System for Flexible Electrical and Mechanical Installation of an Electric Vehicle Charging Station

• US 20130020990A1
• Filed: 05/29/2012
• Published: 01/24/2013
• Est. Priority Date: 07/19/2011
• Status: Active Grant

• Current Assignee: Siemens Industry Incorporated (Siemens AG)
• Original Assignee: Siemens Industry Incorporated (Siemens AG)
• Inventors: DeBoer, John, Cowans, John Quentin, Biedrzycki, Timothy
• Granted Patent: US 9,610,851 B2
• Time in Patent Office: Days
• US Class Current: 320/109
• CPC Class Codes: B60L 53/16 Connectors, e.g. plugs or sockets, specially adapted for charging electric vehicles
• CPC Class Codes: B60L 53/18 Cables specially adapted for charging electric vehicles
• CPC Class Codes: B60L 53/30 Constructional details of charging stations
• CPC Class Codes: B60L 53/305 Communication interfaces
• CPC Class Codes: B60L 53/68 Off-site monitoring or control, e.g. remote control
• CPC Class Codes: H02J 2310/48 for electric vehicles [EV] or hybrid vehicles [HEV]
• CPC Class Codes: H02J 3/322 the battery being on-board an electric or hybrid vehicle, e.g. vehicle to grid arrangements [V2G], power aggregation, use of the battery for network load balancing, coordinated or cooperative battery charging
• CPC Class Codes: H02J 7/0042 characterised by the mechanical construction
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 90/12 Electric charging stations
• CPC Class Codes: Y02T 90/14 Plug-in electric vehicles

Abstract

An electric vehicle charging apparatus is disclosed. The electric vehicle charging apparatus has a housing body that is configurable to provide a number of electrical connection options, such as bottom and rear corded options as well as direct wired options. In another aspect, a mounting installation of the electric vehicle charging apparatus is provided. In yet another aspect, a housing body having a first front cavity and a second front cavity is provided. An inner cover covers the second front cavity, and a maximum amperage set switch is operable to set a maximum charge amperage for the electric vehicle charging apparatus. Methods of configuring the electric vehicle charging apparatus are provided, as are other aspects.

Claims

1. An electric vehicle charging apparatus, comprising:

a housing having a body with a first front cavity, a first rear cavity, and at least one electrical terminal in the first front cavity, the body having a first wiring entry and a second wiring entry being configured to provide a plurality of electrical power connection options to the at least one electrical terminal, the plurality of electrical power connection options comprising;

an outside cord option wherein an outside cord and coupled outside electrical plug are adapted to electrically connect to an electrical receptacle located outside of a footprint of the body, and the electrical cord is received through the first wiring entry; and

a rear receptacle mount option wherein a rear cord and coupled rear electrical plug are received in the first rear cavity and the adapted to electrically connect to an electrical receptacle located inside of the footprint of the body wherein the rear electrical cord is received through the second wiring entry.

2. The electric vehicle charging apparatus of claim 1, wherein the plurality of electrical power connection options further comprises:

an outside direct wire option wherein an outside electrical cable is adapted to electrically connect to a panel, and the electrical cable is received through the first wiring entry.

3. The electric vehicle charging apparatus of claim 1, wherein the plurality of electrical power connection options further comprises:

a rear direct wire option wherein a rear electrical cable is adapted to electrically connect through a gang box, and the rear electrical cable is adapted to pass through the second wiring entry.

4. The electric vehicle charging apparatus of claim 1, comprising a second rear cavity receiving a portion of a charging cable adapted to electrically connect to an electric vehicle.

5. The electric vehicle charging apparatus of claim 1, comprising a removable plug in the first wiring entry, or the second wiring entry.

6. The electric vehicle charging apparatus of claim 1, comprising a second front cavity and divider wall separating the first front cavity from the second front cavity.

7. The electric vehicle charging apparatus of claim 6, comprising a contactor and at least one printed circuit board mounted in the second front cavity.

8. The electric vehicle charging apparatus of claim 6, comprising a first inner cover covering the second front cavity.

9. The electric vehicle charging apparatus of claim 8, comprising a second inner cover covering the first inner cover wherein the second inner cover comprises a transparent or translucent material.

10. The electric vehicle charging apparatus of claim 9, wherein the second inner cover comprises a light guide.

11. The electric vehicle charging apparatus of claim 8, comprising a lid received over the first inner cover and at least a portion of the second inner cover.

12. The electric vehicle charging apparatus of claim 6, comprising a lid coupled to the body and a post on the lid adapted to mount a charging connector.

13. The electric vehicle charging apparatus of claim 1, comprising a safety cover mounted over the at least one electrical terminal in the first front cavity.

14. The electric vehicle charging apparatus of claim 11, comprising one or more low voltage electrical terminals or communication terminals located within the first front cavity.

15. The electric vehicle charging apparatus of claim 1, comprising:

a second front cavity;

a first inner cover covering the second front cavity; and

a maximum amperage set switch operable by a user with the first inner cover secured to the body.

16. The electric vehicle charging apparatus of claim 1, comprising a maximum amperage set switch operable to set a maximum charge amperage of the electric vehicle charging apparatus.

17. An electric vehicle charging apparatus installation, comprising:

a housing having a lower housing mounting feature and an upper housing mounting feature; and

a mounting bracket having a location feature adapted to locate relative to an electrical receptacle, the mounting bracket having one or more installation features adapted to install the mounting bracket to a structure adjacent to the electrical receptacle, a lower bracket mounting feature adapted to receive the lower housing mounting feature, and an upper bracket mounting feature adapted to receive the upper housing mounting feature.

18. An electric vehicle charging apparatus, comprising:

a housing having a body, a first inner cover coupled to the body; and

a maximum amperage set switch operable to set a maximum charge amperage for the electric vehicle charging apparatus, wherein the maximum amperage set switch is operable with the first inner cover installed.

19. The electric vehicle charging apparatus of claim 18, comprising a lid at least partially covering the first inner cover.

20. The electric vehicle charging apparatus of claim 18, wherein the maximum charge amperage setting for the maximum amperage set switch is between about 8 A and about 75 A.

21. The electric vehicle charging apparatus of claim 18, comprising a first front cavity in the body, at least one electrical terminal in the first front cavity, and a safety cover mounted over the at least one electrical terminal.

22. The electric vehicle charging apparatus of claim 21, comprising a lid covering the first front cavity and the first inner cover.

23. The electric vehicle charging apparatus of claim 21, comprising one or more low voltage electrical terminals or communication terminals located within the first front cavity.

24. The electric vehicle charging apparatus of claim 18, comprising a lower housing mounting feature and an upper housing mounting feature on the body, a mounting bracket coupled to the body, the mounting bracket having a location feature adapted to locate on an electrical receptacle, the mounting bracket having one or more installation features adapted to install the mounting bracket to a structure adjacent to the electrical receptacle, a lower bracket mounting feature adapted to receive the lower housing mounting feature, and an upper bracket mounting feature adapted to receive the upper housing mounting feature.

25. An electric vehicle charging apparatus, comprising:

a housing having a body with a first front cavity, a second front cavity, a dividing wall separating the first front cavity from the second front cavity, a first inner cover covering the second front cavity, a first rear cavity on a rear of the body, a first wire entry into the first front cavity from a location outside the body, and a second wire entry located between the first front cavity and the first rear cavity;

at least one electrical terminal mounted in the first front cavity;

a safety cover mounted over the at least one electrical terminal;

one or more low voltage electrical terminals or communication terminals located within the first front cavity; and

one of a plurality of electrical power connection options to the at least one electrical terminal, the plurality of electrical power connection options including;

an outside electrical cord and coupled outside electrical plug adapted to electrically connect to an electrical receptacle located outside of a footprint of the body, wherein the outside electrical cord is received through the first wiring entry; and

a rear cord and rear electrical plug received in the first rear cavity and adapted to electrically connect to an electrical receptacle located inside of the footprint of the body with a through connector installed in the second wiring entry.

26. A method of configuring an electric vehicle charging apparatus, comprising:

providing a housing having a body with a first front cavity, a first rear cavity, and at least one electrical terminal in the first front cavity, the body having a first wiring entry and a second wiring entry;

configuring an electrical connection to the at least one electrical terminal of the electric vehicle charging apparatus in one of a plurality of electrical power connection options, the plurality of electrical power connection options comprising;

an outside cord option wherein an outside cord and coupled outside electrical plug are adapted to electrically connect to an electrical receptacle located outside of a footprint of the body, and the outside electrical cord is received through the first wiring entry; and

a rear receptacle mount option wherein a rear cord and coupled rear electrical plug are received in the first rear cavity and adapted to electrically connect to an electrical receptacle located inside of the footprint of the body wherein the rear electrical cord is received through the second wiring entry.