ROTARY HYBRID AC POWER OUTLET FOR VEHICLES

An AC power outlet for an automotive center console comprises a bezel housing containing an array of terminals forming sockets for receiving power plugs according to a plurality of standardized plug layouts. Fixed and pivotable faceplates have respective openings according to first and second patterns for passage of respective prongs of the power plugs into the sockets. The pivotable faceplate is moved to (A) a first rotational position to reveal a first subset of openings on the fixed faceplate corresponding to a first standardized plug layout while blocking other openings, and (B) to a second rotational position reveal a second subset of the openings on the fixed faceplate corresponding to a second standardized plug layout while blocking other ones of the openings. A cover assembly has a cap and a mounting ring to install on the housing at any one of a plurality of angular positions.

CROSS REFERENCE TO RELATED APPLICATIONS

Not Applicable.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH

Not Applicable.

BACKGROUND OF THE INVENTION

The present invention relates in general to automotive trim panels having an integrated power outlet, and, more specifically, to an AC power outlet which is configurable to a plurality of standardized plug layouts and a plurality of cover hinge orientations.

Automotive vehicles (e.g., cars and trucks) typically include trim panels such as a center console or a dashboard disposed within the interior passenger compartment of the vehicle. The trim panels may provide a mounting location for an integrated electrical outlet, such as an AC power outlet for delivering AC power to electrical devices through a plug and socket arrangement. Since electrical systems of vehicles usually operate on DC power, a DC-to-AC power inverter may be used in the vehicle to generate the AC power which is fed to the power outlet. Typically, the power outlet is configured for use with a particular type of standard plug layout which is used in the region where the vehicle is sold and operated.

For specific models of vehicles, the respective automobile manufacturers may often produce nearly identical versions of the model for sale in different regions or countries of the world (e.g., North American and European versions of a vehicle). Variations between versions may include minor styling differences, functional differences driven by regulatory requirements, and differences in interfaces with or connections to different auxiliary/peripheral accessories used by occupants of the vehicle. For example, a North American version of a vehicle which provides an AC power outlet may be configured with a plug/socket layout as defined by NEMA (e.g., a NEMA 5-15 layout), which is also defined as a Type B plug by the International Trade Administration. A European version of the same vehicle may have the power outlet configured with a plug/socket layout according to Type G or Type C as defined by the International Trade Administration or the Europlug as defined by the International Electrotechnical Commission. Since the power outlet is not a common component across all the versions of the vehicle model, the costs of design, development, and testing must be incurred by the manufacturer for each distinct design. Especially for a manufacturer making many models of vehicle, with each model being made in multiple versions for respective worldwide markets, the costs and effort devoted to customizing power outlets for each distinct version becomes significant.

An automotive trim panel, such as a center console, with an integrated AC power outlet typically carries other devices such as USB outlets, climate control and radio buttons and dials, and air duct registers. Styling needs may necessitate placement of a cover or cap for the AC power outlet to be at a particular position and/or orientation relative to other components. Since cover or cap (which is usually tethered to the outlet by a hinge and which snaps on and off of the outlet) requires available adjacent space for its normal operation to avoid interference with other components or with portions of the trim panel itself, the side where the hinge is located may be dictated by other elements of the vehicle design. For example, the hinge may be along a right edge in one version while a different placement of the power outlet on a center console for a different version requires the hinge to be at the top edge. This may result in larger differences between designs for power outlets, and it may increase the need for producing many different outlet designs (i.e., increase the number of difference parts that mush be released in the manufacturer's parts systems).

SUMMARY OF THE INVENTION

One object of the invention is to reduce the duplication of component parts by providing a power outlet which is adaptable to many different standardized plug layouts and which provides a cover assembly which is adjustable to many different hinge orientations without changing the main orientation of the plug/socket arrangement.

In one aspect of the invention, an AC power outlet comprises a bezel housing containing an array of terminals forming sockets for receiving power plugs according to a plurality of standardized plug layouts. A fixed faceplate is disposed in the bezel housing at a front side of the array of terminals including a first plurality of openings in a first pattern for passage of respective prongs of the power plugs into the sockets. A pivotable faceplate is disposed in the bezel housing at a front side of the fixed faceplate and rotatable with respect to the fixed faceplate. The pivotable faceplate has a second plurality of openings in a second pattern which is configured to (A) reveal a first subset of the first openings corresponding to a first one of the standardized plug outlets while blocking other ones of the first openings when the pivotable faceplate is in a first rotational position, and (B) reveal a second subset of the first openings corresponding to a second one of the standardized plug outlets while blocking other ones of the first openings when the pivotable faceplate is in a second rotational position.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Referring toFIG.1, a vehicle10includes a center console11with a storage compartment covered by a lid12. A rearward face of trim panel13provides a mounting surface for an AC power outlet14(e.g., for use by vehicle passengers in a back seat area of the passenger compartment). Other components mounted on panel13may include another electrical outlet15such as a USB connector and cover for in-vehicle device charging or data use. Power outlet14is configured to accept standardized plug layouts of various types and has a cover assembly with a design enabling the cover to be installed with a selected orientation in order to accommodate a large number of potential hinge orientations. From a user perspective, as shown inFIG.2, power outlet14has a main outlet portion16, a lid17, and a hinge18. Lid17may include a snap-on feature (e.g., a mechanical interlock opposite from the hinge) or other means for being locked into a closed position over outlet portion16as known in the art.

FIG.3shows the elements of a first embodiment of power outlet14. Cover assembly20comprises lid17connected by hinge18to a mounting ring21with a series of serrations22along an inner radial edge of ring21. A generally cylindrical bezel housing23has a front flange24providing a forward lip disposed on the trim panel front surface. Mounting ring21is installed from the rearward end of bezel housing23in order to nest against a rearward surface of flange24as described below. A base plate25includes slots26for receiving ends of an array of terminals27forming electrical sockets which are configured to receive plugs of different standardized layouts in different orientations. Base25and terminal assembly27are received inside a cylindrical portion of bezel housing23behind a fixed faceplate28and pivotable faceplate30. Fixed faceplate28has a first plurality of openings31having a first pattern for passage of respective prongs of power plugs to be plugged into corresponding sockets provided by terminal array27. Pivotable faceplate30is disposed at a front side of fixed faceplate28and has a second plurality of openings32and a second pattern which is also configured to pass respective prongs of the power plugs. The second pattern is configured such that when pivotable faceplate30is in a first rotational position then a first subset of openings31are revealed, and when pivotable faceplate30is in a second rotational position then a second subset of openings31are revealed while at least some of the first subset are blocked. Pivotable faceplate30may include a series of protrusions33disposed circumferentially around a front side of pivotable faceplate30for gripping by a user's fingers when rotating faceplate30. Pivotable faceplate30is captured in a recess between fixed faceplate28and flange24as described later.

FIG.4shows terminal array27arranged on faceplate25. Slots for supporting terminal array27include bushings35for mounting terminal blades36which are coupled by jumper wires37to respective sockets37-42. Each socket may be comprised of a respective double-wipe or triple-wipe contact, for example. Some sockets may include terminal structures which are shaped to provide more than one set of wipe contacts, such as terminal42with double-wipe contacts42A and double-wipe contacts42B and terminal39with double-wipe contacts39A and triple-wipe contacts39B. Tabs43on base plate25interface with corresponding features of the bezel housing to retain base plate25.

Bushings35include openings through base plate25for receiving terminal blades36. Terminal blades36are commonized such that they are shared between the standardized plug layouts (e.g., as a result of the sets of wipe contacts configured to receive more than one plug layout).FIG.5shows a collar44into which blades36extend, whereby a wiring pigtail connector can be joined to the AC power outlet.FIG.5also shows the alignment of fixed faceplate28with terminal array27, wherein openings31are adapted to guide respective prongs of a plug into corresponding sockets. Fixed faceplate28may include radial tabs46which extend into corresponding notches in the bezel housing to keep faceplate28in proper alignment.

FIG.6shows fixed faceplate28with an example pattern for holes47-51which accommodates particular examples of standardized plug layouts. For example, a plug52with a North American NEMA 5-15 (Type B) layout is insertable through hole47(for the grounding prong), hole48(for the hot or line prong), and hole49(for the neutral or common prong). A plug53has an ITA Type G layout, and it is insertable through hole47(for ground), a hole50(for hot), and hole51(for neutral). A plug54has an ITA Type I layout, and it is insertable through hole47(for ground), a hole50(for hot), and hole51(for neutral). Together with a matching terminal arrangement, a “universal” power outlet is provided with is compatible with the corresponding global standards.

The terminal arrangement of an embodiment combining terminal sockets for Type B and Type G layouts is shown in greater detail inFIGS.7and8. A terminal55provides contacts for receiving grounding prongs for both Type B and Type G. One continuous terminal structure42includes a double-wipe contact54A/54B for the Type B plug and a double-wipe contact55A/55B for the Type G plug, wherein hole47of fixed faceplate28is aligned with terminal42. Jumper wire56connects terminal42to a terminal blade57which is fitted into the base plate.

A terminal39provides contacts for receiving the neutral or common prongs for both Type B and Type G. One continuous terminal structure includes a double-wipe contact40for the Type B plug and a triple-wipe contact58for the Type G plug, wherein holes49and51of fixed faceplate28is aligned with contact40and contact51, respectively. Jumper wire59connects terminal39to a terminal blade60which is fitted into the base plate.

Terminal41provides contacts for receiving the hot prong for Type B comprised of a triple-wipe contact64, wherein hole48of fixed faceplate28is aligned with contact64. Jumper wire65connects terminal41to a terminal blade66which is fitted into the base plate. Terminal38provides contacts for receiving the hot prong for Type G comprised of a triple-wipe contact61, wherein hole50of fixed faceplate28is aligned with contact61. Jumper wire62connects terminal38to a terminal blade63which is fitted into the base plate.

FIG.9depicts the interaction of faceplates28and30with terminal array27. Fixed faceplate28has a first pattern of openings which remains fixed with respect to array27and ensures that only plugs with predetermined standard arrangements can be guided into the sockets of array27. Pivotable faceplate30has a second pattern of openings which is different from the first pattern which is configured to (A) reveal a first subset of the fixed openings corresponding to a first one of the standardized plug layouts (e.g., Type B) while blocking at least some of the openings in fixed faceplate28(e.g., openings exclusively used by Type G) when pivotable faceplate30is in a first rotational position, and (B) reveal a second subset of the first openings corresponding to a second one of the standardized plug layouts (e.g., Type G) while blocking at least some of the first openings (e.g., openings exclusively used by Type B) when pivotable faceplate30is in a second rotational position. For a terminal socket which is shared by all (e.g., both) of the standardized plug types, one convenient location is at the central axis of the rotation of pivotable faceplate30. When the power outlet is configured for two rotational positions in order to reveal two different sets of sockets, and when the two rotational positions are 180° apart, then the second pattern may be configured according to a mirror image of the first pattern as shown inFIGS.10and11. In the first rotational position ofFIG.10, openings47,48, and49provide paths68-70to respective sockets through faceplate28. In the second rotational position ofFIG.11, openings47,50, and51provide paths71-73to respective sockets through faceplate28.

As shown inFIG.12, a rim flange75at an outer edge of pivotable faceplate30is adapted to be captured in a circular track76on a front side of fixed faceplate28. Faceplates28and30are insertable into the cylindrical interior of bezel housing23and pressed against front flange24so that a plurality of clips78formed in the cylindrical wall of bezel housing23capture fixed faceplate28at a predetermined orientation. Rim flange75rotates within a gap between track76and a rearward surface78of front flange24.FIG.13shows pivotable faceplate30bearing against front flange24(with fixed faceplate28not shown).

FIG.13further shows cover assembly20as a unitary molded body in which lid17, hinge18, and ring21are comprised of thermoplastic. Hinge18is comprised of a living hinge such that lid17can be opened and closed by pivoting from hinge18. Ring21can be installed from the rearward side of bezel housing23to bear against flange24on its rearward surface.

In order to permit various orientations of cover assembly20which can place hinge18at almost any desired radial angle, ring21is configured to engage bezel housing23via a multi-position interlock. As shown inFIGS.14and15, a rearward surface80of front flange24is bounded by a keyed surface81behind flange24which is adapted to fit within an inner edge of ring21. Keyed surface81may be comprised of a series of serrations following a concentric path. Adjacent serrations of keyed surface81may be separated by respective gaps82. Mounting ring21has a complementary surface for engaging keyed surface81so that mounting ring21can be nonrotatably retained at any one of a plurality of angular positions. The complementary surface may be comprised of another series of serrations along an inner radial edge of mounting ring21. Serrations22and81may have convex, circular shapes or any appropriate interlocking profile. Gaps82can increase the interpenetration of serrations22and81in order to improve the robustness of retention of mounting ring21in a desired orientation.

FIG.16-18illustrate the ability to adjust an opening direction of the cap of the power outlet toward different radial directions so that the motion of the cap/lid can be integrated according to different center console designs using the same power outlet components. The rear view inFIG.19shows that the radial angle toward which the hinge is oriented can be selected during installation of the cover assembly by aligning the hinge with any one of the serrations of the keyed surface on the bezel housing. A greater or lesser number of serrations can be provided around the circumferences of the surfaces when it is desired to provide either a greater angular resolution for orienting the hinge (more serrations) or a lower angular resolution to simplify assembly and reduce the likelihood of placement errors (fewer serrations).