U.S. patent application number 12/397852 was filed with the patent office on 2010-09-09 for charge receptacle for plug-in electric vehicle.
This patent application is currently assigned to GM GLOBAL TECHNOLOGY OPERATIONS, INC.. Invention is credited to CRAIG R. MARKYVECH.
Application Number | 20100227505 12/397852 |
Document ID | / |
Family ID | 42678658 |
Filed Date | 2010-09-09 |
United States Patent
Application |
20100227505 |
Kind Code |
A1 |
MARKYVECH; CRAIG R. |
September 9, 2010 |
CHARGE RECEPTACLE FOR PLUG-IN ELECTRIC VEHICLE
Abstract
A vehicular electrical system includes an electrical energy
storage device, a charge receptacle shaped to mate with a charge
plug, at least one fuse connected to the charge receptacle, and a
plurality of conductors electrically interconnecting the electrical
energy storage device and the at least one fuse. Substantially all
of the plurality of conductors are electrically connected between
the electrical storage device and the at least one fuse.
Inventors: |
MARKYVECH; CRAIG R.;
(ROMULUS, MI) |
Correspondence
Address: |
INGRASSIA FISHER & LORENZ, P.C. (GM)
7010 E. COCHISE ROAD
SCOTTSDALE
AZ
85253
US
|
Assignee: |
GM GLOBAL TECHNOLOGY OPERATIONS,
INC.
DETROIT
MI
|
Family ID: |
42678658 |
Appl. No.: |
12/397852 |
Filed: |
March 4, 2009 |
Current U.S.
Class: |
439/620.29 |
Current CPC
Class: |
Y02T 90/40 20130101;
Y02T 90/12 20130101; H01R 2201/26 20130101; Y02T 10/72 20130101;
B60L 53/16 20190201; H01R 13/68 20130101; Y02T 10/7072 20130101;
Y02T 90/14 20130101; Y02T 10/70 20130101; B60L 58/40 20190201; B60L
50/16 20190201; B60L 2210/40 20130101 |
Class at
Publication: |
439/620.29 |
International
Class: |
H01R 13/68 20060101
H01R013/68 |
Claims
1. A vehicular electrical system comprising: an electrical energy
storage device; a charge receptacle shaped to mate with a charge
plug; at least one fuse connected to the charge receptacle; and a
plurality of conductors electrically interconnecting the electrical
energy storage device, the charge receptacle, and the at least one
fuse, wherein substantially all of the plurality of conductors are
electrically connected between the electrical storage device and
the at least one fuse.
2. The vehicular electrical system of claim 1, wherein the
plurality of conductors comprises a plurality of conductive members
connected to the charge receptacle and a plurality of conductive
wires, and all of the plurality of conductive wires are
electrically connected between the electrical energy storage device
and the at least one fuse.
3. The vehicular electrical system of claim 2, wherein the
plurality of conductive members comprises a plurality of conductive
pins electrically connected to a first side of the at least one
fuse and the plurality of conductive wires are electrically
connected to a second side of the at least one fuse.
4. The vehicular electrical system of claim 3, further comprising a
wire harness at least partially housing at least some of the
plurality of conductive wires.
5. The vehicular electrical system of claim 4, wherein the charge
receptacle comprises first and second opposing sides, a first
engagement formation on the first side thereof and shaped to mate
with the charge plug, and a second engagement formation on the
second side thereof and shaped to mate with the wire harness.
6. The vehicular electrical system of claim 5, wherein the
plurality of conductors further comprises a second plurality of
conductive members connected to the charge receptacle, wherein the
second plurality of conductive members and the wire harness are
arranged such that when the wire harness is mated with the second
engagement formation, the second plurality of conductive members
electrically interconnect the at least one fuse and the plurality
of conductive wires.
7. The vehicular electrical system of claim 1, wherein the at least
one fuse is removably connected to the charge receptacle in a
substantially fixed position.
8. The vehicular electrical system of claim 7, wherein the at least
one fuse is at least partially housed within the charge
receptacle.
9. The vehicular electrical system of claim 8, wherein the charge
receptacle is configured such that the at least one fuse is
manually removable from the charge receptacle only when the charge
plug is not mated with the charge receptacle.
10. The vehicular electrical system of claim 9, wherein the charge
receptacle is shaped to mate with a Society of Automotive Engineers
(SAE) standard 1772 compliant charge plug.
11. (canceled)
12. (canceled)
13. (canceled)
14. (canceled)
15. (canceled)
16. An electric vehicular charging system comprising: a battery
charger comprising a power supply and a charge plug electrically
connected to the power supply; and a charge receptacle having an
engagement formation shaped to mate with the charge plug; at least
one fuse removably housed within the charge receptacle, wherein the
charge plug and the charge receptacle are configured such that the
at least one fuse is not manually removable from the charge
receptacle when the charge plug is mated with the engagement
formation; a battery; and a plurality of conductors electrically
interconnecting the battery, the at least one fuse, and the
engagement formation, wherein substantially all of the plurality of
conductors are electrically connected between the battery and the
at least one fuse.
17. The electric vehicle charge system of claim 16, wherein the
charge plug is a Society of Automotive Engineers (SAE) standard
1772 compliant charge plug.
18. (canceled)
19. The electric vehicle charge system of claim 16, wherein the
plurality of conductors comprises a plurality of conductive members
connected to the charge receptacle and electrically interconnecting
the engagement formation and the at least one fuse and a plurality
of conductive wires, all of the plurality of conductive wires being
electrically connected between the battery and the at least one
fuse.
20. The electrical vehicle charge system of claim 19, wherein the
plurality of conductive members comprises a plurality of conductive
pins that electrically interconnect the charge plug and the at
least one fuse when the charge plug is mated with the engagement
formation.
21. A vehicular electrical system comprising: an electrical energy
storage device; a charge receptacle shaped to mate with a charge
plug; at least one fuse removably connected to the charge
receptacle in a substantially fixed position and at least partially
housed within the charge receptacle; and a plurality of conductors
electrically interconnecting the electrical energy storage device
and the at least one fuse, wherein substantially all of the
plurality of conductors are electrically connected between the
electrical storage device and the at least one fuse, wherein the
charge receptacle is configured such that the at least one fuse is
manually removable from the charge receptacle only when the charge
plug is not mated with the charge receptacle.
22. The vehicular electrical system of claim 21, wherein the charge
receptacle is shaped to mate with a Society of Automotive Engineers
(SAE) standard 1772 compliant charge plug.
Description
TECHNICAL FIELD
[0001] The present invention generally relates to vehicular
electrical systems, and more particularly relates to a vehicular
charge receptacle and systems associated with the charge
receptacle.
BACKGROUND OF THE INVENTION
[0002] In recent years, advances in technology, as well as
ever-evolving tastes in style, have led to substantial changes in
the design of automobiles. One of the changes involves the
complexity of the electrical systems within automobiles,
particularly alternative fuel vehicles, such as hybrid, battery
electric, and fuel cell vehicles. Such alternative fuel vehicles
typically use one or more electric motors, perhaps in combination
with another actuator, to drive the wheels. With recent
fluctuations in fossil fuel prices, it is now more desirable than
ever to power automobiles with electric power, as with hybrid
vehicles.
[0003] "Plug-in" electric vehicles and plug-in hybrid electric
vehicles may meet this need, as they allow the vehicle's battery
system to be charged while the vehicle is not in use. The charging
of the battery system may be performed at public charging stations,
such as while the driver is at a shopping mall, or private charging
stations that are set up in the driver's garage at home and may be
used overnight. However, such charging stations are connected to
the power grid, which is capable of providing more than the maximum
amount of current that may typically be safely carried by wiring
used in electric vehicles. Therefore, in the event of a fault or
short, an over-current condition may occur which may damage the
wiring, as well as generate an undesirable amount of heat.
[0004] Fuses are often provided in the vehicles to prevent such
conditions from occurring. However, because of the placement of the
fuses, some of the wiring in the vehicle that is used to provide
grid power (i.e., power from the electrical grid) to the charger
that is used to charge the battery may not be protected by the
fuses.
[0005] Accordingly, it is desirable to provide a charge receptacle
and associated systems that minimize the amount of wiring that is
not protected by the fuses in such vehicles and are fully compliant
with the standards set by the appropriate regulatory authorities.
Furthermore, other desirable features and characteristics of the
present invention will become apparent from the subsequent
description taken in conjunction with the accompanying drawings and
the foregoing technical field and background.
SUMMARY OF THE INVENTION
[0006] A vehicular electrical system is provided. The vehicular
electrical system includes an electrical energy storage device, a
charge receptacle shaped to mate with a charge plug, at least one
fuse connected to the charge receptacle, and a plurality of
conductors electrically interconnecting the electrical energy
storage device and the at least one fuse. Substantially all of the
plurality of conductors are electrically connected between the
electrical storage device and the at least one fuse.
[0007] An automotive charge receptacle is provided. The automotive
charge receptacle includes a main body having an engagement
formation thereon, the engagement formation being shaped to mate
with a charge plug, and at least one fuse removably connected to
the main body in a substantially fixed position.
[0008] An electric vehicular charging system is provided. The
electric vehicular charging system includes a battery charger
having a power supply and a charge plug electrically connected to
the power supply, a charge receptacle having an engagement
formation shaped to mate with the charge plug, and at least one
fuse removably housed within the charge receptacle. The charge plug
and the charge receptacle are configured such that the at least one
fuse is not manually removable from the charge receptacle when the
charge plug is mated with the engagement formation.
DESCRIPTION OF THE DRAWINGS
[0009] The present invention will hereinafter be described in
conjunction with the following drawing figures, wherein like
numerals denote like elements, and
[0010] FIG. 1 is a schematic view of an exemplary vehicle according
to one embodiment of the present invention;
[0011] FIG. 2 is a perspective view of a battery charge port on a
body of the vehicle of FIG. 1;
[0012] FIG. 3 is an isometric view of a first side of a charge
receptacle within the charge port of FIG. 2;
[0013] FIG. 4 is an isometric view of a second side of the charge
receptacle of FIG. 3 and a wire harness; and
[0014] FIG. 5 is a schematic view of a battery charger, including a
charge plug, according to one embodiment of the present
invention.
DESCRIPTION OF AN EXEMPLARY EMBODIMENT
[0015] The following detailed description is merely exemplary in
nature and is not intended to limit the invention or the
application and uses of the invention. Furthermore, there is no
intention to be bound by any expressed or implied theory presented
in the preceding technical field, background, and brief summary, or
the following detailed description.
[0016] The following description refers to elements or features
being "connected" or "coupled" together. As used herein,
"connected" may refer to one element/feature being mechanically
joined to (or directly communicating with) another element/feature,
and not necessarily directly. Likewise, "coupled" may refer to one
element/feature being directly or indirectly joined to (or directly
or indirectly communicating with) another element/feature, and not
necessarily mechanically. However, it should be understood that
although two elements may be described below, in one embodiment, as
being "connected," in alternative embodiments similar elements may
be "coupled," and vice versa. Thus, although the schematic diagrams
shown herein depict example arrangements of elements, additional
intervening elements, devices, features, or components may be
present in an actual embodiment.
[0017] Further, various components and features described herein
may be referred to using particular numerical descriptors, such as
first, second, third, etc., as well as positional and/or angular
descriptors, such as horizontal and vertical. However, such
descriptors may be used solely for descriptive purposes relating to
drawings and should not be construed as limiting, as the various
components may be rearranged in other embodiments. It should also
be understood that FIGS. 1-5 are merely illustrative and may not be
drawn to scale.
[0018] FIG. 1 to FIG. 5 illustrate a vehicular electrical system,
according to one aspect of the present invention. The vehicular
electrical system includes an electrical energy storage device, a
charge receptacle shaped to mate with a charge plug, at least one
fuse connected to the charge receptacle, and a plurality of
conductors electrically interconnecting the electrical energy
storage device and the at least one fuse. Substantially all of the
plurality of conductors are electrically connected between the
electrical storage device and the at least one fuse.
[0019] According to another aspect of the present invention, an
automotive charge receptacle is provided. The automotive charge
receptacle includes a main body having an engagement formation
thereon, the engagement formation being shaped to mate with a
charge plug, and at least one fuse removably connected to the main
body in a substantially fixed position.
[0020] An electric vehicular charging system is also provided. The
electric vehicular charging system includes a battery charger
having a power supply and a charge plug electrically connected to
the power supply, a charge receptacle having an engagement
formation shaped to mate with the charge plug, and at least one
fuse removably housed within the charge receptacle. The charge plug
and the charge receptacle are configured such that the fuses can
not be manually removed from the charge receptacle when the charge
plug is mated with the engagement formation.
[0021] FIG. 1 illustrates a vehicle (or "automobile") 10, according
to one embodiment of the present invention. The vehicle 10 includes
a chassis 12, a body 14, four wheels 16 (although other embodiments
may have two or three wheels), and an electronic control system 18.
The body 14 is arranged on the chassis 12 and substantially
encloses the other components of the vehicle 10. The body 14 and
the chassis 12 may jointly form a frame. The wheels 16 are each
rotationally coupled to the chassis 12 near a respective corner of
the body 14.
[0022] The vehicle 10 may be any one of a number of different types
of automobiles, such as, for example, a sedan, a wagon, a truck, or
a sport utility vehicle (SUV), and may be two-wheel drive (2WD)
(i.e., rear-wheel drive or front-wheel drive), four-wheel drive
(4WD), or all-wheel drive (AWD). The vehicle 10 may also
incorporate any one of, or combination of, a number of different
types of engines, such as, for example, a liquid-fueled internal
combustion engine, a gaseous compound (e.g., hydrogen and/or
natural gas) fueled engine, a combustion/electric motor hybrid
engine, and an electric motor.
[0023] Examples of fuels that may be used for combustion engines
intended to be included within the scope of this invention include
gasoline, diesel, "flex fuel" (i.e., a mixture of gasoline and
alcohol), methanol, methyl tetrahydrofuran mixtures, various
biodiesels, and liquefied petroleum gas (LPG). It should also be
understood that the combustion engines may be either internal
combustion engines or external combustion engines (e.g., a Carnot
heat engine).
[0024] In the exemplary embodiment illustrated in FIG. 1, the
vehicle 10 is a plug-in hybrid electric vehicle (or plug-in hybrid
vehicle), and further includes an actuator assembly 20, a battery
system (or battery) 22, a power converter assembly (e.g., an
inverter assembly) 24, and a battery charge port 26. The actuator
assembly 20 includes an internal combustion engine 28 and an
electric motor/generator (or motor) 30.
[0025] As will be appreciated by one skilled in the art, the
electric motor 30 includes a transmission therein, and although not
illustrated also includes a stator assembly (including conductive
coils), a rotor assembly (including a ferromagnetic core), and a
cooling fluid (i.e., coolant). The stator assembly and/or the rotor
assembly within the electric motor 30 may include multiple
electromagnetic poles (e.g., sixteen poles), as is commonly
understood.
[0026] Still referring to FIG. 1, in one embodiment, the combustion
engine 28 and the electric motor 30 are integrated such that both
are mechanically coupled to at least some of the wheels 16 through
one or more drive shafts 32.
[0027] Although not shown, the battery system (or direct current
(DC) power supply or electrical energy storage device source) 22
may include a 12V, lead-acid starter-lighting-ignition (SLI)
battery, as well as a high voltage battery suitable for powering
the electric motor 30 (e.g., a lithium ion battery).
[0028] Although not shown in detail, in one embodiment, the
inverter 24 includes a three-phase circuit coupled to the motor 30.
More specifically, the inverter 24 includes a switch network having
a first input coupled to a voltage source Vdc (e.g., the battery
22) and an output coupled to the motor 30. The switch network
comprises three pairs (a, b, and c) of series switches with
antiparallel diodes (i.e., antiparallel to each switch)
corresponding to each of the phases of the motor 30. As is commonly
understood, each of the switches may be in the form of individual
semiconductor devices such as insulated gate bipolar transistors
(IGBTs) within integrated circuits formed on semiconductor (e.g.
silicon) substrates (e.g., die).
[0029] The electronic control system 18 is in operable
communication with the actuator assembly 20, the high voltage
battery 22, the inverter assembly 24, and the fuel tank 26.
Although not shown in detail, the electronic control system 18
includes various sensors and automotive control modules, or
electronic control units (ECUs) or modules (ECMs), such as an
inverter control module and a vehicle controller, and at least one
processor and/or a memory which includes instructions stored
thereon (or in another computer-readable medium) for carrying out
the processes and methods as described below.
[0030] As shown in FIG. 1, the battery charge port 26 and the
battery 22, as well as other components within the vehicle 10, are
in operable communication and/or electrically connected through
conductors (e.g., flexible conductive wires) 33. In one embodiment,
the conductive wires 33 are 14 American wire gauge (AWG), as is
commonly understood, although different gauges may be used in other
embodiments. The components of the vehicle 10 interconnected by the
conductors 33 may be understood to form an electrical system within
the vehicle 10.
[0031] As shown in FIG. 1, the battery charge port 26 is located on
an outer wall of the body 14 of the vehicle 14 near one of the
wheels 16 (e.g., the front, driver's side wheel). FIG. 2
illustrates the battery charge port 26 in greater detail. As shown,
the battery charge port 26 extends through a substantially circular
opening 34 in an outer wall of the body 14. In the depicted
embodiment, the body 14 of the vehicle 10 includes a door 36 that
is connected to the remainder of the body 14 in a hinged fashion
such that it is moveable between "opened" position (as shown) and a
"closed" position in which the charge port 26 is covered.
[0032] Referring to FIGS. 2, 3, and 4, the battery charge port 26
includes a charge receptacle 38 that is connected to an inner wall
of the body 14 by a spacer 40. The charge receptacle 38 includes a
substantially integral main body 40 that is, in one embodiment,
made of an injection-molded plastic. The main body 40 is
substantially plate-shaped and has first and second opposing sides
42 and 44.
[0033] Referring specifically to FIG. 3, the first side 42 of the
main body 40 (and/or the charge receptacle 38) includes a first
engagement formation 46 connected thereto. The first engagement
formation 46 (and/or the first side 42 of the main body 40) is
sized and shaped to mate with a charge plug. In one specific
embodiment, the first engagement formation 46 is sized and shaped
to mate with a charge plug that is in compliance with a Society of
Automotive Engineers (SAE) standard 1772 (described below), as will
be understood by one skilled in the art.
[0034] Referring specifically to FIG. 4, the second side 44 of the
main body 40 includes a second engagement formation 48 connected
thereto. The second engagement formation 48 (and/or the second side
44 of the main body 40) is sized and shaped to mate with a wire
harness 50 that is included within the electrical system of the
vehicle 10 and at least partially houses the ends of the conductive
wires 33.
[0035] Still referring to FIGS. 2, 3, and 4, the charge receptacle
38 also includes fuses 52, a first set of conductive members 54,
and a second set of conductive members 56. The fuses 52 (FIG. 3)
are removably housed within fuse cavities 58 formed on the first
side 42 of the main body 40 above the first engagement formation
46. It should be noted that when the fuses 52 are housed within the
fuse cavities 58, the fuses are connected to the charge receptacle
38 is a substantially fixed position. That is, if the charge
receptacle is removed from the body 14 of the vehicle 10, the fuses
52 are also removed.
[0036] In the depicted embodiment, the fuse cavities 58 are covered
by removable fuse covers 60 that are made of a flexible rubber-like
material and connected to the main body 40 at adjacent ends of the
fuse cavities 58. In one embodiment, the fuses 52 are ceramic
fuses. The fuses may be rated to, for example, 20 amperes (A) and
120 alternating current volts (VAC).
[0037] The first set of conductive members 54 includes a series of
pins positioned within the first engagement formation 46 that are
electrically connected to a first side of the fuses 52, while the
second set of conductive members 56 includes a series of pins
positioned within the second engagement formation 48 that are
electrically connected to a second side of the fuses 52. It should
be noted that the pins used in the first and second sets of
conductive members 54 and 56 may be partially embedded into the
charge receptacle 38 and thus fixed in placed relative to the
charge receptacle 38.
[0038] As such, an electrical pathway is formed through the first
set of conductive members 54, the fuses 52, and the second set of
conductive members 56 and into the conductive wires 33 when the
wire harness 50 is mated with the second engagement formation 48.
Of particular interest is the relative length of the conductive
pathway on the opposing electrical sides of the fuses. That is, the
electrical pathway as measured from the ends of the first set of
conductive members 54 to the fuses 52 may be as short as 1 inch or
less, while the electrical pathway as measured from the fuses 52 to
the battery 22 (and/or the other components of the electrical
system) may be as long as 15 feet. In other words, virtually all of
the conductors and wires (and all of the other components of the
electrically system) that are electrically connected to the charge
receptacle 38 are electrically connected to the second sides of the
fuses 52.
[0039] During operation, referring to FIG. 1, the vehicle 10 is
operated by providing power to the wheels 16 with the combustion
engine 28 and the electric motor 30 in an alternating manner and/or
with the combustion engine 28 and the electric motor 30
simultaneously. In order to power the electric motor 30, DC power
is provided from the battery 22 (and, in the case of a fuel cell
automobile, a fuel cell) to the inverter 24, which converts the DC
power into AC power, before the power is sent to the electric motor
30.
[0040] When the vehicle 10 is not in use, or any time the user
wishes to charge the battery 22 (e.g., the high voltage battery), a
battery charger, or charging station, may be connected to the
charge port 26. One example of a battery charger 62 is shown in
FIG. 5. The battery charger 62 includes a power supply (and/or
inverter) 64 and a charge plug 66. The power supply 64 provides DC
power to the charge plug 66 from an AC power source (e.g., a wall
socket connected to the main power grid). The charge plug 66 is
electrically connected to the power supply 64 and includes an
alignment prong 68 extending from an upper side thereof. In one
embodiment, the charge plug is a SAE standard 1772 compliant charge
plug.
[0041] To charge the battery 22, the charge plug 66 may be mated
with the battery charge port 26 (and/or the charge receptacle 38).
When the charge plug 66 is mated with charge receptacle 38,
conductors within charge plug 66 (not shown) contact the first set
of conductive members 54 such that current flows through the charge
receptacle 38 and the conductive wires 33 to the battery 22. As
such, the battery 22 is charged.
[0042] When the charge plug 66 is mated with the charge receptacle
38, the alignment prong 68 on the charge plug 66 substantially
covers, or blocks, the fuse covers 60 and/or the fuse cavities 58
on the charge receptacle 38. Therefore, when the charge plug 66 is
connected to the charge receptacle 38 (i.e., when the battery 22 is
being charged), the fuses 52 may not be accessed by opening the
fuse covers 60 and/or manually removed from the charge receptacle
38, even if the charge receptacle 38 is taken off the body 14 of
the vehicle 10. In other words, a user may only manually remove the
fuses 52 from the charge receptacle 38 when the charge plug 66 is
not connected to, or mated with, the charge receptacle 38.
[0043] One advantage is that because all of the wiring (i.e., the
flexible conductive wires), and virtually all of the conductors,
within the vehicle are electrically connected to the charger (and
thus the power grid) through the fuses. Thus, all of the wiring
(and virtually all of the conductors) is protected by the fuses. As
a result, the likelihood that any of the wiring (and/or conductors)
will be damaged by an over-current condition. Another advantage is
that because of the arrangement of the first engagement formation
and the fuse cavities on the charge receptacle, as well as the
shape of the charge plug, the fuses may not be accessed and removed
while the battery is being charged. Thus, the system described
above may fully comply with safety standards set by the appropriate
regulatory authorities.
[0044] As described above, the automobile shown in the drawings and
described above is merely intended as one example of a vehicle in
which the charge receptacle may be used. It should be noted that
the charge receptacle may also be used in other types of land
vehicles, such as motorcycles and personal transportation devices,
as well as other categories of vehicles, such as watercraft and
aircraft.
[0045] While at least one exemplary embodiment has been presented
in the foregoing detailed description, it should be appreciated
that a vast number of variations exist. It should also be
appreciated that the exemplary embodiment or exemplary embodiments
are only examples, and are not intended to limit the scope,
applicability, or configuration of the invention in any way.
Rather, the foregoing detailed description will provide those
skilled in the art with a convenient road map for implementing the
exemplary embodiment or exemplary embodiments. It should be
understood that various changes can be made in the function and
arrangement of elements without departing from the scope of the
invention as set forth in the appended claims and the legal
equivalents thereof.
* * * * *