CROSS REFERENCE
The present disclosure is a cognate of Indian Patent Application No.
201741020339 filed on 9 June 2017 and Indian Patent Application No.
201741020340 filed on 9 June 2017.
TECHNICAL FIELD
The present disclosure relates to a charger unit. More particularly, the disclosure relates to a charging connector for charging an energy storage unit.
(B60L11/1818 Adaptations of plugs or sockets for charging electric vehicles)
BACKGROUND
As electric vehicles are increasing all around the world, the problems associated with the use and maintenance of the electric vehicles are also increasing. Electric vehicles are powered using batteries and need to be recharged after the consumption of the charge stored in the batteries. Similarly, the batteries may be employed in various other energy distribution devices such as power generators, battery banks etc.
Currently, the majority of such devices are required to be taken to a charging station for recharging. The existing charging stations have a lot of shortcomings associated with themselves, such as shortage of charging stations, shortage of power supply, non-standardized charging connector, size and weight of charging connector, etc.
The present disclosure aims at solving the problem associated with the size and weight of the charging connectors. The currently used charging connectors are big, bulky, and are designed for large devices such as car, bus, truck, generators etc. Due to the larger size of such devices, there is plenty of spaces available for installing the charging equipment and charging port. Therefore, the currently

used charging connectors are designed big and bulky for ease of production. However, the handling/usage of such big and bulky charging connectors is laborious. Further, small devices (such as small electric vehicles, small electric power banks) have space restrictions and need to be recharged more frequently. Therefore, the big and bulky charging connectors becomes less useful for small electric devices and also lacks in ergonomics aspect.
Therefore, in light of the aforementioned drawbacks and the other inherent in the existing arts, there is a need for a compact, ergonomic, and light-weight charging connectors.
SUMMARY
Accordingly, one aspect of the present invention relates to a charging socket configured to transfer at least one data and an energy to a device, the charging socket comprises: a first plurality of terminals configured to transfer the at least one data, wherein each of the first plurality of terminals, having a first central axis, is inter-spaced with a first gap [Gl], and the first gap [Gl] corresponds to a distance between the first central axis of each of the first plurality of terminals; a second plurality of terminals configured to transfer a first power, wherein each of the second plurality of terminals, having a second central axis, is inter-spaced with a second gap [G2], and the second gap [G2] corresponds to a distance between the second central axis of each of the second plurality of terminals; a third plurality of terminals configured to transfer a second power, wherein each of the third plurality of terminals, having a third central axis, is inter-spaced with a third gap [G3], and the third gap [G3], corresponds to a distance between the third central axis of each of the third plurality of terminals; a fourth plurality of terminals configured to transfer at least one signal, wherein the fourth plurality of terminals comprises at least a control pilot terminal and a proximity terminal, and each of the fourth plurality of terminals, having a fourth central axis, is inter¬spaced with a fourth gap, and the fourth gap [G4] corresponds to a distance

between the fourth central axis of each of the fourth plurality of terminals; wherein the first plurality of terminals, the second plurality of terminals, the third plurality of terminals, and the fourth plurality of terminals, maintaining a minimum required electrical clearance and minimum required creepage distance, mate with a corresponding plurality of plugs of the device for transferring at least one data and the energy to the device.
Another aspect of the present invention relates to a charging connector configured to transfer at least one data and an energy to a device. The charging connector comprises a charging socket and a handheld unit. The charging socket, maintaining a minimum required electrical clearance and minimum required creepage distance, is configured to transfer at least one data and an energy to a device, the charging socket comprises: a first plurality of terminals configured to transfer the at least one data, wherein each of the first plurality of terminals, having a first central axis, is inter-spaced with a first gap [Gl], and the first gap [Gl] corresponds to a distance between the first central axis of each of the first plurality of terminals; a second plurality of terminals configured to transfer a first power, wherein each of the second plurality of terminals, having a second central axis, is inter-spaced with a second gap [G2], and the second gap [G2] corresponds to a distance between the second central axis of each of the second plurality of terminals; a third plurality of terminals configured to transfer a second power, wherein each of the third plurality of terminals, having a third central axis, is inter-spaced with a third gap [G3], and the third gap [G3], corresponds to a distance between the third central axis of each of the third plurality of terminals; a fourth plurality of terminals configured to transfer at least one signal, wherein the fourth plurality of terminals comprises at least a control pilot terminal and a proximity terminal, and each of the fourth plurality of terminals, having a fourth central axis, is inter-spaced with a fourth gap, and the fourth gap [G4] corresponds to a distance between the fourth central axis of each of the fourth plurality of terminals; wherein the first plurality of terminals,

the second plurality of terminals, the third plurality of terminals, and the fourth plurality of terminals, maintaining a minimum required electrical clearance and minimum required creepage distance, mate with a corresponding plurality of plugs of the device for transferring at least one data and the energy to the device. Further, the handheld unit comprises a first end and a second end, wherein the first end is configured to mount the charging socket, and the second end is configured to connect a power source. Lastly, the charging connector is configured to mate with a corresponding socket of the device for transferring the at least one data and the energy to the device.
Other objects, features, and advantages of the present disclosure will become apparent from the following detailed description.
BRIEF DESCRIPTION OF THE DRAWING
The accompanying drawings, which are incorporated herein and constitute a part of this disclosure, illustrate exemplary embodiments of the present disclosure like reference numerals refer to the same parts throughout the different drawings. Components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present disclosure. Also, the embodiments shown in the figures are not to be construed as limiting the disclosure, but the possible variants of present disclosure are illustrated herein to highlight the advantages.
Figure 1 illustrates a front view of the charging connector, in accordance with an exemplary embodiment of the present disclosure.
Figure 2 illustrates a top view of the charging connector, in accordance with an exemplary embodiment of the present disclosure.
Figure 3 illustrates a top view of the charging connector, in accordance with an exemplary embodiment of the present disclosure.

It may be evident to skilled artisans that mechanical components in the figure are only illustrative, for simplicity and clarity, and have not necessarily been drawn to scale. For example, the dimensions of some of the mechanical components in the figure may be exaggerated relative to other elements to help to improve understanding of embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
In the following description, for the purposes of explanation, various specific details are set forth in order to provide a thorough understanding of the present disclosure. It will be apparent, however, that the present disclosure can be practiced without these specific details. Several features described hereafter can each be used independently of one another or with any combination of other features. However, any individual feature may not address any of the problems discussed above or might address only one of the problems discussed above. Some of the problems discussed above might not be fully addressed by any of the features described herein. Although, headings are provided, information related to a particular heading, but not found in the section having that heading, may also be found elsewhere in the specification. Example embodiments of the present disclosure are described below, as illustrated in various drawings in which like reference numerals refer to the same parts throughout the different drawings.
The present disclosure relates to a compact, light-weight and ergonomic charging connector for transferring an energy and at least one data to a device.
As used herein above the term "device" may refer to a unit configured with an energy storage unit and a control unit. The device may include, but not limited to a vehicle and a power distribution system. Further, the energy storage unit may be configured to store energy/power, such as battery, cell, power bank etc., whereas the control unit may be configured to manage the functioning/working

of either the device or the energy storage unit. The control unit may be, but not limited to, a controller of a power distribution system, Vehicle Control Unit (VCU) of the vehicle and Battery management system (BMS) of the vehicle. As explained above, the charging connector transfers the energy and the data to the device. In order words, the charging connector transfers power to the energy storage unit, whereas the data is transferred to the control unit.
Figure 1 illustrates the front view of the charging connector [100]. As shown in Figure 1, the charging connector [100] comprises a charging socket [110] and a handheld unit [120].
The charging connector [100] is configured to connect with the device and transfer a power/energy and at least one data. The charging connector [100] is configured to receive power from at least one power source, such as a charging station, direct grid lines etc. and transfer/provide the received power to the device. The charging connector [100] also comprises plurality of lines/cables /configured to communicate at least one data with the device.. Further, the charging connector [100] may be dust proof, water proof or standard compliant such as IP67, IP68 proof etc. Lastly, as shown in Figure 1, the charging connector [100] comprises the charging socket [110] and the handheld unit [120]. In one embodiment, the charging socket [110] and the handheld unit [120] are integrally connected to form the charging connector [100]. In another embodiment, the charging socket [110] and the handheld unit [120] are modular in nature and are connected to form the charging connector [100].
The charging socket [110] comprises a handheld unit end and a lip end. The handled unit end of the charging socket [110] is configured to be mounted on a first end [122] of the handheld unit [120] whereas the lip end of the charging socket [110] is configured to semi-enclose or fully enclose the plurality of terminals (male mating members) extending out of the charging socket [112]. In another embodiment, the lip end of the charging socket [100] may be configured

to semi-enclose or fully enclose a plurality of plugs (female mating members). The lip end actually comprises a lip portion which encloses (semi or fully) the plurality of terminals. Further, the lip portion provides mechanical strength to the charging socket [110].
As shown in Figure 2, the charging socket [110] comprises of the plurality of terminals, namely, a first plurality of terminals [102], a second plurality of terminals [104], a third plurality of terminals [106], and a fourth plurality of terminals [108]. In another embodiment, the charging socket [100] may comprise the plurality of plugs, namely, a first plurality of plugs, a second plurality of plugs, a third plurality of plugs and a fourth plurality of plugs. In an event, the charging socket comprise the plurality of terminals, the corresponding socket on the device comprises the plurality of plugs or vice-versa. Further the plurality of terminals is configured to mate with the plurality of plugs and vice-versa. In other words, the charging connector [100] is configured to mate with a corresponding socket of the device.
Further, Figure 3 illustrates the structural arrangement of the plurality of terminals (the first plurality of terminals [102], the second plurality of terminals [104], the third plurality of terminals [106], and the fourth plurality of terminals [108].
The first plurality of terminals [102] are configured to communicate the at least one data between the power source and the device. The at least one data may include, but not limited to, a proximity data, a weather data, battery data, vehicle data, user data, location data, temperature, and a control data. The first plurality of terminals [102] may use TRS, TS, TRRS, TRRRS connectors for communicating multiple signals and thereby, reducing the size (form factor). In an embodiment, the first plurality of terminals [102] may include Controlled Area Network Terminals (CAN Terminals). The CAN terminals may be configured to communicate the at least one data between the power source and the device

(eg. VCU, BMS), for authentication of the device. The at least one data may also include, a charging status, an electrical characteristic, a rating of power source, etc. Further, the power source may also use high data bandwidth network techniques for communicating location-based information and supporting services. The first plurality of terminals [102] may also establish a communication network with the device and share multiple parameters or data points.
The second plurality of terminals [104] is configured to transfer a first power to the device. The first power may be an alternating current (AC) power. The second plurality of terminals [104] includes at least one AC terminal, one neutral terminal, and one ground terminal and a combination. The AC terminal is configured to provide AC power to the device, whereas the neutral terminal and the ground terminal are configured to act as neutral and ground, respectively.
The third plurality of terminals [106] is configured to transfer a second power to the device. The second power may be a direct current (DC) power. The third plurality of terminals [106] includes at least one DC terminal. The DC terminal may be a positive DC terminal or a negative DC terminal or both. The at least one DC terminal is configured to provide DC power to the device.
The fourth plurality of terminals [108] is configured to communicate at least one signal between the power source and the device. The at least one signal may be at least one of a proximity signal, a control signal, and an earth continuity signal. Further, the fourth plurality of terminals [108] includes a control pilot terminal and a proximity terminal. The control terminal is configured to check the earth continuity and check the working of all the control signals. On detecting a continuous earth continuity, the control terminal signals the first plurality of terminals [102] (CAN terminals) to communicate with the device and authenticate the device. The proximity terminal is configured to detect the successful mating of the charging connector [110] with the corresponding socket of the device and communicate this information in-between the device and the

power source. Further, the proximity terminal either intermittently or continuously checks the mating status of the charging connecter i.e. either connected or detached. In other words, the proximity terminal is configured to detect the successful mating of the first plurality of terminals [102], the second plurality of terminals [104], the third plurality of terminals [106], and the fourth plurality of terminals [108] with the corresponding plurality of plugs of the device and communicate this information in-between the device and the power source. Further, on receiving the information of successful mating at both the device and the power source, the source transfers the energy to the device.
Further, each of the first plurality of terminals [102] have a first central axis. The first central axis is an imaginary line/axis which passes through the center of the each of the first plurality of terminals [102]. As illustrated in Figure 3, each of the first plurality of terminals [102] is inter-spaced with a first gap [Gl]. The first gap [Gl] corresponds to a distance between the first central axis of each of the first plurality of terminals [102].
Similarly, each of the second plurality of terminals [104] have a second central axis. The second central axis is an imaginary line/axis which passes through the center of the each of the second plurality of terminals [104]. Further, each of the second plurality of terminals [104] is inter-spaced with a second gap [G2]. The second gap [G2] corresponds to a distance between the second central axis of each of the second plurality of terminals [104].
Similarly, each of the third plurality of terminals [106] have a third central axis. The third central axis is an imaginary line/axis which passes through the center of the each of the third plurality of terminals [106]. Further, each of the third plurality of terminals [106] is inter-spaced with a third gap [G3]. The third gap [G2] corresponds to a distance between the third central axis of each of the third plurality of terminals [106].

Similarly, each of the fourth plurality of terminals [108] have a fourth central axis. The fourth central axis is an imaginary line/axis which passes through the center of the each of the fourth plurality of terminals [108]. Further, each of the fourth plurality of terminals [108] is inter-spaced with a fourth gap [G4]. The fourth gap [G4] corresponds to a distance between the fourth central axis of each of the fourth plurality of terminals [108].
Further, a distance between any of the first central axis of the first plurality of terminals [102], the second central axis of the second plurality of terminals [104], the third central axis of the third plurality of terminals [106], the fourth central axis of the fourth plurality of terminals [108], and combination thereof varies between 2 mm and 28 mm. The range varying in-between 2 mm and 28 mm maintains a required electrical clearance and minimum required creepage distance. The required electrical clearance is the minimum gap required to electrical isolate each of the plurality of terminals. Similarly, the minimum required creepage distance is the minimum gap required to prevent creepage of charge in-between the each of the plurality of terminals. Furthermore, this range also allows the charging socket [110] to be compact (small form factor) and cheap in manufacturing. In an event, said in-between distance is below 2 mm, the charging socket [110] fails to maintain the required electrical clearance and the minimum required creepage gap. In another event, said in-between distance is more than 28 mm, the compactness (small form factor) of the charging socket [110] is decreased considerably and the manufacturing cost of the charging socket [110] is increased considerably. In another embodiment, the distance between any of the first central axis of the first plurality of terminals [102], the second central axis of the second plurality of terminals [104], the third central axis of the third plurality of terminals [106], the fourth central axis of the fourth plurality of terminals [108], and combination thereof varies between 3.3 mm and 27.6 mm.

Further, the diameter of the first plurality of terminals [102], the second plurality of terminals [104], the third plurality of terminals [106], and the fourth plurality of terminals [108] varies in the range between 1.1 mm and 6 mm. This range varying in-between 1.1 mm and 6 mm ensures a small form factor and also ensure safety of the plurality of terminals considering high voltages. In an event, the above said diameter is below 1.1 mm, the plurality of terminals fails/burns due to high voltage. In another event, the above said diameter is above 6 mm, the compactness (small form factor) of the charging socket [110] decreases considerably and the manufacturing cost of the charging socket [110] also increases considerably. In an embodiment, the diameter of the first plurality of terminals [102] and the fourth plurality of terminals [108] varies between 1.1 mm and 3.5 mm, whereas in another embodiment, the diameter of the second plurality of terminals [104] and the third plurality of terminals [106] varies between 2.8 mm and 6 mm.
Further, an engagement length of the first plurality of terminals [102], the second plurality of terminals [104], the third plurality of terminals [106], and the fourth plurality of terminals [108] varies between 10 mm and 22 mm. As used herein, the engagement length refers to the length of the terminal. This range varying in-between 10 mm and 22 mm ensures a small form factor and also ensure safety of the plurality of terminals considering high voltages. In an event, the above said engagement length is less than 10 mm, the plurality of terminals fails/burns due to high voltage. In another event, the above said diameter is more than 22 mm, the compactness (small form factor) of the charging socket [110] decreases considerably and the manufacturing cost of the charging socket [110] also increases considerably. In an embodiment, the engagement length of the first plurality of terminals [102] and the fourth plurality of terminals [108] varies between 10 mm to 18 mm. In another embodiment, the engagement length of the second plurality of terminals [104] and the third plurality of terminals [106] varies between 13 mm to 22 mm. Lastly, it is clear from the

above the first plurality of terminals [102] and the fourth plurality of are smaller than the second plurality of terminals [104] and the third plurality of terminals [106]. The smaller first plurality of terminals [102] and the fourth plurality of terminals [108] allows the source to know that there is proper mating and proper earth available and thereafter only, the transfer of energy starts. Therefore, during the mating of the first plurality of terminals [102], the second plurality of terminals [104], the third plurality of terminals [106], and the fourth plurality of terminals [108] with the corresponding plugs on the device, the first plurality of terminals [102] and the fourth plurality of terminals [108] get electrically connected after the second plurality of terminals [104] and the third plurality of terminals [106].
Similarly, during un-mating of the first plurality of terminals [102], the second plurality of terminals [104], the third plurality of terminals [106], and the fourth plurality of terminals [108] from the corresponding plugs of the device, the first plurality of terminals [102] and the fourth plurality of terminals [108] get electrically disconnected before the second plurality of terminals [104] and the third plurality of terminals [106].
Most importantly, the distance between the plurality of axis (the first axis, the second axis, the third axis, and the fourth axis), the diameter of the plurality of terminals and the engagement length of the terminals ensures that the form factor of the charging socket [110] is very low and the required electrical clearance and minimum required creepage distance is also maintained. This makes the charging socket [110] socket very compact, light-weight and cheap due to low manufacturing cost. This in turn makes the charging connector [100] very compact, light-weight and cheap due to low manufacturing cost.
Lastly, the plurality of terminals is designed to handle rated electrical voltage and current in a smaller form factor. The plurality of terminals may use lower resistance material for better electrical characteristic. The plurality of terminals

may also include high quality insulation material to protect against electrical accidents, e.g. short circuit. Additionally, plurality of terminals is designed to withstand continuous ambient temperatures in the range of 0 °C to +50 °C during operation when supplied with the power source and continuous ambient temperatures in the range of 25 -10 °C and +80 °C during shipping or storage.
In an embodiment, the charging socket [110] may include a magnetic ring around the lip portion. The magnetic ring may be used to correctly hold the charging connector [100] at the power source/charging station. In another embodiment, a horse shoe magnet is used in place of magnetic ring. The charging socket [110] may also use multiple magnetic blocks arranged to form a pattern. The magnetic block pattern may be utilized to suitably orient the charging connector [100] in the power source/charging station. Such an arrangement may enhance the user experience and limit mechanical abuse. In another embodiment, the charging connector [100] may include an electromagnet and the power source/charging station comprises a permanent magnet or patterned permanent magnet arrangement.
Further, a potting material may be filled around the plurality of terminals to enable passive cooling. The potting material may be a thermosetting plastics or silicone rubber gels or silicone or epoxy or Araldite potting compound. All plurality of terminals is arranged to provide sufficient clearance & creepage protection. The connector socket [110] may include a removable or movable lid for ingress protection. The connector socket [110] may include a tactile and/or audible feedback mechanism to provide notification to the user when the device is engaged/operational. In an embodiment, the plurality of terminals may comprise a built-in fuse element to prevent damages caused due to overcurrent or overvoltage. In another embodiment, the plurality of terminals is designed to include special geometric features that function as an overcurrent fuse. Further, the charging socket [110] may comprise a hole on which is used to mechanically lock

the corresponding socket of the device during charging operations. The corresponding socket of the device also comprises an extruded member which effectively locks against the hole of the charging socket [110]. In another embodiment, the charging socket [110] may comprise an extruded member to lock against a hole on the corresponding socket on the device.
Further, the handheld unit [120] is a mechanical member configured to hold the charging connector [100]. The handheld unit [120] comprise the first end [122] and a second end [14]. The first end [122] is configured to mount the charging socket [110], whereas the second end [124] is configured to receive the power cables/lines from the power source/charging station. The handheld unit [120] may be designed to include an angular grip for increasing the ergonomics of the charging connector [100]. The angled grip may ease the mating of the charging connector [100] with the corresponding socket of the device. The angled grip may also be provided with an orientation mark of charging connector [100] for the user. In another embodiment, corresponding socket of the device may require a non-angled straight grip for easy mating, therefore the grip may have movable angular joint or a flexible middle portion. The grip may be made of a rubber or rubber felt surface for providing better grip to the user. The rubber surface may also be made of a polymer soft material surface for longer life and ease of manufacturing. Further, the handheld unit [120] is designed in such a way that the user gets a sense of orientation of the charging socket [110] for fast and safe mating with corresponding socket of the device. In an embodiment, the handheld unit [120] may utilize physical features such a small depression area on the handheld unit in line with the hole on the charging socket [110] for the lock. The thumb depression may be replaced with a mark to indicate the correct sense of orientation. In another embodiment, the thumb depression may also comprise a biometric sensor for authorizing/enabling the charging. The connector may also use a haptic feedback for communicating information to the user. The information may be availability of power for charging or charging status of the device, error in the charging connector [100]. Additionally, the handheld unit [120] is economically designed to prevent any wrong usage of the charging

connector [110]. The maximum external touch temperature of the coupling formed due to the mating of the charging connector 100 with the device may not be greater than 60 °C when the ambient temperature is 40 °C.
Lastly, the charging connector [100] may further comprise of multiple light emitting devices (LED) around the periphery of the charging socket [110] or handheld unit [120]. The LEDs may provide illumination for proper visibility of charging port on an EV. The LEDs may also provide feedback to user regarding charging process or powering conditions. The LED may use any limit producing electronic component such as diodes, lasers, or OLED.
In a nutshell, the present disclosure provides a charging connector which is easy to use, compact in size, light-weight and user friendly.
Although, the present disclosure has been described in considerable detail with reference to certain preferred embodiments and examples thereof, other embodiments and equivalents are possible. Even though numerous characteristics and advantages of the present disclosure have been set forth in the foregoing description, together with functional and procedural details, the disclosure is illustrative only, and changes may be made in detail, within the principles of the disclosure to the full extent indicated by the broad general meaning of the terms. Thus, various modifications are possible of the presently disclosed system and process without deviating from the intended scope and spirit of the present disclosure. Accordingly, in one embodiment, such modifications of the presently explained disclosure are included in the scope of the present disclosure.