Embodiments of the present application relates to field of electric vehicle (EV) charging
5 infrastructure. More specifically, it pertains to the design and engineering of EV charging
connectors and systems.
BACKGROUND OF THE INVENTION
Background description includes information that may be useful in understanding the present
10 invention. It is not an admission that any of the information provided herein is prior art or
relevant to the presently disclosed invention, or that any publication specifically or implicitly
referenced is prior art.
In the current scenario of electric vehicles, there exists charging guns without a latching
15 mechanism, which leads to several operational issues in real-world scenarios. Users have
reported instances where the charging gun becomes accidentally disconnected from the
vehicle’s charging inlet. This disconnection often occurs due to inadvertent pulling of the cable
or when the vehicle is moved without noticing that the charging gun is still connected.
Additionally, there's a challenge with the partial engagement of the charging gun, which is not
20 easily detectable. This partial connection can lead to either no charging or incomplete charging,
adversely affecting the customer experience.
To address these problems, a foolproof retrofit design is required to ensure that the charging
gun remains securely connected and to prevent accidental disconnections. This solution must
25 be retrofittable, allowing the existing charging guns in the field to be upgraded without the
need for additional components or significant modifications. The proposed retrofit design aims
to enhance the reliability and user experience of the charging system by providing a robust and
secure connection mechanism.
30 SUMMARY OF THE INVENTION
The following presents a simplified summary of the subject matter in order to provide a basic
understanding of some of the aspects of subject matter embodiments. This summary is not an
extensive overview of the subject matter. It is not intended to identify key/critical elements of
3
the embodiments or to delineate the scope of the subject matter. Its sole purpose to present
some concepts of the subject matter in a simplified form as a prelude to the more detailed
description that is presented later.
5 A latch assembly (100) disclosed herein addresses the need for a foolproof retrofit design is
required to ensure that the charging gun (102) remains securely connected and to prevent
accidental disconnections. The latch assembly (100) comprises a charging gun (102), a
charging socket (104), an annular base member (106), and a longitudinal latch member (108).
The annular base member (106) comprises a radius R and width W with a first side (106a) and
10 a second side (106b), configured to be securely fastened to the charging gun (102). The
longitudinal latch member (108) extends tangentially in a direction along the width of the
annular base member (106). The latch member (108) comprises a wider first section (108a)
attached via slits (110) at the first side (106a) of the annular base member (106) and narrower
second section (108b) extending from the wider first section (108a) towards the second side
15 (106b) of the annular base member (106). The narrower second section (108b) is distally bent
at an angle to form a hook (112).
In an embodiment, upon connecting the charging gun (102) to the charging socket (104), the
hook (112) at the narrower second section (108b) of the latch member (108) engages with a tab
20 (118) on the charging socket (104). In an embodiment, the second side (106b) of the annular
base member (106) comprises an inner flange (124) with holes (120) to receive at least one
fastener (122) to fasten the charging gun (102). In an embodiment, the latch member (108)
further comprises a reinforcement element (114) that is positioned within latch member (108)
and between the slits (110) of the latch member (108). The reinforcement element (114) is
25 covered by the latch member (108) that is formed of plastic, and the reinforcement element
(114) extends till distal end of the hook (112).
In an embodiment, to release the locked position of the charging gun (102) with the charging
socket (104), a force is applied on a first end (108c) of the latch member (108) to lift the
30 opposite second end (108d) of the latch member (108) that contains the hook (112), which
disengages the hook (112) from the tab (118) of the charging socket (104). In an embodiment,
the hook (112) is deflectable within a range of 4.5mm to 5.5 mm. In an embodiment, the annular
base member (106) comprises multiple pairs of the slits (110) and notches (116). Each slit (110)
4
is opposingly cut with respect to each adjacent notch (116) to provide a tilt along an area that
stretches across the slits (110) and the notches (116), and each slit (110) is lesser in length
compared to each notch (116). In an embodiment, the reinforcement element (114) is a steel
insert.
5
Furthermore, a locking connector (200) is disclosed here that comprises an annular base
member (106) and a longitudinal latch member (108). The annular base member (106)
comprises a radius R and width W with a first side (106a) and a second side (106b). The
longitudinal latch member (108) extends tangentially in a direction along the width of the
10 annular base member (106). The latch member (108) comprises a wider first section (108a)
attached via slits (110) at the first side (106a) of the annular base member (106) and a narrower
second section (108b) extending from the wider first section (108a) towards the second side
(106b) of the annular base member (106). The narrower second section (108b) is distally bent
at an angle to form a hook (112).
15
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
The following drawings are illustrative of particular examples for enabling systems and
methods of the present disclosure, are descriptive of some of the methods and mechanism, and
are not intended to limit the scope of the invention. The drawings are not to scale (unless so
20 stated) and are intended for use in conjunction with the explanations in the following detailed
description.
FIGURE 1 shows an isometric view of a locking connector, as an example embodiment of the
present disclosure.
25
FIGURE 2 shows a side sectional view of a locking connector, as an example embodiment of
the present disclosure.
FIGURE 3A (1) shows an isometric view of the latch assembly before engagement, as an
30 example embodiment of the present disclosure.
FIGURE 3A (2) shows a side view of the latch assembly before engagement, as an example
embodiment of the present disclosure.
5
FIGURE 3B (1) shows an isometric view of the latch assembly after engagement, as an
example embodiment of the present disclosure.
5 FIGURE 3B (2) shows a side view of the latch assembly after engagement, as an example
embodiment of the present disclosure.
FIGURE 4A shows an isometric view of the latch assembly during assembly where the latch
member attached to the charging gun is pressed and lifted so that the latch member engages on
10 the tab of the charging socket, as an example embodiment of the present disclosure.
FIGURE 4B shows a side view of the latch assembly during assembly where the latch member
attached to the charging gun is pressed and lifted so that the latch member engages on the tab
of the charging socket, as an example embodiment of the present disclosure.
15
FIGURES 5A and 5B illustrate the second side of the annular base member featuring an inner
flange with holes designed to receive fasteners for securely attaching the charging gun, as an
example embodiment of the present disclosure.
20 Persons skilled in the art will appreciate that elements in the figures are illustrated for simplicity
and clarity and may represent hardware components of the system. Further, the dimensions of
some of the elements in the figure may be exaggerated relative to other elements to improve
understanding of various exemplary embodiments of the present disclosure. Throughout the
drawings, it should be noted that like reference numbers are used to depict the same or similar
25 elements, features, and structures.
DETAILED DESCRIPTION OF THE INVENTION
Exemplary embodiments now will be described. The disclosure may, however, be embodied
30 in many different forms and should not be construed as limited to the embodiments set forth
herein; rather, these embodiments are provided so that this disclosure will be thorough and
complete, and will fully convey its scope to those skilled in the art. The terminology used in
the detailed description of the particular exemplary embodiments illustrated in the
6
accompanying drawings is not intended to be limiting. In the drawings, like numbers refer to
like elements.
It is to be noted, however, that the reference numerals used herein illustrate only typical
5 embodiments of the present subject matter, and are therefore, not to be considered for limiting
of its scope, for the subject matter may admit to other equally effective embodiments.
The specification may refer to “an”, “one” or “some” embodiment(s) in several locations. This
does not necessarily imply that each such reference is to the same embodiment(s), or that the
10 feature only applies to a single embodiment. Single features of different embodiments may also
be combined to provide other embodiments.
As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms
as well, unless expressly stated otherwise. It will be further understood that the terms
15 “includes”, “comprises”, “including” and/or “comprising” when used in this specification,
specify the presence of stated features, integers, steps, operations, elements, and/or
components, but do not preclude the presence or addition of one or more other features,
integers, steps, operations, elements, components, and/or groups thereof. It will be understood
that when an element is referred to as being “connected” or “coupled” to another element, it
20 can be directly connected or coupled to the other element or intervening elements may be
present. Furthermore, “connected” or “coupled” as used herein may include operatively
connected or coupled. As used herein, the term “and/or” includes any and all combinations and
arrangements of one or more of the associated listed items.
25 Unless otherwise defined, all terms (including technical and scientific terms) used herein have
the same meaning as commonly understood by one of ordinary skill in the art to which this
disclosure pertains. It will be further understood that terms, such as those defined in commonly
used dictionaries, should be interpreted as having a meaning that is consistent with their
meaning in the context of the relevant art and will not be interpreted in an idealized or overly
30 formal sense unless expressly so defined herein.
Referring to FIGURES 1, 2, 3A (1,2) and 3B (1,2), a latch assembly (100) is introduced to
meet the necessity for a foolproof retrofit design that ensures the charging gun (102) remains
7
firmly attached and prevents accidental disconnections. This latch assembly (100) includes a
charging gun (102), a charging socket (104), an annular base member (106), and a longitudinal
latch member (108). The annular base member (106) features a radius R and width W, with a
first side (106a) and a second side (106b). The annular base member (106) is designed to be
5 securely affixed to the charging gun (102). The longitudinal latch member (108) extends
tangentially along the width of the annular base member (106). It has a broader first section
(108a) connected through slits (110) at the first side (106a) of the annular base member (106),
and a narrower second section (108b) that extends from the broader first section (108a) towards
the second side (106b). This narrower second section (108b) bends at an angle to form a hook
10 (112). As used herein, a “Charging Gun (102)” acts as the primary interface for engaging with
the charging socket (104). It is equipped with the necessary features to securely hold the latch
assembly (100) during operation. A “Charging Socket (104)” is the counterpart to the charging
gun (102), allowing for the reception and secure engagement of the gun, ensuring a stable
connection for charging.
15
The charging gun (102) is connected to the annular base member (106) at the first side (106a),
ensuring that the latch assembly (100) is aligned correctly for insertion into the charging socket
(104). When the charging gun (102) is brought close to the charging socket (104), the
longitudinal latch member (108) comes into contact with the socket’s latch receiving features.
20 The broader first section (108a) provides a sturdy attachment to the annular base member (106)
through the slits (110), allowing for a firm grip. As the charging gun (102) is further inserted,
the hook (112) formed by the narrower second section (108b) engages with the socket, securing
the connection between the charging gun (102) and the charging socket (104). This mechanism
ensures that the charging gun (102) remains locked in place during the charging process,
25 preventing accidental disconnections.
Additionally, the annular base member (106) may include multiple pairs of slits (110) and
notches (116). Each slit (110) is positioned opposite to each adjacent notch (116) to create a
tilt across the area spanning the slits (110) and notches (116), with each slit (110) being shorter
30 in length compared to each notch (116). In other words, the annular base member (106) is
designed with several pairs of slits (110) and notches (116). Each slit (110) is strategically
placed directly opposite its corresponding notch (116). This arrangement induces a tilt across
8
the region where the slits (110) and notches (116) are positioned. Notably, the slits (110) are
shorter in length than the notches (116), contributing to the desired tilting effect.
Referring to FIGURES 3A (1,2) and 3B (1,2), when the charging gun (102) is connected to
5 the charging socket (104), the hook (112) on the narrower second section (108b) of the latch
member (108) engages with a tab (118) on the charging socket (104). As soon as the charging
gun (102) is inserted into the charging socket (104), the system ensures a secure connection.
The hook (112), located on the slimmer part (108b) of the latch member (108), automatically
catches onto a corresponding tab (118) on the charging socket (104), locking the two
10 components together. The second side (106b) of the annular base member (106) features an
inner flange equipped with pre-drilled holes. These holes are specifically designed to hold
fasteners that secure the charging gun (102) in place, ensuring a stable and reliable attachment
during the charging process.
15 Referring to FIGURE 2, the latch member (108) incorporates a reinforcement element (114)
situated inside the latch member (108) and between the slits (110). The latch member (108),
made of plastic, covers this reinforcement element (114), which extends to the distal end of the
hook (112). The Reinforcement Element (114) is embedded inside the plastic structure of the
latch member (108). The reinforcement element (114) is positioned strategically between the
20 slits (110), as it plays a vital role in maintaining the rigidity and stability of the latch member
(108), ensuring it can withstand repeated use and substantial force without deforming or
breaking. This reinforcement is likely made from a material with higher tensile strength than
plastic, such as metal (e.g., steel or aluminium), or a high-strength composite material. The
slits (110) are intentional openings or cuts in the latch member's (108) body. They might serve
25 various functions such as allowing for the flexing of the latch member (108) during engagement
or providing points for mechanical interaction with other components. The positioning of the
reinforcement element (114) between these slits (110) is crucial. It ensures that the areas around
the slits (110), which are potential weak points, are supported and reinforced, preventing any
undue stress concentration that could lead to failure.
30
Furthermore, the latch member (108) extends towards a distal end, which includes a hook (112)
mechanism. This hook (112) is the part of the latch that physically engages with a
corresponding catch or loop to secure the connection. The reinforcement element (114) is
9
designed to extend all the way to this distal end, particularly around and supporting the hook
(112). This extension ensures that the hook (112) remains strong and effective even under
considerable load or repeated mechanical engagement and disengagement. The plastic material
not only forms the body of the latch member (108) but also encases the reinforcement element
5 (114). This encasement protects the reinforcement from corrosion and integrates it seamlessly
into the latch’s overall structure. By covering the reinforcement element (114), the plastic
ensures that the latch member (108) maintains a smooth and functional exterior surface, which
is important for consistent performance and aesthetic purposes. In one embodiment, the
reinforcement element (114) is a steel insert. The combined use of a plastic exterior and an
10 internal reinforcement element (114) ensures the latch member (108) balances flexibility with
strength. The plastic allows the latch member (108) to flex slightly, facilitating easy
engagement and disengagement, while the reinforcement element (114) prevents permanent
deformation and ensures longevity. The design consideration to extend the reinforcement to
the distal end and around the hook (112) area highlights the importance of maintaining strength
15 at the points where mechanical forces are most concentrated during use.
Referring to FIGURES 4A and 4B shows an isometric view of the latch assembly (100) during
assembly where the latch member (108) is attached to the charging gun (102) is pressed and
lifted so that the latch member (108) disengages from the tab (118) of the charging socket
20 (104), as an example embodiment of the present disclosure. To disengage the charging gun
(102) from the charging socket (104) in a locked state, one can apply force to the first end
(108c) of the latch member (108), lifting the opposite second end (108d) with the hook (112),
thereby releasing the hook (112) from the tab (118) on the charging socket (104). In other
words, to disconnect the charging gun (102) from the charging socket (104) when it's locked,
25 a user needs to apply force to the first end (108c) of the latch member (108). This action lifts
the opposite second end (108d), which holds the hook (112). As the hook (112) lifts, it releases
from the tab (118) on the charging socket (104), allowing the charging gun (102) to be easily
removed. In yet another embodiment, the hook (112) can deflect within a range of 4.5 mm to
5.5 mm.
30
Referring to FIGURES 5A and 5B, the second side (106b) of the annular base member (106)
comprises an inner flange (124) with holes (120) to receive at least one fastener (122) to fasten
the charging gun (102). The annular base member (106) is a circular or ring-shaped base
10
component. The term "annular" means it has a shape resembling a ring. The inner flange (124)
is on the second side (106b) of the annular base member, there is an inner flange. A flange is a
projecting flat rim or edge used for attachment or strengthening. The term "inner" suggests that
this flange is located on the inner part of the annular base member (106). The holes (120) are,
5 for example, but not limited to be evenly spaced around the inner flange (124) and are intended
to accommodate fasteners (122). As an example, at least one fastener (122) can be inserted into
the holes (120). The fastener (122) is, for example, screws, bolts, or other types of hardware
used to join or secure components together. The purpose of the fasteners (122) and the holes
(120) in the inner flange (124) is to securely attach the charging gun (102).
10
Furthermore, referring to FIGURES 1 and 2, a locking connector (200) is described,
comprising an annular base member (106) and a longitudinal latch member (108). The annular
base member (106) has a radius R and width W with a first side (106a) and a second side
(106b). The longitudinal latch member (108) extends tangentially along the width of the
15 annular base member (106). It includes a wider first section (108a) that is attached through slits
(110) at the first side (106a) of the annular base member (106) and a narrower second section
(108b) that stretches from the wider first section (108a) towards the second side (106b). This
narrower second section (108b) is bent at an angle at its distal end to form a hook (112).
20 Current invention has been discussed specifically with full disclosure. However, numerous
changes can be made in the detail of structures, combinations, and part arrangement along with
technical advancements that will be implemented in near future without changing the spirit and
scope of the invention.
25 Although the invention has been described with reference to specific embodiments, this
description is not meant to be construed in a limiting sense. Various modifications of the
disclosed embodiments, as well as alternate embodiments of the invention, will become
apparent to persons skilled in the art upon reference to the description of the invention. It is
therefore, contemplated that such modifications can be made without departing from the scope
30 of the present invention as defined.
11
We claim:
1. A latch assembly (100) comprising:
5 a charging gun (102);
a charging socket (104);
an annular base member (106) comprising a radius R and width W with a first
side (106a) and a second side (106b), configured to be securely fastened to the charging
gun (102); and
10 a longitudinal latch member (108) extending tangentially in a direction along
the width of the annular base member (106), wherein the latch member (108)
comprising a wider first section (108a) attached via slits (110) at the first side (106a) of
the annular base member (106) and narrower second section (108b) extending from the
wider first section (108a) towards the second side (106b) of the annular base member
15 (106), wherein the narrower second section (108b) is distally bent at an angle to form a
hook (112).
2. The latch assembly (100) as claimed in claim 1, wherein upon connecting the
charging gun (102) to the charging socket (104), the hook (112) at the narrower
20 second section (108b) of the latch member (108) engages with a tab (118) on the
charging socket (104).
3. The latch assembly (100) as claimed in claim 1, wherein the second side (106b) of the
annular base member (106) comprises an inner flange (124) with holes (120) to
25 receive at least one fastener (122) to fasten the charging gun (102).
4. The latch assembly (100) as claimed in claim 1, wherein the latch member (108)
further comprises a reinforcement element (114) that is positioned within latch
member (108) and between the slits (110) of the latch member (108), wherein the
30 reinforcement element (114) is covered by the latch member (108) that is formed of
plastic, and wherein the reinforcement element (114) extends till distal end of the
hook (112).
12
5. The latch assembly (100) as claimed in claim 1, wherein to release the locked position
of the charging gun (102) with the charging socket (104), a force is applied on a first
end (108c) of the latch member (108) to lift the opposite second end (108d) of the
latch member (108) that contains the hook (112), which disengages the hook (112)
5 from the tab (118) of the charging socket (104).
6. The latch assembly (100) as claimed in claim 1, wherein the hook (112) is deflectable
within a range of 4.5mm to 5.5 mm.
10 7. The latch assembly (100) as claimed in claim 1, wherein the annular base member
(106) comprises multiple pairs of the slits (110) and notches (116), wherein each slit
(110) is opposingly cut with respect to each adjacent notch (116) to provide a tilt
along an area that stretches across the slits (110) and the notches (116), and wherein
each slit (110) is lesser in length compared to each notch (116).
15
8. The latch assembly (100) as claimed in claim 1, wherein the reinforcement element
(114) is a steel insert.
9. A locking connector (200) comprising:
20 an annular base member (106) having a radius R and width W with a first side
(106a) and a second side (106b); and
a longitudinal latch member (108) extending tangentially in a direction along
the width of the annular base member (106), wherein the latch member (108)
comprising a wider first section (108a) attached via slits (110) at the first side (106a)
25 of the annular base member (106) and a narrower second section (108b) extending
from the wider first section (108a) towards the second side (106b) of the annular base
member (106), wherein the narrower second section (108b) is distally bent at an angle
to form a hook (112).
30 10. The locking connector (200) as claimed in claim 9, wherein the second side (106b) of
the annular base member (106) comprises an inner flange (124) with holes (120) to
receive at least one fastener (122) to fasten the charging gun (102).
13
11. The locking connector (200) as claimed in claim 9, wherein the latch member (108)
further comprises a reinforcement element (114) that is positioned within latch
member (108) and between the slits (110) of the latch member (108), wherein the
reinforcement element (114) is covered by the latch member (108), and wherein the
5 reinforcement element (114) extends till distal end of the hook (112).
12. The locking connector (200) as claimed in claim 10, wherein to release the locked
position of the charging gun (102) with a charging socket (104), a force is applied on
a first end (108c) of the latch member (108) to lift the opposite second end (108d) of
10 the latch member (108) that contains the hook (112), which disengages the hook (112)
from a tab (118) of the charging socket (104).
13. The locking connector (200) as claimed in claim 9, wherein the annular base member
(106) comprises multiple pairs of the slits (110) and notches (116), wherein each slit
15 (110) is opposingly cut with respect to each adjacent notch (116) to provide a tilt
along an area that stretches across the slits (110) and the notches (116), and wherein
each slit (110) is lesser in length compared to each notch (116).