Connector assembly for vehicle charging

• US 8,206,184 B2
• Filed: 12/16/2010
• Issued: 06/26/2012
• 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:
  US12/969,798
• Publication Number:
  US 20120003861A1
• Time in Patent Office: 558 Days
• Field of Search: 439/474, 439/475, 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 is provided with a support structure having an elongate shape and an inlet for receiving a charging cable. A fitting is disposed in mechanical interlocking engagement with a distal end of the support structure for interconnecting the support structure with a vehicle charging receptacle. The support structure and the fitting are configured for disconnecting from each other when the connector assembly is subjected to a lateral load above a predetermined threshold value.

Claims

1. A connector assembly comprising:

a support structure having an elongate shape with an inlet for receiving a charging cable;

a fitting disposed in mechanical interlocking engagement with a distal end of the support structure for interconnecting the support structure with a vehicle charging receptacle;

at least one connecting member extending longitudinally from at least one of the fitting and the distal end of the support structure, wherein the other of the fitting and the distal end of the support structure includes an external wall with at least one aperture formed therethrough; and

an enlarged portion extending radially from an intermediate portion of the connecting member, the enlarged portion being received by the aperture for connecting the fitting to the support structure;

wherein the support structure and the fitting being configured for disconnecting from each other when the connector assembly is subjected to a lateral load above a predetermined threshold value.

2. The connector assembly of claim 1 wherein the at least one connecting member is formed of a flexible and elastic material, the at least one connecting member extending from a peripheral edge of at least one of the fitting and the distal end of the support structure.

3. The connector assembly of claim 1 wherein the fitting is configured for disconnecting from the support structure when the connector assembly is subjected to a generally perpendicular load above the predetermined threshold value.

4. The connector assembly of claim 1 wherein the fitting is configured for plastically deforming and disconnecting from the support structure when the connector assembly is subjected to a load above 160 Newtons.

5. The connector assembly of claim 1 wherein the at least one connecting member extends from the fitting for engaging the distal end of the support structure.

6. The connector assembly of claim 5 wherein the at least one connecting member further comprises at least two connecting members, each connecting member being equally spaced from one another about a circumference of the fitting.

7. The connector assembly of claim 6 wherein the distal end of the support structure includes the external wall, and wherein the at least one aperture further comprises at least two apertures formed therethrough, the at least two apertures being equally spaced from one another about a circumference of the distal end and each sized for receiving the enlarged portion of one of the connecting members extending from the fitting for connecting the fitting to the support structure.

8. The connector assembly of claim 1 wherein the support structure further comprises a clamshell support structure having a front portion, and a rear portion connected to the front portion about a peripheral edge to collectively form a cavity for enclosing a wire harness extending from the charging cable.

9. The connector assembly of claim 8 wherein the support structure is adapted to receive a molded material within the cavity for encapsulating and insulating a portion of the electrical harness.

10. The connector assembly of claim 9 further comprising an LED supported by at least one of the support structure and the fitting and connected to the electrical harness, wherein a portion of the LED is encapsulated by the molded material.

11. A connector assembly comprising:

a support structure having an elongate shape; and

a fitting disposed in mechanical interlocking engagement with a distal end of the support structure, the fitting having at least one connecting member extending longitudinally therefrom, and an enlarged portion extending radially from an intermediate portion of the connecting member for engaging the support structure;

wherein the support structure is configured for disconnecting from the fitting when the connector assembly is subjected to a lateral load above a predetermined threshold value;

wherein the support structure further comprises an external wall formed at the distal end, the external wall having at least one aperture formed therethrough for receiving the enlarged portion.

12. The connector assembly of claim 11 wherein the fitting is configured for plastically deforming and disconnecting from the support structure when the connector assembly is subjected to a load above 160 Newtons.

13. A system comprising:

a charging cable for connecting to an external power supply; and

a connector assembly attached to the charging cable, the connector assembly provided with;

a support structure having an elongate shape with an inlet for receiving a charging cable, and

a fitting disposed in mechanical interlocking engagement with a distal end of the support structure for interconnecting the support structure with a vehicle charging receptacle, the support structure and the fitting being configured for disconnecting from each other when the connector assembly is subjected to a lateral load above a predetermined threshold value,

an LED disposed within at least one of the support structure and the fitting for projecting light toward the vehicle charging receptacle; and

a lever pivotally connected to the support structure and extending longitudinally beyond the fitting, wherein the lever is actuated to selectively attach the connector assembly to the vehicle charging receptacle.

14. The system of claim 13 wherein the connector assembly further comprises at least one connecting member formed of a flexible material, the at least one connecting member extending longitudinally from a peripheral edge of at least one of the fitting and the distal end of the support structure for engaging the other of the fitting and the support structure.

15. The system of claim 13 wherein the support structure is configured for disconnecting from the fitting when the connector assembly is subjected to a generally perpendicular load above the predetermined threshold value.

16. The system of claim 13 wherein at least one of the fitting and the support structure is configured for plastically deforming and disconnecting from the other of the fitting and the support structure when the connector assembly is subjected to a load above 160 Newtons.