Electromechanical pawl for controlling vehicle charge inlet access

• US 8,651,875 B2
• Filed: 08/18/2012
• Issued: 02/18/2014
• Est. Priority Date: 09/28/2011
• Status: Active Grant

• Current Assignee: Tesla Inc.
• Original Assignee: Tesla Motors Incorporated (Tesla Inc.)
• Inventors: Ferguson, Joshua Willard, Baglino, Andrew David, Kalayjian, Nicholas Robert
• Primary Examiner(s): HARVEY, JAMES R
• Application Number:
  US13/589,098
• Publication Number:
  US 20130078841A1
• Time in Patent Office: 549 Days
• Field of Search: 320/109, 320/107, 320/108, 320/111, 320/162, 439/34, 439/372
• US Class Current: 439/34
• CPC Class Codes: B60L 53/16 Connectors, e.g. plugs or sockets, specially adapted for charging electric vehicles
• CPC Class Codes: H01R 13/6397 with means for preventing unauthorised use
• 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 charge connector latching mechanism integrated into a vehicle'"'"'s charge inlet is provided, where the latching mechanism includes a retractable latching pawl. The retractable pawl is configured to be positioned in at least a first, default position where the pawl extends through an inlet surface of the charge inlet, and a second position where the pawl is retracted and does not extend through the inlet surface. In the first position the retractable pawl prevents insertion of a charge connector into the charge inlet if the charge connector is uncoupled from the inlet, and prevents removal of the charge connector if the charge connector is coupled to the inlet. In the second position the retractable pawl allows insertion/withdrawal of the charge connector into/from the charge inlet. The front surface of the retractable pawl may include a nub configured to fit within a recess within the front face of the charge connector.

Claims

1. A vehicle charge inlet integrated within a vehicle, 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;

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; and

a connector latching mechanism integrated within said inlet housing, said connector latching mechanism further comprising;

a retractable pawl, wherein said retractable pawl is configured to be positioned in at least a first position and a second position, wherein said first position corresponds to an extended position wherein said retractable pawl extends through said inlet surface, wherein said second position corresponds to a retracted position wherein said retractable pawl does not extend through said inlet surface, wherein said retractable pawl in said first position prevents insertion of said charge connector if said charge connector is uncoupled from said vehicle charge inlet, wherein said retractable pawl in said first position fits within a slot in said charge connector and prevents removal of said charge connector if said charge connector is coupled to said vehicle charge inlet, wherein said retractable pawl in said second position allows insertion and withdrawal of said charge connector into and from said vehicle charge inlet, wherein said first position is a default position for said retractable pawl, and wherein said default position corresponds to a pre-charging condition for said vehicle and corresponds to a normal operational, non-charging condition for said vehicle.

2. The vehicle charge inlet of claim 1, said retractable pawl further comprising a nub extending from a front surface of said retractable pawl, said nub configured to fit within a recess within a front face of said charge connector during insertion of said charge connector into said vehicle charge inlet when said retractable pawl is in said first position, wherein a rocking motion of said charge connector when said nub is within said recess causes said retractable pawl to track said rocking motion.

3. The vehicle charge inlet of claim 1, said connector latching mechanism further comprising a lever assembly and a spring, wherein said retractable pawl is mechanically coupled to said lever assembly, and wherein said spring maintains said retractable pawl via said lever assembly in said first position.

4. The vehicle charge inlet of claim 1, said connector latching mechanism further comprising a lever assembly and a solenoid actuator, wherein said retractable pawl is mechanically coupled to said lever assembly, and wherein said solenoid actuator controls movement of said retractable pawl from said first position to said second position via said lever assembly.

5. The vehicle charge inlet of claim 4, said connector latching mechanism further comprising a spring coupled to said retractable pawl via said lever assembly, wherein when said solenoid actuator is un-energized said spring maintains said retractable pawl in said first position, and wherein when said solenoid actuator is energized said solenoid actuator repositions said retractable pawl from said first position to said second position.

6. The vehicle charge inlet of claim 5, said lever assembly further comprising a first lever member and a second lever member, wherein a first end portion of said first lever member is comprised of said retractable pawl, wherein said first lever member rotates about a first axis, wherein said second lever member is mechanically coupled to said first lever member and rotates about said first axis, wherein rotation of said second lever member causes rotation of said first lever member, and wherein said solenoid actuator is coupled to said second lever member.

7. The vehicle charge inlet of claim 1, said connector latching mechanism further comprising:

a lever assembly, wherein said retractable pawl is mechanically coupled to said lever assembly;

a spring, wherein said spring maintains said retractable pawl via said lever assembly in said first position;

a solenoid actuator coupled to said retractable pawl via said lever assembly; and

a controller coupled to said solenoid actuator, wherein said controller controls when said solenoid actuator is energized, wherein when said solenoid actuator is un-energized said spring maintains said retractable pawl in said first position, and wherein when said solenoid actuator is energized said solenoid actuator repositions said retractable pawl from said first position to said second position.

8. The vehicle charge inlet of claim 7, wherein said controller is configured to perform a set of pre-connection diagnostics before said controller energizes said solenoid actuator to allow insertion of said charge connector into said vehicle charge inlet.

9. The vehicle charge inlet of claim 7, wherein said controller is configured to perform a set of pre-de-coupling diagnostics before said controller energizes said solenoid actuator to allow withdrawal of said charge connector from said vehicle charge inlet.

10. The vehicle charge inlet of claim 7, wherein said controller is configured to determine if a vehicle battery is electrically connected to a pair of power connectors of said plurality of electrical contacts, wherein said controller is further configured to only energize said solenoid actuator if said pair of power connectors are not electrically connected to said vehicle battery.

11. The vehicle charge inlet of claim 1, wherein said retractable pawl is fabricated from anodized aluminum.

12. The vehicle charge inlet of claim 1, 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.

13. The vehicle charge inlet of claim 1, 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.

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

15. The vehicle charge inlet of claim 1, further comprising 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.

16. The vehicle charge inlet of claim 15, wherein said divider has a three pointed star shape.

17. The vehicle charge inlet of claim 15, 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, 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.