Patent Publication Number: US-2023158902-A1

Title: Ejector for electric vehicle charging connectors

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Patent Application No. 63/282,671 which was filed on Nov. 23, 2021. 
    
    
     BACKGROUND 
     Electric vehicles (or EVs), whether cars, trucks or otherwise, must be frequently recharged. For this purpose, EVs have charging ports that are typically located on the side of the EV.  FIGS.  1 A and  1 B  provide an example of a Tesla  100  that has a charging port  110  into which a charging connector  120  can be plugged. Charging connector  120  can be electrically connected to a power source such as a 240-volt outlet at home or a public charging station. Other makes of EVs have similar charging ports that require similar charging connectors. 
     Charging port  110  may be formed of an outer cover  111  that forms an opening that exposes an internal housing  112  which forms a socket  113 . Charging connector  120  is physically inserted into socket  113  to form the necessary electrical connections.  FIGS.  1 C and  1 D  are isolated external and internal views respectively of charging port  110  when outer cover  111  is removed. As is visible in  FIG.  1 D , a contact housing  115  may be secured to internal housing  112  surrounding socket  113  and may include the electrical contacts for forming the electrical connection. Wires  114  may connect the contacts of contact housing  115  to the battery of Tesla  100 . Although this example is specific to Tesla  100 , similar charging port configurations are employed on other types of EVs. 
     It can take a relatively long time to fully charge an EV. For example, with a typical 240-volt at-home charger, a full charge may take 8 hours. Even with high-voltage superchargers, it usually takes at least 30-40 minutes to reach a full charge. 
     Most EVs are designed to prevent any motion of the EV while the EV is connected to a charger. Therefore, the vehicle must remain parked while connected to the charger and cannot be shifted to drive, reverse, or neutral. Additionally, current charger designs require manual removal of the charging connector from the charging port. This can create various difficulties. For example, if a driver is in a rush to leave, he or she may forget to unplug the charger before getting into the EV. Similarly, if a driver&#39;s hands are full, he or she may have difficulty removing the charging connector from the charging port and managing the storage of the charging cable. 
     Greater difficulties may arise in scenarios where the driver is waiting in the EV while it charges. For example, a thunderstorm or other severe weather could occur when charging is complete thus forcing the driver to brave the elements to unplug the EV. As another example, a charging station may be in a remote or dangerous location where it may be unsafe for the driver to exit the EV such as due to the presence of wildlife or a lurking assailant. In such cases, the driver will in essence be trapped inside the EV given that he or she cannot drive away until the EV is unplugged. 
     BRIEF SUMMARY 
     The present invention extends to an ejector for electric vehicle charging connectors. An ejector can be configured to be secured on the inside of the charging port of an EV and to automatically eject or push the charging connector from the charging port. The ejector may include a pusher assembly that can be selectively retracted to allow a charging connector to be plugged into the charging port and can be selectively released to eject the charging connector from the charging port. The ejector can include a retracting assembly for selectively retracting the pusher assembly and a locking assembly for retaining the pusher assembly in the retracted position until it is desired to eject the charging connector. 
     In some embodiments, the present invention may be implemented as an ejector that includes one or more pusher assemblies that are configured to push a connector from a socket, one or more retracting assemblies that are configured to move the one or more pusher assemblies into a retracted position, and a locking assembly that is configured to retain the one or more pusher assemblies in the retracted position until a signal is received to eject the connector from the socket. 
     In some embodiments, each of the one or more pusher assemblies may include a pusher and a shaft. 
     In some embodiments, each pusher may be configured to extend through a housing surrounding the socket. 
     In some embodiments, each of the one or more retracting assemblies includes a grabber assembly that interfaces with the shaft of the corresponding pusher assembly to move the pusher assembly into the retracted position. 
     In some embodiments, the grabber assembly includes opposing grabbers that interface with a flange of the shaft of the corresponding pusher assembly. 
     In some embodiments, the grabber assembly selectively pivots the opposing grabbers between an open position and a closed position. 
     In some embodiments, each of the one or more retracting assemblies includes a driving assembly that moves the corresponding grabber assembly. 
     In some embodiments, the locking assembly interfaces with the shaft of the one or more pusher assemblies to retain the one or more pusher assemblies in the retracted position. 
     In some embodiments, each of the one or more pusher assemblies includes a spring that forces the corresponding pusher against the connector when the locking assembly releases the one or more pusher assemblies from the retracted position. 
     In some embodiments, the locking assembly includes one or more arms that interface with a flange on the shaft of the one or more pusher assemblies. 
     In some embodiments, the present invention may be implemented as an ejector for a charging connector. The ejector may include a housing configured to be secured to a housing of a charging port and a pusher assembly having a pusher that is configured to be selectively extended through the housing of the charging port. The pusher may be coupled to a shaft. The ejector may also include a retracting assembly having a grabber assembly and a driving assembly for driving the grabber assembly. The grabber assembly may be configured to interface with the shaft to transition the pusher into a retracted position. The ejector may further include a locking assembly that interfaces with the shaft to retain the pusher in the retracted position. The locking assembly may be configured to release the shaft to thereby enable the pusher to extend through the housing of the charging port to eject a charging connector. 
     In some embodiments, the pusher may extend through a cutout formed in the housing of the charging port. 
     In some embodiments, the shaft may include a flange and the grabber assembly may include one or more grabbers that interface with the flange. 
     In some embodiments, the locking assembly may include an arm that interfaces with a flange of the shaft. 
     In some embodiments, the pusher assembly may include a spring that is compressed between the pusher and the housing when the pusher is in the retracted position. 
     In some embodiments, the shaft may have a front flange and a rear flange, the grabber assembly may interface with the rear flange to transition the pusher into the retracted position, and the locking assembly may interface with the front flange to retain the pusher in the retracted position. 
     In some embodiments, the present invention may be implemented as an ejector that includes a housing, opposing pusher assemblies, each pusher assembly having a pusher, opposing retracting assemblies, each retracting assembly having a grabber assembly that retracts the corresponding pusher assembly into a retracted position, and a locking assembly that locks the pusher assemblies in the retracted position. The locking assembly may be configured to release the pusher assemblies from the retracted position in response to a signal. 
     In some embodiments, the housing may be coupled to an interior side of a housing of a charging port of an electric vehicle. 
     In some embodiments, each pusher may extend through the housing of the charging port of the electric vehicle. 
     In some embodiments, each pusher assembly may include a spring that is compressed when the pusher assembly in retracted into the retracted position. 
     This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which: 
         FIGS.  1 A- 1 D  provide an example of an electric vehicle charging system with which an ejector configured in accordance with embodiments of the present invention may be used; 
         FIG.  2    provides an example of how an ejector configured in accordance with embodiments of the present invention may be integrated into the electric vehicle charging system shown in  FIGS.  1 A- 1 D ; 
         FIGS.  2 A- 2 E  are rear perspective, front perspective, top, side, and bottom views respectively of the ejector of  FIG.  2    in isolation; 
         FIG.  3    provides an example of a pusher assembly that may be used in an ejector configured in accordance with embodiments of the present invention; 
         FIG.  4    provides an example of a retracting assembly that may be used in an ejector configured in accordance with embodiments of the present invention; 
         FIG.  5    provides an example of a locking assembly that may be used in an ejector configured in accordance with embodiments of the present invention; 
         FIGS.  6 A- 6 C  are front, front perspective and side views respectively representing the state of the charging system shown in  FIGS.  1 A- 1 D  after the ejector of  FIG.  2    has ejected the charging connector from the charging port; and 
         FIGS.  7 A- 7 C  provide an example of how the ejector of  FIG.  2    can be transitioned back into the retracted/loaded state after ejecting the charging connector. 
     
    
    
     DETAILED DESCRIPTION 
     Embodiments of the present invention encompass ejectors that are configured to enable the driver (or other user) to automatically eject (or remove) the charging connector from the charging port of an EV. As a result, the driver need not exit the EV or be present at the EV to eject the charging connector. Any suitable mechanism could be used to communicate with the ejector to cause it to eject the charging connector including any wired or wireless connection. In some embodiments, a communication mechanism may be integrated into the EV. In other embodiments, a separate device, such as a mobile application or fob, may be used to communicate with the ejector. 
       FIG.  2    shows an example of an ejector  200  that is configured in accordance with embodiments of the present invention when it is secured to internal housing  112  of charging port  110  of Tesla  100 . It is noted, however, that ejector  200  could be used with a charging port of any other EV. Also, an ejector configured in accordance with embodiments of the present invention could be used to eject other types of connectors, and therefore, embodiments of the present invention should not be limited to charging port scenarios. 
     Ejector  200  includes a housing  201  that is configured to be coupled or mounted to the inside of internal housing  112  and surrounds or is adjacent to socket  113  and contact housing  115  and can accommodate wires  114 . Housing  201  could be secured to internal housing  112  or to any other component of a charging port in any suitable manner including by screws, welding, an adhesive, etc. For example, a front  201   f  of housing  201  could be positioned against internal housing  112  and secured thereto via one or more screws, while a rear  201   r  of housing  201  could be overtop contact housing  115 . 
       FIGS.  2 A- 2 E  are rear perspective, front perspective, top, side, and bottom views respectively of ejector  200  in isolation. As shown, ejector  200  may include one or more pusher assemblies  300  (two are included in the depicted embodiment), one or more retracting assemblies  400  (two are included in the depicted embodiment) and a locking assembly  500 . 
     As an overview, each pusher assembly  300  is configured to be retracted into/towards and locked within/against housing  201  and then selectively released to apply a force on the charging connector to thereby eject it from the charging port. Each retracting assembly  400  is configured to retract a corresponding pusher assembly  300 . Locking assembly  500  is configured to lock each pusher assembly  300  in the retracted/loaded position. As in the depicted embodiment, it may be preferable to include a pair of pushing assemblies  300  positioned on opposing sides of socket  113  so that they may apply an evenly distributed force on opposing sides of charging connector  120 . However, in some embodiments, a single pushing assembly  300  could be sufficient to force a charging connector  120  from a charging port. 
       FIG.  3    is a top view of pusher assemblies  300  in isolation. Each pusher assembly  300  may include a pusher  301  that is connected to a shaft  302 . A front flange  303   a  and a rear flange  303   b  may be formed on shaft  302  towards an end  302   a  opposite pusher  301 . A spring  304  (or other biasing member) can be positioned around shaft  302  adjacent pusher  301 . 
       FIG.  4    is a front perspective view of retracting assemblies  400  in isolation. Each retracting assembly  400  can include a grabber assembly  410  and a driving assembly  420 . Grabber assembly  410  is configured to grab a corresponding pusher assembly  300 , and driving assembly  420  is configured to move a corresponding grabber assembly  410  to retract the corresponding pusher assembly  300 . 
     Grabber assembly  410  includes a housing  411  from which one or more grabbers  412  extend frontwardly (two of which are shown in the depicted embodiment) and an actuator  413  that is configured to cause grabbers  412  to open and close. Actuator  413  can include an actuator arm  413   a  that contacts shaft  302  of the corresponding pusher assembly  300 . As described in greater detail below, as actuator arm  413   a  contacts end  302   a  of shaft  302 , actuator  413  can move rearwardly within housing  411  to cause grabbers  412  to open and close in a generally similar manner as a clicker mechanism of a ballpoint pen. 
     Driving assembly  420  includes a belt  421  having ends  421   a  that are coupled to housing  411  of grabber assembly  410 . Belt  421  is routed around a pair of pullies  422  so that, when pullies  422  are rotated, ends  421   a  will move frontwardly or rearwardly to thereby drive grabber assembly  410  frontwardly or rearwardly. Driving assembly  420  may include a motor  424  for rotating pullies  422  such as via gears  423  and  422   a.    
       FIG.  5    is a rear view of locking assembly  500  in isolation. Locking assembly  500  may include a locking member  510  forming one or more arms  511  (two or which are shown in the depicted embodiment). Each arm  511  may form a notch  512  that is configured to at least partially receive shaft  302  to thereby position arm  511  in front of front flange  303   a . However, arm  511  could be configured in any suitable way to enable it to interface with front flange  303   a  for the purpose of locking pusher assembly  300  in the retracted/loaded position. 
     Locking member  510  can be configured to be moved between a raised position in which arms  511  do not interface with front flange  303   a  and a lowered position in which arms  511  interface with front flange  303   a . To move locking member  510  between these raised and lowered positions, locking assembly  500  may include a driving assembly  520  having a motor  521 , a shaft  522 , a pivoting arm  523  and a pin  524 . Pin  524  may insert into a slot  513  formed in a locking member  510 . Because pin  524  is positioned at an end of pivoting arm  523  opposite shaft  522 , as motor  521  rotates shaft  522 , pin  524  will move locking mechanism  510  up or down as it slides within slot  513 . 
       FIGS.  6 A- 6 C  are front, front perspective and side views respectively showing ejector  200  in its released configuration when it is used on Tesla  100  to eject charging connector  120 . In other words, these figures can represent the state of ejector  200  immediately after it has ejected charging connector  120  or at least prior to being returned to a retracted/loaded configuration. To enable ejector  200  to be used on Tesla  100 , cutouts  600  may be formed in internal housing  112  to allow pushers  301  to extend through internal housing  112 . Notably, pushers  301 , and therefore cutouts  600 , can be within socket  113  so that pushers  301  will contact charging connector  120  when charging connector  120  is inserted into socket  113 . 
     As shown in  FIG.  6 C , locking assembly  500  has been moved into the raised position which released pusher assemblies  300  thereby allowing springs  304  to force pushers  301  through cutouts  600  which in turn forced charging connector  120  from socket  113 . In this released configuration, retracting assemblies  400  can be in a rearward position with grabbers  412  open. With retracting assemblies  400  in the rearward position, actuator  413  may be in a frontward position but actuator arm  413   a  may not contact end  302   a  of shaft  302  (or at least not sufficiently to force actuator  413  rearwardly). Notably, grabber assembly  410  may include a spring  414  (or other biasing member) that moves between connected V-shaped channels as actuator  413  is moved frontwardly and rearwardly. This configuration may cause grabber assembly  410  to function in a generally similar manner as a clicker mechanism of a ballpoint pen. However, the configuration causes grabbers  412  to repeatedly open and close as actuator  413  is moved. In particular, when actuator  413  is in a frontward position, it causes grabbers  412  to pivot open. In contrast, when actuator  413  is in a rearward position, it enables grabbers  412  to pivot closed. In some embodiments, grabbers  412  may be biased into the closed position such that they remain in the closed position unless actuator  413  is forced frontwardly against them to pivot them open (such as is shown in  FIG.  6 C ). 
       FIGS.  7 A- 7 C  illustrate how ejector  200  can be transitioned from the released configuration into a loaded configuration to await the next ejection.  FIG.  7 A  represents a grabbing stage of the transition. In comparison to  FIG.  6 C , in  FIG.  7 A , driving assemblies  420  have driven grabber assemblies  410  frontwardly to thereby force actuator arm  413   a  against shaft  302 . As a result, actuator  413  is moved rearwardly within housing  411  thereby enabling grabbers  412  to pivot to the closed position. When in the closed position, grabbers  412  can extend around rear flange  303   b  to thereby interlock grabbers  412  and shaft  302 . Notably, spring  414  is in the frontward V-shaped channel and will retain actuator  413  in the rearward position until actuator  413  is forced further rearwardly into housing  411  to cause spring  414  to escape the frontward V-shaped channel. 
       FIG.  7 B  represents a retracting stage of the transition. In comparison to  FIG.  7 A , in  FIG.  7 B , driving assemblies  420  have driven grabber assemblies  410  rearwardly. Because grabbers  412  are interlocked with rear flange  303   b , the rearward movement of grabber assemblies  410  will pull pusher assemblies  300  rearwardly. Importantly, pushers  301  are pulled rearwardly out from socket  113  so that charging connector  120  can be inserted into socket  113 . Driving assemblies  420  may be configured to drive grabber assemblies  410  sufficiently rearward to ensure that front flange  303   a  is positioned rearward of arms  511 . With pushers  301  pulled rearwardly, springs  304  will be compressed between pushers  301  and housing  201 . This compression of springs  304  creates the potential energy for subsequently forcing pushers  301  against charging connector  120  to eject it from socket  113 . In some embodiments, shafts  302  may include only a single flange. In such embodiments, grabber  412  and arm  511  may interface with the same, single flange. 
       FIG.  7 C  represents a locking stage of the transition. In comparison to  FIG.  7 B , in  FIG.  7 C , driving assembly  520  has driven locking member  510  downwardly to position notches  512  around shafts  302 . Accordingly, arms  511  are positioned in front of front flanges  303   a . Once arms  511  are positioned in front of front flanges  303   a , driving assemblies  420  can drive grabber assemblies  410  frontwardly sufficient to release spring  414  from the front V-shaped channel to thereby allow actuator  413  to move freely within housing  411 . As a result, grabbers  412  can pivot into the open position. Accordingly, after locking assembly  500  has locked pusher assemblies  300  in the retracted/loaded position and grabber assemblies  410  have released shafts  302 , pusher assemblies  300  will be ready to be released to eject charging connector  120 . Ejector  200  can remain in this state until triggered by the driver or another mechanism. Once triggered, ejector  200  can transition back into the position shown in  FIGS.  6 A- 6 C  and the process shown in  FIGS.  7 A- 7 C  can be repeated. 
     Although not shown, ejector  200  may include suitable control circuitry to control the operation of motors  424  and motor  521 . For example, ejector  200  may include control circuitry for receiving a wired or wireless signal, and in response, can cause motor  521  to lift locking member  510  to thereby eject a charging connector. Then, the control circuitry can control motors  424  and motor  521  in proper sequence to perform the functionality shown in  FIGS.  7 A- 7 C . 
     The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description.