Patent Abstract:
A charge cord lock system for a vehicle having rechargeable batteries. The system includes a charging receptacle; and a charge cord assembly having a charge plug slidably received in the charging receptacle and including a recess defining a retention flange. The system also includes a cord lock including a catch mounted to a plunger, with the plunger mounted to an actuator that moves the plunger toward and away from the charging receptacle, the catch engaged with the retention flange when the plunger is in an extended position and not engaged with the retention flange when the plunger is in a retracted position; and a controller in communication with a door lock mechanism and the actuator to cause the plunger to move to the retracted position when a door unlock signal is received and to cause the plunger to move to the extended position when a door lock signal is received.

Full Description:
BACKGROUND OF INVENTION 
       [0001]    The present invention relates generally to charging systems for electric and hybrid electric types of vehicles, and more particularly to selectively retaining a charging plug in the vehicle while the vehicle&#39;s batteries are being charged. 
         [0002]    Some recent automotive vehicles employ on-board battery packs that can be charged while the vehicle is parked. For these vehicles, one end of a plug may be inserted into an electrical outlet in a garage, for example, and the other end is plugged into a receptacle in the vehicle. While plugged in, the vehicle batteries charge, thus providing the driver with maximum operating range on battery when the vehicle is next used. 
       SUMMARY OF INVENTION 
       [0003]    An embodiment contemplates a charge cord lock system for a vehicle having a rechargeable battery. The charge cord lock system may comprise a vehicle structure defining a charging receptacle; and a charge cord assembly having a charge plug slidably received in the charging receptacle, with the charge plug including a retention recess recessed into a side of the charge plug to define a retention flange. The charge cord lock system also may comprise a cord lock including a catch resiliently mounted to a plunger, with the plunger mounted to an actuator that selectively moves the plunger toward and away from the charging receptacle, the catch engageable with the retention flange when the plunger is in an extended position to prevent removal of the charge plug from the charging receptacle and not engageable with the retention flange when the plunger is in a retracted position; and a controller in communication with a vehicle door lock/unlock request mechanism and the actuator to cause the actuator to move the plunger to the retracted position when a door unlock signal is received from the lock/unlock request mechanism and to cause the actuator to move the plunger to the extended position when a door lock signal is received from the lock/unlock request mechanism. 
         [0004]    An embodiment contemplates a method of selectively retaining a charge plug of a charge cord assembly in a charging receptacle of vehicle structure for a vehicle having a rechargeable battery, the method comprising the steps of: receiving a vehicle door lock signal; after receiving the vehicle door lock signal, moving a plunger of a cord lock to an extended position, causing a catch mounted on the plunger to move into engagement with a retention flange on the charge plug when the charge plug is installed in the charging receptacle; receiving a vehicle door unlock signal; and after receiving the vehicle door unlock signal, moving the plunger of the cord lock to a retracted position, causing the catch to remain out of engagement with the retention flange on the charge plug when the charge plug is installed in the charging receptacle. 
         [0005]    An advantage of an embodiment is that the charge cord assembly can be easily locked into the charging receptacle on the vehicle so that it is not accidentally pulled out while charging. In addition, the charge cord assembly can be easily unlocked and removed when the vehicle is going to be driven. The locking and unlocking of the charge cord is accomplished in an intuitive manner, making it easy for a new vehicle owner to operate the cord lock. Moreover, the charge plug can be inserted in the receptacle whether the charge cord assembly is locked or unlocked. 
         [0006]    Another advantage of an embodiment is that only one additional electrical actuator assembly needs to be packaged in the vehicle, without additional vehicle switches or controls required, thus minimizing cost and complexity of the assembly. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         [0007]      FIG. 1  is a schematic drawing of a charge cord assembly and cord lock, with the cord lock in an unlocked position. 
           [0008]      FIG. 2  is a schematic drawing similar to  FIG. 1 , but with the cord lock in a locked position. 
           [0009]      FIG. 3  is a schematic drawing of a charge cord assembly and a cord lock according to a second embodiment. 
       
    
    
     DETAILED DESCRIPTION 
       [0010]    Referring to  FIGS. 1 and 2 , a vehicle with plug-in electrical charging, indicated generally at  20 , is shown. The vehicle  20  includes vehicle structure  22  that forms a vehicle charging receptacle (charging socket)  24  that is sized and shaped to receive a charge plug  26  of a charge cord assembly  28 . The charge plug  26  connects to electronic hardware (not shown) on the vehicle for charging vehicle batteries (not shown). The charge cord assembly  28  also includes a charge cord  30 , the other end of which connects to a source of electricity (not shown). 
         [0011]    The charge plug  26  includes a main body  32  that telescopically slides into the receptacle  24  and has a sloped insertion surface  34  adjacent to a terminal end  36  of the plug  26 . A retention recess  38  is recessed into a side of the plug  26  and forms a retention flange  40  adjacent to the sloped surface  34 . The sloped surface  34 , recess  38  and retention flange  40  all include at least a portion that faces a cord lock  42 . 
         [0012]    The cord lock  42  is mounted to the vehicle structure  22  and includes a catch  44  that is pivotally mounted on a plunger  46 . A catch spring  47  is secured between the catch  44  and plunger  46  to bias the catch  44  into a position where it extends toward the retention recess  38 . The spring  47  may be a coil spring or may be something else, such as an elastically flexible material that can be relatively easily flexed and when released will return the catch  44  to its original position. The plunger  46  is mounted to and telescopically slidable by a motor and gear assembly (actuator)  48 . The motor and gear assembly  48  may be, for example, much like a conventional power door lock actuator as is used on common automotive vehicles. When actuated, the motor and gear assembly  48  can selectively push the plunger  46  outward toward the retention recess  38  or retract the plunger  46  inward away from the retention recess  38 . 
         [0013]    The motor and gear assembly  48  may be controlled by a controller  50 , such as, for example, a body controller. Although, it may be a separate controller or another type of vehicle controller, if so desired. This controller  50  may also be in communication with a door lock/unlock switch  52  for a vehicle door (not shown) or a wirelessly transmitting key fob  54  or both. The controller  50  door lock switch  52  and key fob  54  are part of a power door lock system of the vehicle. 
         [0014]    In addition, a manual release assembly  64  may be included as a backup cable release, if so desired. The manual release assembly  64  may include a Bowden cable  58 . A first end  56  of the Bowden cable  58  may be attached to the catch  44 , with a second end  60  attached to a manual release handle  62  that is accessible to a vehicle operator. The release handle  62  can be located anywhere in the vehicle where it is generally out of the way of vehicle occupants but still accessible should one need to manually release the cord lock  42  from the charge plug  26 . 
         [0015]    The operation of the charge cord assembly  28  and cord lock  42  will now be discussed. When the controller  50  receives a signal from the key fob  54  or the door lock switch  52  to unlock the vehicle doors (not shown), not only does the controller  50  cause the vehicle doors to unlock, but it also activates the motor and gear assembly  48  to move the plunger  46  to the retracted position (shown in  FIG. 1 ). In this position, the charge plug  26  can be easily slid into and out of the charging receptacle  24  without engagement with the catch  44  of the cord lock  42 . 
         [0016]    When the controller receives a signal from the key fob  54  or the door lock switch  52  to lock the vehicle doors, not only does the controller  50  cause the vehicle doors to lock, but it also activates the motor and gear assembly  48  to move the plunger  46  to the extended position (shown in  FIG. 2 ). In this position, the charge plug  26  can still be easily slid into the receptacle  24  because, as one holds the main body  32  and pushes the charge plug  26  into the receptacle  24 , the sloped insertion surface  34  will cause the catch  44  to pivot outward against the bias of the catch spring  47  until the catch  44  aligns with the retention recess  38 . At this point, the catch spring  47  will pivot the catch  44  into the retention recess  38 . Once in this position, the charge plug  26  cannot be removed while the vehicle doors are still locked. If one tries to pull the charge plug  26  out, the catch  44  will engage the retention flange  40 , preventing removal. 
         [0017]    Thus, the cord lock  42  is able to selectively lock the charge plug  26  into the charging receptacle  24  without the need for additional controllers, vehicle switches or key fob switches. The charge plug  26  can always be slid into the receptacle  24 , but the charge plug can be prevented from being inadvertently removed when one wishes to charge the vehicle batteries. 
         [0018]    Additionally, should the motor and gear assembly  48  or other component malfunction or the vehicle lose power while the charge plug  26  is plugged in and the doors locked, removal of the charge plug  26  is still possible. One only needs to pull on the manual release handle  62 , which will cause the catch  44  to pivot away from the retention recess  38  against the bias of the catch spring  47 . The charge plug  26  can then be slid out of the receptacle  24  without the catch  44  engaging the retention flange  40 . 
         [0019]      FIG. 3  illustrates a second embodiment. This embodiment is similar to the first and so similar elements will have similar numbers but in the 100-series. The vehicle  120  includes vehicle structure  122  that forms a vehicle charging receptacle  124  that is sized and shaped to receive a charge plug  126  of a charge cord assembly  128 . The charge cord assembly  128  includes a charge cord  130 , the other end of which connects to a source of electricity (not shown). 
         [0020]    The charge plug  126  includes a main body  132  that telescopically slides into the receptacle  124  and has a sloped insertion surface  134  adjacent to a terminal end  136  of the plug  126 . A retention recess  138  is recessed into a side of the plug  126  and forms a retention flange  140  below the sloped surface  134 . The sloped surface  134 , recess  138  and retention flange  140  all include at least a portion that faces a cord lock  142 . 
         [0021]    The cord lock  142  is mounted to the vehicle structure  122  and includes a catch  144  that is telescopically mounted on a plunger  146 . A catch spring  147  is located between the catch  144  and plunger  146  to bias the catch  144  into a position where it extends toward the retention recess  138 . The spring  147  may be a coil spring or may be something else, such as an elastically flexible material that can be relatively easily compressed and when released will return the catch  144  to its original position. The plunger  146  is mounted to and telescopically slidable by a motor and gear assembly  148 . The motor and gear assembly  148  may include a motor  168  that drives a driving spur gear  170 , which, in turn, drives a driven spur gear  172 . The driven spur gear  172  rotationally drives a jack screw  174 , which engages the plunger  146  to cause the plunger to extend and retract as the jack screw  174  is rotated in one direction or the other. When actuated, the motor and gear assembly  148  can selectively push the plunger  146  outward toward the retention recess  138  or retract the plunger  146  inward away from the retention recess  138 . 
         [0022]    An over center spring  176  may have one end mounted to a flange  178  that extends from the plunger  146  and another end  180  that is mounted in a fixed position relative to vehicle structure. The over center spring  176  and a portion of the plunger  146  are shown in phantom in the retracted position. The solid lines show the components of the second embodiment in the extended position. The over center spring  176  helps to bias the plunger  146  into the fully retracted or fully extended positions. 
         [0023]    The motor and gear assembly  148  may be controlled by a controller  150 . This controller  150  may also be in communication with a door lock/unlock switch  152  for a vehicle door (not shown) or a wirelessly transmitting key fob  154  or both. The controller  150 , door lock switch  152  and key fob  154  are part of a power door lock system of the vehicle. 
         [0024]    In addition, a manual release assembly  164  may be included as a backup cable release, if so desired. The manual release assembly  164  may include a Bowden cable  158 . A first end of the Bowden cable  158  may be attached to the catch  144 , with a second end attached to a manual release handle  162  that is accessible to a vehicle operator. 
         [0025]    The operation of the charge cord assembly  128  and cord lock  142  are similar to the first embodiment. Again, the vehicle door lock and unlock function controls the when the motor and gear assembly  148  extends and retracts the plunger  146 . The difference being that the spur gears  170 ,  172 , jack screw  174  and over center spring  176  are now employed for the extension and retraction of the plunger  146 . 
         [0026]    And again, the charge plug  126  can be inserted into the receptacle  124 , even when the plunger  146  is extended. In this case, as the charge plug  126  is inserted, the sloped insertion surface  134  pushes on the catch angled surface  184 , causing the catch  144  to telescopically retract against the bias of the catch spring  147  until the catch  144  reaches the retention recess  138 , at which point the spring  147  will push the catch  144  into the retention recess  138 . The charge plug  126  cannot be pulled out until the vehicle doors are unlocked, at which time the plunger  146  is retracted. 
         [0027]    A backup manual release may also be employed with this embodiment. One only needs to pull on the manual release handle  162 , which will cause the catch  144  to slide away from the retention recess  138  against the bias of the catch spring  147 . The charge plug  126  can then be slid out of the receptacle  124  without the catch  144  engaging the retention flange  140 . 
         [0028]    While the spur gears and jack screw are shown in the second embodiment, such an arrangement may also be employed in the first embodiment to extend and retract the plunger. Also, the shape of the insertion surface on the second embodiment may be employed with the first embodiment and vice versa. Additionally, for either embodiment, the motor and gear assembly that extends and retracts the plunger could be a motor engaging a rack and pinion type of gear arrangement. And, additionally, the over center spring shown in the second embodiment may be employed with the first embodiment as well, if so desired. 
         [0029]    While certain embodiments of the present invention have been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention as defined by the following claims.

Technology Classification (CPC): 8