a plastics material. In the latter situation, the inner hollow cylindrical core 2 and the outer casing 3 may be combined at the installation site. The outer casing 3 is filled with a non-compressible ballast material, such as coarse sand, pea shingle or grout. Preferably, the diameter d of the electric vehicle charger installation base is 0.4m with a height h of 0.35m, leading to a weight of 75kg. This is required to ensure that the electric vehicle charger installation base 1 is sufficient to withstand a tipping moment from a vehicle im- pacting the electric vehicle charger 16. A typical bollard electric vehicle charger has a diameter of 0.2m, a height of 1.005m and a weight of 5kg. Assuming that the bumper of a typical electric vehicle sits at 0.375m above the ground, and that the impact force of a slow-moving vehicle is 300N, it is possible to calculate the tipping moment of the corn-bined electric vehicle charger 16 and the electric vehicle charger installation base 1. The fulcrum of the tipping moment will sit at the edge of the electric vehicle charger installation base 1 furthest away from impact, leading to a tipping moment of: My= 300x(0.375+0.350)= 217.5Nm (anticlockwise) The standing moment from the combination of the electric vehicle charger 16 and the electric vehicle charger installation base 1 (assuming that the centre of mass is in the cen-tre): Mw = 80x0.2 = 160Nm (clockwise) Therefore, unless the electric vehicle installation base 1 is surrounded by compacted soil it will tip on impact by an electric vehicle. However, including a wedge of compacted soil on the side opposite the fulcrum creates an additional weight to include in the calcula-tion. For soil with a density of 20kN/m3, the weight of the soil wedge will be given by: 20x(0.4x0.4x0.25)/2 = 1.12kN This leads to an additional soil moment M, of 448nM (clockwise). The total clockwise moment is therefore 608nM, significantly larger than the tipping moment of the electric vehicle charger 16 and electric vehicle charger installation base 1 combination. An alternative calculation is based on that for the ground resistance moment in PD6547:2004 Guidance on the use of BS EN 40-3-1 and BS EN 40-3-3, BSI and IHE Structures Guide 2021. This gives the ground resistance moment Mg as: GD P3 M = Where G is a factor dependent on the ground support and given as 630kN/m3 for good, solid, well-compacted material, D is the effective diameter of the foundation in the ground and P is the planting depth. Using the same parameters as above, 630 x 0.4 x 0.353 = 10 = 1080Nm The destabilising moment is considered about a fulcrum located 1/V2of the planting depth below ground, giving the level arm as: (0.35x1/V2) + 0.375 = 0.622m such that the destabilising moment is: Mv = 300v0.622 = 186.6Nm Given that 1080Nm»186.6Nm, the combination of the electric vehicle charger 16 and electric vehicle charger installation base 1 will remain in place following a vehicle impact. Figure 7 is a flowchart of a method of manufacture of an electric vehicle charger installation base in accordance with embodiments of the present invention. The method comprises a first step 102 of moulding an inner hollow cylindrical core 2 having a base 10, a continuous sidewall 11, and at least one inlet aperture 12 provided in the continuous sidewall 11 from a plastics material. This is preferably done using injection mounding, but other moulding techniques, such as rotational moulding may also be used.
At step 104, a cabling duct 13 is inserted into the or each of the at least one inlet aper-tures 12. Next, at step 106, the inner hollow cylindrical core 2 is inserted into an outer casing 3, the outer casing 3 having an inner surface in contact with the inner hollow cylindrical core 2 and an outer textured surface. The outer casing may be a mouldable material, overmoulded onto the inner hollow cylindrical core, and wherein the method further comprises the step of demoulding the electric vehicle installation base. The outer casing 3 is also provided with at least one inlet aperture 4, 5 adapted to communicate with the at least one inlet aperture 12 of the inner cylindrical core 2. At step 108 the electric vehicle installation base 1 may be demoulded. Preferably, as an additional final step, at step 110, any excess cabling duct 13 is trimmed away such that it terminates at the outer tex- tured surface of the outer casing 3. It may be desirable to split the moulding and over-moulding steps between two different moulds, such that the inner hollow cylindrical core 2 is removed from a first mould, placed into a second mould and then the outer casing 3 overmoulded. The mould for the outer casing 3 may include silicone inserts to create the textured outer surface and/or the lip on the continuous sidewall 11 of the inner hollow cylindrical core 2. In one embodiment, the outer casing 3 is formed of a composite material such as concrete. In alternative embodiments, the outer casing 3 comprises a hollow, flexible receptacle. This may be moulded from the same plastics material as the inner hollow cylindrical core 2 in the same moulding process, or moulded separately from either the same material as the inner hollow cylindrical core 2 or an alternative plastics material. Alternatively, the outer casing 3 may be a metal cage, such as a wire cage. In the latter situation, the inner hollow cylindrical core 2 and the outer casing 3 may be com-bined at the installation site. The outer casing 3 is filled with a non-compressible ballast material, such as coarse sand, pea shingle or grout.
Figure 8 is a flowchart of a method of installation of an electric vehicle charger installation base in accordance with embodiments of the present invention. The method 200 beings at step 202 by drilling a circular hole in a substrate in which an electric vehicle charger 16 is to be installed to a depth greater than that required to accommodate the electric vehicle charger installation base 1. The drilling may be done using a tungsten or diamond-tipped core drill, which has the advantage that any compacted material under the substrate, such as a footway, is undisturbed other than where it is removed. Next, at step 204, the electric vehicle charger installation base 1 is secured within the hole. This may be done by laying a layer of mortar into the circular hole and placing the electric ve- hicle charger installation base 1 into the circular hole. At step 206, cabling is installed into the apertures 12, 14 in both the inner hollow cylindrical core 2 and the outer casing 3. Finally, at step 208, an electric vehicle charger 16 is locked to the electric vehicle charger installation base 1. It may also be desirable to cut a trench in the substrate to accommo-date cabling, but this may have been done in advance. Preferably the circular hole is cut adjacent to any trench, but may be cut at a given distance away or overlapping the trench, depending upon individual circumstances. Cabling should be buried at least 0.25m below the surface of the substrate, with the base of the trench preferably sitting at at least 0.285m below the surface of the substrate. Mortar may be injected or gravity poured around the outer casing 3 to retain the electric vehicle charging base 1 within the circular hole. The mortar is injected into the channels provided in the outer textured surface of the continuous wall of the outer casing 3. It may also be desirable to include additional holes in the outer casing 3 to retain steel reinforcing bars to help in securing the electric vehicle charger installation socket 1, if installing where the ground is soft and fragmented. Installation in this way would preclude the drill coring method with the base being installed conventionally with a much larger excavation required.
Claims (18)
- Claims 1. An electric vehicle charger installation base, comprising: an inner hollow cylindrical core having a base, a continuous sidewall, and at least one inlet aperture provided in the continuous sidewall; and an outer casing having an inner surface in contact with the inner hollow cylindrical core, the outer casing being provided with at least one inlet aperture adapted to communicate with the at least one inlet aperture of the inner cylindrical core; wherein the inner hollow cylindrical core is sized and shaped to receive and retain an electric vehicle charger, and wherein the inner hollow cylindrical core further compris-es a locking mechanism adapted to lock an electric vehicle charger into the inner hollow cylindrical core.
- 2. Electric vehicle charger installation base as claimed in claim 1, wherein the outer casing further comprises an outer textured surface.
- 3. Electric vehicle charger installation base as claimed as claim 2, wherein the textured surface comprises a plurality of channels.
- 4. Electric vehicle charger installation base as claimed in claim 2 or 3, wherein the inner hollow cylindrical core further comprises a cabling duct connected with the or each of the at least one inlet apertures, and wherein the cabling duct passes through the outer casing and terminates at the outer textured surface of the outer casing.
- 5. Electric vehicle charger installation base as claimed in any of claims 1 to 4, wherein the locking mechanism comprises an aperture in the base of the inner hollow cylindrical core adapted to receive a locking lug provided on the base of an electric vehicle charger in a first orientation.
- 6. Electric vehicle charger installation base as claimed in any of claims 1 to 4, wherein the locking mechanism comprises an aperture in the continuous sidewall of the inner hollow cylindrical core and a resilient retainer positioned within the aperture.
- 7. Electric vehicle charger installation base as claimed in any preceding claim, where- 3 5 in the hollow inner cylindrical core is formed from a plastics material.
- 8. Electric vehicle charger installation base as claimed in any preceding claim, where-in the outer casing is a composite material.
- 9. Electric vehicle charger installation base as claimed in any of claims 1 to 7, wherein the outer casing comprises a hollow, flexible receptacle filled with a non-compressible ballast material.
- Method of manufacturing an electric vehicle charger installation base, comprising: moulding an inner hollow cylindrical core having a base, a continuous sidewall, and at least one inlet aperture provided in the continuous side wall from a plastics material; inserting a cabling duct into the or each of the at least on inlet apertures; and inserting the hollow cylindrical core into an outer casing, the outer casing having an inner surface in contact with the inner hollow cylindrical core and an outer textured surface, the outer casing being provided with at least one inlet aperture adapted to communicate with the at least one inlet aperture of the inner cylindrical core.
- 11. Method as claimed in claim 10, wherein the outer casing is a mouldable material, overmoulded onto the inner hollow cylindrical core, and wherein the method further comprises the step of demoulding the electric vehicle installation base.
- 12. Method as claimed in claim 10 or 11, further comprising the step of: trimming any excess cabling duct such that it terminates at the outer textured surface of the outer casing.
- 13. Method as claimed in claim 10 or 11, wherein the outer casing is a hollow, flexible receptacle, and wherein the method further comprises the step of: filling the outer casing of the electric vehicle installation base with a non-compressible ballast material
- 14. Method as claimed in claim 13, wherein the outer casing is one of a plastics mate- 3 0 rial or a metal cage.
- 15. Method of installing an electric vehicle charger installation base as claimed in any of claims 1 to 9, comprising: drilling a circular hole in a substrate in which an electric vehicle charger is to be installed to a depth greater than that required to accommodate the electric vehicle charger installation base; securing the electric vehicle charger installation base within the hole;IIinstalling cabling into the apertures in both the inner hollow cylindrical core and the outer casing; and locking an electric vehicle charger to the electric vehicle charger installation base.
- 16. Method as claimed in claim 15, further comprising the step of: cutting a trench in the substrate to accommodate cabling.
- 17. Method as claimed in claim 115 or 16, further comprising the step of: injecting or gravity pouring mortar around the outer casing to retain the electric vehicle charging base within the circular hole.
- 18. Method as claimed in any of claims 15 to 17, wherein the outer casing is a hollow, flexible receptacle, and wherein the method further comprises the step of: filling the outer casing of the electric vehicle installation base with a non-compressible ballast material.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB2209480.9A GB2620374A (en) | 2022-06-28 | 2022-06-28 | Electric vehicle charger installation base and method of installation |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB2209480.9A GB2620374A (en) | 2022-06-28 | 2022-06-28 | Electric vehicle charger installation base and method of installation |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| GB202209480D0 GB202209480D0 (en) | 2022-08-10 |
| GB2620374A true GB2620374A (en) | 2024-01-10 |
Family
ID=82705443
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB2209480.9A Pending GB2620374A (en) | 2022-06-28 | 2022-06-28 | Electric vehicle charger installation base and method of installation |
Country Status (1)
| Country | Link |
|---|---|
| GB (1) | GB2620374A (en) |
Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20130309022A1 (en) * | 2011-01-28 | 2013-11-21 | Unimi Solutions Ab | Foundation system for charging poles |
| WO2022055413A1 (en) * | 2020-09-11 | 2022-03-17 | Unimi Holding Ab | Charging station foundation |
-
2022
- 2022-06-28 GB GB2209480.9A patent/GB2620374A/en active Pending
Patent Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20130309022A1 (en) * | 2011-01-28 | 2013-11-21 | Unimi Solutions Ab | Foundation system for charging poles |
| WO2022055413A1 (en) * | 2020-09-11 | 2022-03-17 | Unimi Holding Ab | Charging station foundation |
Also Published As
| Publication number | Publication date |
|---|---|
| GB202209480D0 (en) | 2022-08-10 |
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