Funnel Shaped Charge Inlet

• US 20130078839A1
• Filed: 07/13/2012
• Published: 03/28/2013
• Est. Priority Date: 09/28/2011
• Status: Active Grant

• Current Assignee: Tesla Inc.
• Original Assignee: Tesla Motors Incorporated (Tesla Inc.)
• Inventors: Musk, Elon Reeve, Ferguson, Joshua Willard, Zalan, Daryl, Van Dyke, Christopher Hugo
• Granted Patent: US 8,579,635 B2
• Time in Patent Office: Days
• US Class Current: 439/345
• CPC Class Codes: B60L 2270/147 electro magnetic [EMI]
• CPC Class Codes: B60L 53/16 Connectors, e.g. plugs or sockets, specially adapted for charging electric vehicles
• CPC Class Codes: H01R 13/631 for engagement only
• CPC Class Codes: H01R 13/64 Means for preventing incorrect coupling
• 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 90/14 Plug-in electric vehicles

Abstract

A vehicle charge inlet integrated into a port assembly surface is provided. The charge inlet includes an inlet housing with a perimeter that is curvilinear, non-cylindrical and shaped so that only a single orientation of a complementary sized and shaped electrical connector may be inserted into the inlet. A plurality of electrical contacts, a latching mechanism and a divider are also integrated into the charge inlet housing, the divider extending from the bottom surface of the inlet housing and configured to fit within a complementary slot of the charge connector, the divider providing further electrical isolation between the electrical contacts. A funneling surface connects the open end of the inlet housing to the port assembly surface.

Claims

1. A vehicle charge inlet integrated into a port assembly surface, the vehicle charge inlet comprising:

a plurality of electrical contacts configured to be electrically coupled to a second plurality of electrical contacts integrated into a charge connector, said plurality of electrical contacts comprising a first power contact, a second power contact, a ground contact, a pilot contact, and a proximity sense contact;

an inlet housing having an inlet surface, a first end and a second end, wherein said first end is closed by a bottom surface and said second end is open and sized to accept said charge connector, wherein said plurality of electrical contacts are integrated into said bottom surface of said inlet housing, wherein a perimeter of said inlet surface is curvilinear and non-cylindrical, wherein a second perimeter corresponding to said charge connector is complementary to said perimeter of said inlet surface and sized to allow insertion of said charge connector into said inlet housing, and wherein said perimeter of said inlet surface and said second perimeter of said charge connector permit only a single orientation of said charge connector upon insertion of said charge connector into said vehicle charge inlet, wherein said single orientation aligns said charge connector to said vehicle charge inlet and aligns said plurality of electrical contacts to said second plurality of electrical contacts;

a divider extending from said bottom surface and configured to fit within a complementary slot of said charge connector, said divider fabricated from an electrically insulating material, wherein said divider is separate from said plurality of electrical contacts; and

a latching mechanism integrated within said inlet housing, wherein said latching mechanism is comprised of a pawl configured to pass through said inlet surface and fit within a slot in said charge connector when said charge connector is inserted into said vehicle charge inlet during vehicle charging.

2. The vehicle charge inlet of claim 1, wherein all curvatures comprising said perimeter of said inlet surface have a radius of curvature of at least 2 millimeters.

3. The vehicle charge inlet of claim 1, wherein all curvatures comprising said perimeter of said inlet surface have a radius of curvature of at least 6 millimeters.

4. The vehicle charge inlet of claim 1, wherein a shape corresponding to said perimeter of said inlet surface approximates a trapezoidal shape.

5. The vehicle charge inlet of claim 1, wherein said inlet surface of said inlet housing is continuous and does not incorporate an alignment key or key slot.

6. The vehicle charge inlet of claim 1, further comprising a funneling surface, wherein said funneling surface connects said open end of said inlet housing to said port assembly surface, and wherein said funneling surface extends said curvilinear and non-cylindrical shape of said perimeter of said inlet surface to said port assembly surface.

7. The vehicle charge inlet of claim 6, wherein a width of said funneling surface is between 2 and 30 millimeters, and wherein a depth of said funneling surface is between 2 and 30 millimeters.

8. The vehicle charge inlet of claim 6, wherein a cross-section corresponding to said funneling surface maintains a constant curvilinear shape around said perimeter of said inlet surface.

9. The vehicle charge inlet of claim 6, wherein a radius of curvature corresponding to said funneling surface is constant between said open end of said inlet housing and said port assembly surface.

10. The vehicle charge inlet of claim 6, wherein a cross-section corresponding to said funneling surface is curvilinear with all curvatures corresponding to said curvilinear funnel surface being greater than 2 millimeters in radius.

11. The vehicle charge inlet of claim 6, wherein a curvature corresponding to a cross-section of said funneling surface at the juncture of said funneling surface and said port assembly surface is between 2 and 30 millimeters in radius.

12. The vehicle charge inlet of claim 6, wherein a curvature corresponding to a cross-section of said funneling surface at the juncture of said funneling surface and said port assembly surface is between 4 and 15 millimeters in radius.

13. The vehicle charge inlet of claim 6, wherein a shape corresponding to said funneling surface approximates a trapezoidal shape.

14. The vehicle charge inlet of claim 6, further comprising a plurality of lights mounted beneath said funneling surface.

15. The vehicle charge inlet of claim 14, wherein said plurality of lights are comprised of a plurality of light emitting diodes.

16. The vehicle charge inlet of claim 14, wherein said plurality of lights are not visible beneath said funneling surface when said plurality of lights are off, and wherein output light generated by said plurality of lights is visible through said funneling surface.

17. The vehicle charge inlet of claim 14, wherein activation of said plurality of lights provides charge status information.

18. The vehicle charge inlet of claim 1, wherein said divider has a three pointed star shape.

19. The vehicle charge inlet of claim 1, wherein a first portion of said divider extends between said first and second power contacts, wherein a second portion of said divider extends between said first power contact and said pilot contact, and wherein a third portion of said divider extends between said second power contact and said proximity sense contact.