Key information

Title: Power output connector assembly
Application number: 20240404
Case type: National
Status: 14.04.2025 Patent meddelt (B1)
Filed: 29.04.2024
Effective date: 29.04.2024
Publicly available: 14.04.2025
Next annual fee due: 30.04.2027
Applicant: EVLY AS (NO)
Owner: EVLY AS (NO)
Inventor: Per Morten Brun (NO)
Agent: ACAPO ONSAGERS AS (NO)
Granted: 14.04.2025
Patent number: 348632
Expiry date: 29.04.2044

Abstract and drawing

Disclaimer: This text has been machine-scanned and may contain errors – please refer to "Publications" for legally binding content.

Power output connector assembly (100) for an electric vehicle charging station (200), the power input connector assembly (100) comprising power (130a-e) and signal (140a-b) connection pins to be arranged to a base member (110) thereof via respective receptacles (120a-b), wherein the respective receptacle (120a-b) is provide with at least one respective resilient locking member (122a-b) provided with a retaining member (123a-b) at a distal end thereof configured for interaction with an attachment interface (134, 144) of the power (130a-e) and signal (140a-b) connection pins, respectively, for attachment of the respective power (130a-e) and signal (140a-b) connection pins to the respective receptacles (120a-b).

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Date

Date	Doc. No.	Process	Case number	In/Out	Journal description	To/from
02.03.2026	12-01	Saksbehandling	20240404(348632)	UT	PT Varsel om betaling av første årsavgift (3317) (PT20240404)	ACAPO ONSAGERS AS
23.04.2025	11-02	Saksbehandling	20240404	INN	Korrespondanse (Hovedbrev inn)	CURO AS
23.04.2025	11-01	Saksbehandling	20240404	INN	PDF_677225377	CURO AS
16.04.2025	10-01	Saksbehandling	20240404(348632)	UT	PT Registreringsbrev nasjonal patent (15) (PT20240404)
26.02.2025	09-03	Saksbehandling	20240404	INN	GPOA EVLY AS	ACAPO ONSAGERS AS
26.02.2025	09-02	Saksbehandling	20240404	INN	01-Intention to grant	ACAPO ONSAGERS AS
26.02.2025	09-01	Saksbehandling	20240404	INN	Korrespondanse (Hovedbrev inn)	ACAPO ONSAGERS AS
26.02.2025	08-01	Saksbehandling	20240404	UT	Koriggert Intention to grant	ACAPO ONSAGERS AS AVD OSLO MUNKEDAMSVEIEN
26.02.2025	07-01	Saksbehandling	20240404	UT	Intention to grant	CURO AS
20.02.2025	06-07	Saksbehandling	20240404	INN	P31524NO00-trykningsklar_tekst_clean 1216799	ACAPO ONSAGERS AS
20.02.2025	06-06	Saksbehandling	20240404	INN	P31524NO00-trykningsklar_tekst_annotated 1216795	ACAPO ONSAGERS AS
20.02.2025	06-05	Saksbehandling	20240404	INN	P31524NO00-norske_krav 1216797	ACAPO ONSAGERS AS
20.02.2025	06-04	Saksbehandling	20240404	INN	P31524NO00-figures-trykningsklar_clean 1216798	ACAPO ONSAGERS AS
20.02.2025	06-03	Saksbehandling	20240404	INN	P31524NO00 -Letter_to_NIPO_Feb_2025 1216796	ACAPO ONSAGERS AS
20.02.2025	06-02	Saksbehandling	20240404	INN	GPOA EVLY AS	ACAPO ONSAGERS AS
20.02.2025	06-01	Saksbehandling	20240404	INN	Korrespondanse (Hovedbrev inn)	ACAPO ONSAGERS AS
13.11.2024	02-01	Overdragelse av søknad/rettighet	2024/16326	UT	GH Forespørsel	CURO AS
11.11.2024	01-03	Overdragelse av søknad/rettighet	2024/16326	INN	powerofattorney	CURO AS
11.11.2024	01-02	Overdragelse av søknad/rettighet	2024/16326	INN	patent_assignment	CURO AS
11.11.2024	01-01	Overdragelse av søknad/rettighet	2024/16326	INN	Generell henvendelse	CURO AS
20.08.2024	05-02	Saksbehandling	20240404	UT	PT report 08:00:13
20.08.2024	05-01	Saksbehandling	20240404	UT	Substantive examination	CURO AS
15.05.2024	04-03	Saksbehandling	20240404	INN	20240404_fullmakt	CURO AS
15.05.2024	04-02	Saksbehandling	20240404	INN	20240404_assignment	CURO AS
15.05.2024	04-01	Saksbehandling	20240404	INN	Korrespondanse (Hovedbrev inn)	CURO AS
29.04.2024	03-01	Saksbehandling	20240404	UT	Formal Examination 1	CURO AS
29.04.2024	02-01	Saksbehandling	20240404	UT	Informasjon til oppfinner	Per Morten Brun
29.04.2024	01-03	Saksbehandling	20240404	INN	U4512-text	CURO AS
29.04.2024	01-02	Saksbehandling	20240404	INN	U4512-figures	CURO AS
29.04.2024	01-01	Saksbehandling	20240404	INN	Søknadsskjema Patent	CURO AS

Description, claims and drawings

Disclaimer: This text has been machine-scanned and may contain errors – please refer to "Publications" for legally binding content.

Description

The disclosed embodiments relate to a power output connector assembly suitable for use in an electric vehicle charging station.

Background

With the green shift ongoing there has been a considerable increase in electric vehicles, wherein this brings along a requirement for charging stations both at home and at work, as well as fast chargers. There exist a number of different solutions and type of chargers and charging stations. Lately, there has also been an increasing focus on safety of such chargers and charging stations, especially for home and work charging stations that are not fast chargers.

For electric vehicle charging stations intended for home use it has been common to use a standardized Type-2 connector. A Type-2 connector usually comprises seven contact points in the form of two signal connection pins and five power connection pins. The mentioned signal and power connection pins are arranged in a standardized pattern, forming upper, middle and lower rows. The two signal connection pins, which usually are of smaller size than the power connection pins, are forming the upper row, which signal connection pins are used for signalling between the electric vehicle charging station and the electric vehicle. The middle row is formed by three power connection pins and the lower row is formed by two power connection pins. The power connection pin in centre of the middle row is used for earthing while the other power connection pins of the middle row are used for power supply, optimally together with the power connection pins of the lower row, depending on the mode of operation. Typical modes of operation are Single-phase AC, Three-phase AC, Combined single-phase AC and Low-current DC, Low-current DC and Mid-current DC. By the standard Type-2 connector, the same connector can be used in different countries and connected to different electric vehicle charging stations with different properties/modes.

The electric vehicle charging stations are configured with a female part/socket enabling connection of a charging cable with a corresponding male part/plug for connecting an electric vehicle that needs charging.

Examples of state of art (Type-2) connectors are found in, among others, NO347170B1, US 2018331475 A1, DE102019119504A1, NO346763B1, all related to electric vehicle charging stations, as well as US2019047426A1 describing an interface socket.

A drawback of some of the prior art solutions is that they require intermediate connection means, such as terminal blocks, adding length of the conductive components in the power output connection, something that will result in power loss.

The use of intermediate connection means also results in that the mentioned prior art solutions involve many components and are cumbersome to assemble. Each additional connection point will also result in power loss, as well as each additional connection point will result in a weakness in the electric vehicle charging station that could results in error, at least over time.

By adding additional connection points, one also increases the size required for the power output connector in the electric vehicle charging station and thus the size of the electric vehicle charging station per se, in addition to increased costs of production.

Many of the prior art solutions further suffer from not meeting the requirements for dust and water tightness, requiring that the outer encapsulation/housing satisfies the Ingress Protection (IP) requirements, resulting in problems with internal cooling of the electric vehicle charging station.

Another disadvantage with some of the prior art solutions is the lack of a robust locking mechanism for locking a connector of a charging cable to the power output connection connector. The prior art solutions further suffer from that, if the charging cable is attempted to be removed while the locking member is still in locking position, the locking member becomes jammed and it becomes impossible to remove/disconnect the charging cable. In the prior art solutions, one further does not know the accurate position of the locking member of the locking mechanism.

There is thus a need for a power input connector assembly for an electric vehicle charging station partly or entirely solving the issues of the prior art solutions.

Summary

The disclosed embodiments provide a power output connector assembly suitable for use in an electric vehicle charging station.

Provided herein is a power output connector assembly partly or entirely solving the drawbacks and lacks of prior art solutions.

Also provided herein is a power output connector assembly with integrated resilient locking members ensuring that the power connection pins are fixed accurately at mounting/assembly.

Provided herein is a power output connector assembly meeting the requirements for creepage and clearance.

Also provided herein is a power output connector assembly having few parts and being easy to assemble.

Also provided herein is a power output connector assembly having minimal size.

Provided herein is a power output connector assembly reducing the building height of the electric vehicle charging station so that a plug of a charging cable protrudes as short as possible from the electric vehicle charging station, making it less exposed to exterior affection that may result in damages on the charging cable and/or electric vehicle charging station.

Also provided herein is a power output connector assembly having low total power loss due to few parts in the current carrying path.

Also provided herein is a power output connector assembly not requiring intermediate connections for connecting power connection pins to the circuitry (printed circuit board (PCB)) of the electric vehicle charging station.

Also provided herein is a power output connector assembly not suffering from derating, resulting in that the charging current must be reduced due to increased temperature, by comprising a dust safe sealing according to IP54 which is required to meet the requirements of OVCIII (over voltage category III).

Also provided herein is a power output connector assembly being cheaper to produce and assemble compared to prior art solutions.

Also provided herein is a power output connector assembly meeting the demands of international standards IEC 61851-1 and IEC 62196-2 defining designs of vehicle connectors.

Provided herein is a power output connector assembly provided with a robust locking mechanism for locking a plug or connector of a charging cable to the electric vehicle charging station.

Also provided herein is a power output connector assembly wherein the locking mechanism thereof enables knowledge of accurate position of a locking member thereof.

Provided herein is a power output connector assembly simplifying mass production of the power output connector and electric vehicle charging station and reducing the possibility for error in connection of power and signal connection pins to the PCB.

Also provided herein is a power output connector assembly providing a fixation mechanism for accurate mounting of power and signal connection pins enabling the soldering process of these to the PCB to be performed in a controlled manner with high precision and in a repeatable manner for mass production.

Further preferable features and advantageous details of the present invention will appear from the following description, claims and attached drawings.

The invention

A power output connector assembly suitable for use in an electric vehicle charging station is defined by the technical features of claim 1. Preferable features of the power output connector assembly are described in the dependent claims.

The main components of an electric vehicle charging station is a power input connector assembly (PICA) and a power output connector assembly (POCA), wherein the PICA is arranged to a power supply and the POCA is arranged to a plug or connector of a charging cable enabling connection to an electric vehicle for charging. The electric vehicle charging station further comprises electronics for controlling the electric vehicle charging station, such as a printed circuit board (PCB), communication means, etc. The mentioned components are arranged in a housing for attachment of the electric vehicle charging station to a support structure, such that the only accessible component is the POCA for connecting the charging cable via a socket in the housing of the electric vehicle charging station. These components are well known for a skilled person and needs no further detailed description herein.

The present invention is related to a POCA suitable for use in such an electric vehicle charging station.

The POCA according to the present invention comprises multiple power and signal connection pins. In accordance with one embodiment of the POCA according to the present invention, the power and signal connection pins are formed by a lower termination connection member and an upper connection member, respectively.

The POCA according to the present invention further comprises a base member and wherein the power and signal connection pins are arranged to an upper side of the base member via respective receptacles configured to receive and accommodate the respective power and signal connection pins.

In accordance with one embodiment of the present invention, the base member is configured to be arranged to a printed circuit board of the electric vehicle charging station and provided with holes allowing the respective termination connection member of the power and signal connection pins to extend through the base member with a gap therebetween for integration and connection with the PCB.

According to the POCA according to the present invention, the respective receptacle is provided with at least one respective resilient locking member provided with a retaining member at a distal end thereof configured for interaction with an attachment interface of the power and signal connection pins, respectively, for attachment of the respective power and signal connection pins to the respective receptacles, and thus base member.

According to the POCA according to the present invention, the POCA further comprises a plug or connector locking assembly comprising a mainly L-shaped support structure positioning a locking member in a parallel plane above the base member. The locking member is configured to be movable between a locking position, wherein the locking member protrudes from the support structure and towards the power and signal connection pins for engagement with a plug or connector of a charging cable, and a releasing position, wherein the locking member is retracted from engagement with the plug or connector of the charging cable and into the support structure.

In accordance with one embodiment of the POCA according to the present invention, the POCA comprises at least one seal member integrated in the upper connection member configured to seal against socket members of an interior encapsulation of the electric vehicle charging station. Accordingly, in the present invention, the sealing will be provided at a distance from the base member and PCB.

According to one embodiment of the POCA according to the present invention, the power and signal connection pins are silver plated. Other alternative materials are within the knowledge of a skilled person.

In accordance with one embodiment of the POCA according to the present invention, the power and signal connection pins are provided with integrated spring-based connectors. Other alternative connectors are within the knowledge of a skilled person.

In accordance with one embodiment of the POCA according to the present invention, an interior encapsulation the electric vehicle charging station is provided with a hole in a socket thereof for receiving and accommodating the plug or connector of the electric vehicle charging station, enabling the locking member to protrude into the socket and retract therefrom.

According to one embodiment of the POCA according to the present invention, the locking member is provided with at least one magnet arranged at a rear part thereof and a Hall-effect sensor arranged in vicinity of the locking member in the electric vehicle charging station, reading the magnet field, and thus accurate position of the locking member.

In accordance with one embodiment of the POCA according to the present invention, the receptacles for the power and signal connection pins are formed by mainly tubular bodies, respectively, wherein the at least one integrated resilient locking member, respectively, extends in longitudinal direction thereof, and wherein the retaining member protrudes perpendicularly inwards into the mainly tubular body.

According to one embodiment of the POCA according to the present invention, the receptacle is provided with an interior inclined annular recess extending a distance inwards from the distal end of the mainly tubular bodies, respectively.

In accordance with one embodiment of the POCA according to the present invention, the attachment interface of the power connection pin is arranged below the upper connection member and formed by a mainly tubular body provided with an inclined flange at an upper part thereof, at a distance from the upper end, facing the upper connection member, which distance corresponds to the height of the retaining member of the resilient locking member.

According to one embodiment of the POCA according to the present invention, the attachment interface of the signal connection pin is arranged below the upper connection member and is formed by a mainly truncated cone-shaped body ending in a disc-shaped base. The truncated coneshaped body is arranged upside down with the disc-shaped base facing the upper connection member and arranged at a distance below the upper connection member corresponding to the height of the retaining member of the resilient locking member.

The POCA according to the present invention provides an alternative configuration of a Type-2 connector, meeting the requirements of the international standards IEC 61851-1 and IEC 62196-2 for electric vehicle connectors.

The POCA according to the present invention, by the integrated resilient locking members, ensures that the power connection pins are fixed accurately at mounting, making the assembly easier as well as enabling accurate integration and connection and soldering to the PCB.

The POCA according to the present invention meets the requirement for creepage and clearance in an electric vehicle charging station by ensuring that the physical positioning of and distance between the power pins and soldering points on the PCB are according to the requirements.

By the present invention is further provided a POCA having few parts, being easy to assemble and having minimal size.

Due to POCA has few parts in the current carrying path, as well as do not require intermediate connections for connecting power connection pins to the circuitry (PCB) of the electric vehicle charging station, the total power loss will be low and lower than prior art solutions.

Due to the POCA according to the present invention comprises sealing means sealing against the interior encapsulation of the electric vehicle charging station, a dust safe sealing according to IP54 meeting the requirements of OVCIII (over voltage category III) is achieved. By this is achieved that an electric vehicle charging station with a POCA according to the present invention will not suffer from derating, resulting in that the charging current do not need to be reduced due to increased temperature, as is the case for the prior art solutions. This also enables the electric vehicle charging station to include ventilating devices.

Also provided herein is a POCA for an electric vehicle charging station that is cheaper to produce and assemble, compared to prior art solutions.

By the POCA according to the present invention is provided a robust locking mechanism for locking a connector of a charging cable to the electric vehicle charging station, which in addition enables knowledge of accurate position of a locking member thereof. The locking mechanism according to the present invention is based on a solution where an electric motor, directly or via one or more gear units, is arranged to a locking member and in this manner increases the force/transmission between the electric motor and locking member substantially, compared to the prior art solutions. The locking mechanism according to the present invention is further robust and will sustain countless locking and opening cycles. The locking mechanism according to the present invention further comprises an integrated contactless position reader enabling that one at all time will be able to determine if the locking member is in locked or unlocked position with 100 % certainty.

Further preferable features and advantageous details of the present invention will appear from the following description, claims and attached drawings.

Example

The present invention will below be described in further detail with reference to the attached drawings, where:

Fig.1a is a principle drawing of a power output connector assembly according to one embodiment of the present invention, seen inclined from a front side,

Fig.1b is a principle drawing of the power output connector assembly of Fig.1a, seen inclined from a rear side,

Fig.1c is a further principle drawing of the power output connector assembly in Fig. 1a-b with power and signal connection pins removed,

Fig.1d is a principle drawing of a power connection pin according to the present invention,

Fig.1e is a principle drawing of a signal connection pin according to the present invention,

Fig.1f-g are cross-sectional views showing the interaction between power and signal connection pins and receptacles,

Fig.2a-b are principle drawings of the power output connector assembly of Fig.1a-b arranged to a printed circuit board of an electric vehicle charging station, seen inclined from a front side and inclined from a rear side, respectively,

Fig.3a-c are principle drawings of an electric vehicle charging station provided with a power output power connector assembly according to the present invention, and

Fig.3d-e are principle drawings of the electric vehicle charging station and power output power connector assembly showing further details.

Reference is now made to Fig. 1a-g showing principle drawings of a power output connector assembly (POCA) 100 according to the present invention, which POCA 100 is suitable for use in an electric vehicle charging station 200, see Fig.3a-e. The POCA 100 according to the present invention comprises as main components a base member 110, power connection pins 130a-e, signal connection pins 140a-b and a plug and connector locking assembly 150. Reference is also made to Figures 2a-b showing principle drawings of the power output connector assembly 100 of Fig.1a-b arranged to a printed circuit board (PCB) 300 of an electric vehicle charging station 200.

The mentioned base member 110 is of a mainly planar shape and is configured to be arranged on the mentioned PCB 300 by a planar rear side 111 thereof. The base member 110 further comprises multiple receptacles 120a-b protruding upwards from an upper side 112 of the base member 110 configured to receive and accommodate, as well as fixate the mentioned power 130a-e and signal 140a-b connection pins in an accurate manner during assembly. In accordance with a preferred embodiment of the present invention, the mentioned receptacles 120a-b are arranged in a pattern according to the standard for Type-2 connectors, further described below.

The base member 110 is further provided with through holes 113 aligned with each of the receptacles 120a-b configured to receive and accommodate a termination connecting member 131 of the power connection pins 130a-e and termination connecting member 141 of the signal connection pins 130a-b. In accordance with the present invention it is a gap between the through hole 113 and at least the power connection pins 130a-e. In a further embodiment it is also a gap between the through hole 113 and the signal connection pin 140a-b.

In accordance with one embodiment of the POCA 100 according to the present invention, the respective through holes 113 of the base member 110 is at lower side configured with a respective recess 114 enclosing the mentioned through holes 113. The mentioned respective recesses 114 will ensure that the tin solder will flow out on both sides to achieve the best possible connection between the PCB 300 and the power 130a-e and signal 140a-b connection pins.

As shown in detail in Fig. 1d, the power connection pin 130a-e is formed by a lower termination connection member 131 for connection to the PCB 300 and an upper connection member 132 configured to receive and accommodate a power connection pin (not shown) of a plug or connector of a charging cable. As shown in detail in Fig.1e, the signal connection pin 140a-b is formed by a lower termination connection member 141 for connection to the PCB 300 and an upper connection member 142 configured to receive and accommodate a signal connection pin (not shown) of a plug or connector of a charging cable.

The respective upper connection member 132, 142 is of a larger exterior circumference than the respective termination connection member 131, 141, which will be utilized in connection with arrangement to the respective receptacles 120a-b, further described below.

The mentioned power connection pin 130a-e is further provided with an attachment interface 134 configured for engagement with the respective receptacles 120a and the mentioned signal connection pin 140a-b is provided with an attachment interface 144 for engagement with the respective receptacle 120b.

In accordance with one embodiment of the POCA 100 according to the present invention, as shown in detail in Fig.1c, the receptacle 120a-b are formed by mainly tubular bodies 121a-b, respectively, with at least one integrated resilient locking member 122a-b, respectively, extending in longitudinal direction thereof. In accordance with one embodiment of the present invention, the integrated resilient locking member 122a-b, respectively, is provided with a retaining member 123a-b, respectively, arranged at the distal (free) end thereof, protruding perpendicularly inwards into the respective mainly tubular body 121a-b.

According to a further embodiment of the POCA 100 according to the present invention, the mentioned receptacle 120a-b is further provided with an interior annular inclined recess 124a-b extending a distance inwards from the distal (free/open) end of the mainly tubular bodies 121a-b, respectively.

According to one embodiment of the POCA 100 according to the present invention, the mentioned base member 110 and receptacles 120a-b are moulded as one part or 3D-printed as one part, including the mainly tubular bodies 121a-b, at least one integrated resilient locking member 122ab and retaining member 123a-b. In accordance with a further embodiment of the POCA 100 according to the present invention, a support structure 151, further described below, for an integrated plug or connector locking assembly 150 of the POCA 100 is also included in the moulded or 3D-printed one-part.

The attachment interface 134 of the power connection pin 130a-e is arranged below the upper connection member 132 and is formed by a mainly tubular body 135 provided with an inclined flange 136 at an upper part thereof, at a distance from the upper end facing the upper connection member 132, which distance corresponds to the height of the mentioned retaining member 123a.

The attachment interface 134 is according to the present invention arranged to the termination connection member 131 or integrated as a part of the connection member 132. The mentioned tubular body 135 and inclined flange 136 are configured to fit with the mentioned tubular body 121a of the receptacle 120a, such that when the power connection pin 130a-e is inserted therein, the mainly tubular body 135 is positioned with a gap to the bottom of the receptacle 120a, and wherein the lower end of the upper connection member 132 rests on the upper/distal end of the receptacle 120a. The mentioned inclined flange 136 and interior annular inclined recess 124a serves to position/centre the termination connection member 131 in the through hole 113 of the base member 110. The inclined flange 136 will further guide the resilient locking member 122a outwards during insertion in the receptacle 120a, as well as ensure that the resilient locking member 122a will not get jammed during insertion of the power connection pin 130a-e in the receptacles 120a.

The mentioned termination connection member 131 extends a distance below the base member 110 and PCB 300, as shown in Fig. 2a-b, such that the distal lower ends thereof protrude through the PCB 300 and are at the lower or upper side of the PCB 300 connected to corresponding connectors (not shown) of the PCB 300, e.g., by press-fit or soldering or a combination of these techniques.

The attachment interface 144 of the signal connection pin 140a-b is arranged below the upper connection member 141 and is formed by a mainly truncated cone-shaped body 145 ending in a disc-shaped base 146, wherein truncated cone-shaped body 145 is arranged upside down with the disc-shaped base 146 facing the upper connection member 142 and arranged a distance below the upper connection member 142 corresponding to the height of the mentioned retaining member 123b. The mentioned truncated cone-shaped body 145 and disc-shaped base 146 are configured to fit with the mentioned tubular body 121b of the receptacle 120b, such that when the signal connection pin 140a-b is inserted therein, the lower end of the upper connection member 142 rests on the upper/distal end of the receptacle 120b. The mentioned truncated cone-shaped body 145 and interior annular inclined recess 124b serves to position/centre the termination connection member 141 in the through hole 113 of the base member 110. The truncated cone-shaped body 145 will further guide the resilient locking member 122b outwards during insertion in the receptacle 120b, as well as ensure that the resilient locking member 122b will not get jammed during insertion of the signal connection pin 140a-e in the receptacles 120b. The mentioned termination connection members 141 extends a distance below the base member 110 and PCB 300, as shown in Fig.2a-b, such that the distal lower ends thereof protrude through the PCB 300 and are at the lower or upper side of the PCB 300 connected to corresponding connectors (not shown) of the PCB 300, e.g., by press-fit or soldering or a combination of these techniques.

Accordingly, when the power 130a-e and signal 140a-b connection pins are inserted into the respective receptacle 120a-b by an axial movement, the resilient locking member 122a-b will be forced outwards by the inclined surfaces of the flange 136 and truncated cone-shaped body 145 allowing insertion therein. When the power 130a-e and signal 140a-b connection pins are completely inserted into the receptacles 120a-b, the flange 136 and disc-shaped base 146 have passed the retaining member 123a-b and the resilient locking member 122a-b returns to the original state and retains the respective power 130a-e and signal 140a-b connection pins in the receptacle 120a-b by axially locking them in place. In this manner, the power 130a-e and signal 140a-b connection pins are accurately fixated during the mounting of POCA 100 in the electric vehicle charging station, and ensures that the termination connection members 131, 141 in an accurate manner can be connected to the PCB 300 by press-fit or soldering or a combination of these techniques.

According to one embodiment of the present invention, the mentioned power 130a-e and signal 140a-b connection pins are silver plated. Other materials will be within the knowledge of a skilled person.

In accordance with a further embodiment of the present invention, the upper connection members 132, 142 are further provided with integrated spring-based connectors (not shown) for connection with the connection pins of the plug or connector of the charging cable. Other connectors will be within the knowledge of a skilled person.

According to one embodiment of the POCA 100 according to the present invention, the mentioned base member 110 is attached/secured to the PCB 300 by attachment means (not shown), such as a screw, extending through an attachment hole 301 (see Fig.2b) in the PCB 300 and into a threaded hole 116 (see Fig.1b-c, 2a) in the base member 110 of the POCA 100. In an alternative embodiment the PCB 300 is provided with a threaded attachment hole 301 and the hole 116 in the base member 110 is a through hole. In this manner the POCA 100 is secured/fixated as one unit to the PCB 300 so that the POCA 100 stays stable during the soldering process of the power 130a-e and signal 140a-b connection pins to the PCB 300.

The mentioned base member 110 and thus POCA 100 will be retained between the PCB 300 and an interior encapsulation 250, see Fig.3b-e, further described below.

Accordingly, the power 130a-e and signal 140a-b connection pins provide a total of seven contact points, wherein the two connection pins 140a-b for signalling are smaller than the connection pins 130a-e for power. According to the Type-2 standard, the power 130a-e and signal 140a-b are arranged in a standard patter forming three rows of connection pins, i.e. upper, middle and lower rows. The upper row is formed by the two signal connection pins 140a-b, where signal connection pin 140a is the Control pilot (CP) (post-insertion signalling) and signal connection pin 140b is the Proximity pilot (PP) (pre-insertion signalling). The middle row is formed by the power connection pins 130a-c, wherein power connection pin 130a is N-Neutral, power connection pin 130b is PE-Protective earth and power connection pin 130c is L1-Line 1. In the lower row, the power connection pin 130d is L3-Line 3 and power connection pin 130e is L2-Line 2. Other configurations are well known for a skilled person. The power connection pins 130a-e are used for power supply that vary depending on the mode of operation. The mentioned power 130a-e and signal 140a-b connection pins thus form a female connector/socket for connection with a corresponding plug/male connector of a charging cable.

Communication takes place over the CP/PP signalling pins 140a-b between the electric vehicle charging station 200, cable, and vehicle to ensure that the highest common denominator of voltage and current is selected.

In accordance with a further embodiment of the present invention, the POCA 100 further comprises an integrated plug or connector locking assembly 150 configured to detachably secure a plug or connector of a charging cable to the POCA 100 and thus the electric vehicle charging station 200. In accordance with one embodiment of the present invention, as shown in Fig. 1a-c, 2a, 3d-e, the locking assembly 150 is formed by a support structure 151, a locking member 152 and controllable drive unit 153.

The support structure 151 is according to the shown embodiment mainly L-shaped, wherein the L-shaped support structure 151 protrudes perpendicularly upwards from the upper side 112 of the base member 110 by the shortest leg 151a thereof, and wherein the longest leg 151b of the support structure 151 is positioned in a parallel plane to the upper side 112 of the base member 110. The support structure 151 is further configured for receiving and accommodating the locking member 152 and allowing the locking member 152 to move in axial direction of the longest leg 151b under affection of the drive unit 153, i.e. in a parallel plane to the base member 110.

In accordance with one embodiment of the locking assembly 150 according to the present invention, the support structure 151 is provided with a guiding and retaining track 154 extending in axial direction of the longest leg 151b and wherein the locking member 152 is provided with a corresponding recess 155 extending in axial direction, at lower side thereof. In this manner the locking member 152 is configured to move in axial direction of the support structure 151, between a locking position, wherein the locking member 152 is protruding from the support structure 151 and towards the power 130a-e and signal 140a-b connection pins and into engagement with a locking recess (not shown) of a plug or connector of a charging cable, and a releasing position, wherein the locking member 152 is retracted from engagement with the plug or connector of the charging cable and into the support structure 151.

In the shown embodiment, the controllable drive unit 153, such as an electric motor, is arranged to upper side of the support structure 151 and extends towards the locking member 152 by a drive shaft 156 positioning a cogwheel 157, arranged to distal end of the drive shaft 156, in engagement with a corresponding tooth rack 158 of the locking member 152. The controllable drive unit 153 may further be provided with one or more gear units 159. In the shown embodiment the controllable drive unit 153 is an electric motor, in the form of a spur gear motor.

To find an accurate position of the locking member 152 at all time, the locking member 152 is provided with at least one magnet 160, such as at least one permanent magnet, arranged at rear end thereof, by a support member 161, and a Hall-effect sensor 162 (Fig.3e) arranged in vicinity of the locking member 152 in the electric vehicle charging station 200. By reading the strength of the magnet field by means of the Hall-effect sensor 162, the accurate position of the locking member 152 can be decided as the position will be related to the strength of the measured magnet field. This in contrast to prior art, where one only has two states in the form of locked or unlocked, and no information therebetween. It is only safe to start a charging operation when one is sure that the plug or connector of the charging cable is properly connected to the POCA 100/socket 240, something that only is achieved by having the accurate position of the locking member 152.

Reference is no made to Fig. 3a-e showing examples of an electric vehicle charging station 200 suitable for making use of the POCA 100 according to the present invention, as well as details of further integration between the POCA 100 and parts of the electric vehicle charging station 200. The shown electric vehicle charging station 200 comprises a housing formed by a front part 210 and rear part 220, detachable from each other. The electric vehicle charging station 200 further comprises the POCA 100 according to the present invention arranged to one (upper) side of the PCB 300 that is arranged to the rear part 220 at the other (lower) side, as shown in Fig.3e. The electric vehicle charging station 200 further comprises a power input connector assembly (PICA) 230 arranged to the rear part 220 as shown in Fig. 3b-c, wherein the PICA 230 is arranged to a power supply (not shown).

The electric vehicle charging station 200 further comprises a socket 240, shown with a lid 241 in Fig. 3a-b, which socket 240 enables connection of a plug or connector (not shown) of a charging cable (not shown) to the electric vehicle charging station 200. The electric vehicle charging station 200 further comprises electronics for controlling the electric vehicle charging station 200, such as a printed circuit board (PCB) 300 as discussed above, communication means (not shown), etc., and wherein the components are arranged in the housing formed by the parts 210, 220 for attachment of the electric vehicle charging station 200 to a support structure (not shown), such that the only accessible component is the socket 240 for connecting the charging cable.

As can be seen from Fig.3b-e, the electric vehicle charging station 200 further comprises an interior encapsulation 250 providing a dust-proof sealed interior environment for components of the electric vehicle charging station 200.

The mentioned socket 240 is an integrated part of the interior encapsulation 250 and the socket 240 is configured to enclose each of the mentioned power 130a-e and signal 140 connection pins by comprising corresponding socket members 251a-b provided with respective holes 252a-b enabling insertion of corresponding connection pins of a plug or connector of a charging cable, as well as providing a receiving compartment 253 enclosing the socket members 251a-b designed to receive and accommodate the plug or connector of the charging cable.

Reference in addition made to Fig.1a, 1d-g, 2a-b and 3e. As mentioned, the socket members 251ab are configured to enclose the respective power 130a-e and signal 140a-b connection pins. To ensure that the interior encapsulation 250 provides a dust-proof sealed interior environment, the power 130a-e and signal 140a-b are provided with at least one seal member 137, 147, respectively, such as an O-ring, arranged in a circumferential recess 138, 148, respectively, arranged in the lower part of the respective upper connection member 132, 142, above the mentioned receptacles 120ab to ensure that a sealing is achieved between the interior encapsulation 250 and the respective power 130a-e and signal 140a-b connection member. In accordance with the present invention the sealing is thus provided at a distance above the base member 110 and PCB 300. The mentioned seal member 137, 147 will in the present invention provide both dust and water intrusion/penetration into the electric vehicle charging station 200.

Further, as Fig.3e shows, the mentioned base member 110 is retained between the PCB 300 and the interior encapsulation 250.

As mentioned above, the POCA 100 according to the present invention comprises a locking assembly 150 for detachable securing the plug or connector of a charging cable to the electric vehicle charging station 200, i.e. the socket 240 and the POCA 100 for safe charging. As shown in Fig. 3d, the mentioned socket 240, in the receiving compartment 253, is provided with a through hole 254 aligned with the locking member 152 of the locking assembly 150, allowing the locking member 152 to protrude into the receiving compartment 253 and into engagement with the plug or connector of the charging cable for securing the charging cable to the electric vehicle charging station 200 and the POCA 100, as well as for allowing the locking member 152 to retract from engagement therewith and into the support structure 151 allowing the plug or connector of the charging cable to be removed from connection with the electric vehicle charging station 200.

In accordance with a further embodiment of the POCA 100 according to the present invention, a sealant, such as Vaseline, and/or mechanical sliding seal (not shown) is arranged for sealing around the locking member 152 in connection with the through hole 254 to prevent intrusion/penetration of dust and/or water. Due to this through hole 254 being designed at the uppermost position in the socket 240, when the electric vehicle charging station 200 is fixed to a vertical structure, the risk of water or dust entering is limited.

Reference is now made to Fig. 3c showing a further embodiment the interior encapsulation 250, wherein the interior encapsulation 250 is provided with at least one touch switch or button 260, such as capacitance, resistance or piezo, integrated to maintain the dust and water tightness of the interior encapsulation 250. In the shown embodiment a test of the RCD ground fault protection of the electric vehicle charging station can be activated by pressing the mentioned switch or button 260 a pre-set time, such as e.g., but not limited to, 3-5 seconds. The mentioned interior encapsulation 250 in accordance with a further embodiment comprises a display 261, such as an LCD, LED or similar, integrated to maintain the dust and water tightness of the interior encapsulation 250 and configured to indicate that the test of the RCD ground fault protection is being performed.

In accordance with the present invention, the interior encapsulation 250 is partly or entirely transparent. The interior encapsulation 250 is preferably at least transparent in areas with displays 310 or indicators of the PCB 300 are located.

According to a further embodiment of the electric vehicle charging station 200 according to the present invention, the same touch switch or button 260 is configured for setting the fuse size of the electric vehicle charging station 200, wherein the fuse size is shown on a display 310 of the PCB 300, viewable through the transparent, at least parts thereof, interior encapsulation 250. In an alternative embodiment, the interior encapsulation 250 is provided with a separate touch switch or button 260 for setting the fuse size.

The mentioned fuse size will typically be set by pushing the touch switch or button 260 enabling toggling between pre-set fuse sizes. In this manner, the electric vehicle charging station 200 can be set up without the use of applications on a phone or other communication means, as well as without danger of breaking the barrier of the interior encapsulation 250.

Claims

1. Power output connector assembly (100) suitable for use in an electric vehicle charging station (200), the power input connector assembly (100) comprising power (130a-e) and signal (140a-b) connection pins formed by a lower termination connection member (131, 141) and an upper connection member (132, 142), respectively, wherein the power (130a-e) and signal (140a-b) connection pins are arranged to an upper side (112) of a base member (110) via respective receptacles (120a-b) configured to receive and accommodate the respective power (130a-e) and signal (140a-b) connection pins, wherein the base member (110) is configured to be arranged to a printed circuit board (300) of the electric vehicle charging station (200) and provided with holes (113) allowing the respective termination connection member (131, 141) to extend through the base member (100) with a gap therebetween for integration and connection with the printed circuit board (300), characterized in that

- the respective receptacle (120a-b) is provided with at least one respective resilient locking member (122a-b) provided with a retaining member (123a-b) at a distal end thereof configured for interaction with an attachment interface (134, 144) of the power (130a-e) and signal (140a-b) connection pins, respectively, for attachment of the respective power (130a-e) and signal (140a-b) connection pins to the respective receptacles (120a-b), and

- the power output connector assembly (100) comprises a plug or connector locking assembly (150) comprising a mainly L-shaped support structure (151) positioning a locking member (152) in a parallel plane above the base member (110), wherein the locking member (152) is movable between a locking position, wherein the locking member (152) protrudes from the support structure (151) and towards the power (130a-e) and signal (140a-b) connection pins for engagement with a plug or connector of a charging cable, and a releasing position, wherein the locking member (152) is retracted from engagement with the plug or connector of the charging cable and into the support structure (151).

2. Power output connector assembly (100) according to claim 1, wherein at least one seal member (137) is integrated in the upper connection member (131, 141) configured for sealing against socket members (251a-b) of an interior encapsulation (250) of the electric vehicle charging station (200).

3. Power output connector assembly (100) according to claim 1, wherein the power (130a-e) and signal (140a-b) connection pins are silver plated.

4. Power output connector assembly (100) according to claim 1, wherein the power (130a-e) and signal (140a-b) connection pins are provided with integrated spring-based connectors.

5. Power output connector assembly (100) according to claim 1, wherein an interior encapsulation (250) of the electric vehicle charging station (200) is provided with a hole (254) in a socket (240) thereof, enabling the locking member (152) to protrude into the socket (240) and retract therefrom.

6. Power output connector assembly (100) according to claim 1, wherein the locking member (152) is provided with at least one magnet (160) arranged at a rear part thereof, and a Hall-effect sensor (161) arranged in vicinity of the locking member (152) in the electric vehicle charging station (200), reading the magnet field, and thus accurate position of the locking member (152).

7. Power output connector assembly (100) according to claim 1, wherein the receptacles (120a-b) are formed by mainly tubular bodies (121a-b), respectively, wherein the at least one integrated resilient locking member (122a-b), respectively, extends in longitudinal direction thereof, and wherein the retaining member (123a-b) protrudes perpendicularly inwards into the mainly tubular body (121a-b).

8. Power output connector assembly (100) according to claim 7, wherein the receptacle (120a-b) is provided with an interior annular inclined recess (124a-b) extending a distance inwards from the distal end of the mainly tubular bodies (121a-b), respectively.

9. Power output connector assembly (100) according to claim 1 and 8, wherein the attachment interface (134) of the power connection pin (130a-e) is arranged below the upper connection member (132) and formed by a mainly tubular body (135) provided with an inclined flange (136) at an upper part thereof, at a distance from the upper end, facing the upper connection member (132), which distance corresponds to the height of the retaining member (123a).

10. Power output connector assembly (100) according to claim 1, wherein the attachment interface (144) of the signal connection pin (140a-e) is arranged below the upper connection member (141) and is formed by a mainly truncated cone-shaped body (145) ending in a disc-shaped base (146), wherein the truncated cone-shaped body (145) is arranged upside down with the disc-shaped base (146) facing the upper connection member (142) and arranged at a distance below the upper connection member (142) corresponding to the height of the retaining member (123b).

11. Power output connector assembly (100) according to any preceding claim, wherein the power output connector assembly (100) is a Type-2 connector.

PATENTKRAV

1. Energi-output-koblingssammenstilling (100) egnet for bruk i en ladestasjon (200) for elektriske biler, hvori energi-output-koblingssammenstilling (100) omfatter energi- (130a-e) og signal- (140a-b) koblingspinner dannet av et nedre termineringskoblingsmedlem (131, 141) og henholdsvis et øvre koblingsmedlem (132, 142), hvori energi- (130a-e) og signal- (140a-b) koblingspinnene er innrettet til en øvre side (112) av et fundamentmedlem (110) via respektive beholdere (120ab) konfigurert for mottak og innretning av de respektive energi- (130a-e) og signal-(140a-b) koblingspinnene, hvori fundamentmedlemmet (110) er konfigurert til å innrettes til et kretskort (300) til ladestasjonen (200) for elektriske biler og forsynt med hull (113) hvilke tillater de respektive termineringskoblingsmedlemmene (131, 141) å strekke seg gjennom fundamentmedlemmet (100) med et mellomrom for integrasjon og kobling med kretskortet (300), karakterisert ved at

- den respektive beholderen (120a-b) er forsynt med minst et respektivt, fleksibelt låsemedlem (122a-b) forsynt med et holdemedlem (123a-b) ved en distal ende derav konfigurert for samhandling med et festegrensesnitt (134, 144) av respektive energi-(130a-e) og signal- (140a-b) koblingspinnene, for festing av de respektive energi-(130a-e) og signal- (140a-b) koblingspinnene til de respektive beholderne (120a-b), og

- energi-output-koblingssammenstillingen (100) omfatter en plugg- eller koblingslåsesammenstilling (150) hvilken omfatter en hovedsakelig L-formet støttestruktur (151) hvilken posisjonerer et låsemedlem (152) i et parallelt plan over fundamentmedlemmet (110), hvori låsemedlemmet (152) er bevegelig mellom en låseposisjon, hvori låsemedlemmet (152) rager frem fra støttestrukturen (151) og mot energi- (130a-e) og signal- (140a-b) koblingspinnene for inngripen med en plugg eller kobling av en ladekabel, og en frigjøringsposisjon, hvori låsemedlemmet (152) er trukket tilbake fra inngripen med pluggen eller koblingen til ladekabelen og inn i støttestrukturen (151).

2. Energi-output-koblingssammenstilling (100) i samsvar med krav 1, hvori minst et tetningsmedlem (137) er integrert i det øvre koblingsmedlemmet (131, 141) konfigurert for tetning mot sokkelmedlemmer (251a-b) til en indre innkapsling (250) av ladestasjonen (200) for elektriske biler.

3. Energi-output-koblingssammenstilling (100) i samsvar med krav 1, hvori energi-(130a-e) og signal- (140a-b) koblingspinnene er forsølvet.

4. Energi-output-koblingssammenstilling (100) i samsvar med krav 1, hvori energi-(130a-e) og signal- (140a-b) koblingspinnene er forsynt med integrerte fjærbaserte koblinger.

5. Energi-output-koblingssammenstilling (100) i samsvar med krav 1, hvori en indre innkapsling (250) av ladestasjonen (200) for elektriske biler er forsynt med et hull (254) i en sokkel (240) derav, hvilken gjør det mulig for låsemedlemmet (152) å rage inn i sokkelen (240) og trekke seg tilbake derfra.

6. Energi-output-koblingssammenstilling (100) i samsvar med krav 1, hvori låsemedlemmet (152) er forsynt med minst en magnet (160) innrettet ved en bakre del derav, og en Halleffektsensor (161) innrettet i nærheten av låsemedlemmet (152) i ladestasjonen (200) for elektriske biler, hvilken leser magnetfeltet, og dermed nøyaktig posisjon til låsemedlemmet (152).

7. Energi-output-koblingssammenstilling (100) i samsvar med krav 1, hvori beholderne (120a-b) er dannet av respektive hovedsakelig rørformede kropper (121a-b), hvori det respektive minst ene integrerte, fleksible låsemedlemmet (122ab), strekker seg i lengderetning derav, og hvori holdemedlemmet (123a-b) rager vinkelrett innover inn i den rørformede kroppen (121a-b).

8. Energi-output-koblingssammenstilling (100) i samsvar med krav 7, hvori beholderen (120a-b) er forsynt med en indre ringformet fordypning (124a-b) hvilken strekker seg en avstand innover fra den distale enden av de respektive hovedsakelig rørformede kroppene (121a-b).

9. Energi-output-koblingssammenstilling (100) i samsvar med krav 1 og 8, hvori festegrensesnittet (134) til energikoblingspinnen (130a-e) er innrettet nedenfor det øvre koblingsmedlemmet (132) og dannet av en hovedsakelig rørformet kropp (135) forsynt med en skråstilt flens (136) ved en øvre del derav, ved en avstand fra den øvre enden, vendt mot det øvre koblingsmedlemmet (132), hvilken avstand samsvarer med høyden til holdemedlemmet (123a).

10. Energi-output-koblingssammenstilling (100) i samsvar med krav 1, hvori festegrensesnittet (144) til signalkoblingspinnen (140a-e) er innrettet under det øvre koblingsmedlemmet (141) og er dannet av en hovedsakelig avkortet, kjegleformet kropp (145) hvilken ender i en skiveformet grunndel (146), hvori den avkortede, kjegleformede kroppen (145) er innrettet opp-ned med den skiveformede grunndelen (146) vendt mot det øvre koblingsmedlemmet (142) og innrettet ved en avstand under det øvre koblingsmedlemmet (142) samsvarende høyden til holdemedlemmet (123b).

11. Energi-output-koblingssammenstilling (100) i samsvar med et av de foregående krav, hvori energi-output-koblingssammenstillingen (100) er en Type-2 kobling.

Drawings

Priority

No priority

Patent classes

IPC classes

B60L 53/16

H01R 13/66

H01R 13/52

H01R 13/428

CPC classes

B60L 53/16

H01R 13/6683

H01R 13/5202

H01R 13/428

Citations

WO 2022167604 A1 (A1)

US 2018331475 A1 (A1)

DE 202017105818 U1 (U1)

EP 4059767 A1 (A1)

Applicants, owners and inventors

Owners

EVLY AS

Østre Strandvei 52

3482 TOFTE

NO (ASKER Municipality, Akershus county)

Org. number: 932966689

Inventors

Per Morten Brun

Østre Strandvei 52

3482 TOFTE

NO (ASKER Municipality, Akershus county)

Agent

ACAPO ONSAGERS AS

Edvard Griegs vei 1

5059 BERGEN

NO (BERGEN Municipality, Vestland county)

Org. number: 932214636

Reference: P31524NO00

Status history

Payment history

Oppositions and appeals

No oppositions or appeals

Administrative limitation

No administrative limitation

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No liens or licenses registered

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Only events from 2024.03.04 and onwards are shown.