1. A charging port module for an Electric Vehicle (EV), the module comprising:

a charging port body having a first side, an opposing second side, and an interface for mounting to a body of the EV;

a socket secured to a first side of the charging port body and configured to accept a charging plug;

an electrical connector secured to a second side of the charging port body, in electrical communication with the receptacle, and configured to engage an electrical system including a battery of the EV;

a channel defined by a first side of the charging port body; and

a cartridge configured to slidingly engage the channel, the cartridge comprising:

a cartridge body defining an access opening configured to facilitate entry of the charging plug into the receptacle after the cartridge has been engaged and has been seated in the channel; and

a light emitting element disposed on the cartridge body and configured to illuminate the socket.

2. The charging port module of claim 1, wherein the charging port body and the cassette have complementary interlocking features configured to maintain engagement of the cassette with the channel.

3. The charging port module of claim 1, wherein the cartridge body is defined by an outer perimeter, wherein the cartridge body defines a protrusion disposed on at least a portion of the outer perimeter, and wherein the protrusion is configured to slidingly engage the channel.

4. The charging port module of claim 3, wherein the light emitting element forms at least part of the protrusion.

5. The charging port module of claim 3, wherein the first side of the charging port body comprises a lip configured to overlap at least a portion of the protrusion after the cassette has been engaged and seated in the channel.

6. The charging port module of claim 1, wherein the light emitting element is configured to electrically connect to an electrical system of the EV and receive current from the electrical system after the cartridge has been engaged and has been seated in the channel.

7. The charging port module of claim 1, wherein the light emitting element surrounds the access opening.

8. The charging port module of claim 1, wherein the access opening is defined by an inner perimeter, and wherein the light emitting element covers a portion of the inner perimeter of the access opening.

9. The charging port module of claim 1, wherein the light emitting element comprises a translucent covering, and at least one Light Emitting Diode (LED) and a light pipe connected to the at least one LED, and wherein each of the at least one LED and light pipe is housed within the covering.

10. An Electric Vehicle (EV) comprising:

an EV body;

a traction motor configured to generate EV propulsion torque;

an EV electrical system comprising a rechargeable battery configured to generate an electrical current for powering the traction motor; and

a charging port module having:

a charging port body having a first side, a second side, and an interface for mounting to the EV body;

a socket secured to a first side of the charging port body and configured to accept a charging plug;

an electrical connector secured to the second side of the charging port body, in electrical communication with the receptacle, and configured to engage the EV electrical system; and

a channel defined by a first side of the charging port body; and

a cartridge configured to slidingly engage the channel, the cartridge comprising:

a cartridge body defining an access opening configured to facilitate entry of the charging plug into the receptacle after the cartridge has been engaged and has been seated in the channel; and

a light emitting element disposed on the cartridge body and configured to illuminate the socket.

Background

Electric vehicles, also known as EVs, use one or more electric or traction motors for propulsion. Electric vehicles may be powered by electricity from a source external to the vehicle through a collector system, or may be a self-contained battery, solar panel, or generator to convert fuel into electricity.

Plug-in electric vehicles (PEVs) are motor vehicles that include a rechargeable battery pack that can be recharged from an external power source (e.g., a wall outlet), while the electricity stored in the rechargeable battery pack powers or assists in driving the wheels. PEVs are a sub-class of electric vehicles that include all-electric or Battery Electric Vehicles (BEVs), plug-in hybrid electric vehicles (PHEVs), and electric vehicle conversion of hybrid electric vehicles and conventional internal combustion engine vehicles. Hybrid Electric Vehicles (HEVs) combine a conventional (typically fossil fuel-powered) powertrain with some form of electric propulsion.

EVs are typically charged from a conventional power outlet or a dedicated charging station, a process that typically takes a considerable amount of time, but can be performed at night, and are typically given a charge sufficient to satisfy normal daily usage. EV users can plug their cars into the power source while at work and have them charged all day long, expanding the possible range of commuting and eliminating mileage anxiety.

Disclosure of Invention

A charging port module for an Electric Vehicle (EV) includes a charging port body having a first side, an opposing second side, and an interface for mounting to an EV body. The charging port module also has a receptacle secured to the first side of the charging port body and configured to accept a charging plug. The charging port module also has an electrical connector secured to the second side of the charging port body, in electrical communication with the receptacle, and configured to engage an electrical system including a battery of the EV. The charging port module also has a channel defined by a first side of the charging port body. The charging port module also includes a cartridge configured to slidingly engage the channel. The cassette includes a cassette body defining an access opening configured to facilitate entry of the charging plug into the receptacle after the cassette has been engaged and has been seated in the channel. The cartridge also includes a light emitting element disposed on the cartridge body and configured to illuminate the socket.

The charging port body and the cassette may have complementary interlocking features configured to maintain engagement of the cassette with the channel.

The cartridge body may be defined by an outer periphery. The cartridge body may define a projection disposed on at least a portion of the outer periphery. In such embodiments, the protrusion may be configured to slidingly engage the channel.

The light emitting element may form at least part of the protrusion.

The first side of the charging port body may include a lip configured to overlap at least a portion of the protrusion after the cassette has been engaged and seated in the channel.

The light emitting element may be configured to electrically connect to an electrical system of the EV and receive current from the electrical system after the cartridge has been engaged and has been placed in the channel.

The light emitting element may surround the access opening.

Alternatively, the access opening may be defined by an inner perimeter, and the light emitting element may cover a portion of the inner perimeter of the access opening.

The light emitting element may include a translucent covering and at least one Light Emitting Diode (LED) and a light pipe coupled to the at least one LED. In such embodiments, each of the at least one LED and the light pipe may be housed within the cover.

The charging port module may include a plurality of LEDs, each LED emitting a different color of light.

Also disclosed is an electric vehicle comprising an EV body, a traction motor configured to generate EV propulsion torque, an EV electrical system comprising a rechargeable battery configured to generate electrical current for powering the traction motor, and a charging port module as described above.

The invention may include the following scheme:

1. a charging port module for an Electric Vehicle (EV), the module comprising:

a charging port body having a first side, an opposing second side, and an interface for mounting to a body of the EV;

a socket secured to a first side of the charging port body and configured to accept a charging plug;

an electrical connector secured to a second side of the charging port body, in electrical communication with the receptacle, and configured to engage an electrical system including a battery of the EV;

a channel defined by a first side of the charging port body; and

a cartridge configured to slidingly engage the channel, the cartridge comprising:

a cartridge body defining an access opening configured to facilitate entry of the charging plug into the receptacle after the cartridge has been engaged and has been seated in the channel; and

a light emitting element disposed on the cartridge body and configured to illuminate the socket.

2. The charging port module of claim 1, wherein the charging port body and the cassette have complementary interlocking features configured to maintain engagement of the cassette with the channel.

3. The charging port module of claim 1, wherein the cartridge body is defined by an outer periphery, wherein the cartridge body defines a protrusion disposed on at least a portion of the outer periphery, and wherein the protrusion is configured to slidingly engage the channel.

4. The charging port module of claim 3, wherein the light emitting element forms at least part of the protrusion.

5. The charging port module of claim 3, wherein the first side of the charging port body comprises a lip configured to overlap at least a portion of the protrusion after the cassette has been engaged and seated in the channel.

6. The charging port module of claim 1, wherein the light emitting element is configured to electrically connect to an electrical system of the EV and receive current from the electrical system after the cartridge has been engaged and has been seated in the channel.

7. The charging port module of claim 1, wherein the light emitting element surrounds the access opening.

8. The charging port module of claim 1, wherein the access opening is defined by an inner perimeter, and wherein the light emitting element covers a portion of the inner perimeter of the access opening.

9. The charging port module of claim 1, wherein the light emitting element comprises a translucent covering, and at least one Light Emitting Diode (LED) and a light pipe connected to the at least one LED, and wherein each of the at least one LED and light pipe is housed within the covering.

10. The charging port module of claim 9, wherein the at least one light emitting diode comprises a plurality of light emitting diodes, each light emitting diode projecting a different color of light.

11. An Electric Vehicle (EV) comprising:

an EV body;

a traction motor configured to generate EV propulsion torque;

an EV electrical system comprising a rechargeable battery configured to generate an electrical current for powering the traction motor; and

a charging port module having:

a charging port body having a first side, a second side, and an interface for mounting to the EV body;

a socket secured to a first side of the charging port body and configured to accept a charging plug;

an electrical connector secured to the second side of the charging port body, in electrical communication with the receptacle, and configured to engage the EV electrical system; and

a channel defined by a first side of the charging port body; and

a cartridge configured to slidingly engage the channel, the cartridge comprising:

a cartridge body defining an access opening configured to facilitate entry of the charging plug into the receptacle after the cartridge has been engaged and has been seated in the channel; and

a light emitting element disposed on the cartridge body and configured to illuminate the socket.

12. The electric vehicle of claim 11, wherein the charging port body and the cassette have complementary interlocking features configured to maintain engagement of the cassette with the channel.

13. The electric vehicle of claim 11, wherein the cartridge body is defined by an outer perimeter, wherein the cartridge body defines a protrusion disposed on at least a portion of the outer perimeter, and wherein the protrusion is configured to slidingly engage the channel.

14. The electric vehicle of claim 13, wherein the light emitting element forms at least part of the protrusion.

15. The electric vehicle of claim 13, wherein the first side of the charging port body includes a lip configured to overlap at least a portion of the protrusion after the cassette has been engaged and has been seated in the channel.

16. The electric vehicle of claim 11, wherein the light emitting element is configured to electrically connect to the EV electrical system and receive current from the EV electrical system after the cartridge has been engaged and has been seated in the channel.

17. The electric vehicle according to claim 11, wherein the light emitting element surrounds the access opening.

18. The electric vehicle of claim 11, wherein the access opening is defined by an inner perimeter, and wherein the light emitting element covers a portion of the inner perimeter of the access opening.

19. The electric vehicle of claim 11, wherein the light emitting element comprises a translucent covering and at least one Light Emitting Diode (LED) and a light pipe connected to the at least one LED, and wherein each of the at least one LED and light pipe is housed within the covering.

20. The electric vehicle of claim 19, wherein the at least one LED comprises a plurality of LEDs, each LED projecting a different color of light.

The above features and advantages and other features and advantages of the present disclosure are readily apparent from the following detailed description of the best modes (or embodiments) for carrying out the described disclosure when taken in connection with the accompanying drawings and appended claims.

Drawings

Fig. 1 is a schematic perspective view of an electric motor vehicle employing a charging port module according to the present disclosure.

Fig. 2 is a schematic exploded perspective side view of the charging port module shown in fig. 1, particularly depicting a lighting box, according to the present disclosure.

Fig. 3 is a schematic front view of the charging port module shown in fig. 1 and 2, particularly depicting an embodiment of a lighting box and a horizontally hinged charging port door, according to the present disclosure.

Fig. 4 is a schematic perspective rear view of the charging port module shown in fig. 1 and 2 according to the present disclosure.

Fig. 5 is a schematic exploded perspective rear view of the charging port module shown in fig. 1 and 2 according to the present disclosure.

Fig. 6 is a schematic partial cross-sectional view of the charging port module shown in fig. 5 according to the present disclosure.

FIG. 7 is a schematic perspective view of another embodiment of the lighting box shown in FIG. 2 according to the present disclosure.

Fig. 8 is a schematic front view of the charging port module shown in fig. 1 and 2, particularly depicting a vertically hinged charging port door, according to the present disclosure.

Detailed Description

Referring to fig. 1, an Electric Vehicle (EV)10 having an EV body 10A is depicted. The vehicle 10 may include, but is not limited to, a commercial vehicle, an industrial vehicle, a passenger vehicle, an aircraft, a watercraft, a train, and the like. It is also contemplated that EV 10 may be a mobile platform, such as an aircraft, an All Terrain Vehicle (ATV), a boat, a personal mobile device, a robot, etc., for purposes of this disclosure. As shown, EV 10 includes a powertrain 12. Powertrain 12 includes a power source 14, and power source 14 is configured to generate a power source torque T (shown in FIG. 1) for propelling EV 10 via driven wheels 16 relative to a roadway 18. The power source 14 is depicted as an electric motor-generator or a traction motor. As shown in FIG. 1, power system 12 may also include an additional power source 20, such as an internal combustion engine. Power sources 14 and 20 may cooperate to power EV 10.

As shown, the EV 10 also includes a programmable electronic controller 22 and an EV electrical system 24. The electrical system 24 is connected to the power sources 14 and 20, the electronic controller 22, and other vehicle systems via a high voltage bus 24A. As shown in fig. 2, the electrical system 24 includes a battery module 26 having one or more rechargeable energy storage cells or batteries 28. Battery module 26 is configured to generate electrical current for powering traction motor 14 and to supply electrical energy to power source 20. Electronic controller 22 may be programmed to control power system 12 and electrical system 24 to produce a predetermined amount of power source torque T, as well as various other vehicle systems such as lights, infotainment, and Heating Ventilation and Air Conditioning (HVAC).

In particular, the electronic controller 22 may be configured as a vehicle body controller or Central Processing Unit (CPU) programmed to regulate various systems and functions of the vehicle 10. To this end, electronic controller 22 includes a processor and tangible, non-transitory memory, such as instructions programmed therein for operation of power system 12 and electrical system 24. The memory may be a suitable recordable medium that participates in providing computer-readable data or process instructions. Such recordable media may take many forms, including but not limited to, non-volatile media and volatile media. Non-volatile media for electronic controller 22 may include, for example, optical or magnetic disks and other persistent memory. Volatile media may include, for example, Dynamic Random Access Memory (DRAM), which may constitute a main memory.

The operating instructions may be transmitted over one or more transmission media, including coaxial cables, copper wire and fiber optics, including the wires that comprise a system bus coupled to the processor of the computer; or via a wireless connection. The memory of electronic controller 22 may also include a floppy disk, a hard disk, a magnetic tape, another magnetic medium, a CD-ROM, a DVD, another optical medium, etc. The electronic controller 22 may be configured or equipped with other required computer hardware, such as a high speed clock, the necessary analog-to-digital (a/D) and/or digital-to-analog (D/a) circuitry, input/output circuitry and devices (I/O), and appropriate signal conditioning and/or buffer circuitry. Algorithms required by, or accessible by, electronic controller 22 may be stored in memory and executed automatically to provide the functionality required by power system 12 and electrical system 24.

The electronic controller 22 may be specifically configured, i.e., programmed, to detect a request 30 to charge the battery module 26. The request 30 to charge the battery(s) 28 may be the result of detecting that the battery module state of charge (SOC) has fallen below a predetermined SOC. The electronic controller 22 will then command a particular charge rate 32 of the battery(s) 28 by setting the value of the charging current I flowing into the battery module 26 in response to the detected request 30. The EV 10 also includes a charging port module 34. As shown in fig. 2, the charging port module 34 includes a charging port body 36, the charging port body 36 having a first side 38 and a second side 40. The charging port module 34 also includes an interface 42 (shown in fig. 2 and 4), the interface 42 being disposed on the second side 40 for mounting to the EV body 10A, such as a clip for fixedly retaining the charging port module 34 to a fender of the EV body. The charging port module 34 also includes a port or receptacle 44 (shown in fig. 3) secured to the first side 38 of the charging port body 36. The socket 44 is equippedIs configured to receive a charging plug 46 (shown in FIG. 1) connected to an external power source 48 (e.g., a charging station), and thereby receive a charging currentITo recharge the battery(s) 28 of the EV 10.

As can be seen in fig. 2, the charging port module 34 also includes an electrical connector 50 secured to the second side 40 of the charging port body 36. The electrical connector 50 is in electrical communication with the receptacle 44 and is configured to engage the EV electrical system 24. The charging port module 34 also includes a positioning track or channel 52 defined by the first side 38 of the charging port body 36. The channel 52 defines a pocket 52A. As shown, the charging port module 34 also includes a cartridge 54, the cartridge 54 being configured to slidingly engage the channel 52, i.e., to connect with the channel 52 and slide relative to the channel 52. The sliding engagement of the cartridge 54 relative to the charging port body 36 is specifically represented in fig. 2 by the double arrow 55. The case 54 includes a peripheral frameP _o Defining a cartridge body 56.

With continued reference to fig. 2, the cartridge body 56 may define a projection 58. The projection 58 may be disposed at the outer periphery of the cartridge main body 56P _o At least a portion of (a). The projections 58 may be located on the outer periphery on at least two sides of the cartridge body 56P _o The above. In particular embodiments, the tabs 58 may be located on three sides of the cartridge body 56, such as on sides 56-1, 56-2, and 56-3, as depicted in FIG. 5. The projection 58 is specifically configured to slidingly engage the channel 52 for assembling the cartridge 54 with the charging port body 36. In other words, the projection 58 is designed and configured to fit into the channel 52 and slide along the channel 52 until the cartridge 54 is fully seated in the pocket 52A formed by the channel within the charging port body 36.

The first side 38 of the charging port body 36 may include a lip 38A configured to overlap at least a portion of the projection 58 after the cartridge 54 has been engaged and has been seated in the channel 52. The lip 38A is thus shaped to cover the seam 39 between the first side 38 of the charging port body 36 and the cartridge body 56 when the cartridge 54 is disposed in the channel 52. The cartridge body 56 also defines a cartridge body having an inner peripheryP _i As shown in fig. 5. The access opening 60 is configured to facilitate a charging plug46 enter the socket 44 after the cartridge has been engaged and fully seated in the channel 52. The cartridge 54 also includes a light emitting element 62 disposed proximate the access opening 60.

As shown, the light emitting element 62 is disposed on the cartridge body 56 and is configured to illuminate the socket 44, i.e., project light onto the socket 44. The light emitting element 62 may form at least part of the protrusion 58. As shown in fig. 6, which shows the cross-sectional view 6-6 depicted in fig. 5, the light emitting element 62 extends into the tab 58. As shown in fig. 2, 7, and 8, the light emitting element 62 may be a substantially continuous member that surrounds the access opening 60. Alternatively, as shown in FIG. 3, the light emitting element 62 may cover the inner perimeter of the access opening 60P _i The specific portion of (a). Specifically, the light emitting element 62 may be a compact member that is integral with the cartridge body 56 and positioned to direct a light beam at the socket 44 (as shown in fig. 3) when the cartridge 54 is seated in the charging port body 36.

The light emitting element 62 may be configured to connect to the electrical system 24 of the EV 10 and receive the current I therefrom after the cartridge 54 has been engaged and has been seated in the channel 52. The light emitting element 62 may include a combination of a translucent covering 64 and a fiber optic element, such as at least one Light Emitting Diode (LED) 66A and a light pipe 66B connected thereto (as shown in fig. 7). As shown, each LED 66A and light pipe 66B may be housed within the cover 64. When multiple LEDs 66A are used in the light emitting element 62, each of the LEDs 66A can selectively project a different color of light into the light pipe 66B. The selective activation of a particular LED 66A may be commanded by the vehicle operator via a user interface (not shown) within the vehicle, or automatically regulated by electronic controller 22. In other words, a charging port module 34 with multiple LEDs 66A may enable individually selected or "customizable" lighting.

For example, the electronic controller 22 may be programmed to activate a particular color LED 66A associated with a particular vehicle, such as the vehicle 10 into which the charging port module 34 is installed. Thus, different vehicles or vehicle lines may be configured to accept a charging port module 34 having multiple LEDs 66A, each vehicle employing different color illumination of its respective receptacle 44. The electronic controller 22 may also be programmed to activate a particular light display, such as a blinking pattern, a repeating pattern of illumination with varying intensities or colors, via the light emitting elements 62. This different mode may be used, for example, during charging of the battery module 26 to alert the vehicle operator to the achieved SOC. The alert 68 may be programmed into the electronic controller 22 by the vehicle manufacturer or vehicle user and indicate, for example, full charge, 50% charge, or other SOC.

As shown in fig. 2, the charging port body 36 and the cassette 54 may have complementary corresponding interlocking features 70A and 70B (shown in fig. 2). The interlock features 70A, 70B are configured to fix and maintain the position of the cartridge 54 relative to the charging port body 36, i.e., maintain engagement of the cartridge within the channel 52. The interlock feature 70A may be configured, for example, as a receptacle(s) as part of the charging port body 36 (as shown in fig. 2), while the interlock feature 70B may be configured as a tab(s) as part of the cartridge body 56 (as shown in fig. 2 and 7). Alternatively, the specific arrangement of the interlocking features 70A, 70B may be reversed such that, for example, the tab(s) are part of the charging port body 36 and the receptacle(s) are part of the cartridge 54 (not shown). The interlocking features 70A, 70B may allow the cartridge 54 to be removed and replaced as desired. The cartridge body 56 may include a handle portion 72, the handle portion 72 being specifically configured to allow the cartridge to be grasped by a vehicle user or technician for removal from the charging port module 34.

As shown in fig. 3 and 8, the charging port module 34 also includes a charging gate 74. Charging port door 74 may be connected to charging port body 36 via a hinge 76 and configured to swing substantially in a horizontal plane X (as shown in fig. 3), i.e., to one side of receptacle 44, or to drop substantially in a vertical plane Y (as shown in fig. 8) below the receptacle. Charging port door 74 is configured to selectively cover outlet 44 and provide access to outlet 44. The charging port module 34 may have a mechanical, electromechanical or electromagnetic latch mechanism 78, the latch mechanism 78 being configured to selectively maintain the charging port door 74 closed, and unlocked when access to the outlet 44 is required. The electronic controller 22 may be programmed to activate the light element 62 in response to the door 74 being opened, for example, upon triggering the locking mechanism 78, so as to initiate illumination of the socket 44 in a timely manner.

The detailed description and the drawings or figures are supportive and descriptive of the disclosure, but the scope of the disclosure is limited only by the claims. While some of the best modes and other embodiments for carrying out the claimed disclosure have been described in detail, various alternative designs and embodiments exist for practicing the disclosure defined in the appended claims. Furthermore, features of the embodiments shown in the drawings or of the various embodiments mentioned in the description are not necessarily to be understood as embodiments independent of each other. Rather, each feature described in one example of an embodiment can be combined with one or more other desired features from other embodiments to yield yet further embodiments that are not described in text or with reference to the figures. Accordingly, such other embodiments are within the scope of the following claims.