Laminous multi-polymeric high amperage over-molded connector assembly for plug-in hybrid electric vehicle charging

• US 8,562,365 B2
• Filed: 08/17/2011
• Issued: 10/22/2013
• Est. Priority Date: 12/30/2010
• Status: Active Grant

• Current Assignee: General Cable Technologies Corporation (General Cable Corporation)
• Original Assignee: General Cable Technologies Corporation (General Cable Corporation)
• Inventors: Sebald, Damien T., Smith, Brian D.
• Primary Examiner(s): Luebke, Renee
• Assistant Examiner(s): TSUKERMAN, LARISA Z
• Application Number:
  US13/211,867
• Publication Number:
  US 20120171887A1
• Time in Patent Office: 797 Days
• Field of Search: 439/206, 439/358, 439/582, 439/607.41, 439/310, 439/304
• US Class Current: 439/310
• CPC Class Codes: B60L 2240/667 Precipitation
• 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 13/504 different pieces being moulded, cemented, welded, e.g. ultrasonic, or swaged together
• CPC Class Codes: H01R 13/5227 with evacuation of penetrating liquids
• CPC Class Codes: H01R 13/6275 Latching arms not integral with the housing H01R13/6276, H01R13/6277, H01R13/6278 take precedence
• CPC Class Codes: H01R 13/717 with built-in light source
• 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 10/72 Electric energy management in electromobility
• CPC Class Codes: Y02T 90/14 Plug-in electric vehicles
• CPC Class Codes: Y02T 90/16 Information or communication technologies improving the operation of electric vehicles
• CPC Class Codes: Y10T 29/49176 with molding of electrically insulating material

Abstract

In an electrical connector for an electric vehicle, the spring latch is not sealed; instead, the connector body has holes allowing water entering the spring latch mechanism to drain harmlessly out of the connector. A forward-facing LED or other light source acts as a flashlight. Once the connector is connected, the forward-facing LED is switched off, and a rear-facing LED or other light source is switched on to confirm that the connector is connected and capable of charging the vehicle. The connector is produced by overmolding in a three-layer configuration, where each layer is formed of a material having advantageous materials for that layer'"'"'s position in the connector.

Claims

1. An electrical connector for an electric vehicle, the electrical connector comprising:

a connector body having a latch area formed therein;

a plurality of connector pins in the connector body; and

a latch mounted in the latch area on the connector body for holding the electrical connector to the electric vehicle;

wherein the connector body has a plurality of holes extending from the latch area to a surface of the connector body separate from the latch area for allowing water entering the latch area to exit the latch area.

2. The electrical connector of claim 1, further comprising a light adjacent to the plurality of connector pins.

3. The electrical connector of claim 2, further comprising a second light on a portion of the connector body opposite to the connector pins.

4. The electrical connector of claim 1, wherein the connector body is formed by overmolding.

5. The electrical connector of claim 1, wherein the connector body comprises:

a potting compound;

a premold formed over the potting compound; and

an outer connector body formed in a single piece over the premold.

6. The electrical connector of claim 5, wherein the potting compound comprises a two-part dielectric potting compound.

7. The electrical connector of claim 5, wherein the premold is formed to provide at least one of cross-linking adhesion, mechanical bonding, and mechanical locking with the outer connector body.

8. The electrical connector of claim 6, wherein the premold comprises a material selected from the group consisting of polyamide-based materials, glass-filled polyethylene terephthalate, acrylonitrile butadiene styrene, thermoplastic elastomer, thermoplastic vucanizate, and polypropylene.

9. The electrical connector of claim 8, wherein the outer connector body comprises a material selected from the group consisting of EPT, EPDM and silicone or liquid silicone injection.

10. The electrical connector of claim 1, wherein the latch area is defined by a depression formed in the connector body.

11. A method for making an electrical connector for an electric vehicle, the method comprising:

(a) providing a charging cable and a connector body having at least one connector pin;

(b) providing an electrical connection between the charging cable and the at least one connector pin;

(c) applying a potting compound over the electrical connection and portions of the connector body and of the charging cable adjacent to the electrical connection to provide a water-impermeable barrier between the electrical connection and components of the electrical connector that may become exposed to water;

(d) applying a premold over the potting compound, the connector body, and the portion of the charging cable adjacent to the connector body; and

(e) overmolding an outer connector body in a single piece over the premold to form the connector.

12. The method of claim 11, further comprising providing circuitry to control operation of the connector, and wherein step (c) comprises applying the potting compound over the circuitry.

13. The method of claim 11, wherein the potting compound comprises a two-part dielectric potting compound.

14. The method of claim 13, wherein the premold comprises a material selected from the group consisting of polyamide-based materials, glass-filled polyethylene terephthalate, acrylonitrile butadiene styrene, thermoplastic elastomer, thermoplastic vucanizate, and polypropylene.

15. The method of claim 14, wherein the outer connector body comprises a material selected from the group consisting of EPT, EPDM and silicone or liquid silicone injection.

16. The method of claim 11, wherein the premold is formed to provide at least one of cross-linking adhesion, mechanical bonding, and mechanical locking with the outer connector body.

17. The method of claim 11, further comprising attaching a latch to the connector for latching the connector onto the vehicle.

18. The method of claim 17, wherein the outer connector body has a latch area formed therein.

19. The method of claim 18, wherein the outer connector body has a plurality of holes for allowing water entering the latch area to exit the latch area.

20. The method of claim 19, wherein step (e) comprises overmolding the outer connector body to have the plurality of holes.