Connector assembly for vehicle charging

• US 7,878,866 B1
• Filed: 07/02/2010
• Issued: 02/01/2011
• Est. Priority Date: 07/02/2010
• Status: Active Grant

• Current Assignee: Lear Corporation
• Original Assignee: Lear Corporation
• Inventors: Kwasny, Keith, Poulin, Marc
• Primary Examiner(s): TA, THO DAC
• Application Number:
  US12/829,490
• Time in Patent Office: 214 Days
• Field of Search: 439/474, 439/589, 439/598, 439/599, 439/695, 439/903, 439/923
• US Class Current: 439/695
• 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: H01R 13/506 assembled by snap action of the parts
• CPC Class Codes: H01R 13/5804 comprising a separate cable clamping part H01R13/5841 takes precedence
• CPC Class Codes: H01R 13/633 for disengagement only in combination with safety switch H01R13/7132
• 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
• CPC Class Codes: Y10S 439/903 Special latch for insert
• CPC Class Codes: Y10S 439/923 Separation or disconnection aid

Abstract

A connector assembly couples an electrical power supply to a vehicle charging circuit. The assembly includes an elongate handle and a plug coupled to each other. The handle forms an internal cavity for supporting an electrical harness. The plug includes a first end that is attached to the outlet of the handle, and a second end opposite the first end for engaging a vehicle charging receptacle. The plug includes a series of tabs that longitudinally extend from the first end to engage a series of slots formed in the outlet of the handle for attaching the plug to the handle. The series of tabs and the series of slots collectively form a structural weak point for failure by localizing deformation between the tabs and the slots when the assembly is subjected to a predetermined side load applied to an intermediate portion of the assembly.

Claims

1. A connector assembly comprising:

an elongate handle forming an internal cavity for receiving and supporting an electrical harness, the handle having an outlet with a series of peripherally spaced slots formed through an external wall; and

a plug having a first end releasably attached to the outlet of the handle, and a second end opposite the first end for engaging a vehicle charging receptacle for facilitating electrical charging of a vehicle, the plug having a series of tabs longitudinally extending from a peripheral edge of the first end, each tab having a transverse projection extending radially outward for engaging one of the series of slots for attaching the plug to the handle;

wherein the series of tabs and the series of slots collectively form a structural weak point for failure by localizing deformation between the tabs and the slots when the assembly is subjected to a predetermined side load applied to an intermediate portion of the assembly.

2. The connector assembly of claim 1 wherein the plug is generally cylindrical.

3. The connector assembly of claim 2 wherein the series of tabs are equally spaced about the peripheral edge of the first end.

4. The connector assembly of claim 1 wherein the series of tabs further comprises three tabs, each having common dimensions.

5. The connector assembly of claim 1 wherein each projection extends from an intermediate portion of the tab and is formed with a rounded profile providing an interference fit with the engaged slot for providing line contact load distribution.

6. The connector assembly of claim 1 wherein the tabs are formed of a nylon material.

7. The connector assembly of claim 1 wherein the series of tabs are configured to withstand a maximum transverse load of 160 Newtons applied to an intermediate portion of the assembly without disengaging the series of slots.

8. The connector assembly of claim 1 wherein the series of tabs are configured to deform and disengage the series of slots when a minimum transverse load of 160 Newtons is applied to an intermediate portion of the assembly.

9. The connector assembly of claim 1 wherein the outlet of the handle further comprises a peripheral edge formed longitudinally adjacent the series of slots, the edge being configured for deformation for allowing the handle to disconnect from the plug when an intermediate portion of the assembly is subjected to the predetermined transverse load.

10. A connector assembly comprising:

an elongate handle attached to an electrical harness, the handle having an inlet, an outlet and a body formed therebetween, the inlet being adapted to receive the electrical harness, the body forming an internal cavity and adapted to receive a molded material for encapsulating a portion of the harness therein, the outlet forming an pocket for enclosing a compressed flexible portion of the harness, the outlet having a series of circumferentially spaced slots formed through an external wall; and

a sealed plug having a first end releasably attached to the outlet of the handle, and a second end opposite the first end for engaging a vehicle charging receptacle for facilitating electrical charging of a vehicle, the plug having a series of circumferentially spaced tabs longitudinally extending from the first end, each tab having a transverse projection extending radially outward for engaging one of the series of slots for attaching the plug to the handle, the series of tabs each having a thickness sized for allowing the tabs to deform and disengage the engaged slots when an intermediate portion of the assembly is subjected to a predetermined side load;

wherein the flexible portion of the harness is configured for extending when the projections disengage the slots for facilitating disconnection of the handle.

11. The connector assembly of claim 10 wherein the molded material further comprises a polyamide material.

12. The connector assembly of claim 10 wherein the sealed plug further comprises:

a terminal cover having a disc with a first side and a second side opposite the first side, the disc being oriented at the first end of the plug, the series of tabs extend from a circumference of the first side of the disc, and a plurality of terminal receptacles extending from a inner portion of the second side of the disc, the terminal receptacles adapted to receive female terminals that are attached to the ends of the flexible portion of the harness;

a seal disposed adjacent a circumference of the second side of the disc; and

a tubular shroud attached to an outer periphery of the terminal cover for enclosing the cover and retaining the seal to the terminal cover.

13. The connector assembly of claim 12 further comprising a back plate attached to the first side of the terminal cover for retaining the female terminals within the recesses.

14. The connector assembly of claim 10 wherein each projection is formed with a rounded profile providing an interference fit with the engaged slot for providing line contact load distribution.

15. The connector assembly of claim 10 wherein the plug further comprises a frangible plug where at least one of the series of tabs is configured to plastically deform when a minimum transverse load of 160 Newtons is applied to a side of the assembly.

16. A electrical power connecting system comprising:

an electrical harness connected to a power supply; and

a connector assembly having an elongate handle formed at a proximal end and attached to the electrical harness, the connector assembly having a plug formed at a distal end, the plug being configured for engaging a vehicle charging receptacle that is mounted for external access for facilitating electrical charging of the vehicle, the elongate handle and the plug being releasably connected to each other by a series of tabs, the tabs being configured to fail when a transverse load greater than 160 Newtons is applied to an intermediate portion of the assembly.

17. The system of claim 16 wherein the elongate handle further comprises a body forming an internal cavity for receiving and supporting the electrical harness, the body having an outlet formed at a distal end, the outlet having a series of peripherally spaced slots formed through an external wall for connecting to the plug.

18. The system of claim 17 wherein the plug further comprises:

a first end releasably attached to the outlet of the handle;

a second end opposite the first end for engaging the vehicle charging receptacle, wherein the series of tabs longitudinally extend from a peripheral edge of the first end; and

a transverse projection extending radially outward from an intermediate portion of each tab for engaging one of the series of slots and attaching the plug to the handle.

19. The system of claim 18 wherein each projection is formed with a rounded profile for providing an interference fit with the engaged slot.

20. The system of claim 17 wherein the external wall of the handle outlet further comprises a peripheral edge formed adjacent the series of slots, the edge being configured for plastic deformation for allowing the handle to disconnect from the plug when an intermediate portion of the assembly is subjected to a transverse load greater than 160 Newtons.