Patent Application
20230099692
This disclosure is directed to an electrical power supply cord for electric vehicle supply equipment (EVSE), i.e., a portable electric charger interface for an electrical vehicle.
Electric vehicle supply equipment is a portable charging cord set that supplies alternating current (AC) electrical power to on-board battery chargers present in electric vehicles (EVs) or plug-in hybrid electric vehicles (PHEVs). There are many portable charging cord sets available for consumers to purchase and use with their EVs or PHEVs. A typical EVSE power supply cord used in North America and illustrated in
The subject matter discussed in the background section should not be assumed to be prior art merely as a result of its mention in the background section. Similarly, a problem mentioned in the background section or associated with the subject matter of the background section should not be assumed to have been previously recognized in the prior art. The subject matter in the background section merely represents different approaches, which in and of themselves may also be inventions.
According to one or more aspects of the present disclosure, an electrical power supply cord includes a wire cable comprising a plurality of separate conductors, a plurality of plug terminals connected to the plurality of separate conductors, a molded inner plug encasing a connection between the plurality of plug terminals and the plurality of separate conductors, and in-mold bonding adhesive disposed intermediate the connection between the plurality of plug terminals and the plurality of separate conductors and the molded inner plug.
In one or more embodiments of the electrical power supply cord according to the previous paragraph, the molded inner plug is formed of an injection moldable polymer.
In one or more embodiments of the electrical power supply cord according to any one of the previous paragraphs, the molded inner plug is formed of polybutylene terephthalate.
In one or more embodiments of the electrical power supply cord according to any one of the previous paragraphs, the electrical power supply cord further includes a molded outer plug encasing the molded inner plug and a portion of the wire cable.
In one or more embodiments of the electrical power supply cord according to any one of the previous paragraphs, the molded outer plug is formed of a thermoplastic elastomer.
In one or more embodiments of the electrical power supply cord according to any one of the previous paragraphs, the molded outer plug is shaped to provide strain relief between the molded inner plug and the wire cable.
In one or more embodiments of the electrical power supply cord according to any one of the previous paragraphs, the electrical power supply cord further includes a plurality of socket terminals connected to the plurality of separate conductors, a molded inner socket encasing a connection between the plurality of socket terminals and the plurality of separate conductors, a molded outer socket encasing the molded inner socket and a portion of the wire cable, and in-mold bonding adhesive disposed intermediate the molded inner socket and the molded outer socket.
In one or more embodiments of the electrical power supply cord according to any one of the previous paragraphs, the molded inner socket is formed of an injection moldable polymer.
In one or more embodiments of the electrical power supply cord according to any one of the previous paragraphs, the molded inner socket is formed of polybutylene terephthalate.
In one or more embodiments of the electrical power supply cord according to any one of the previous paragraphs, the molded outer socket is formed of a thermoplastic elastomer.
In one or more embodiments of the electrical power supply cord according to any one of the previous paragraphs, the molded outer socket is shaped to provide strain relief between the molded inner socket and the wire cable.
According to one or more aspects of the present disclosure, a method of assembling a electrical power supply cord includes connecting a plurality of plug terminals, a plurality of separate conductors in a wire cable, depositing an in-mold bonding adhesive on the plurality of plug terminals and the plurality of separate conductors, and forming a molded inner plug encasing a connection between the plurality of plug terminals and the plurality of separate conductors using an injection molding process.
In one or more embodiments of the method according to the previous paragraph, the molded inner plug is formed of polybutylene terephthalate.
In one or more embodiments of the method according to any one of the previous paragraphs, the method further includes forming a molded outer plug encasing the molded inner plug and a portion of the wire cable using an injection molding process.
In one or more embodiments of the method according to any one of the previous paragraphs, the molded outer plug is formed of a thermoplastic elastomer.
In one or more embodiments of the method according to any one of the previous paragraphs, the method further includes shaping the molded outer plug to provide strain relief between the molded inner plug and the wire cable.
In one or more embodiments of the method according to any one of the previous paragraphs, the method further includes connecting a plurality of socket terminals to the plurality of separate conductors, forming a molded inner socket encasing a connection between the plurality of socket terminals and the plurality of separate conductors using an injection molding process, deposing the in-mold bonding adhesive on the molded inner socket, and forming a molded outer socket encasing the molded inner socket and a portion of the wire cable using an injection molding process, such that the in-mold bonding adhesive is deposited intermediate the molded inner socket and the molded outer socket.
In one or more embodiments of the method according to any one of the previous paragraphs, the molded inner socket is formed of polybutylene terephthalate.
In one or more embodiments of the method according to any one of the previous paragraphs, the molded outer socket is formed of a thermoplastic elastomer.
In one or more embodiments of the method according to any one of the previous paragraphs, the method further includes shaping the molded outer socket to provide strain relief between the molded inner socket and the wire cable.
The present invention will now be described, by way of example with reference to the accompanying drawings, in which:
The plug faceplate 112 also retains a printed circuit board assembly (PCBA) 114 containing temperature sensors 116, such as thermistors. As shown in
The plug 104 also includes a molded inner plug 120 that is formed of a thermoplastic material, such as polybutylene terephthalate. The components of the plug 104 are placed in a mold (not shown) and the thermoplastic material is injected into the mold, thereby forming the inner plug 120 and encapsulating the interface between the terminals 106, 108, 110 and wires of the cable 102, the inside of the plug faceplate 112, the encapsulated PCBA 114, 118, and the signal wires. The protective covering 118 on the PCBA 114 provides thermal protection for the PCBA 114 during the injection molding process, thereby inhibiting reflow of solder connecting electronic components in the PCBA 114.
Prior to forming the inner plug 120, an in-mold bonding adhesive 122, such as one produced by Lord Corporation of Cary, N.C., USA (or equivalent), is applied to portions of the components of the plug 104 as shown in
The plug 104 further includes a molded outer plug 124 that is formed of a thermoplastic elastomer material over the inner plug 120 and a portion of the cable 102, thereby providing strain relief for the cable 102.
The power cord 100 also has a socket 126 on the end of the cable 102 opposite the plug 104 that is configured to connect the power, neutral, ground, and signal wires to the EVSE. The socket 126 includes socket terminals 128 connected to the power, neutral, ground, and signal wires. The socket terminals 128 are held in a terminal cartridge 130 that is placed within a socket connector housing 132 having cavities configured to receive the socket terminals 128. O-rings 134 are placed between the socket terminals 128 and the terminal cartridge 130 to inhibit fluid intrusion into the socket 126. The socket 126 also includes an inner socket member 136 that is formed of a thermoplastic material, such as polybutylene terephthalate. The components of the socket 126 are placed in a mold (not shown) and the thermoplastic material is inserted into the mold, thereby forming the inner socket member 136 and thereby encapsulating the terminal cartridge 130, O-rings 134, inner socket member 136, wires, and the inside of the socket connector housing 132.
The socket 126 further includes an outer socket member 138 formed of a thermoplastic elastomer material over the inner socket member 136 and a portion of the cable 102, thereby providing strain relief for the cable 102.
Prior to forming the outer socket member 138, the in-mold bonding adhesive 122 is also applied to outer portions of inner socket member 136 as shown in
The EVSE power supply cord presented herein provides enhanced resistance to fluid intrusion in the plug and socket that could damage terminals, wires, or other components in the plug or socket. This enhances resistance to fluid intrusion is at least partially due to the use of the in-mold bonding adhesive to provide a more robust bond between the plug and socket components, thereby sealing potential leak paths into or through the plug and socket.
While the illustrated examples contained herein show an EVSE power supply cord that conforms to either NEMA 5-15 or NEMA 14-50 technical standards used primarily in North America, other embodiments may be envisioned where the power and ground pins of the plug conform to other standards used in different parts of the world, such as Europlug CCE 7/16, British Standard (BS) 1363, Australian/New Zealand Standard AS/NZS 3112, or Chinese PPCS-CCC technical standards.
While the invention has been described with reference to an exemplary embodiment(s), it will be understood by those skilled in the art that various changes may be made, and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention is not limited to the disclosed embodiment(s), but that the invention will include all embodiments falling within the scope of the appended claims.
As used herein, ‘one or more’ includes a function being performed by one element, a function being performed by more than one element, e.g., in a distributed fashion, several functions being performed by one element, several functions being performed by several elements, or any combination of the above.
It will also be understood that, although the terms first, second, etc. are, in some instances, used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first contact could be termed a second contact, and, similarly, a second contact could be termed a first contact, without departing from the scope of the various described embodiments. The first contact and the second contact are both contacts, but they are not the same contact.
The terminology used in the description of the various described embodiments herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used in the description of the various described embodiments and the appended claims, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term “and/or” as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. It will be further understood that the terms “includes,” “including,” “comprises,” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
As used herein, the term “if” is, optionally, construed to mean “when” or “upon” or “in response to determining” or “in response to detecting,” depending on the context. Similarly, the phrase “if it is determined” or “if [a stated condition or event] is detected” is, optionally, construed to mean “upon determining” or “in response to determining” or “upon detecting [the stated condition or event]” or “in response to detecting [the stated condition or event],” depending on the context.
Additionally, while terms of ordinance or orientation may be used herein these elements should not be limited by these terms. All terms of ordinance or orientation, unless stated otherwise, are used for purposes distinguishing one element from another, and do not denote any particular order, order of operations, direction or orientation unless stated otherwise.
This application claims benefit of priority to U.S. Application No. 63/247,933 filed on Sep. 24, 2021, the entire disclosure of which is hereby incorporated by reference.
| Number | Date | Country | |
|---|---|---|---|
| 63247933 | Sep 2021 | US |
