The teachings herein relate to a modular housing for an electric vehicle (EV) charger. More particularly the teachings herein relate to apparatus and methods that employ two separate housings that allow an electric charger to be easily reconfigured for different types of EV charging connectors or easily installed in different locations.
The slower adoption of EVs in some countries has been linked to the lack of availability of EV chargers. Although EV chargers are widely available for purchase and have been on the market for some time, several factors have led to their lack of use in many locations. First, and most importantly, the standards for EV charging have continued to evolve. For example, in the United States, many EV manufacturers have decided to abandon previous charger types in favor of the Tesla connector. Consumers are unlikely to purchase an EV charger if it is unlikely to work with the next EV they purchase.
Another factor limiting the purchase of EV chargers is the applicability of the chargers to the wide variety of locations where they can be installed. Like gas station pumps, conventional EV chargers all seem to have a similar design. Unlike gas stations, however, an EV charger can be installed almost anywhere. As a result, an EV charger with one design may not fit well in all locations. The problem often arises when installing an EV charger in the home. For example, the electrical outlet in a home garage may be on the side of the EV opposite the side with the charging port. As a result, a homeowner is often faced with having to rewire their garage to make the EV charger more convenient. Then, if the homeowner gets a car with a charging port on the other side, the wiring has to be changed again.
As a result, there is an unmet need for EV chargers that provide flexibility in changing the type of connectors used and that are adaptable to the location in which they are installed.
The skilled artisan will understand that the drawings, described below, are for illustration purposes only. The drawings are not intended to limit the scope of the present teachings in any way.
Before one or more embodiments of the present teachings are described in detail, one skilled in the art will appreciate that the present teachings are not limited in their application to the details of construction, the arrangements of components, and the arrangement of steps set forth in the following detailed description or illustrated in the drawings. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.
As described above, although EV chargers are widely available and have been on the market for some time, several factors have led to their lack of availability in many locations. First, and most importantly, the standards for EV charging, such as the types of EV connectors used, have continued to evolve. Another factor limiting the purchase of EV chargers is the applicability of the chargers to the wide variety of locations where they can be installed.
As a result, there is an unmet need for EV chargers that provide flexibility in changing the type of connectors used and that are adaptable to the location in which they are installed.
In various embodiments, a modular EV charger provides both flexibility in changing the type of connectors used and adaptability in tailoring the charger to the location in which it is installed. More particularly, the modular EV charger is easily converted to a tether type, socket type, extended socket, or post-mounted EV charger.
In various embodiments, the modular EV charger includes a first housing and a second housing. The first housing is, for example, adapted to include the electrical power management circuitry. The second housing is, for example, adapted to receive electrical power from the first housing and provide that power to an EV through an onboard socket or a tethered EV charger connector. Should the EV connector type needed by a consumer change, the second housing is easily replaced with a different housing that includes a different type of onboard socket or tethered EV charger connector.
In various embodiments, for a particular location, the first housing and the second housing can be connected. In various alternative embodiments, for a different location, the first housing in a second housing can be separated but electrically connected via a wire or wire and conduit. In other words, the use of two separate housings provides flexibility in adapting the EV charger to a particular location.
First housing 110 is adapted to enclose first electrical circuitry (not shown) that connects power source inputs from a power source input cable (not shown) to EV charging outputs of an EV charging output cable (not shown). First electrical circuitry can be any type of circuitry that connects the input cable to the output cable. For example, first electrical circuitry can simply be analog circuitry that connects the input cable to the output cable. In various alternative embodiments, first electrical circuitry can include analog circuitry, digital circuitry, or both analog and digital circuitry that is used not only to connect the input cable to the output cable but also to communicate data or control information to and from a user.
First housing 110 includes first port 111 and second port 112. First port 111 is adapted to receive the input cable into first housing 110. Second port 112 is adapted for sending the output cable from first housing 110.
Second housing 120 includes third port 123, fourth port 124, and fifth port 125. Second housing 120 is further adapted to enclose an EV charging socket (not shown). Third port 123 is adapted to receive the input cable. Fourth port 124 is adapted to send the input cable to first port 111 of first housing 110. Fifth port 125 is adapted to receive the output cable from second port 112 of first housing 110.
Fourth port 124 further includes threaded male portion 140 that extends from second housing 120. Fifth port 125 further includes threaded male portion 150 that extends from second housing 120. Fourth port 124 and fifth port 125 are positioned in size so that, when second housing 120 is connected to first housing 110, fourth port 124 is coaxially aligned with first port 111 and fits within first port 111, and fifth port 125 is coaxially aligned with second port 112 and fits within second port 112.
In various embodiments, second housing 120 includes sixth port 126 for receiving a cable of a tethered EV connector (not shown).
In various embodiments, first housing 110 is separated or extended from second housing 120 using a conduit (not shown). In various alternative embodiments, first housing 110 and second housing 120 are directly connected. These different embodiments show the housing system can easily be modified to use different types of connectors or to be installed in different types of locations.
First housing 110 receives the input cable (not shown) through the first port (not shown) and includes the first electrical circuitry (not shown) that connects the input cable to the output cable (not shown). Second housing 120 includes second electrical circuitry (not shown) that connects the output cable to EV charging socket 220 to provide power to EV charging socket 220. EV charging socket 220 is then used for EV charging.
The second electrical circuitry can be any type of circuitry that connects the output cable to EV charging socket 220. For example, the second electrical circuitry can simply be a direct connection of the wires of the output cable to the terminals of EV charging socket 220.
In
First housing 110 receives the input cable (not shown) through the first port (not shown) and includes the first electrical circuitry (not shown) that connects the input cable to the output cable (not shown). Second housing 120 includes sixth port 126 that receives connector cable 311. Second housing 120 includes second electrical circuitry (not shown) that connects the output cable to connector cable 311 to provide power to EV connector 310. EV connector 310 is then used for EV charging.
Again, the second electrical circuitry can be any type of circuitry that connects the output cable to EV connector 310. For example, the second electrical circuitry can simply be a direct connection of the wires of the output cable to the terminals of EV connector 310.
Second housing 120 also includes EV charging socket 320. In various embodiments, EV charging socket 320 is a dummy socket. In other words, EV charging socket 320 is a socket that is not connected to any power source. However, EV charging socket 320, for example, can be used to hold EV connector 310 when it is not in use. In other words, EV charging socket 320 can be used as an EV connector holder.
In various alternative embodiments, the second electrical circuitry can also connect the output cable to EV charging socket 320. In this case, EV charging socket 320 can also be used for EV charging.
Again, the second electrical circuitry can be any type of circuitry that connects the output cable to EV connector 310 and EV charging socket 320. For example, the second electrical circuitry can simply be a direct connection of the wires of the output cable to the terminals of EV connector 310 and the terminals of EV charging socket 320.
In the system of
Third port 123 of second housing 120 receives the input cable (not shown). Fourth port 124 of second housing 120 sends the input cable to first port 111 of first housing 110. First housing 110 receives the input cable through first port 111. First housing 110 includes the first electrical circuitry (not shown) that connects the input cable to the output cable (not shown). First housing 110 sends the output cable to second housing 120 through second port 112 to fifth port 125.
In various embodiments, second housing 120 is directly connected to first housing 110 to provide power to the EV charging socket (not shown) included in second housing 120. Second housing 120 includes second electrical circuitry (not shown) that connects the output cable (not shown) to the EV charging socket to provide power to the EV charging socket.
Again, the second electrical circuitry can be any type of circuitry that connects the output cable to the EV charging socket. For example, the second electrical circuitry can simply be a direct connection of the wires of the output cable to the terminals of the EV charging socket.
Again, the second electrical circuitry can be any type of circuitry that connects the output cable to the EV charging socket 520. For example, the second electrical circuitry can simply be a direct connection of the wires of the output cable to the terminals of the EV charging socket 520.
Second housing 120 receives the input cable (not shown) through the third port (not shown). The fourth port (not shown) of second housing 120 sends the input cable to the first port (not shown) of first housing 110. First housing 110 receives the input cable through the first port. First housing 110 includes the first electrical circuitry (not shown) that connects the input cable to the output cable (not shown). First housing 110 sends the output cable to second housing 120 through the second port of first housing 110 to the fifth port of second housing 120.
Second housing 120 includes sixth port 126 that receives connector cable 611. Second housing 120 includes second electrical circuitry (not shown) that connects the output cable to connector cable 611 to provide power to EV connector 610. EV connector 610 is then used for EV charging.
Again, the second electrical circuitry can be any type of circuitry that connects the output cable to EV connector 610. For example, the second electrical circuitry can simply be a direct connection of the wires of the output cable to the terminals of EV connector 610.
Second housing 120 also includes EV charging socket 620. In various embodiments, EV charging socket 620 is a dummy socket. In other words, EV charging socket 620 is a socket that is not connected to any power source. However, EV charging socket 620, for example, can be used to hold EV connector 610 when it is not in use. In other words, EV charging socket 620 can be used as an EV connector holder.
In various alternative embodiments, the second electrical circuitry can also connect the output cable to EV charging socket 620. In this case, EV charging socket 620 can also be used for EV charging.
Again, the second electrical circuitry can be any type of circuitry that connects the output cable to EV connector 610 and EV charging socket 620. For example, the second electrical circuitry can simply be a direct connection of the wires of the output cable to the terminals of EV connector 610 and the terminals of EV charging socket 620.
In step 710 of method 700, a power source input cable is received through a first port of a first housing that includes first electrical circuitry that connects the input cable to an EV charging output cable. The first housing is adapted to enclose the first electrical circuitry that connects power source inputs from the input cable to EV charging outputs of the output cable. The first housing includes the first port that is adapted to receive the input cable and a second port that is adapted to send the output cable. A second housing is adapted to enclose an EV charging socket and includes a fifth port adapted to receive the output cable from the second port.
In step 720, a first conduit is connected between the first housing and the second housing.
In step 730, the output cable is sent from the first housing to the second housing through the first conduit. The first conduit connects the second port to the fifth port.
In step 810 of method 800, a first nut is screwed onto a threaded portion of a fourth port of a second housing to secure the second housing to a first housing.
In step 820, a second nut is screwed onto a threaded portion of a fifth port of the second housing to secure the second housing to the first housing. The first housing encloses first electrical circuitry that connects power source inputs from a power source input cable to EV charging outputs of an EV charging output cable.
The first housing includes a first port adapted to receive the input cable and a second port adapted to send the output cable. The second housing is adapted to enclose an EV charging socket and includes a third port adapted to receive the input cable, the fourth port adapted to send the input cable to the first port, and the fifth port adapted to receive the output cable from the second port. The fourth port includes the threaded male portion that extends from the second housing. The fifth port includes the threaded male portion that extends from the second housing. The fourth port and the fifth port are positioned and sized so that the fourth port is coaxially aligned with the first port and fits within the first port and the fifth port is coaxially aligned with the second port and fits within the second port.
In step 830, the input cable is received through the third port of the second housing.
In step 840, the input cable is sent to the first port of the first housing from the fourth port of the second housing.
In step 850, the input cable is received in the first housing through the first port.
In step 860, the output cable is sent from the first housing to the second housing through the second port to the fifth port.
When connected to the second housing, as shown in
When first housing 110 of
In various embodiments, second housing 120 connects output cable 1412 to connector cable 311 of EV connector 310. In various embodiments, second housing 120 connects output cable 1412 to EV charging socket 320. In various embodiments, second housing 120 connects output cable 1412 to both connector cable 311 of EV connector 310 and EV charging socket 320.
In various embodiments, second housing 120 connects output cable 1412 to connector cable 311 of EV connector 310, EV charging socket 320, or both connector cable 311 of EV connector 310 and EV charging socket 320 using second electrical circuitry 1420. Again, second electrical circuitry 1420 can be any type of circuitry that connects output cable 1412 to EV connector 310, charging socket 320, or both EV connector 310 and charging socket 320. For example, second electrical circuitry 1420 can simply be a direct connection of the wires of output cable 1412 to the wires of connector cable 311 of EV connector 310 and/or the terminals of EV charging socket 320.
In various embodiments, second housing 120 connects output cable 1512 to connector cable 611 of EV connector 610. In various embodiments, second housing 120 connects output cable 1512 to EV charging socket 620. In various embodiments, second housing 120 connects output cable 1512 to both connector cable 611 of EV connector 610 and EV charging socket 620.
In various embodiments, second housing 120 connects output cable 1512 to connector cable 611 of EV connector 610, EV charging socket 620, or both connector cable 611 of EV connector 610 and EV charging socket 620 using second electrical circuitry 1520. Again, second electrical circuitry 1520 can be any type of circuitry that connects output cable 1512 to EV connector 610, charging socket 620, or both EV connector 610 and charging socket 620. For example, second electrical circuitry 1520 can simply be a direct connection of the wires of output cable 1512 to the wires of connector cable 611 of EV connector 610 and/or the terminals of EV charging socket 620.
While the present teachings are described in conjunction with various embodiments, it is not intended that the present teachings be limited to such embodiments. On the contrary, the present teachings encompass various alternatives, modifications, and equivalents, as will be appreciated by those of skill in the art.
Further, in describing various embodiments, the specification may have presented a method and/or process as a particular sequence of steps. However, to the extent that the method or process does not rely on the particular order of steps set forth herein, the method or process should not be limited to the particular sequence of steps described. As one of ordinary skill in the art would appreciate, other sequences of steps may be possible. Therefore, the particular order of the steps set forth in the specification should not be construed as limitations on the claims. In addition, the claims directed to the method and/or process should not be limited to the performance of their steps in the order written, and one skilled in the art can readily appreciate that the sequences may be varied and still remain within the spirit and scope of the various embodiments.
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 63/508,911, filed on Jun. 19, 2023, the content of which is incorporated by reference herein in its entirety.
Number | Date | Country | |
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63508911 | Jun 2023 | US |