Patent Description:
<CIT> discloses a charging connector that comprises a connector main, a lever and a regulating portion. The lever has a latch portion. The latch portion is provided with a locking lug. The locking lug has a locking surface. The lever comprises a main portion and a reinforcing portion. The main portion is made of resin. The reinforcing portion is made of metal plate. The reinforcing portion is held by the main portion. The reinforcing portion has a locking portion and a regulated portion. The locking portion is exposed on the locking surface. When the lever is positioned at a locked position, the regulated portion is positioned rearward beyond the regulating portion in a front-rear direction and faces the regulating portion in the front-rear direction. When the lever is positioned at the locked position, the regulating portion regulates forward movement of the regulated portion in the front-rear direction.

<CIT> discloses: A connector mateable with a mating connector having a locked portion. The connector comprises a lock member, a position detection mechanism, a lock maintenance member and a state detection mechanism. The lock member has a lock portion. The lock member is selectively positionable at a lock position or an unlock position. When the lock member is positioned at the lock position, the lock portion locks the locked portion to lock the mating of the connector with the mating connector. When the lock member is positioned at the unlock position, the connector is removable from the mating connector. The position detection mechanism detects whether the lock member is positioned at the lock position or the unlock position. The lock maintenance member is selectively takable a maintenance state or a permission state. The state detection mechanism detects whether the lock maintenance member is under the maintenance state or the permission state.

<CIT> discloses a charging connector that includes a connector housing to be fitted to a power receiving connector, a connector case housing the connector housing, a lock arm arranged to be swingable about a swing fulcrum between a lock position and a release position, and a coil spring located toward a power receiving connector away from the swing fulcrum to bias the lock arm toward the lock position. The lock arm is provided with a spring compartment housing the coil spring in a manner such that the periphery of the coil spring is enclosed. The spring compartment is provided, on a bottom portion thereof, with a penetration hole extending in the lock arm.

For example, the above mentioned type of connector is disclosed in <CIT> (Patent Document <NUM>), the content of which is incorporated herein by reference.

Referring to <FIG>, Patent Document <NUM> discloses a connector <NUM> mateable with a mating connector <NUM>. The connector <NUM> supplies electric power to the mating connector <NUM> under a mated state where the connector <NUM> is mated with the mating connector <NUM>. Thus, the connector <NUM> is a charging connector.

The connector <NUM> comprises a lock lever <NUM>, a switch <NUM> and a pressable portion (operation portion) <NUM>. The lock lever <NUM> has an engagement portion (latch) <NUM>. The switch <NUM> has a driving portion <NUM>. The operation portion <NUM> can operate a release portion <NUM>. The lock lever <NUM> is supported by a shaft so that the latch <NUM> is vertically movable.

The latch <NUM> has been moved downward under an intermediate state shown in <FIG> where the connector <NUM> is in process of being mated with the mating connector <NUM>. The latch <NUM> is moved upward under the mated state (not shown). When the latch <NUM> is moved upward, the latch <NUM> is engaged with an engagement portion (mating latch) <NUM> of the mating connector <NUM> to be locked. Electric power is supplied to the mating connector <NUM> under this state. When the operation portion <NUM> is operated after the charging of electric power, the release portion <NUM> pushes the lock lever <NUM> from below so that the latch <NUM> is moved downward. As a result, the latch <NUM> is unlocked.

When the latch <NUM> is moved downward, the lock lever <NUM> pushes the driving portion <NUM> of the switch <NUM> downward so that the switch <NUM> takes a released state which indicates that the lock is unlocked. When the latch <NUM> is moved upward, the driving portion <NUM> is not pressed, and thereby the switch <NUM> takes a state different from the released state.

As described above, according to the Patent Document <NUM>, the state of the switch is changed in accordance with the operation of the operation portion. However, two requirements described below are required for a charging connector. The first requirement is that the state of the switch is not changed to the released state even if the operation portion is operated under a locked state where the latch is locked. The second requirement is that the release state of the switch is maintained until the mating of the connector is completed.

It is therefore an object of the present invention to provide a charging connector comprising a switch whose state is not changed to a released state even if an operation portion is operated under a locked state and is maintained to the released state until the mating of the connector is completed.

In general, when a latch is engaged, a lock portion regulates a movement of a lock lever to lock the latch. However, considering tolerance, the lock lever under the thus-locked state is provided with a play. The first requirement requires that the state of the switch is not changed as long as the lock lever is moved within the range defined by this play. Therefore, in order to satisfy the first requirement, the switch should be arranged in the vicinity of a part of the lock lever which is only slightly moved in accordance with an operation of an operation portion. More specifically, the switch should be arranged in the vicinity of a rotation shaft of the lock lever.

In order to satisfy the second requirement, the switch should continuously maintain the released state unless the latch is engaged with a mating latch. In other words, the switch should continuously maintain the released state even when the latch is merely slightly moved vertically. Therefore, in order to satisfy the second requirement, the switch should be arranged in the vicinity of a part of the lock lever which is largely moved in accordance with the operation of the operation portion. More specifically, the switch should be arranged to be apart from the rotation shaft of the lock lever.

As can be seen from the explanation described above, when a charging connector comprises a small switch which is typically used, the charging connector cannot meet both the first and second requirements.

The inventors of the present invention have conceived a new structure of a charging connector which meets the first and second requirements. According to this new structure, the charging connector is provided with a switch mechanism, a temporary maintenance mechanism and a cooperation portion. The temporary maintenance mechanism temporarily maintains the switch mechanism at an initial position. The cooperation portion controls the position of the switch mechanism in cooperation with the movement of a lock lever. In detail, the temporary maintenance mechanism locates the switch mechanism at the initial position unless the latch is moved beyond the range defined by the play of the lock lever. Moreover, the cooperation portion moves the switch mechanism against the temporary maintenance mechanism when the latch is moved beyond the range defined by the play of the lock lever. The first and second requirements can be satisfied by the functions of the switch mechanism, the temporary maintenance mechanism and the cooperation portion described above. More specifically, an aspect of the present invention provides a charging connector described below.

The above mentioned abject of the present invention is achieved by the charging connector as defined by claim <NUM>.

The temporary maintenance mechanism of an aspect of the present invention temporarily maintains the switch mechanism at the initial position where the switch mechanism takes the initial state when the latch is located between the engageable position and the predetermined position or is close to the engageable position. Therefore, under a state where the latch is locked, the switch mechanism is maintained at the initial position as long as the lock lever is moved within the range defined by the play in accordance with an operation of the operation portion. Thus, the first requirement is satisfied. Moreover, the cooperation portion moves the switch mechanism from the initial position to change the state of the switch body to the released state when the latch is located between the predetermined position and the released position or is apart from the engageable position beyond the predetermined position. Therefore, the released state of the switch mechanism is maintained until the mating of the charging connector is completed so that the latch is located between the engageable position and the predetermined position. Thus, the second requirement is satisfied.

As described above, an aspect of the present invention provides a charging connector comprising a switch whose state is not changed to a released state even if an operation portion is operated under a locked state and is maintained to the released state until the mating of the charging connector is completed.

An appreciation of the objectives of the present invention and a more complete understanding of its structure may be had by studying the following description of the preferred embodiment and by referring to the accompanying drawings.

While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the scope of the present invention as defined by the appended claims.

Referring to <FIG>, a charging connector <NUM> according to an embodiment of the present invention is a connector which is configure to supply electric power of a power system (not shown) such as an electric vehicle (EV) station to a mating device (not shown) such as a power charging device incorporated in an electric vehicle.

Referring to <FIG>, the charging connector <NUM> is connected to the power system (not shown) via a cable <NUM>. The mating device (not shown) has an inlet <NUM> incorporated therein. The charging connector <NUM> is mateable with the inlet <NUM> along a front-rear direction. The front-rear direction of the present embodiment is the X-direction. In the present embodiment, "forward" means the positive X-direction, and "rearward" means the negative X-direction. Under a mated state where the charging connector <NUM> and the inlet <NUM> are mated with each other as shown in <FIG>, electric power of the power system is supplied to the mating device via the cable <NUM>, the charging connector <NUM> and the inlet <NUM>.

Hereafter, explanation will be made about the charging connector <NUM> of the present embodiment.

Referring to <FIG> and <FIG>, the charging connector <NUM> of the present embodiment comprises a front cover <NUM> mainly made of insulator, two side covers <NUM> each mainly made of insulator, a charging unit <NUM>, a sub-assembly <NUM> and a rotation axis <NUM> made of metal. The front cover <NUM>, the side covers <NUM> and the charging unit <NUM> are combined into a connector body <NUM>. Thus, the charging connector <NUM> comprises the connector body <NUM>, the sub-assembly <NUM> and the rotation axis <NUM>. The connector body <NUM> includes the front cover <NUM>, the side covers <NUM> and the charging unit <NUM>.

The charging unit <NUM> is a member which provides a charging function to the charging connector <NUM> and is connected to the cable <NUM>. The sub-assembly <NUM> is a member for controlling the charging. The rotation axis <NUM> is a member for attaching the sub-assembly <NUM> to the charging unit <NUM>. The rotation axis <NUM> is a pin which has a cylindrical shape and extends straight along a lateral direction. The sub-assembly <NUM> and the charging unit <NUM> are combined with each other into an inner assembly <NUM> by using the rotation axis <NUM>. The front cover <NUM> and the side covers <NUM> cover and protect the inner assembly <NUM>.

The inner assembly <NUM> is accommodated in the charging connector <NUM> and is attached to the side covers <NUM> so as to be located between the two side covers <NUM> in the lateral direction perpendicular to the front-rear direction. The lateral direction of the present embodiment is the Y-direction. The inner assembly <NUM> which is attached to the side covers <NUM> is covered by the front cover <NUM> from front.

The charging unit <NUM> of the present embodiment includes two terminals <NUM> each made of conductor. Each of the terminals <NUM> is connected to a core wire (not shown) of the cable <NUM> and can receive electric power of the power system (not shown). Referring to <FIG>, the charging unit <NUM> has two side walls <NUM>. Each of the side walls <NUM> is located on an upper end of the charging unit <NUM> in an upper-lower direction perpendicular to both the front-rear direction and the lateral direction. The upper-lower direction of the present embodiment is the Z-direction. In the present embodiment, "upward" means the positive Z-direction, and "downward" means the negative Z-direction. The two side walls <NUM> are apart from each other in the lateral direction and extend in parallel to each other along a vertical plane (XZ-plane) perpendicular to the lateral direction.

Each of the side walls <NUM> is formed with a press-fit hole <NUM>. Each of the press-fit holes <NUM> is a circular hole and passes through the side wall <NUM> in the lateral direction. Each of the press-fit holes <NUM> has a size which allows the rotation axis <NUM> to be press-fit thereto. The two press-fit holes <NUM> are located at positions same as each other in the XZ-plane.

The charging unit <NUM> has a catch portion <NUM>. Thus, the connector body <NUM> comprises the catch portion <NUM>. The catch portion <NUM> is located at lower ends of the side walls <NUM> in the upper-lower direction and is located between the two side walls <NUM> in the lateral direction. The catch portion <NUM> is a part for catching a part of a lower end of the sub-assembly <NUM> as described later. Referring to <FIG> and <FIG>, the catch portion <NUM> of the present embodiment is a planar surface which extends along a horizontal plane (XY-plane) perpendicular to the upper-lower direction. However, the present invention is not limited thereto. For example, the shape of the catch portion <NUM> is not specifically limited. Moreover, the catch portion <NUM> may be a part of a member other than the charging unit <NUM>.

Referring to <FIG>, the sub-assembly <NUM> is formed with a central hole <NUM>. The central hole <NUM> is a circular hole and passes through the sub-assembly <NUM> in the lateral direction. The central hole <NUM> has a size which allows the rotation axis <NUM> to be inserted therein substantially with no friction. Referring to <FIG> together with <FIG>, the sub-assembly <NUM> is attached to the charging unit <NUM> and is arranged so that the central hole <NUM> is located between the two press-fit holes <NUM> of the charging unit <NUM> in the lateral direction. The rotation axis <NUM> is press-fit into the two press-fit holes <NUM> while a part thereof passes through the central hole <NUM>. The thus-attached sub-assembly <NUM> is movable relative to the charging unit <NUM>. More specifically, the sub-assembly <NUM> is movable in a seesaw manner about the rotation axis <NUM>. For example, when a rear end of the sub-assembly <NUM> is pushed downward, a front end of the sub-assembly <NUM> is moved upward.

Referring to <FIG>, the inner assembly <NUM> which is assembled as described above is covered by the front cover <NUM> and the side covers <NUM> of the connector body <NUM> as previously described. The charging unit <NUM> of the inner assembly <NUM> is fixed so as not to be moved relative to the front cover <NUM> and the side covers <NUM>. In contrast, the sub-assembly <NUM> of the inner assembly <NUM> is incorporated so as to be movable in a seesaw manner relative to the connector body <NUM> including the charging unit <NUM>.

Referring to <FIG>, the terminals <NUM> of the charging unit <NUM> extend through the front cover <NUM> along the front-rear direction. Referring to <FIG> together with <FIG>, each of the terminals <NUM> is connected to the mating device (not shown) of the inlet <NUM> under the mated state so that electric power can be supplied to the mating device.

Referring to <FIG>, the charging connector <NUM> of the present embodiment has the aforementioned structure. However, the present invention is not limited thereto, but the structure of the charging connector <NUM> can be variously modified as necessary. For example, the charging connector <NUM> may further comprise another member in addition to the connector body <NUM>, the sub-assembly <NUM> and the rotation axis <NUM>. The connector body <NUM> may further include another member in addition to the front cover <NUM>, the side covers <NUM> and the charging unit <NUM>. The structure of the charging unit <NUM> is not specifically limited.

The sub-assembly <NUM> may be attached to the charging unit <NUM> via a member different from the rotation axis <NUM>, provided that the front end thereof is vertically movable. The sub-assembly <NUM> may be directly attached to the side covers <NUM>. The sub-assembly <NUM> may be supported by a member such as a spring (not shown) so that the front end thereof is not vertically moved unless an external force is applied to the sub-assembly <NUM>.

Hereafter, more specific explanation will be made about the sub-assembly <NUM> of the present embodiment. The structure of the sub-assembly <NUM> is not limited to those of the present embodiment and modifications described below but can be further modified as described later.

Referring to <FIG>, the sub-assembly <NUM> of the present embodiment includes a lock lever <NUM>, a switch mechanism <NUM>, a temporary maintenance mechanism (coil spring) <NUM>, a screw <NUM> made of metal and a shaft <NUM> made of metal. Thus, the charging connector <NUM> of the present embodiment comprises the lock lever <NUM>, the switch mechanism <NUM>, the temporary maintenance mechanism <NUM>, the screw <NUM> and the shaft <NUM>. The sub-assembly <NUM> of the present embodiment comprises only the aforementioned members. However, the present invention is not limited thereto, but the sub-assembly <NUM> may further comprise another member in addition to the aforementioned members.

Referring to <FIG> together with <FIG>, the sub-assembly <NUM> is attached to the charging unit <NUM> of the connector body <NUM> as previously described and is thereby incorporated in the connector body <NUM>. Thus, each of the lock lever <NUM>, the switch mechanism <NUM>, the temporary maintenance mechanism <NUM>, the screw <NUM> and the shaft <NUM> is incorporated in the connector body <NUM>.

Referring to <FIG>, the lock lever <NUM> of the present embodiment includes a lever body <NUM> made of insulator such as resin and a reinforcement member <NUM> made of metal. The lever body <NUM> extends along the front-rear direction. The lever body <NUM> is formed with a press-fit groove <NUM>. The press-fit groove <NUM> is formed in a lower part of the lever body <NUM> and extends along the front-rear direction between a front end and a rear end of the lever body <NUM>. The reinforcement member <NUM> is a single metal plate which has a constant size in the lateral direction. The reinforcement member <NUM> has a size in the front-rear direction which is substantially same as that of the press-fit groove <NUM>. The reinforcement member <NUM> is press-fit into the press-fit groove <NUM> from below. According to the present embodiment, the lever body <NUM> can be reinforced by the reinforcement member <NUM>.

The lock lever <NUM> of the present embodiment has an operation portion <NUM>, a latch <NUM> and a cooperation portion <NUM>. Thus, the sub-assembly <NUM> includes the operation portion <NUM>, the latch <NUM> and the cooperation portion <NUM>. The charging connector <NUM> comprises the operation portion <NUM>, the latch <NUM> and the cooperation portion <NUM>.

The operation portion <NUM> is located at the rear end of the lever body <NUM> and protrudes upward. The operation portion <NUM> of the present embodiment is a part of the lever body <NUM> of the lock lever <NUM>. However, the present invention is not limited thereto. For example, the operation portion <NUM> may be a member formed separately from the lock lever <NUM>.

The latch <NUM> is located at the front end of the lock lever <NUM>. The latch <NUM> of the present embodiment projects downward. In other words, the latch <NUM> faces downward. The latch <NUM> has a front end which has an arc shape. The latch <NUM> has a rear end which is a sloping surface sloping rearward. The latch <NUM> of the present embodiment is formed of the front end of the lever body <NUM> and a front end of the reinforcement member <NUM> and has a high strength. However, the present invention is not limited thereto. For example, the latch <NUM> may be formed only of the front end of the lever body <NUM>. Moreover, the latch <NUM> may face upward as described later.

Referring to <FIG> and <FIG>, the cooperation portion <NUM> of the present embodiment is a part of the reinforcement member <NUM>. Thus, the reinforcement member <NUM> has the cooperation portion <NUM>. In detail, the reinforcement member <NUM> has a lower end which partially protrudes downward and then extends forward. The cooperation portion <NUM> of the present embodiment is an upper edge surface of this forward extending part.

Referring to <FIG>, the switch mechanism <NUM> of the present embodiment includes a switch body <NUM> and a switch plate <NUM> made of metal. The switch body <NUM> has a flat-plate shape in parallel to the XZ-plane. The switch plate <NUM> is a single metal plate which has a constant size in the lateral direction and is formed with bends.

Referring to <FIG> together with <FIG>, the switch body <NUM> is formed with a screw hole <NUM>. The screw hole <NUM> passes through the switch body <NUM> in the lateral direction. The switch body <NUM> has a positioning projection <NUM>. The positioning projection <NUM> is provided on one of opposite surfaces of the switch body <NUM> in the lateral direction and project outward therefrom. The switch plate <NUM> is formed with a screw hole <NUM> and a positioning hole <NUM>. Each of the screw hole <NUM> and the positioning hole <NUM> passes through the switch plate <NUM> in the lateral direction. The screw hole <NUM> and the positioning hole <NUM> are located at positions in the XZ-plane which coincide with positions of the screw hole <NUM> and the positioning projection <NUM> in the XZ-plane, respectively.

The switch body <NUM> and the switch plate <NUM> are combined with each other as described below. First, the positioning projection <NUM> is inserted into the positioning hole <NUM> so that the switch body <NUM> and the switch plate <NUM> are positioned to each other. Then, the screw <NUM> is screwed into the screw hole <NUM> through the screw hole <NUM>. As a result, the switch body <NUM> and the switch plate <NUM> are combined with each other and fixed to each other. The switch body <NUM> of the present embodiment is fixed to and supported by the switch plate <NUM> as described above.

Referring to <FIG> and <FIG>, the switch body <NUM> of the present embodiment has a pressed portion <NUM> and a button <NUM>. Thus, the switch mechanism <NUM> includes the pressed portion <NUM> and the button <NUM>. The charging connector <NUM> comprises the pressed portion <NUM> and the button <NUM>.

The pressed portion <NUM> is proved on one of the opposite surfaces of the switch body <NUM> in the lateral direction and projects outward therefrom in the lateral direction, the one of the opposite surfaces being opposite to the surface on which the positioning projection <NUM> (see <FIG>) is provided. The pressed portion <NUM> is located at a position in the XZ-plane which is same as the position of the positioning projection <NUM> in the XZ-plane. As can be seen from this structure, the switch plate <NUM> of the present embodiment is attachable to any one of the opposite surfaces of the switch body <NUM> in the lateral direction.

The button <NUM> of the present embodiment is a push button. The switch body <NUM> takes one of two states different from each other in accordance with whether the button <NUM> is pushed or not. The switch mechanism <NUM> of the present embodiment includes two signal wires <NUM> in addition to the switch body <NUM> and the switch plate <NUM>. For each of the signal wires <NUM>, one of opposite ends thereof is connected to the switch body <NUM>, and a remaining one (not shown) of the opposite ends is connected to the power system (not shown). The signal wires <NUM> send the state of the switch body <NUM> to the power system.

Hereafter, explanation will be made about an assembling method of the sub-assembly <NUM> of the present embodiment and an incorporating method of the sub-assembly <NUM> into the connector body <NUM>.

Referring to <FIG>, the lever body <NUM> of the present embodiment is formed with two shaft holes <NUM>. Each of the shaft holes <NUM> is a circular hole and passes through a part of the lever body <NUM> in the lateral direction. The two shaft holes <NUM> are located at positions same as each other in the XZ-plane and apart from each other in the lateral direction. The reinforcement member <NUM> of the present embodiment is formed with a shaft hole <NUM>. The shaft hole <NUM> is a circular hole and passes through the reinforcement member <NUM> in the lateral direction. Referring to <FIG> together with <FIG>, when the reinforcement member <NUM> is attached to the lever body <NUM>, the shaft hole <NUM> is located between the two shaft holes <NUM> in the lateral direction. Each of the shaft holes <NUM> and the shaft hole <NUM> which are arranged as described above has a size which allows the shaft <NUM> to be press-fit therein.

Referring to <FIG>, the switch plate <NUM> of the present embodiment is formed with a shaft hole <NUM>. The shaft hole <NUM> is a circular hole and passes through the switch plate <NUM> in the lateral direction. The shaft hole <NUM> has a size which allows the shaft <NUM> to be inserted therein substantially with no friction. Referring to <FIG> together with <FIG>, the shaft <NUM> passes through the shaft hole <NUM> and is press-fit into the shaft holes <NUM> of the lever body <NUM> and the shaft hole <NUM> of the reinforcement member <NUM>. Thus, the shaft <NUM> is fixed to the lock lever <NUM>. The thus-fixed shaft <NUM> is formed with the aforementioned central hole <NUM>. Referring to <FIG>, the rotation axis <NUM> is inserted into the central hole <NUM> as previously described. Referring to <FIG>, when the switch plate <NUM> (see <FIG>) is attached to the lock lever <NUM> (see <FIG>) as described above, the switch mechanism <NUM> is located just above the catch portion <NUM>.

Referring to <FIG>, according to the aforementioned structure, the lock lever <NUM> is turnable about the rotation axis <NUM>. Referring to <FIG> together with <FIG>, the shaft <NUM> is not fixed to the switch plate <NUM> of the switch mechanism <NUM>. Therefore, the switch mechanism <NUM> is turnable relative to the lock lever <NUM> about the shaft <NUM>, or about the rotation axis <NUM>. Thus, the lock lever <NUM> and the switch mechanism <NUM> of the present embodiment are turnable independently from each other about a shaft common to them.

As described above, the switch plate <NUM> of the present embodiment is attached to the lock lever <NUM> to be turnable. The sub-assembly <NUM> of the present embodiment can be easily assembled by using the shaft <NUM> while the switch body <NUM> is reinforced by the switch plate <NUM>. However, the present invention is not limited thereto. For example, the switch body <NUM> may be provided with no switch plate <NUM> and may be formed with a shaft hole (not shown). Instead, the switch mechanism <NUM> may be attached by a member other than the shaft <NUM> to be turnable relative to the lock lever <NUM>. The center of turn of the lock lever <NUM> and the center of turn of the switch mechanism <NUM> may be different from each other.

Referring to <FIG> and <FIG>, the reinforcement member <NUM> of the present embodiment has an attachment portion <NUM>. The attachment portion <NUM> is a part of the reinforcement member <NUM>. The attachment portion <NUM> projects downward from a lower edge surface of the reinforcement member <NUM>. Referring to <FIG> and <FIG>, the switch plate <NUM> of the present embodiment has an attachment portion <NUM>. The attachment portion <NUM> is a part of the switch plate <NUM>. The attachment portion <NUM> extends in the lateral direction from a lower edge surface of the switch plate <NUM> and then projects upward.

Referring to <FIG>, the temporary maintenance mechanism <NUM> of the present embodiment is a coil spring which has opposite ends <NUM> and <NUM>. The end <NUM> is located at an upper end of the coil spring <NUM>. The end <NUM> is located at a lower end of the coil spring <NUM>. One of the opposite ends <NUM> and <NUM> of the coil spring <NUM>, or the end <NUM>, is attached to the switch mechanism <NUM>. A remaining one of the opposite ends <NUM> and <NUM> of the coil spring <NUM>, or the end <NUM>, is attached to the lock lever <NUM>. In detail, in the present embodiment, the end <NUM> is attached to the attachment portion <NUM> of the reinforcement member <NUM>, and the end <NUM> is attached to the attachment portion <NUM> of the switch plate <NUM>. The thus-attached coil spring <NUM> can apply a downward force to the switch plate <NUM>.

Referring to <FIG>, the lock lever <NUM> and the switch mechanism <NUM> of the present embodiment are combined with each other into the one sub-assembly <NUM> by using the only one shaft <NUM> and the only one coil spring <NUM> as described above. Referring to <FIG>, the sub-assembly <NUM> and the charging unit <NUM> are combined into the inner assembly <NUM> by using the only one rotation axis <NUM>.

Referring to <FIG>, the charging connector <NUM> of the present embodiment can be easily manufactured only by attaching the only one inner assembly <NUM>, which is an assembly of a large number of members, to the side covers <NUM>. However, the present invention is not limited thereto. For example, the sub-assembly <NUM> may be supported by the side covers <NUM> with use of the rotation axis <NUM> without being combined with the charging unit <NUM>.

Referring to <FIG>, the button <NUM> of the switch mechanism <NUM> of the present embodiment is easily damaged if a force is applied along a direction perpendicular to an axis direction of the button <NUM>, or the upper-lower direction in <FIG>. According to the assembling method of the present embodiment, the button <NUM> can be prevented from being applied with a force which might damage the button <NUM> in the assembling process. Moreover, since the position of the switch mechanism <NUM> is fixed at the time when the inner assembly <NUM> is assembled, the position of the switch mechanism <NUM> can be precisely adjusted during the assembling process of the inner assembly <NUM>.

As described above, according to the assembling method of the present embodiment, the charging connector <NUM> can be easily assembled while tolerance is reduced. In particular, the lock lever <NUM> and the switch mechanism <NUM> of the present embodiment are combined with each other by using the coil spring <NUM> in addition to the shaft <NUM>. The lock lever <NUM> and the switch mechanism <NUM> which are combined with each other are incorporated in the connector body <NUM> (see <FIG>) while the switch mechanism <NUM> is presses against the catch portion <NUM> (see <FIG>) by the compressed coil spring <NUM>.

It is difficult to properly attach the coil spring <NUM> in a process where the lock lever <NUM> and the switch mechanism <NUM> are incorporated in the connector body <NUM> (see <FIG>) one by one. According to the present embodiment, the charging connector <NUM> can be easily assembled even though the charging connector <NUM> includes a member such as the coil spring <NUM> which is not easily attached. However, the present invention is not limited thereto. For example, the members included in the sub-assembly <NUM> may be incorporated in the connector body <NUM> one by one. In this instance, the upper end <NUM> of the coil spring <NUM> may be attached to the connector body <NUM>.

Referring to <FIG>, the switch body <NUM> of the present embodiment is attached to the lock lever <NUM> via the switch plate <NUM>. Since the switch plate <NUM> is formed of a metal plate, the switch plate <NUM> can be shaped in various shapes and can be easily attached to the lock lever <NUM>. For example, the switch plate <NUM> can be easily formed with the attachment portion <NUM>. According to the present embodiment, the sub-assembly <NUM> can be more easily assembled with no increase of components. However, the present invention is not limited thereto. For example, the attachment portion <NUM> may be a member formed separately from the switch plate <NUM>. The switch plate <NUM> may be provided as necessary.

As previously described, the lever body <NUM> of the present embodiment is reinforced by the reinforcement member <NUM>. Since the reinforcement member <NUM> is formed of a metal plate, the reinforcement member <NUM> is easily shaped into various shapes. For example, the reinforcement member <NUM> can be easily formed with the cooperation portion <NUM> and the attachment portion <NUM>. According to the present embodiment, various portions can be provided with no increase of components while the lever body <NUM> is reinforced. In particular, the latch <NUM> which tends to receive a force is reinforced. However, the present invention is not limited thereto. For example, each of the cooperation portion <NUM> and the attachment portion <NUM> may be a member formed separately from the reinforcement member <NUM>. The reinforcement member <NUM> mat be provided as necessary.

The charging connector <NUM> which is assembled as described above is mateable with the inlet <NUM> (see <FIG>) as described below.

Referring to <FIG>, when the inner assembly <NUM> is accommodated in the charging connector <NUM>, the latch <NUM> of the lock lever <NUM> projects forward from the front cover <NUM>, and the operation portion <NUM> projects upward from the side covers <NUM>. The thus-arranged latch <NUM> is insertable into the inlet <NUM>. The thus-arranged operation portion <NUM> is operable by an operator.

Referring to <FIG>, when the charging connector <NUM> is under a separated state where the charging connector <NUM> is separated from the inlet <NUM> as shown in <FIG>, the latch <NUM> of the lock lever <NUM> is located at an engageable position (see solid line in <FIG>). The latch <NUM> is temporarily maintained at the engageable position because of its own weight or by a mechanism such as a spring (not shown), for example. When the operation portion <NUM> is pushed downward, the lock lever <NUM> is turned about the rotation axis <NUM>, and thereby the latch <NUM> is moved upward (see chain dotted lines in <FIG>).

Referring to <FIG>, in an attempt of mating the charging connector <NUM> with the inlet <NUM>, the charging connector <NUM> is moved forward and toward the inlet <NUM>. When the charging connector <NUM> is moved forward, the arc-like front end of the latch <NUM> is brought into abutment with the inlet <NUM> and receive an upward force from the inlet <NUM>. As a result, the latch <NUM> is inserted into the inlet <NUM> while being moved upward. The state of the charging connector <NUM> at that time is referred to as an intermediate state or a half-mated state where the charging connector <NUM> is not completely mated with the inlet <NUM>. When the charging connector <NUM> is under the intermediate state, the latch <NUM> is located at an illustrated released position.

Referring to <FIG>, the inlet <NUM> is formed with a recessed portion which is recessed downward. The recessed portion is provided with a mating latch <NUM>. The mating latch <NUM> is a planar surface in parallel to a predetermined plane (YZ-plane). When the charging connector <NUM> is moved forward, the latch <NUM> is moved to the recessed portion of the inlet <NUM> and is then moved downward. The latch <NUM> which is moved downward is located at the engageable position to be engaged with the mating latch <NUM>. At that time, the charging connector <NUM> takes the mated state.

When the charging connector <NUM> under the mated state is pulled rearward, the sloping surface of the rear end of the latch <NUM> is pressed against the mating latch <NUM>. Thus, the engagement between the latch <NUM> and the mating latch <NUM> is not released when the charging connector <NUM> is merely pulled rearward. The charging connector <NUM> under the mated state can be detached from the inlet <NUM> as described below.

Referring to <FIG> together with <FIG>, first, the operation portion <NUM> is pushed downward so that the latch <NUM> is moved upward. Then, when the charging connector <NUM> is pulled rearward, the charging connector <NUM> takes a state which is equal to the intermediate state. Referring to <FIG> together with <FIG>, when the charging connector <NUM> is further pulled rearward, the charging connector <NUM> takes the separated state.

Hereafter, explanation will be made about the switch mechanism <NUM> of the present embodiment.

Referring to <FIG> and <FIG>, as described above, the latch <NUM> is moved between the engageable position shown in <FIG> and the released position shown in <FIG> in accordance with an operation of the charging connector <NUM>. Referring to <FIG> and <FIG>, when the latch <NUM> is located at the engageable position, the temporary maintenance mechanism <NUM> pushes the switch mechanism <NUM> downward. As a result, the switch mechanism <NUM> is partially pressed against the catch portion <NUM>. This position of the switch mechanism <NUM> is referred to as an initial position. When the switch mechanism <NUM> is located at the initial position, the pressed portion <NUM> of the switch mechanism <NUM> is apart from the cooperation portion <NUM> of the lock lever <NUM> and is located above the cooperation portion <NUM>.

As can be seen from <FIG>, <FIG> and <FIG>, in a process where the latch <NUM> is moved from the engageable position toward the released position, the cooperation portion <NUM> of the lock lever <NUM> is moved upward and is brought into abutment with the pressed portion <NUM> of the switch mechanism <NUM>. The position of the latch <NUM> at that time is referred to as a predetermined position. The predetermined position is a position shown in <FIG> and is a position between the engageable position and the released position. Thus, the latch <NUM> is movable in the upper-lower direction between the engageable position and the released position via the predetermined position in accordance with the operation of the operation portion <NUM>.

The cooperation portion <NUM> is moved in the upper-lower direction in cooperation with the movement of the latch <NUM> in the upper-lower direction. The cooperation portion <NUM> of the present embodiment is moved upward when the latch <NUM> is moved upward and is moved downward when the latch <NUM> is moved downward. However, the present invention is not limited thereto. As described later, the cooperation portion <NUM> may be moved downward when the latch <NUM> is moved upward and may be moved upward when the latch <NUM> is moved downward.

When the latch <NUM> is moved upward beyond the predetermined position, the cooperation portion <NUM> pushes the pressed portion <NUM> upward. As a result, the switch mechanism <NUM> is moved upward to be away from the initial position. As described above, the switch mechanism <NUM> is incorporated in the connector body <NUM> (see <FIG>) so as to be movable in the upper-lower direction. The switch mechanism <NUM> is located at the initial position when the latch <NUM> is located at the engageable position. When the latch <NUM> is located at the released position, the switch mechanism <NUM> is located at a position shown in <FIG> which is referred to as an intermediate position. Thus, the switch mechanism <NUM> is located at the intermediate position when the latch <NUM> is located at the released position.

Referring to <FIG> together with <FIG>, when the switch mechanism <NUM> is located at the initial position, the button <NUM> of the switch body <NUM> is pressed against the catch portion <NUM> and is pushed by the catch portion <NUM>. The state of the switch body <NUM> at that time is referred to as an initial state. Thus, the switch body <NUM> takes the initial state when the switch mechanism <NUM> is located at the initial position. Referring to <FIG>, under a state where the switch mechanism <NUM> is located at the intermediate position, the button <NUM> is not pressed against the catch portion <NUM> even if the button <NUM> is in contact with the catch portion <NUM>. Therefore, the button <NUM> is not pushed. The state of the switch body <NUM> at that time is referred to as a released state. Thus, the switch body <NUM> takes the released state when the switch mechanism <NUM> is located at the intermediate position.

Referring to <FIG>, <FIG> and <FIG>, the switch body <NUM> of the present embodiment takes the initial state when the latch <NUM> is located between the engageable position shown in <FIG> and the predetermined position shown <FIG>. The switch body <NUM> takes the released state when the latch <NUM> is located between the predetermined position and the released position shown in <FIG>. However, in general, the switch body <NUM> takes the initial state even when the button <NUM> is pressed to some extent. Therefore, the state of the switch body <NUM> may be changed to the released state when the latch <NUM> is moved toward the released position beyond the predetermined position to some extent.

Referring to <FIG>, as previously describe, the state of the switch body <NUM> is sent to the power system (not shown) via the signal wires <NUM>. The power system determines, by using a method based on a predetermined standard, whether the charging connector <NUM> is under a state where charging is allowed or not. For example, the power system supplies electric power to the charging connector <NUM> when the switch body <NUM> is under the initial state and the charging connector <NUM> is under the mated state. The power system does not supply electric power to the charging connector <NUM> unless the aforementioned charging condition is satisfied.

Referring to <FIG>, when the power system (not shown) supplies electric power to the inlet <NUM> via the charging connector <NUM>, high voltage electric current flows between the terminals <NUM> (see <FIG>) of the charging connector <NUM> and mating terminals (not shown) of the inlet <NUM>. The charging connector <NUM> and the inlet <NUM> have a lock mechanism for preventing electric shock which might be caused because of such high voltage electric current. More specifically, when charging starts, the inlet <NUM> of the present embodiment places a lock portion <NUM> above the latch <NUM> to regulate an upward movement of the latch <NUM>. As a result, the latch <NUM> is locked, and thereby the charging connector <NUM> cannot be detached from the inlet <NUM>. When the charging of the mating device (not shown) ends, the lock portion <NUM> is removed. As a result, the latch <NUM> is unlocked, and thereby the charging connector <NUM> can be removed from the inlet <NUM>.

As described above, according to the present embodiment, the state of the switch body <NUM> is changed in accordance with the operation of the operation portion <NUM>. However, two requirements described below are required for the charging connector <NUM>. The first requirement is that the state of the switch body <NUM> is not changed to the released state under a locked state where the latch <NUM> is locked even when the operation portion <NUM> is operated. Second requirement is that the released state of the switch body <NUM> is maintained until the mating of the charging connector <NUM> is completed.

Referring to <FIG>, according to the existing technique, when the latch <NUM> is engaged, the lock portion <NUM> regulates the movement of the lock lever <NUM> to lock the latch <NUM>. However, considering tolerance, the lock lever <NUM> under the thus-locked state has a play. The first requirement requires that the state of the switch body <NUM> is not changed as long as the lock lever <NUM> is moved within the range of this play. Therefore, in order to satisfy the first requirement, the switch body <NUM> should be arranged in the vicinity of a part of the lock lever <NUM> which is only slightly moved in accordance with the operation of the operation portion <NUM>. More specifically, the switch body <NUM> should be arranged in the vicinity of the rotation axis <NUM> of the lock lever <NUM>.

In order to satisfy the second requirement, the switch body <NUM> should continuously maintain the released state unless the latch <NUM> is engaged with the mating latch <NUM>. In other words, the switch body <NUM> should continuously maintain the released state even when the latch <NUM> is merely slightly moved vertically. Therefore, in order to satisfy the second requirement, the switch body <NUM> should be arranged in the vicinity of a part of the lock lever <NUM> which is largely moved in accordance with the operation of the operation portion <NUM>. More specifically, the switch body <NUM> should be arranged to be apart from the rotation axis <NUM> of the lock lever <NUM>.

In contrast, referring to <FIG> and <FIG>, the temporary maintenance mechanism <NUM> of the present embodiment temporarily maintains the switch mechanism <NUM> at the initial position where the switch body <NUM> takes the initial state when the latch <NUM> is located between the engageable position shown in <FIG> and the predetermined position shown in <FIG>, or when the latch <NUM> is close to the engageable position. Therefore, even if the lock lever <NUM> is moved within the range defined by the play in accordance with the operation of the operation portion <NUM> under a state where the latch <NUM> is locked, the initial state of the switch body <NUM> is maintained. Thus, the first requirement is satisfied.

Referring to <FIG> and <FIG>, the cooperation portion <NUM> presses the pressed portion <NUM> of the switch mechanism <NUM> to move the switch mechanism <NUM> from the initial position against the temporary maintenance mechanism <NUM> and thereby changes the state of the switch body <NUM> from the initial state to the released state when the latch <NUM> is located between the predetermined position shown in <FIG> and the released position shown in <FIG>, or the latch <NUM> is apart from the engageable position beyond the predetermined position. Therefore, the released state of the switch body <NUM> is maintained until the mating of the charging connector <NUM> is completed so that the latch <NUM> is located between the engageable position and the predetermined position. Thus, the second requirement is satisfied.

Summarizing the explanation described above, the movement range of the latch <NUM> of the present embodiment is divided into two ranges. In one of the two ranges, only the latch <NUM> is moved. In a remaining one of the two ranges, the switch mechanism <NUM> is moved in accordance with the movement of the latch <NUM>. The present embodiment provides the charging connector <NUM> comprising the switch body <NUM> whose state is not changed to the released state even if the operation portion <NUM> is operated under the locked state and is maintained to the released state until the mating of the charging connector <NUM> is completed.

The present embodiment can be further variously modified in addition to the already described various modifications. Hereafter, explanation will be made about some of modifications of the present embodiment.

Referring to <FIG>, the latch <NUM> of the present embodiment faces downward. When the operation portion <NUM> is pushed downward, the latch <NUM> is moved upward. However, the present invention is not limited thereto. For example, referring to <FIG> together with <FIG>, the latch <NUM> may face upward. In this instance, the operation portion <NUM> may be a member separated from the lock lever <NUM>. Instead, the operation portion <NUM> may be a part of the lever body <NUM> but may be located between the rotation axis <NUM> and the latch <NUM> in the front-rear direction. Thus, when the operation portion <NUM> is pushed downward, the latch <NUM> may be moved downward.

Referring to <FIG>, the switch mechanism <NUM> of the present embodiment is located below the lock lever <NUM>. However, the present invention is not limited thereto. For example, in an instance where the latch <NUM> faces upward, the switch mechanism <NUM> may be located above the lock lever <NUM>. In this instance, the catch portion <NUM> may be a part of the side covers <NUM> (see <FIG>) and may be located above the switch mechanism <NUM>. The temporary maintenance mechanism <NUM> may press the button <NUM> (see <FIG>) of the switch mechanism <NUM> which is located at the initial position against the catch portion <NUM> which is located above the switch mechanism <NUM>. When the latch <NUM> is moved downward, the cooperation portion <NUM> may push the pressed portion <NUM> downward.

The rotation axis <NUM> of the present embodiment is located in the vicinity of a rear end of the switch mechanism <NUM>. However, the present invention is not limited thereto. For example, in an instance where the latch <NUM> faces downward and the switch mechanism <NUM> is located above the lock lever <NUM>, the rotation axis <NUM> may be located in the vicinity of a front end of the switch mechanism <NUM>. In this instance, the temporary maintenance mechanism <NUM> may be located in the vicinity of the rotation axis <NUM>, and the cooperation portion <NUM> and the pressed portion <NUM> may be located rearward of the temporary maintenance mechanism <NUM>. In this instance, the catch portion <NUM> may be a part of the side covers <NUM> (see <FIG>) and may be located above the switch mechanism <NUM>.

The switch body <NUM> of the present embodiment takes the initial state when the button <NUM> (see <FIG>) is pressed against the catch portion <NUM> and takes the released state when the button <NUM> is apart from the catch portion <NUM> to some extent. However, the present invention is not limited thereto. For example, when the latch <NUM> is moved upward in an instance where the switch mechanism <NUM> is located below the lock lever <NUM> and the rotation axis <NUM> is located in the vicinity of the front end of the switch mechanism <NUM>, the cooperation portion <NUM> may be moved downward to push the pressed portion <NUM> downward. Thus, the switch body <NUM> may take the initial state when the button <NUM> is apart from the catch portion <NUM> to some extent and may take the released state when the button <NUM> is pressed against the catch portion <NUM>.

The switch body <NUM> of the present embodiment takes the initial state, or an on-state where its inner contact points (not shown) are electrically connected with each other, when the button <NUM> (see <FIG>) is pressed against the catch portion <NUM> and takes the released state, or an off-state where the inner contact points are apart from each other, when the button <NUM> is apart from the catch portion <NUM> to some extent. However, the present invention is not limited thereto. For example, the switch body <NUM> may take the off-state, or the initial state, when the button <NUM> is pressed against the catch portion <NUM> and may take the on-state, or the released state, when the button <NUM> is apart from the catch portion <NUM> to some extent.

The temporary maintenance mechanism <NUM> is not limited to a coil spring. For example, the temporary maintenance mechanism <NUM> may be another spring such as a torsion spring. Moreover, the temporary maintenance mechanism <NUM> is not limited to a spring. For example, an anchor may be attached to a front end of the switch plate <NUM>. This anchor may work as the temporary maintenance mechanism <NUM>.

The temporary maintenance mechanism <NUM> may be formed as described below. First, the side cover <NUM> (see <FIG>) is modified to be provided with a dome-like projection (bulge). In addition, the switch mechanism <NUM> is modified to be formed with a recessed portion (receiving portion), a groove and a wall. The groove is located below the receiving portion. The wall is located between the receiving portion and the groove. When the switch mechanism <NUM> is located at the initial position, the bulge is received in the receiving portion. When the cooperation portion <NUM> presses the pressed portion <NUM> upward in accordance with a movement of the lock lever <NUM>, the switch mechanism <NUM> is moved upward from the initial position, and the bulge rides over the wall to be received in the groove. According to this structure, the bulge, the receiving portion, the groove and the wall described above work as the temporary maintenance mechanism <NUM>.

Claim 1:
A charging connector (<NUM>) comprising a connector body (<NUM>), a lock lever (<NUM>), an operation portion (<NUM>), a cooperation portion (<NUM>), a switch mechanism (<NUM>) and a temporary maintenance mechanism (<NUM>), wherein:
the lock lever (<NUM>) is incorporated in the connector body (<NUM>);
the lock lever (<NUM>) has a latch (<NUM>);
the latch (<NUM>) is movable in an upper-lower direction between an engageable position and a released position via a predetermined position in accordance with an operation of the operation portion (<NUM>);
the cooperation portion (<NUM>) is moved in the upper-lower direction in cooperation with a movement of the latch (<NUM>) in the upper-lower direction;
the switch mechanism (<NUM>) is located at an initial position when the latch (<NUM>) is located at the engageable position;
the switch mechanism (<NUM>) includes a switch body (<NUM>) and a pressed portion (<NUM>);
the switch body (<NUM>) takes an initial state when the switch mechanism (<NUM>) is located at the initial position;
the temporary maintenance mechanism (<NUM>) temporarily maintains the switch mechanism (<NUM>) at the initial position when the latch (<NUM>) is located between the engageable position and the predetermined position; and
when the latch (<NUM>) is located between the predetermined position and the released position, the cooperation portion (<NUM>) presses the pressed portion (<NUM>) of the switch mechanism (<NUM>) to move the switch mechanism (<NUM>) from the initial position against the temporary maintenance mechanism (<NUM>) and thereby changes a state of the switch body (<NUM>) from the initial state to a released state;
the switch mechanism (<NUM>) is incorporated in the connector body (<NUM>) so as to be movable in the upper-lower direction;
the charging connector (<NUM>) further comprises a sub-assembly (<NUM>);
the sub-assembly (<NUM>) includes the lock lever (<NUM>), the operation portion (<NUM>), the cooperation portion (<NUM>), the switch mechanism (<NUM>) and the temporary maintenance mechanism (<NUM>); and
the sub-assembly (<NUM>) is incorporated in the connector body (<NUM>),
wherein the temporary maintenance mechanism (<NUM>) is a coil spring (<NUM>);
characterized in that one of opposite ends (<NUM>, <NUM>) of the coil spring (<NUM>) is attached to the switch mechanism (<NUM>), and a remaining one of the opposite ends (<NUM>, <NUM>) of the coil spring (<NUM>) is attached to the lock lever (<NUM>).