DESC:CHARGING GUN DOCKING WITH CHARGER
CROSS REFERENCE TO RELATED APPLICTIONS
The present application claims priority from Indian Provisional Patent Application No. 202421002165 filed on 11/01/2024, the entirety of which is incorporated herein by a reference.
TECHNICAL FIELD
The present disclosure generally relates to a charging gun of a charger. Particularly, the present disclosure relates to a charging gun docking mechanism of a charger.
BACKGROUND
Recently, there has been a rapid development in electric vehicles due to their use as a cleaner mode of transportation compared to conventional internal combustion engine vehicles. The electric vehicle comprises a traction motor that propels the vehicle using energy stored in a power pack.
Currently, electric vehicles have a limited driving range determined by the capacity of power pack or battery system. Once the stored energy in the power pack is consumed, the vehicle cannot operate further and needs recharging. The recharging process depends on external infrastructure, such as charging stations, and may take significant time compared to refuelling conventional vehicles. The limited range and dependency on charging infrastructure pose challenges for EV adoption, particularly for long-distance travel. For the recharging, the charging gun docking mechanisms face notable challenges during vehicle charging, impacting usability and reliability. Insecurely held charging guns, often coupled with charging cables looped over the charger body, lack intuitive design and may result in improper cable management, leading to wear and tripping hazards. While secured docking solutions offer stability, they often require a learning curve for users unfamiliar with their operation, diminishing user convenience. Additionally, these solutions involve extra components and mechanical complexity, increasing manufacturing costs, maintenance requirements, and the potential for mechanical failure. Current docking methods include simple holders or clips, mechanical locks, and magnetic couplings. Simple holders are prone to misalignment and fail to secure the gun firmly, leading to accidental disconnections or improper contact. Mechanical locks provide a stable hold but often involve intricate mechanisms that complicate usage and increase system vulnerability. Magnetic couplings, though user-friendly, can lose effectiveness over time due to debris or alignment issues. These limitations emphasize the need for docking solutions that balance user-friendliness, reliability, and mechanical simplicity.
Therefore, there exists a need for an improved docking mechanism for charger to overcome the one or more problems as set forth above.
SUMMARY
An object of the present disclosure is to provide a charging gun docking mechanism of a charger.
In accordance with first aspect of the present disclosure, there is provided a charging gun docking mechanism of a charger. The docking mechanism comprises a charging gun and a gun holder assembly in the charger. The gun holder assembly is configured to receive and securely hold the charging gun via at least one locking mechanism.
The present disclosure provides a charging gun docking mechanism of a charger. The docking mechanism as disclosed by present disclosure is advantageous in terms of functionality, durability, and user convenience. The docking mechanism ensures secure placement of the charging gun through a gun holder assembly which provides stability to the charging gun and preventing accidental dislodgement. The locking mechanism equipped with a resting surface and locking surface, facilitates precise alignment and protection of the charging gun while preventing wear and tear from external forces. Beneficially, the design protects the charging gun from environmental factors, such as dust and moisture. Additionally, the docking mechanism provides electrical isolation, thereby reducing the risks associated with unintended electrical contact.
Additional aspects, advantages, features and objects of the present disclosure would be made apparent from the drawings and the detailed description of the illustrative embodiments constructed in conjunction with the appended claims that follow.
It will be appreciated that features of the present disclosure are susceptible to being combined in various combinations without departing from the scope of the present disclosure as defined by the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present disclosure, exemplary constructions of the disclosure are shown in the drawings. However, the present disclosure is not limited to specific methods and instrumentalities disclosed herein. Moreover, those in the art will understand that the drawings are not to scale. Wherever possible, like elements have been indicated by identical numbers.
Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams wherein:
FIG. 1a & 1b illustrates a perspective view of a charging gun docking mechanism of a charger, in accordance with an aspect of the present disclosure.
FIG. 2 illustrates a front view of a charging gun docking mechanism of a charger, in accordance with another aspect of the present disclosure.
In the accompanying drawings, an underlined number is employed to represent an item over which the underlined number is positioned or an item to which the underlined number is adjacent. A non-underlined number relates to an item identified by a line linking the non-underlined number to the item. When a number is non-underlined and accompanied by an associated arrow, the non-underlined number is used to identify a general item at which the arrow is pointing.
DETAILED DESCRIPTION
The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. Although some modes of carrying out the present disclosure have been disclosed, those skilled in the art would recognise that other embodiments for carrying out or practising the present disclosure are also possible.
The description set forth below in connection with the appended drawings is intended as a description of certain embodiments of a charging gun docking mechanism of a charger and is not intended to represent the only forms that may be developed or utilised. The description sets forth the various structures and/or functions in connection with the illustrated embodiments; however, it is to be understood that the disclosed embodiments are merely exemplary of the disclosure that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimised to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.
While the disclosure is susceptible to various modifications and alternative forms, specific embodiment thereof has been shown by way of example in the drawings and will be described in detail below. It should be understood, however, that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure.
The terms “comprise”, “comprises”, “comprising”, “include(s)”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a setup, system that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or system. In other words, one or more elements in a system or apparatus preceded by “comprises... a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or apparatus.
In the following detailed description of the embodiments of the disclosure, reference is made to the accompanying drawings and which are shown by way of illustration specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the scope of the present disclosure. The following description is, therefore, not to be taken in a limiting sense.
The present disclosure will be described herein below with reference to the accompanying drawings. In the following description, well known functions or constructions are not described in detail since they would obscure the description with unnecessary detail.
As used herein, the terms “electric vehicle”, “EV”, and “EVs” are used interchangeably and refer to any vehicle having stored electrical energy, including the vehicle capable of being charged from an external electrical power source. This may include vehicles having batteries which are exclusively charged from an external power source, as well as hybrid-vehicles which may include batteries capable of being at least partially recharged via an external power source. Additionally, it is to be understood that the ‘electric vehicle’ as used herein includes electric two-wheeler, electric three-wheeler, electric four-wheeler, electric pickup trucks, electric trucks and so forth.
As used herein, the term “charging gun docking mechanism” and “docking mechanism” are used interchangeably and refer to a structural assembly designed to securely hold, align, and store a charging gun when it is not in use. The docking mechanism typically comprises a gun holder assembly integrated into the charging station or charger, featuring components such as locking mechanisms, cavities, resting surfaces, and insulation layers. The docking mechanism facilitates safe and stable storage of the charging gun, ensures the protection from environmental factors, and provides electrical isolation where necessary.
As used herein, the terms “charger” refers to a device or system configured to supply electrical energy to an energy storage device, such as a battery. The charger may include various components, such as power conversion circuits, control units, connectors, and interfaces, designed to regulate the voltage, current, and charging profile to ensure efficient and safe energy transfer. The charger may be integrated into a larger system or standalone and can be designed for various applications, including but not limited to electric vehicles, consumer electronics, and industrial equipment.
As used herein, the term “charging gun” refers to a device used for delivering electric power to an electric vehicle (EV) or other electrical systems via a connector interface. The charging gun typically consists of a handle, a connector end that interfaces with the vehicle or charging port, and a cable or wiring that links the connector to the power source. The charging gun is designed to safely and efficiently transfer electrical energy from the charging station to the vehicle, incorporating safety features such as insulation, locking mechanisms, and user-friendly grips.
As used herein, the term “gun holder assembly” a handheld device configured to establish an electrical connection between an energy source, such as an electric vehicle charger, and an energy storage system, such as the battery of an electric vehicle. The charging gun typically comprises a connector interface compatible with the charging port of the vehicle, conductive elements to facilitate the transfer of electrical energy, and structural components designed to ensure safe and efficient handling. It may further include additional features such as insulation, safety locks, sensors, and ergonomic designs to enhance user convenience and operational reliability.
As used herein, the term “at least one locking mechanism” refers to a structural or functional component or assembly that is designed to selectively engage and secure one element (e.g., a charging gun) to another element (e.g., a holder or dock). The locking mechanism may include, but is not limited to, components such as protrusions, grooves, projections, notches, clamps, latches, or magnetic elements, individually or in combination.
As used herein, the term “protruding metal ring” refers to an annular component fixedly attached to or integrally formed on a lateral surface of the charging gun, wherein the ring extends outwardly from the surface to create a raised structure. The protruding metal ring is configured to interact with the gun holder assembly of the docking mechanism, providing a functional interface for resting, alignment, magnetic retention, or other engagement mechanisms.
As used herein, the term “cavity” refers to a recess, hollow, or space formed within a charger assembly, configured to receive and accommodate another object. The cavity specifically pertains to the recess within the gun holder assembly, designed to securely hold the charging gun. The cavity may include structural features such as stepped surfaces, insulation layers, and magnets to facilitate the secure positioning, electrical isolation, and protection of the charging gun during docking.
As used herein, the term “at least one locking projection” and “locking projection” are used interchangeably and refer to a structural feature or element that extends or protrudes from a surface or body, specifically designed to engage with a complementary structure, such as a locking notch or locking surface, to facilitate locking or securing functionality.
As used herein, the term “resting surface” refers to a surface within a assembly that is specifically designed to support and stabilize the associated protruding metal ring in a stationary position, ensuring proper alignment, balance, or positioning during operation or storage.”
As used herein, the term “locking surface” refers to a designated structural surface in a mechanical assembly that interacts with corresponding components, such as locking projections or elements, to establish a secure engagement. The locking surface is configured to hold or restrain a part in place, preventing unintended movement or displacement.
As used herein, the term “insulation layer” refers to a material or structure configured to electrically isolate one component from another, thereby preventing the flow of electrical current between charging gun and the docking mechanism. The insulation layer may be made of non-conductive materials, such as polymers, ceramics, or composites, and can be applied as a coating, lining, or an integral part of the component.
As used herein, the term "at least one locking notch" refers to a recess, groove, or indentation designed to engage with a corresponding locking feature, such as a projection, to secure two components together. The at least one locking notch serves as a critical feature in a locking mechanism, ensuring stability, alignment, or retention of components, and its configuration can vary based on shape, size, or position to suit the intended functionality of the invention.
As used herein, the term “at least one fastening mechanism” refers to any component or combination of components designed to securely attach or fix the gun holder assembly to the charger. The at least one fastening mechanism may include, but is not limited to, screws, bolts, clips, clamps, adhesives, rivets, latches, interlocking structures, or any other mechanical, adhesive, or magnetic means that provide stability and prevent unintended movement or detachment of the gun holder assembly from the charger.
Figure 1a & 1b, in accordance with an embodiment describes a charging gun docking mechanism 100 of a charger. The docking mechanism 100 comprises a charging gun 102 and a gun holder assembly 104 in the charger. The gun holder assembly 104 is configured to receive and securely hold the charging gun 102 via at least one locking mechanism.
The present disclosure discloses the charging gun docking mechanism 100. The docking mechanism 100 as disclosed by present disclosure is advantageous in terms of providing an enhanced functionality, safety, and ease of use to the vehicle owner. By incorporating at least one locking mechanism, the docking mechanism 100 ensures the stable positioning of the charging gun 102, thereby minimizing the risk of accidental dislodgment during charging or when not in use. Furthermore, the presence of a protruding metal ring 106 with at least one locking projection 108 beneficially allows for efficient locking within the gun holder assembly 104, offers both mechanical stability and ease of use. Additionally, the cavity 110 in the gun holder assembly 104, equipped with a resting surface 112 and locking surface 114, facilitates precise alignment and protection of the charging gun 102 while preventing wear and tear from external forces. Beneficially, the at least one locking projection 108 between the resting surface 112 and locking surfaces 114, further enhances the resistance to environmental factors such as dust, moisture, and vibrations, thereby extending the lifespan of the charging gun 102. Furthermore, the integration of an insulation layer 118 within the cavity 110 ensures electrical isolation between the charging gun 102 and the gun holder assembly 104 which significantly enhances the safety by preventing potential electrical hazards. Moreover, at least one fastening mechanism 120 within the gun holder assembly 104 simplifies installation and maintenance, providing flexibility for integration into various charger designs.
In an embodiment, the charging gun 102 comprises a protruding metal ring 106 fixed on a lateral surface of the charging gun 102. Furthermore, the protruding metal ring 106 comprises at least one locking projection 108. The locking projection 108 may be designed to engage within the gun holder assembly 104. Beneficially, the at least one locking mechanism, facilitated by the protruding metal ring 106 and the at least one locking projection 108, ensures reliable and easy docking of the charging gun 102 within the gun holder assembly 104. Furthermore, the design allows for quick and intuitive operation while maintaining the secure retention of the charging gun 102.
Figure 2 describes, the gun holder assembly 104 comprises a cavity 110 configured to receive the charging gun 102. The cavity 112 may be engineered to ensure a precise fit, which allows the charging gun 102 to be properly seated and aligned within the gun holder assembly 104. Beneficially, the cavity 110 provided in conjunction with structural features on the charging gun 102, such as a protruding metal ring 106 with the at least one locking projection 108 which offers a secure and robust engagement of the charging gun 102 with the gun holder assembly 104.
In an embodiment, the cavity 110 of the gun holder assembly 104 comprises a resting surface 112. The resting surface 112 may be designed to provide a mechanical support to the charging gun 102 when the charging gun 102 is inserted into the cavity 110. Beneficially, the resting surface 112 facilitates proper alignment and stabilization of the charging gun 102, ensures the secure placement of the charging gun 102 within the gun holder assembly 104. Additionally, the integration of the resting surface 112 that the charging gun 102 remains stationary when docked, thereby reduces the risk of wear and tear due to movement or vibrations.
In an embodiment, the gun holder assembly 104 comprises a locking surface 114, wherein the locking surface 114 comprises at least one locking notch 116. Furthermore, the at least one locking projection 108 passes through the at least one locking notch 116 to lock the at least one locking projection 108 between the resting surface 112 and the locking surface 114 to securely hold the charging gun 102. The gun holder assembly 104 comprises a locking surface 114, which incorporates the at least one locking notch 116. The at least one locking notch 116 may be designed to interact with the at least one locking projection 110 present on the protruding metal ring 108 of the charging gun 102. During operation, the at least one locking projections 108 pass through the at least one locking notch 116 in the locking surface 114. Once engaged, the at least one locking projections 110 are held securely in the position between the resting surface 112 and the locking surface 114. Beneficially, the dual-surface locking mechanism ensures that the charging gun 102 is tightly and reliably held within the gun holder assembly 104. Furthermore, the locking of the at least one locking projection 108 between the resting surface 112 and the locking surface 114 protects the charging gun 102 from environmental factors such as dust, moisture, and external impacts.
In an embodiment, the gun holder assembly 104 comprises an insulation layer 118 inside the cavity 110, wherein the insulation layer 118 is configured to electrically isolate the charging gun 102 from the gun holder assembly 104. The insulation layer 118 may be provided within the cavity 110, which serves to electrically isolate the charging gun 102 from the surrounding structure of the gun holder assembly 104. Beneficially, the insulation layer 118 is strategically positioned to line the internal surfaces of the cavity 110, thereby creating a barrier that prevents any direct electrical contact between the charging gun 102 and the conductive materials of the gun holder assembly 104.
In an embodiment, the gun holder assembly 104 comprises at least one fastening mechanism 120 to fasten the gun holder assembly 104 in the charger. The at least one fastening mechanism 120 may include screws, bolts, clips, or other suitable securing components, which ensures a stable and vibration-resistant installation. Beneficially, the at least one fastening mechanism 120 allows for precise positioning of the gun holder assembly 104 within the charger housing, thereby ensures the compatibility with various charger designs and environmental conditions. Furthermore, the at least one fastening mechanism 120 facilitates ease of assembly and disassembly which significantly simplifies the maintenance or replacement of the gun holder assembly 104.
In an embodiment, the docking mechanism 100 comprises the charging gun 102 and the gun holder assembly 104 in the charger. The gun holder assembly 104 is configured to receive and securely hold the charging gun 102 via the at least one locking mechanism. Furthermore, the charging gun 102 comprises the protruding metal ring 106 fixed on the lateral surface of the charging gun 102. Furthermore, the protruding metal ring 106 comprises the at least one locking projection 108. Furthermore, the gun holder assembly 104 comprises the cavity 110 configured to receive the charging gun 102. Furthermore, the cavity 110 of the gun holder assembly 104 comprises the resting surface 112. Furthermore, the gun holder assembly 104 comprises the locking surface 114, wherein the locking surface 114 comprises the at least one locking notch 116. Furthermore, the at least one locking projection 108 passes through the at least one locking notch 116 to lock the at least one locking projection 108 between the resting surface 112 and the locking surface 114 to securely hold the charging gun 102. Furthermore, the gun holder assembly 104 comprises the insulation layer 118 inside the cavity 110, wherein the insulation layer 118 is configured to electrically isolate the charging gun 102 from the gun holder assembly 104. Furthermore, the gun holder assembly 104 comprises the at least one fastening mechanism 120 to fasten the gun holder assembly 104 in the charger.
In the description of the present invention, it is also to be noted that, unless otherwise explicitly specified or limited, the terms “disposed,” “mounted,” and “connected” are to be construed broadly, and may for example be fixedly connected, detachably connected, or integrally connected, either mechanically or electrically. They may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meaning of the above terms in the present invention can be understood in specific cases to those skilled in the art.
Modifications to embodiments and combination of different embodiments of the present disclosure described in the foregoing are possible without departing from the scope of the present disclosure as defined by the accompanying claims. Expressions such as “including”, “comprising”, “incorporating”, “have”, “is” used to describe and claim the present disclosure are intended to be construed in a non- exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural where appropriate.
Although embodiments have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the present disclosure, the drawings and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art.
,CLAIMS:We Claim:
1. A charging gun docking mechanism (100) of a charger, wherein the docking mechanism (100) comprises:
- a charging gun (102); and
- a gun holder assembly (104) in the charger,
wherein the gun holder assembly (104) is configured to receive and securely hold the charging gun (102) via at least one locking mechanism.
2. The docking mechanism (100) as claimed in claim 1, wherein the charging gun (102) comprises a protruding metal ring (106) fixed on a lateral surface of the charging gun (102).
3. The docking mechanism (100) as claimed in claim 2, wherein the protruding metal ring (106) comprises at least one locking projection (108).
4. The docking mechanism (100) as claimed in claim 1, wherein the gun holder assembly (104) comprises a cavity (110) configured to receive the charging gun (102).
5. The docking mechanism (100) as claimed in claim 4, wherein the cavity (110) of the gun holder assembly (104) comprises a resting surface (112).
6. The docking mechanism (100) as claimed in claim 1, wherein the gun holder assembly (104) comprises a locking surface (114), wherein the locking surface (114) comprises at least one locking notch (116).
7. The docking mechanism (100) as claimed in claim 6, wherein the at least one locking projection (108) passes through the at least one locking notch (116) to lock the at least one locking projection (108) between the resting surface (112) and the locking surface (114) to securely hold the charging gun (102).
8. The docking mechanism (100) as claimed in claim 7, wherein the locking of the at least one locking projection (108) between the resting surface (112) and the locking surface (114) protects the charging gun (102) from environmental factors.
9. The docking mechanism (100) as claimed in claim 1, wherein the gun holder assembly (104) comprises an insulation layer (118) inside the cavity (110), wherein the insulation layer (118) is configured to electrically isolate the charging gun (102) from the gun holder assembly (104).
10. The docking mechanism (100) as claimed in claim 1, wherein the gun holder assembly (104) comprises at least one fastening mechanism (120) to fasten the gun holder assembly (104) in the charger.