SG188031A1 - Laminous multi-polymeric high amperage over-molded connector assembly for plug-in hybrid electric vehicle charging - Google Patents
Laminous multi-polymeric high amperage over-molded connector assembly for plug-in hybrid electric vehicle charging Download PDFInfo
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- SG188031A1 SG188031A1 SG2012042966A SG2012042966A SG188031A1 SG 188031 A1 SG188031 A1 SG 188031A1 SG 2012042966 A SG2012042966 A SG 2012042966A SG 2012042966 A SG2012042966 A SG 2012042966A SG 188031 A1 SG188031 A1 SG 188031A1
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- Prior art keywords
- connector
- connector body
- charging mode
- latch
- potting compound
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- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 18
- 239000000463 material Substances 0.000 claims abstract description 17
- 238000004382 potting Methods 0.000 claims description 20
- 150000001875 compounds Chemical class 0.000 claims description 19
- 238000000034 method Methods 0.000 claims description 17
- -1 polyethylene terephthalate Polymers 0.000 claims description 8
- 241000180579 Arca Species 0.000 claims description 7
- 229920001296 polysiloxane Polymers 0.000 claims description 6
- 238000004132 cross linking Methods 0.000 claims description 4
- 239000005020 polyethylene terephthalate Substances 0.000 claims description 4
- 229920000139 polyethylene terephthalate Polymers 0.000 claims description 4
- 229920001169 thermoplastic Polymers 0.000 claims description 4
- 239000004416 thermosoftening plastic Substances 0.000 claims description 4
- 229920002943 EPDM rubber Polymers 0.000 claims description 3
- 239000004743 Polypropylene Substances 0.000 claims description 3
- 239000004676 acrylonitrile butadiene styrene Substances 0.000 claims description 3
- 239000011521 glass Substances 0.000 claims description 3
- 238000002347 injection Methods 0.000 claims description 3
- 239000007924 injection Substances 0.000 claims description 3
- 239000007788 liquid Substances 0.000 claims description 3
- 229920002647 polyamide Polymers 0.000 claims description 3
- 229920001155 polypropylene Polymers 0.000 claims description 3
- XECAHXYUAAWDEL-UHFFFAOYSA-N acrylonitrile butadiene styrene Chemical compound C=CC=C.C=CC#N.C=CC1=CC=CC=C1 XECAHXYUAAWDEL-UHFFFAOYSA-N 0.000 claims 2
- 229920000122 acrylonitrile butadiene styrene Polymers 0.000 claims 2
- 229920002725 thermoplastic elastomer Polymers 0.000 claims 2
- 230000007613 environmental effect Effects 0.000 description 11
- 238000004519 manufacturing process Methods 0.000 description 6
- 239000000243 solution Substances 0.000 description 6
- 241000202755 Areca Species 0.000 description 4
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 4
- 238000010521 absorption reaction Methods 0.000 description 4
- 229910052802 copper Inorganic materials 0.000 description 4
- 239000010949 copper Substances 0.000 description 4
- 238000005260 corrosion Methods 0.000 description 3
- 230000007797 corrosion Effects 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 239000012530 fluid Substances 0.000 description 3
- 238000005476 soldering Methods 0.000 description 3
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 description 2
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 2
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 description 2
- RAHZWNYVWXNFOC-UHFFFAOYSA-N Sulphur dioxide Chemical compound O=S=O RAHZWNYVWXNFOC-UHFFFAOYSA-N 0.000 description 2
- 230000015556 catabolic process Effects 0.000 description 2
- 230000007123 defense Effects 0.000 description 2
- 238000006731 degradation reaction Methods 0.000 description 2
- 239000000428 dust Substances 0.000 description 2
- 239000003063 flame retardant Substances 0.000 description 2
- 239000003921 oil Substances 0.000 description 2
- 239000004417 polycarbonate Substances 0.000 description 2
- 229920000515 polycarbonate Polymers 0.000 description 2
- 230000001737 promoting effect Effects 0.000 description 2
- 229910052709 silver Inorganic materials 0.000 description 2
- 239000004332 silver Substances 0.000 description 2
- 229910001369 Brass Inorganic materials 0.000 description 1
- 241000276573 Cottidae Species 0.000 description 1
- RWSOTUBLDIXVET-UHFFFAOYSA-N Dihydrogen sulfide Chemical compound S RWSOTUBLDIXVET-UHFFFAOYSA-N 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 230000003213 activating effect Effects 0.000 description 1
- 230000000712 assembly Effects 0.000 description 1
- 238000000429 assembly Methods 0.000 description 1
- 239000010951 brass Substances 0.000 description 1
- 229910002092 carbon dioxide Inorganic materials 0.000 description 1
- 239000001569 carbon dioxide Substances 0.000 description 1
- 239000004020 conductor Substances 0.000 description 1
- 230000000994 depressogenic effect Effects 0.000 description 1
- 238000001514 detection method Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000005553 drilling Methods 0.000 description 1
- 229920001971 elastomer Polymers 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 1
- 229910052737 gold Inorganic materials 0.000 description 1
- 239000010931 gold Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 229910000037 hydrogen sulfide Inorganic materials 0.000 description 1
- 238000003780 insertion Methods 0.000 description 1
- 230000037431 insertion Effects 0.000 description 1
- 230000014759 maintenance of location Effects 0.000 description 1
- 230000013011 mating Effects 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 230000002265 prevention Effects 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 229920001187 thermosetting polymer Polymers 0.000 description 1
Classifications
-
- Y02T10/6204—
-
- Y02T10/7005—
-
- Y02T90/121—
Landscapes
- Connector Housings Or Holding Contact Members (AREA)
Abstract
Abstract of the DisclosureLAMINOUS MULTI-POLYMERIC HIGH AMPERAGE OVER-MOLDED CONNECTOR ASSEMBLY FOR PLUG-IN HYBRID ELECTRIC VEHICLE CHARGINGIn an electrical connector for an electric vehicle, the spring latch is not sealed; instead, the connector body has holes allowing water entering the spring latch mechanism to drain harmlessly out of the connector. A forward-facing LED or other light source acts as a flashlight. Once the connector is connected, the forward-facing LED is switched off, and a rear-facing LED or other light source is switched on to confirm that the connector is connected and capable of charging the vehicle. The connector is produced by overmolding in a three-layer configuration, where each layer is formed of a material having advantageous materials for that layer's position in the connector. (Fig. 1)
Description
LAMINOUS MULTI-POLYMERIC HIGH AMPERAGE OVER-MOLDED CONNECTOR
ASSEMBLY FOR PLUG-IN HYBRID ELECTRIC VEHICLE CHARGING
[0001] The present application is a continuation-in-part of U.S. Patent Application No. 13/211,867, filed
August 17, 2011, currently pending, which claims the benefit of U.S. Provisional Patent Application
No. 61/430,456, filed January 6, 2011, and U.S. Provisional Patent Application No. 61/482.,459, filed May 4, 2011. The present application is also a continuation-in-part of U.S. Design Patent
Application No. 29/382,230, filed December 30, 2010, and of U.S. Design Patent Application No. 29/408,312, filed December 9, 2011, both of which are currently pending. The disclosures of the above-referenced applications are hereby incorporated by reference in their entireties into the present application.
[0002] The present invention is directed to an electrical connector for supplying power to an electric vehicle and more particularly to such a connector having improved resistance to water in the environment and improved user-friendliness.
[0003] Electric vehicles are increasingly receiving attention. These include plug-in hybrid vehicles such as the Chevrolet Volt and purely electric vehicles such as the Nissan Leaf.
[0004] Electrical connectors for recharging the batteries of electric vehicles are standardized in North
America by Society of Automotive Engineers (SAE) standard SAE J1772. Other applications, such as forklifts and industrial equipment, may also adopt that standard.
[0005] According to that standard, the front of the connector has a standardized shape and five pins in a standardized layout, so that all connectors work with all electric vehicles. The five pins are two AC power pins, a ground pin, a proximity detection pin and a control pilot pin. Regarding the rest of the connector, the manufacturer of each connector has some discretion. Known connectors typically use spring latches to secure the connector to the vehicle during charging.
[0006] Since such connectors are typically used outdoors, environmental considerations, such as water, must be taken into account. For example, water may get into the mechanism of the spring latch and cause corrosion or other degradation. The usual way to prevent such degradation is to use a rubber seal to protect the spring latch. However, seals fail.
[0007] There are also the problems of using the connector at night, when the motorist may not be able to see properly, and of letting the motorist know when the connector has been fully and properly inserted.
[0008] Morcover, known connectors are typically manufactured from multiple parts. As a consequence, they can be expensive to manufacture and prone to failure.
[0009] To date, all solutions currently available in the Electric Vehicle (EV) market space are constructed from two halves (or clamshells) which are mechanically assembled with tamper-resistant fasteners such as Torx™ screws. The old or current SAE J1772 mechanically assembled connectors currently allow water to enter the handle assembly, leading to an opportunity for ice and debris to become trapped. Additionally, the clamshells add a bulky appearance at the handle and overall body, which is driven by the additional mechanical features required to resist vehicle roll-over and crush requirements, as stated in UL 2251. These current devices are suitable for garage and indoor applications. When used outdoors, these clam-shell designs may exhibit shorter life cycles due to exposure to the elements.
[0010] It is therefore an object of the invention to address the above concerns.
[0011] It is another object of the invention to provide a low-cost, attractive, ergonomic and adaptable solution.
[0012] To achieve the above and other objects, the present invention is directed to a connector having at least one of the following features.
[0013] The spring latch is not sealed; instead, the connector body has holes allowing water entering the spring latch mechanism to drain harmlessly out of the connector. A forward-facing LED or other light source acts as a flashlight. Once the connector is connected, the forward-facing LED is switched off, and a rear-facing LED or other light source is switched on to confirm that the connector is connected and capable of charging the vehicle.
[0014] The connector is produced by overmolding. For example, the connector can be produced in a three-layer configuration, with potting material, a premold, and a one-piece overmold. Each of the layers can be formed of a different material that gives it the properties needed for its location in the connector. The modular design allows for faster product updates and a common platform for product diversification.
[0015] The above features can be combined in any way.
[0016] The problem being solved by this invention is offering the EV (electric vehicle) market space (such as Original Equipment Manufacturers (OEM) and Electric Vehicle Supply Equipment (EVSE) manufacturers) a ruggedized and integrated overmolded SAE J1772 connector and cable assembly solution that offers reduced life-cycle costs and improved product reliability, and that also reduces the risks of tampering and vandalism associated with mechanical locking features and hardware (such as Torx™ Screws). This over-molded solution offers exceptional environmental protection from the extreme environmental elements which may include: water, ice, dust, ultra-violet rays, oils and automotive fluids.
[0017] A preferred embodiment will be set forth in detail with reference to the drawings, in which:
[0018] Figures 1-8 arc various views of the connector according to the preferred embodiment and of various components thereof;
[0019] Figures 9A-21 are views showing steps in the production of the connector of Figures 1-8; and
[0020] Figures 22A-22D are views of a connector according to a variation of the preferred embodiment.
[0021] A preferred embodiment will be set forth in detail with reference to the drawings, in which like reference numerals refer to like elements throughout.
[0022] As shown in Figures 1-8, the connector 100 according to the preferred embodiment includes a connector front piece 102 with a plurality of pins 104, 106, 108, 110, 112. In the preferred embodiment, the connector front piece 102 and the pins 104-112 follow the standard SAE J1772.
The pins 104-112 are electrically connected to a cable 114 at a location which is scaled inside of the connector front piece 102 with potting 116. A connector body 118 is formed over the connector front piece 102 and the cable 114 by a premold 120 and an overmold 122. The premold 120 and the overmold 122 are formed with ridges 124, 126 to increase the strength of the connector body 118.
The connector body has a latch arca 128 with a spring latch 130 having a pin 132 and a spring 134.
[0023] A first LED or other light 136 can be provided to act as a flashlight, so that the user can use the connector at night in situations of poor lighting. A second LED or other light 138 can be provided on the back to indicate when the proper electrical connection between the connector and the vehicle is achieved, at which time the first LED is switched off. Circuitry 140, such as a printed circuit (PC) board to be described below, is provided for controlling the LED's.
[0024] The latch area 128 does not have to be scaled against water. Instead, water entering the latch arca 128 exits through holes 142. As shown, there are three holes 142 on either side of the latch arca 128, extending through the overmold 122 and into the latch area 128. The holes 142 are open to the latch area 128 at a bottom surface 144 of the latch area 128 so that there will be no places for the water to accumulate. However, any suitable number and configuration of holes can be used instead of, or in addition to, the holes shown.
[0025] For example, in use in a rainy situation, rain water incident on the connector 100 enters the latch areca 128 by flowing around the spring latch 130. Instead of accumulating in the latch areca 128, the water exits the latch areca 128 through the holes 142. As noted above, the holes 142 are positioned relative to the bottom surface 144 of the latch area 128 so that all of the water drains out of the latch arca 128 rather than forming puddles below the holes 142.
[0026] The holes 142 are shown as extending horizontally to facilitate overmolding. The left and right components of the mold used in the overmolding can have projections corresponding to the holes 142 and thus form the holes 142. After the overmolding process, the left and right components are pulled off in a horizontal direction to pull the projections out of the holes 142 thus formed.
However, the configuration of the holes 142 can be varied in accordance with various manufacturing techniques. For example, in different manufacturing techniques, the holes 142 could slope downwardly from the latch area 128 or even extend vertically downwardly from the latch areca 128.
Moreover, holes 142 can be formed in any other suitable manner, ¢.g., by drilling.
[0027] Still other configurations are possible. For example, the latch area 128 could have a bottom surface 144 that is flat or that is crowned to urge water out through the holes 142. Also, while the holes 142 are shown as elongated, they could have any suitable shape, e.g., round.
[0028] The preferred embodiment provides an overmolded, ruggedized, and robust high-amperage SAE
J1772 connector assembly. The production of the preferred embodiment begins with an insert molded SAE J1772 10 amp through 90 amp connector, shown in Figures 9A and 9B as 146, made of a polycarbonate material with a UL94 V-0 flame rating with an environmental (f1) ultra-violet rating and a relative thermal index (RTI) equal to or exceeding 100 for electrical and physical impact and strength characteristics, as specified by the standard UL 2251.
[0029] The SAE J1772 connector body architecture 146 is that of a rigid body design, which incorporates mechanical features promoting cross-linking adhesion and/or enabling mechanical bonding and mechanical locking features with the premold 120 and the overmold 122. These mechanical features may include flow-through channels, pierced holes, raised joggles or ridgelines.
[0030] The connector body contains five 353 2 hard brass contacts 104, 106, 108, 110, 112, as described above, which can be silver or gold plated. The two Size 8 power contacts 104, 112 incorporate clliptically wound high amperage and low insertion force internal helical springs 148 to enable higher amperage with reduced opportunities for heating due to micro-arcing, as well as offering additional opportunities of success for reverse compatibility to vehicle inlets (IAW SAE J 1772) manufactured by other manufacturers. These internal helical springs 148 also aid in accommodating the natural tendencies of process shift over time. The springs 148 can be configured as a plurality of toroidal springs, as shown, ¢.g., in U.S. Patent No. 4,810,213 to Chabot, whose disclosure is hereby incorporated by reference in its entirety into the present disclosure.
[0031] The insert molded SAE J1772 connector body 146 also incorporates a flame retardant (FR) UL listed closed cell gasket 150 on the mating face to aid in the prevention of attack on the contacts from corrosive gases such as carbon dioxide, sulfur dioxide, and hydrogen sulfide.
[0032] The connector body 146 is then assembled to an FFSO UL listed cable 114, shown by itself in
Figure 10, by means of a soldering operation to accommodate the pin-out diagram as specified in
SAE J1772, as shown in Figure 11. The soldered contacts of the insert molded SAE J1772 allow for improved cable retention of the overall assembly as well as reduced opportunities for micro-arcing and stray strands, which could lead to risks of shorts and ground faults, reducing the life cycle of the product. Additionally, soldered contacts provide for an additional level of defense to deter the wicking and capillary effect of moisture absorption at the exposed contacts. Water and moisture absorption, or wicking, accelerates copper corrosion and reduces the product life cycle, which may result in higher amperage draw from the branch circuit resulting in excessive heat and customer dissatisfaction.
[0033] An environmentally sealed micro-switch sub assembly 152 is soldered to an FR-4 PC UL listed
PC board 154, which incorporates one 150 Ohm '%2 watt resistor 156 and one 300 Ohm '52 watt resistor 158, to implement the circuitry 140 described above as a micro-switch assembly. A grommet, shown in Figures 13A and 13B as 164, is then added to the micro-switch sub-assembly 140 and assembled into position, as shown in Figure 14. The grommet is manufactured from a polymeric molding compound which is UL94 V-1 flame rating with an environmental (f1) ultra- violet rating and a relative thermal index (RTI) equal to or exceeding 90 for electrical and physical impact and strength characteristics, as specified by UL 2251. The assembly 152 and board 154 are attached to the connector body 146, as shown in Figure 15, by means of soldering the two flying leads (proximity and ground) 160, 162 to the proximity and ground pin contacts 106, 108, enabling the DC pulse signals required by the SAE J1772 Standard. This PC board 154 also provides for the silver path provisions to incorporate LED signals for charge and flashlight requirements that may be activated or required by the EVSE.
[0034] When the soldering operation has been completed, the connector body 146, PC board assembly 154, and cable 114 are environmentally and dielectrically potted, as shown in Figures 16A and 16B, with a two-part potting compound 166 that has a UL94 HB or V-0 flame rating and a relative thermal index (RTI) equal to or greater than 90 for clectrical, physical impact and strength characteristics, as specified by UL 2251, to form the potting 116. This potting compound 166 will then be cured either by overnight stall, or with a heat assist manufacturing aid. The FFSO electric vehicle cable jacket, insulated conductors and soldered connections will be encapsulated with this two part potting compound.
[0035] This potting compound 166 provides for the first level of defense to deter the wicking and capillary effect of moisture absorption at the exposed contacts. Copper stranding can, over time, enable a capillary effect in which moisture wicks from the exposed contact arca into the copper stranding which accelerates copper corrosion and reduces the product life cycle, which may result in higher amperage draw from the branch circuit resulting in excessive heat and customer dissatisfaction. The potting compound 166 also offers dielectric properties, further insulating the assembly from potential in air arcing between the power contacts and ground. This potting compound 166 is the foundation in which the additional polymeric materials will use for additional structure and support within the design.
[0036] After the two-part environmentally and diclectrically potted compound 166 has cured and outgassed completely to form the potting 116, a pre-mold 120 will then be molded over the sub- assembly that includes the connector body 146, the FFSO electric vehicle cable 114, and the potted contact, as shown in Figure 17. The pre-mold is a high impact Polyamide (PA6 or PA66) based material with a UL94 V-0 flame rating and a relative thermal index (RTI) equal to or greater than 100. Other specially engineered compounds, such as glass filled polyethylene terephthalate (PET), acrylonitrile butadiene styrene (ABS), thermoplastic clastomer (TPE), thermoplastic vucanizate (TPV), or high impact polypropylene (HIPP), can be used. The pre-mold 120 encapsulates the subassembly, providing for the ‘backbone’ of the architecture, as well as adding additional environmental and dielectric properties to the overall SAE J1772 molded connector assembly system. The pre-mold 120 includes holes 168 corresponding to the holes 142 of the finished product.
[0037] The pre-mold architecture is that of a rigid body design, which incorporates mechanical features promoting either cross-linking adhesion and/or enabling mechanical bonding and mechanical locking features of an outer ‘over-mold skin’ layer. These mechanical features may include flow- through channels, raised joggles or ridgelines, or depressed valleys and flow-through T-channels.
[0038] The over-mold or skin, shown in Figure 18 as 122, is for user interface, impact energy absorption, abrasion resistance, fluid and gasoline resistance and overall ultra-violet (UV) protection of the overall SAE J1772 molded connector assembly system. The overmold material of the SAE
J1772 Connector Assembly has a UL94 HB or V-1 flame rating and a relative thermal index (RTI) equal to or greater than 90 for electrical, physical impact and strength characteristics, as specified by
UL 2251. Alternate thermoset materials, such as EPT, EPDM, and silicone or liquid silicone injection, may also be incorporated to accommodate the physical and performance requirements of the outer skin.
[0039] Once the system is completely molded, a latch arm 130 manufactured from a polymeric material such as polycarbonate (PC) with a UL94 V-0 flame rating, an environmental (fl) ultra-violet rating and a relative thermal index (RTI) equal to or exceeding 100 for electrical and physical impact and strength characteristics, as specified by UL 2251, is attached. This latch arm is attached by means of a molded or stainless steel (300 Series) pin. The latch provides for the mechanical interlock to the
SAE J1772 vehicle inlet as well as the mechanical lever activating the micro-switch sub-assembly prior to commencing charging as well as upon completion of charging. The steps of attaching the latch arm include inserting the latch spring 134 into the latch area 128, as shown in Figure 19; inserting the latch arm 130 over the spring 134 into the latch arca 128, as shown in Figure 20; and inserting the latch pin 132, as shown in Figure 21.
[0040] Additionally, the market currently only offers 30 AMP and 75 AMP listed assemblies, which are mostly governed by the cable and contact size. The technologies implemented in the preferred embodiment allow a higher current rated (higher amperage) cable assembly to future proof the design for any DC fast charge requirements.
[0041] The preferred embodiment provides a ruggedized and robust SAE J1772 overmolded connector assembly incorporating dielectric and environmental potting compounds, with an integrated polymeric substrate and overmolded polymeric skin offering protection from extreme and harsh environmental conditions. The preferred embodiment combines an overmolded integrated polymeric (laminated) approach and an integrated PC board with micro-switch and provisions for
LED lights for a charge indicator and a flashlight. The solution offers reduced life-cycle costs, improved product reliability, and a reduced risk of tampering and vandalism associated with mechanical locking features and hardware (such as Torx™ screws). This over-molded solution offers exceptional environmental protection from the extreme environmental elements which may include: water, ice, dust, ultra-violet rays, oils and automotive fluids.
[0042] The preferred embodiment, or any other embodiment, can be modified to accommodate both AC charging and rapid DC charging and to allow the user to sclect which charging mode will be used.
Figure 22A shows a head-on view of a connector 2200 thus modified. Figure 22B shows a cross- sectional view of the connector, taken along lines XXIIA-XXIIA in Figure 22A. Figures 22C and 22D show side and top views, respectively. The connector 2200 is constructed and used like the connector 100 previously disclosed, except that in addition to the connector front piece 102 and pins 104-112, the connector 2200 also has two additional pins 2202, 2204 connected to leads 2206 and enclosed in a second connector front piece 2208. Any suitable switch can be provided to allow the user to select between AC charging and rapid DC charging.
[0043] While a preferred embodiment has been set forth above, those skilled in the art who have reviewed the present disclosure will readily appreciate that other embodiments can be realized within the scope of the invention. For example, any suitable latching mechanism can be used, as can any suitable materials. Also, the connector can be adapted to any standard or proprietary layout.
Therefore, the present invention should be construed as limited only by the appended claims.
Claims (23)
1. An electrical connector for an electric vehicle, the electrical connector comprising: a connector body; a plurality of connector pins in the connector body; and a latch mounted in a latch area on the connector body for holding the electrical connector to the electric vehicle; wherein the connector body has a plurality of holes for allowing water entering the latch area to exit the latch area.
2. The electrical connector of claim 1, further comprising a light adjacent to the plurality of connector pins.
3. The electrical connector of claim 2, further comprising a second light on a portion of the connector body opposite to the connector pins.
4. The electrical connector of claim 1, wherein the connector body is formed by overmolding.
5. The electrical connector of claim 1, wherein the connector body comprises: a potting compound; a premold formed over the potting compound; and an outer connector body formed in a single piece over the premold.
6. The electrical connector of claim 5, wherein the potting compound comprises a two-part dielectric potting compound.
7. The electrical connector of claim 6, wherein the premold comprises a material selected from the group consisting of polyamide-based materials, glass-filled polyethylene terephthalate, acrylonitrile butadiene styrene, thermoplastic elastomer, thermoplastic vucanizate, and polypropylene.
8. The electrical connector of claim 7, wherein the outer connector body comprises a material selected from the group consisting of EPT, EPDM and silicone or liquid silicone injection.
9. The clectrical connector of claim 5, wherein the premold is formed to provide at least one of cross-linking adhesion, mechanical bonding, and mechanical locking with the outer connector body.
10. The electrical connector of claim 1, wherein the plurality of connector pins comprise a first set of connector pins for a first charging mode and a second set of connector pins for a second charging mode.
11. The electrical connector of claim 10, wherein the first charging mode is an AC charging mode, and wherein the second charging mode is a DC charging mode.
12. A method for making an electrical connector for an electric vehicle, the method comprising: (a) providing a charging cable and a connector body having at least one connector pin; (b) providing an electrical connection between the charging cable and the at least one connector pin; (¢) applying a potting compound over the connector body and a portion of the charging cable adjacent to the connector body; (d) applying a premold over the potting compound, the connector body, and the portion of the charging cable adjacent to the connector body; and (¢) overmolding an outer connector body in a single piece over the premold to form the connector.
13. The method of claim 12, further comprising providing circuitry to control operation of the connector, and wherein step (¢) comprises applying the potting compound over the circuitry.
14. The method of claim 12, wherein the potting compound comprises a two-part dielectric potting compound.
15. The method of claim 14, wherein the premold comprises a material selected from the group consisting of polyamide-based materials, glass-filled polyethylene terephthalate, acrylonitrile butadiene styrene, thermoplastic elastomer, thermoplastic vucanizate, and polypropylene.
16. The method of claim 15, wherein the outer connector body comprises a material selected from the group consisting of EPT, EPDM and silicone or liquid silicone injection.
17. The method of claim 12, wherein the premold is formed to provide at least one of cross- linking adhesion, mechanical bonding, and mechanical locking with the outer connector body.
18. The method of claim 12, further comprising attaching a latch to the connector for latching the connector onto the vehicle.
19. The method of claim 18, wherein the outer connector body has a latch formed therein.
20. The method of claim 19, wherein the outer connector body has a plurality of holes for allowing water entering the latch area to exit the latch arca.
21. The method of claim 20, wherein step (¢) comprises overmolding the outer connector body to have the plurality of holes.
22. The method of claim 12, wherein step (a) comprises providing a first set of connector pins for a first charging mode and a second set of connector pins for a second charging mode.
23. The method of claim 22, wherein the first charging mode is an AC charging mode, and wherein the second charging mode is a DC charging mode.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US13/211,867 US8562365B2 (en) | 2010-12-30 | 2011-08-17 | Laminous multi-polymeric high amperage over-molded connector assembly for plug-in hybrid electric vehicle charging |
US13/328,150 US8568155B2 (en) | 2010-12-30 | 2011-12-16 | Laminous multi-polymeric high amperage over-molded connector assembly for plug-in hybrid electric vehicle charging |
Publications (1)
Publication Number | Publication Date |
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SG188031A1 true SG188031A1 (en) | 2013-03-28 |
Family
ID=48014638
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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SG2012042966A SG188031A1 (en) | 2011-08-17 | 2012-06-11 | Laminous multi-polymeric high amperage over-molded connector assembly for plug-in hybrid electric vehicle charging |
Country Status (2)
Country | Link |
---|---|
MY (1) | MY154223A (en) |
SG (1) | SG188031A1 (en) |
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2012
- 2012-06-11 SG SG2012042966A patent/SG188031A1/en unknown
- 2012-06-11 MY MYPI2012002612A patent/MY154223A/en unknown
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MY154223A (en) | 2015-05-15 |
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