Field of invention
The present invention relates lo a power socket for two wheeler vehicle for user comfort in an
automobile, particularly, the present invention relates to a Mobile charger socket with extending
feature of protection and current limiting feature. This mobile socket have protective knob
locking & sealing construction, Knob orientation locking construction, sheet metal inner case
design to hold the available standard charger during vibration & protective knob hinge design in
automobile field such as two wheeler vehicle, more particularly, the present invention relates to
specific circuit design consideration for user mobile charging application.
Background of the invention
Jn prior art, two & four wheeler automobile market, this type application is already being used,
in four wheeler this application is known as Cigarette Lighter which is integration of mobile
charger socket and Cigarette Lighter, but major disadvantage is that it is not fully protected from
environmental (due to fitment on car dash panel) and there is no separate electronics protection
available which is necessary to protect the user mobile and battery life. In four wheeler this type
of application is available and have rated as load 1 OAmp or more and in Mechanical type it
means user can use other devices which can take up to 10 Amp or more.
In two wheeler, the fitment and position of product is on vehicle panel near
Speedo-meter and inside the glove box etc in open environment (Dust, Water, Chemicals and
Heat). The battery capacity is less in 2 wheelers and there is no ECU protection to this device. So
application has changed in electronic type with protection and only for mobile charging purpose.
In two-wheeler same electronic type product is also being used but disadvantage is-it is not fully
protected i.e. EMC/EMI, Transients, Cc. in both cases like environment or electronic protection.
In present design available in two wheelers, the mobile charger socket are designed with
resettable fuse protection to charge user mobile which has disadvantage-that output current value
varies with temperature variation. The mobile charger socket can charge the mobile when
available (market), standard charge plug inside the socket when some specific force (Insertion
Force) is applied to standard charger. Upon release of insertion force, the mobile charger into
mobile socket holds by inner case holding snap and inner diameter design and it cannot come
out during vehicle running condition (i.e. vibration).and integrated sealed knob closed and open
in socket by push & pull force to protect from external environmental effects and before
insertion of standard charger in socket
Figure 1 illustrates an existing mobile charger socket (1). The charging socket (1) mainly
includes a plastic protective knob (2), an o-ring (3), a threaded copper rivet (4), a sheet metal
bending part (5) , a plastic insulator base (6), a sheet metal inner case (7), a brass terminal large
(8), a plastic body (9), a brass small terminal (10), a threading nut (11), an electronic PCB assly
(12), an electronic assly plastic" holder (13) and last wire harness (14) which is assemble with
electronic assly (12) for battery current sources to charge the mobile then electronic assly (12)
protected inside the electronic assly holder (13) by epoxy resin
The plastic body (9) is a stationary part and can be mounted on vehicle at different place by
different assembly method. Referring to Figure 2, an o-ring (3) is assemble in knob (2), threaded
rivet (4), a sheet metal bending part (5), a plastic insulator base (6), a sheet metal inner case (7),
a terminal large (8) assembled in a plastic body (9) from top side as shown in figure 2(a) shown
by arrow and a small terminal (10), a threading nut (11) screwed in body (9) from bottom side of
a plastic body (13), a flexible hinge feature (16) of protective knob (2) properly guided in a
plastic body (9) in rectangular cut (17). The electronic PCB assembly (12) assembled in plastic
holder (13) from bottom side and soldered on a small terminal (10) & a terminal large (8). The
electronic PCB assembly (12) to be assembled after assembly of all parts as discussed above and
a electronic assly plastic holder (13) fit with a plastic body (9) by a press fit method and epoxy
resin potted inside the an electronic assly holder vacant area to protect from external
environment. When a standard charger is inserted into mobile charger socket as shown in Fig-1
by insertion force, the charger automatically gets locked by a sheet metal holding strip (5) and
mating charger snap which apply opposite force inside the sheet metal inner case (7) on inner
diameter and charger proper located in center, tip of charger directly touches to a positive rivet
(4) and negative on sheet metal inner case (7).
So that charging circuit completed and current directly supplies to user mobile for charging
purpose via couple of wire (14) and charging pins for different mobile
In the above mentioned existing mobile
charging socket, due to knob dynamic movement in sheet metal inner case (7), an o-ring (3)
fitted knob (2), looses compression properties after certain cycle and water entry happened and
knob (2) flexible hinge(16) breakage also easily & come out during vibration test. The existing
mobile charger socket required additional sheet metal holding strip (5) which is also working for
cigarette lighterfunctfon~Tmd"ro~hold the standard charger to avoid intermittent ourpirrtcriTser
mobile and also existing electronic mobile socket is not fully automotive electronic fully
protected-like surge protection was not provided.
Objective of the present invention
The main objective of the present invention is to overcome at least one of the above problems.
Another objective of the present invention is to provide a power/mobile charger socket having
improved electronic/electric protection
Still another objective of the present invention is to provide a power/mobile charger socket
having locking construction for preventing water leakage
Yet another objective of the present invention is to provide a power/mobile charger socket
having knob sealing sothat knob not come out during usage
Another another objective of the present invention is to provide a power/mobile charger socket
having a drain hole feature(direct hole)
Still another objective of the present invention is to provide power/mobile charger socket having
unique washer/inner case design
Summary of the Invention
The present invention provides a two wheeler mobile charger socket/power socket for vehicle
feature for user mobile charging purpose/rigi • ette lighter/power socket in automobiles.. Below
are invention summary points.
1. Body & Knob locking construction as well as knob seal & sealing design construction is
to avoid the water entry from external as well testing method. Also it helps knob to
remain closed even under vibration condition.
2. Knob orientation locking construction design in mobile charger socket for vehicle
assembly feasibility.
^
3. Knob hinge shape, size & dimensions, design consideration is to increase the cycle life.
4. Sheet metal inner case designed in such a way is to eliminate the existing additional
bimetal sheet strip holding andilso restrict the fitment of cigarette lighter.
5. As discussed existing mobile socket not automotive electronic fully protected but in
current cut-off circuit designed for automotive protection
6. Sealing Washer & PCB holder construction design to eliminate the epoxy leakage at
product assembly joint.
7. Electronic PCB assembly method to'reduce PCB size & product packaging size for
customize design
8. Outer sealing ring provided on plastic body which abuts with panel and protects the
mobile socket fitment area from dust, water, etc.
9. Indirect drain hole channel design to water drainage because of product fitment on
vehicle, because of battery fumes come inside through direct drain hole which may be
harmful for plating parts so direct drain hole not provided.
Brief description of drawings
Further aspects and advantages of the present invention will be readily understood from the
following detailed description with reference to the accompanying figures of the drawings.
The figures together with a detailed description below, are incorporated in and form part of
the specification, and serve to further illustrate the embodiments and explain various
principles and advantages but not limiting the scope of the invention. In the accompanying
drawings,
Figure 4 to figure 12 illustrates show current innovation & embodiment
Figures 6, 6(a), 7(a) & figure 8 illustrate a locking & sealing construction and its components
embodiment with Power socket & Cigrate lighter
Figures 8 show a fitment of sealing washer & hinging profile design is embodiment with power
socket & cigrate lighter
Figures 5 illustrate a mobile socket assembly and sequence of knob locking and sealing assembly
is embodiment with Power socket & Cigrate lighter.
Figure 7 show a protective knob locking with anti rotation step arrangement with body and its
embodiment
With power socket & Cigrate lighter
Figures 11 illustrate a cut section of mobile socket and embodiment of inner case charger locking
lug design (27) & fitment in body at proper orientation (42jTvith power socket & cigrate lighter
Figure 12 illustrate a sealing method between body (30) & PCB holder by annular snap method,
body has semi-circular ring feature (81) and same under-cut in PCB holder (83)
Detailed description of the present invention
Accordingly, it is an object of the present invention to provide a mobile charger socket which
overcomes at least one of the problems associated with the "existing mobile socket. Another
object of the present invention is to provide sealed type mobile charger socket design which has
more durability in regular open environment.
Another objective of this present invention to improve the vehicle battery life by electronic
circuit design which draw a less consumption of current to user mobile and cutoff and reconnect
again.
While the invention is susceptible to various modifications and alternative forms, specific
embodiment thereof has been shown by way of example in the figures and will be
described in detail below. It should be understood, however that it is not intended to limit the
invention to the particular forms disclosed, but on the contrary, the invention is to cover all
modifications, equivalents, and alternative falling within the spirit and the scope of the
invention as defined by the appended claims.
Before describing in detail the various embodiments of the present invention it may be
observed that the novelty and inventive step that are in accordance with the present
invention resides in the construction of mobile charger socket. It is to be noted that a person
skilled in the art can be motivated from the present invention and modify the various
constructions of switch module. However, such modification should be construed within the
scope and spirit of the invention.
Accordingly, the drawings are showing only those specific details that are pertinent to
understanding the embodiments of the present invention so as not to obscure the disclosure
with details that will be readily apparent to those of ordinary skill in the art having benefit
• n
of the description herein.
The following description describes the present invention with reference to Figures 2-1?.
Referring to Figures 5, shows the assembly sequence of mobile charger socket in which top half
and bottom half assembly includes due to design constraint of electronic PCB assembly. Now
below figures descriptions will explained at feature basis assembly
Referring to figure 7, show locking orientation construction of protective knob "(20) is having a
circular ring (56) and guiding slot protrusion (59) before fitment with body (30), a protective
knob guiding slot protrusion (59) initially guided with body (30) locking protrusion (49) to stop
the anti rotation and some external force apply upon circular ring (56) which integrated part of
protective knob (20) through a connecting protrusion (61) to fit properly with body (30), and
guide properly within four locking body (30) snap (51).
Referring to figure 8 shows the assembly of sealing washer (21) is having internal diameter and
outer diameter assemble with protective knob (20) by manual external force. The sealing washer
(21) internal diameter guided with protective knob (20) bosses (85) & sealing washer (21)
internal diameter stop at circular undercut protrusion (54) on circular bosses (85).
Referring to figure 6,6a & 6b shows cut section of knob sealing & locking construction.
The protective knob (20) assembly method shown in figure 7 and protective knob (20) having a
circular undercut continuous ring (86) on internal diameter. The opening and closing of
protective knob (20) by external force and protective knob locked at body four snap (87). The
protective knob (20) is having a flexible hinge (60) which supports to open knob at certain
position for life time durability.
Referring to figure 9 shows the exploded view PCB assembly is having a two PCB situated each
other. A barge connector (71) having a connecting four pins (72) assemble with a large
component PCB (62) by soldering process and a large PCB (62) having guiding part (74) is
placed in small PCB (63) having same cut out slot (73) and other end of burge connector pin (88)
solder on small PCB.
Referring to figure 11 show the cut section of mobile socket (5), a large terminal (29) is assemble
in body (30) through guiding pin (79) and same hole in large terminal (29) and an inner case (26)
having a two locking lug (27) in such a way design, to eliminate the addition part from existing
product and improve the mating part holding force. A locking lug (27) feature of inner case (26)
•which is assembles in body (30) through guiding pin (76). A insulation base (25) having a'
locating pin feature (55) which locate in inner case (26) having same hole then a collar base rivet
(24) assemble in insulation base (25) from top assembly and small terminal (31) assemble from
bottom side for riveting process.
Referring to Figures 10 the whole PCB assembly assembles in body (30) from bottom side and a
small PCB (63) having two guiding holes (64, 69) which locate on body (30) pip and terminal
soldering points soldered on Small PCB (63) at slot (71 & 66) and rubberized based seal rubber
(32) assemble in PCB holder (34) then after assemble with body (30) by applying external force
and both parts assemble each other by annular snap (80) and resign (35)used to filled the PCB
holder (34) vacant electronic area for environment.
Some of the advantages of the mobile charger socket of the present invention are as follows:
1. Existing extra part removed (5)" because sheet metal inner case (26) locking snap design
(27) considerations).
2. "Knob sealing improved" during testing, without using extra parts.
3. Mechanical durability of protective hinge improved during insertion and removal operating
life cycle.
4. Automotive electronic protection provided to reduce the failure.
5. Electronic circuit design for low current from existing design.
6. A damping rubber provides to observe the vehicle vibration.
7. Sealing provide at epoxy area by rubberized sealing washer
8. Indirect Drain hole channel provide for water drainage

* " t l # #
Claims I,
1. A power socket feature for automotive vehicle, which comprising:
(a) The protective knob assembly in which a circular rubberized sealing washer fitted~inside co:
axially, which has an undercut protrusion over knob flexible bosses (85) and resting at knob face
with interference as shown in figure 6 to restrict the falling of rubberized sealing washer during
vehicle running condition.
(b) A sheet metal inner case having two flexible snap (27) assemble with body to hold the standard
charger
(c) Outer seal part assembly with body for sealing & damping
(d) Rubberized sealing rubber for epoxy sealing
(e) Electronic circuit design & protection
(f) Indirect Drain hole outlet for water
(g) Body locking orientation protrusion for knob assembly
2. A power socket as claimed 1, wherein the protective knob assembly is locked with body is having VShape
profile protrusions which compress the sealing washer
3. A power socket as claimed 1 wherein sheet metal inner case assembles with body, is having a guiding
pip & which located through same hole in sheet metal design and mating part locking snap (37) guided
in body through rectangular cutout initially and flexible snap operate within cut out limit when mating
part insert into sheet metal
4. A power socket as claimed 1, wherein, a outer seal rubber fitted with body collar and same collar cut
out provide in rubber for gripping. The rubber act as sealing & damping. Epoxy filling area from bottom
half assembly is sealed design. A rubberized rubber (32) provides into PCB holder and both part joint
each other by annular snap locking through external force.
5. A power socket as claimed 1 wherein a electronic assembly & sequence of each part assembly as
shown in figure 10 & 9 situated over body through two guiding pin and soldered with terminal from
bottom side & the PCB circuit is protected from all automotive protection including surge protection
additional by using a IC which suppress automotive spike.
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6. A power socket as claimed 1 wherein indirect drain hole outlet slot provide on PCB holder and water
inlet provide in body~and both part assemble by flat surface poka yoke and their automatically drain hole
channel completed.
7. A power socket as claimed 1 wherein the body having locking orientation protrusion (49) which
locate & guided in knob (21) guiding slot (49) to locate at proper orientation on vehicle
8. A power socket as claimed in claim 1-9 is used as mobile socket wherein, Current capacity is <=1 A
9 A power socket as claimed in claim 1-9 is used as power socket or cigarette lighter wherein. Current
capacity is <=10A
10.A power socket substantially as herein described with reference to the accompanying drawings
Dated this on 22 day of August 22, 2014 ta^«*»
(JYOTI CHAUHAN)
OF MINDA INDUSTRIES
AGENT FOR THE APPLICANT