Break-away cable connector

• US 20130187601A1
• Filed: 09/07/2012
• Published: 07/25/2013
• Est. Priority Date: 03/08/2010
• Status: Active Grant

• Current Assignee: Webasto Charging Systems, Inc. (Webasto Beteiligungs Verwaltung Gbr)
• Original Assignee: Webasto Charging Systems, Inc. (Webasto Beteiligungs Verwaltung Gbr)
• Inventors: Petrie, Gregory A., Bishop, Steven P., Tong, Davy Ta-Yuan, Patel, Atulkumar M.
• Granted Patent: US 10,044,137 B2
• Time in Patent Office: Days
• US Class Current: 320/109
• CPC Class Codes: B60L 2270/32 of electricity
• CPC Class Codes: B60L 2270/34 of parts
• CPC Class Codes: B60L 53/16 Connectors, e.g. plugs or sockets, specially adapted for charging electric vehicles
• CPC Class Codes: H01R 13/627 Snap or like fastening
• CPC Class Codes: H01R 13/6276 comprising one or more balls engaging in a hole or a groove
• CPC Class Codes: H01R 13/635 by mechanical pressure, e.g. spring force
• 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

An electric vehicle charging station having a console, a cable and a vehicle connector. The cable is connected with a break-away system that allows for a controlled structural failure of one of the cable connections when the vehicle connector is pulled away from the console with a critical level of force. The break-away system could be a body positioned along the length of the cable, and could be a connection between the cable and either the console or the vehicle connector.

Claims

1. A break-away extension system for electrically connecting a first plurality of electrical contacts that are electrically connected to an electric vehicle charging station console to a second plurality of contacts that are electrically connected to a vehicle connector configured to connect to an electric vehicle, the break-away extension system being configured to mechanically fail at a critical load level, comprising:

a first extension including a plurality of electrical wires extending through the first extension, each wire being configured for connecting one respective contact of the first plurality of electrical contacts to one respective contact of the second plurality of electrical contacts;

a break-away connector connected to a break-away end of the extension, the break-away connector being configured to mechanically fail at the critical load; and

one or more longitudinally separable electrical connectors connected to the wires at the break-away end of the extension;

wherein the one or more separable electrical connectors are configured to allow the one or more separable electrical connectors to detach upon mechanical failure of the break-away connector.

2. The break-away extension system of claim 1, and further comprising a second extension including a plurality of electrical wires extending through the second extension, each wire being configured for connecting one respective contact of the first plurality of electrical contacts to one respective contact of the second plurality of electrical contacts, wherein the break-away connector connects the first extension to the second extension.

3. The break-away extension system of claim 2, wherein:

the break-away connector includes a housing that defines a cavity;

each wire of the first extension is attached to one wire of the second extension via a longitudinally severable electrical wire connector; and

each electrical wire connector is contained within the housing cavity.

4. The break-away extension system of claim 3, wherein the break-away connector is configured to fail mechanically at the critical load by way of a structural failure of the housing at a proximal end of the housing, and wherein the break-away connector is further configured to fail mechanically at the critical load by way of a structural failure of the housing at a distal end of the housing.

5. The break-away extension system of claim 1, wherein the break-away connector includes a housing, and wherein the break-away connector is configured to fail mechanically at the critical load by way of a structural failure of the housing.

6. The break-away extension system of claim 1, wherein the break-away connector includes a housing that includes a first housing portion and a second housing portion held together by one or more shear pins, and wherein the break-away connector is configured to fail mechanically at the critical load by way of a shearing failure of the one or more shear pins.

7. The break-away extension system of claim 1, wherein the break-away connector is configured to fail mechanically at the critical load by way of a ball detent mechanism that fails at the critical load.

8. The break-away extension system of claim 7, wherein the ball detent release mechanism includes a rotationally symmetric male pin received in a generally conforming bore in a rotationally symmetric female pin, and a spring and a slide conformingly and slidably received around the female pin, wherein the slide is pushed by the spring such that a groove on the slide pushes one or more balls through one or more holes in the female pin and into mating groves on the male pin, thereby holding the male and female pins together.

10. The break-away extension system of claim 1, wherein the break-away connector directly connects the first extension to the console.

11. The break-away extension system of claim 10, wherein:

the break-away connector includes an extension end-piece rigidly attached to an end of the first extension, and a break-away body;

the breakaway body includes a first portion attached to the extension end-piece, and a second portion attached to the console;

the break-away body first and second portions are held together via a flange; and

wherein the break-away connector is configured to fail mechanically at the critical load by way of a structural failure of the flange.

12. The break-away extension system of claim 10, wherein:

the break-away connector includes an extension end-piece rigidly attached to an end of the first extension, and a break-away body;

the breakaway body includes a first portion attached to the extension end-piece, and a second portion attached to the console via a flange on the second portion; and

wherein the break-away connector is configured to fail mechanically at the critical load by way of a structural failure of the flange.

13. The break-away extension system of claim 10, wherein:

the break-away connector includes an extension end-piece rigidly attached to an end of the first extension, and a break-away body;

the break-away body is a plate extending radially outward around the extension end-piece;

the break-away body extends across and is affixed to an orifice in the console; and

wherein the break-away connector is configured to fail mechanically at the critical load by way of a structural failure of the break-away body.

14. An electric vehicle charging station configured to connect to and charge an electric vehicle, comprising:

a console defining a cavity containing a first plurality of electrical contacts that are electrically connected to a power source for charging the electric vehicle; and

the break-away extension system of claim 10, wherein the wires of the first extension are connected to the first plurality of electrical contacts via a longitudinally severable electrical wire connector;

wherein each electrical wire connector is contained within the console cavity; and

wherein each electrical wire connector is configured to disconnect prior to emerging from the console cavity.

15. The break-away extension system of claim 1, wherein the first extension is a cable.

16. The break-away extension system of claim 1, wherein:

the wires include a signal wire and a power wire; and

the wires and electrical connectors are configured such that, when the break-away connector fails due to the vehicle connector moving away from the console under the application of the critical load, the electrical connection of the signal wire is severed prior to the electrical connection of the power wire.

17. The break-away extension system of claim 16, wherein:

the electrical connector of the signal wire has a signal wire first portion and a signal wire second portion that are longitudinally separable from one another, and the signal wire first and second portions define a signal wire disconnecting distance over which they must be separated to sever the signal wire electrical connection;

the electrical connector of the power wire has a power wire first portion and a power wire second portion that are longitudinally separable from one another, and the power wire first and second portions define a power wire disconnecting distance over which they must be separated to sever the power wire electrical connection; and

the power wire disconnecting distance is greater than the signal wire disconnecting distance.

18. The break-away extension system of claim 17, wherein:

the wires further include a ground wire;

the electrical connector of the ground wire has a ground wire first portion and a ground wire second portion that are longitudinally separable from one another, and the ground wire first and second portions define a ground wire disconnecting distance over which they must be separated to sever the ground wire electrical connection; and

the ground wire disconnecting distance is greater than the power wire disconnecting distance.

19. An electric vehicle charging station configured to connect to and charge an electric vehicle, comprising:

a console providing a first plurality of electrical contacts that are electrically connected to a power source for charging the electric vehicle, the console having a control system being configured to energize and de-energize the first plurality of electrical contacts; and

the break-away extension system of claim 16, wherein the wires of the first extension are connected to the first plurality of electrical contacts;

wherein the control system is configured to de-energize the first plurality of electrical contacts when the electrical connection of the signal wire is severed.

20. An electric vehicle charging station configured to connect to and charge an electric vehicle, comprising:

a console providing a first plurality of electrical contacts that are electrically connected to a power source for charging the electric vehicle; and

the break-away extension system of claim 1, wherein the wires of the first extension are connected to the first plurality of electrical contacts.

21. The break-away extension system of claim 1, wherein one of the one or more longitudinally separable electrical connectors includes:

a conductive male end portion having a distal end;

a conductive female end portion forming a bore having a proximal end and an open distal end, wherein the bore defines a non-overlapping first longitudinal section and second longitudinal section, the second longitudinal section being farther from the distal end of the bore, wherein the second longitudinal section is at least as longitudinally long as the first longitudinal section, and wherein the distal end of the male end portion extends into the bore distal end and through both the first and second longitudinal sections of the bore; and

a conductive high-current band retained solely within the first section of the bore, the band being elastically compressed between the male end portion and the female end portion.

22. The break-away cable of claim 21, wherein the distal end of the male end portion and the proximal end of the female end portion form a conformingly mated shaft and bore that limits lateral movement of the distal end of the male end portion with respect to the female end portion, the conformingly mated shaft and bore having a tighter tolerance than the remaining length of the bore around the male end portion.

23. The break-away cable of claim 22, wherein the conformingly mated shaft is on the distal end of the male end portion and conformingly mated bore is at the proximal end of the female end portion.

24. An electric vehicle charging station appendage for electrically connecting to a first plurality of electrical contacts that are electrically connected to an electric vehicle charging station console, comprising:

a vehicle connector configured to connect to an electric vehicle and having a second plurality of contacts; and

the break-away extension system of claim 1, wherein the plurality of wires are electrically connected to the second plurality of electrical contacts.

9. (canceled)

25. An extension system for electrically connecting a first plurality of electrical contacts that are electrically connected to an electric vehicle charging station console to a second plurality of contacts that are electrically connected to a vehicle connector configured to connect to an electric vehicle, comprising:

a proximal extension including a plurality of electrical wires extending through the proximal extension, each proximal extension wire being electrically connected to a respective contact of the first plurality of electrical contacts;

a distal extension including a plurality of electrical wires extending through the distal extension, each distal extension wire being electrically connected to a respective contact of the second plurality of electrical contacts; and

a connector including a housing that defines a cavity, the connector having a proximal end that is mechanically connected to a distal end of the proximal extension, and a distal end that is mechanically connected to a proximal end of the distal extension;

wherein each wire of the proximal extension is attached to one wire of the distal extension via an electrical wire connector; and

wherein each electrical wire connector is contained within the housing cavity.

26. The extension system of claim 25, wherein the connector housing is configured with a weak structural link that will break apart in tension if the vehicle connector is pulled away from the charging station console with a selected critical force level.

27. The break-away cable of claim 26, wherein the weak structural link is a load-bearing tubular portion of the connector housing having a lower cross-sectional area than all other load-bearing portions of the connector housing.

28. An electric vehicle charging station configured to connect to and charge an electric vehicle, comprising:

a console providing a first plurality of electrical contacts that are electrically connected to a power source for charging the electric vehicle; and

the extension system of claim 25, wherein the wires of the proximal extension are connected to the first plurality of electrical contacts.

29. A longitudinally separable electrical connector, comprising:

a conductive male end portion having a proximal end and a distal end;

a conductive female end portion forming a bore having a proximal end and an open distal end, wherein the bore defines a non-overlapping first longitudinal section and second longitudinal section, the second longitudinal section being farther from the distal end of the bore, wherein the second longitudinal section is at least as longitudinally long as the first longitudinal section, and wherein the distal end of the male end portion extends into the bore distal end and through both the first and second longitudinal sections of the bore; and

a conductive high-current band retained solely within the first section of the bore, the band being elastically compressed between the male end portion and the female end portion.

30. The longitudinally separable electrical connector of claim 29, wherein the distal end of the male end portion and the proximal end of the female end portion form a conformingly mated shaft and bore that limits lateral movement of the distal end of the male end portion with respect to the female end portion, the conformingly mated shaft and bore having a tighter tolerance than the remaining length of the bore around the male end portion.

31. The longitudinally separable electrical connector of claim 30, wherein the conformingly mated shaft is on the distal end of the male end portion and conformingly mated bore is at the proximal end of the female end portion.

32. The longitudinally separable electrical connector of claim 30, wherein the female end portion is provided with an end cap that retains the band, and wherein the proximal end of the male end portion is conformingly fitted to the end-cap when fully mated.