Patent Description:
Socket assemblies comprising flaps for covering a charging terminal are well known. In the closed position, the flap not only covers the charging terminal from an aesthetic point of view, but also protects the charging terminal from external influences, such as moisture or dirt.

A flap may not only be used to entirely cover the charging terminal but also to cover parts thereof. Such kind of configuration is of particular interest if the charging terminal comprises one socket for alternating current (AC) and one socket for direct current (DC). A flap may then be used to cover only one of the respective sockets. Alternatively, each of the charging terminals may be covered by separate flaps. In either case such kind of flap or flaps may be used in addition to a flap for entirely covering the charging terminal.

A well-known socket assembly to protect a DC socket of a charging terminal is for example an inactive DC flap. A user needs to open and close the flap manually by hand to cover or uncover the DC socket. Another example of an inactive socket assembly is covering the sockets by means of caps that are put-on the AC and/or the DC socket of a charging terminal manually by the user to protect the sockets. Furthermore, there are active closing flaps in use that may hold the flaps in the open position. A user needs to open the flap manually, but its closing is realized by a spring mechanism. In some cases, the flap is locked in the open position and must be released to close the flap. On the other hand, there are also known active opening flap systems where the flap comprises a release mechanism and a spring mechanism. The user has to push a hook on the release mechanism and the flap is opening by means of the spring mechanism. The closing of the flap has to be done manually by the user.

In order to reliably keep the flap particularly in the closed position, a mechanism may be provided that guarantees that the flap is in the closed position after charging. Inactive systems, as described above, are fault-prone since the user is responsible for opening and closing the flap or cap covering the socket. Thus, there is a risk that the user forgets to cover the socket after charging. Active closing flap systems, especially systems holding the flap in the open position, may also not reliably work after charging. After releasing the flap from the locked position, the user may unintentionally move the flap back to the open position during removal of a plug from the socket.

<CIT> discloses a socket assembly having a flap that is rotatable between a closed position and an open position, wherein the flap is biased by means of a return spring into the closed position. <CIT> discloses a split-connected new energy vehicle charging pile including a docking device with a shielding mechanism. The shielding mechanism is switchable from a shielded state to a conductive state if a plug is inserted into the docking device. <CIT> discloses a hinging system for pivotally coupling a flap of a covered electrical socket.

Therefore, there is a demand for a socket assembly that overcomes the above-mentioned drawbacks. In particular, there is a need to reliably cover the socket by means of a flap after charging.

These demands are satisfied by a socket assembly comprising the features of claim <NUM>.

The present disclosure provides a socket assembly according to the independent claim. Embodiments are given in the subclaims, the description and the drawings.

In one aspect, the present disclosure may be directed at a socket assembly, wherein the socket assembly comprises a socket for receiving a plug, a flap for covering the socket, wherein said flap is rotatable about a shaft between a closed position and an open position and is biased into the closed position, a locking mechanism that locks the flap in the open position, a release mechanism that releases the locking mechanism, when a plug is inserted in the socket, wherein after a release of the locking mechanism, the locking mechanism can be activated to lock the flap in the open position again only after the flap has been rotated from the open position to the closed position to an extent of at least <NUM>%.

The functionality of the socket assembly is based on the general idea that the flap should not retain in the open position after charging, when a user applies additional movement of the flap and brings the flap back to fully open position, for example during removal of the plug.

The socket may be a charging terminal or a part of a charging terminal, for example an inlet for charging with alternating current (AC) and/or an inlet for charging with direct current (DC). The sockets or inlets for AC or DC charging may be any kind of well-known sockets or inlets. The plug may be a charging plug for charging the vehicle via the socket and may also be any kind of an appropriate plug that fits in the socket. The charging terminal may be mounted on a battery electric vehicle (BEV) or a plug-in hybrid vehicle (PHEV) to charge a battery of the vehicle.

The charging terminal may be covered by a part of a body of the vehicle and additionally by at least one flap that is not part of the vehicle body. The flap covers at least one socket (an AC socket and/or a DC socket) of the charging terminal. The flap is rotatable about a shaft, wherein the shaft defines an axis and the shaft may be of a cylindrical structure. The flap is rotatable about the axis between a closed position and an open position. The closed position may be a position where the flap covers the socket to the full extent, i.e. the socket is protected from external influences, such as moisture or dirt. The closed position of the flap may be defined as a position where the angle of rotation about the shaft is zero degrees (<NUM>°). On the other hand, the open position may be a position where the socket is not covered by the flap, particularly where a plug can be inserted into the socket. The open position of the flap may be defined as a position where the angle of rotation about the shaft approaches at least ninety degrees (<NUM>°), or at least about one hundred degrees (<NUM>°), preferably about one hundred and ten degrees (<NUM>°). The flap is biased into the closed position by means of a spring. The spring may be tensioned when the flap is rotated from the closed position into the open position and the flap may move into the closed position by means of the spring if the flap is released from the open position. The locking mechanism locks or retains the flap in the open position when the flap has been brought in the open position. If the flap is locked by means of the locking mechanism, a rotation of the flap from the open position in the direction of the closed position may not be possible. The release mechanism releases the locking mechanism from the open position and the flap rotates from the open position into the closed position. Thereby, the user does not need to close the flap manually after charging, but the flap is closed automatically after the flap is released from the open position.

According to an embodiment, the release mechanism may comprise a shiftable activation pin that may release the locking mechanism when the plug is inserted in the socket, wherein the activation pin may be shiftable between an activation position and a release position, wherein the activation pin is in the activation position if the flap has been rotated from the open position to the closed position to an extent of at least <NUM>%, wherein the activation pin is in the release position if a plug is inserted in the socket or the flap has been rotated from the open position to the closed position to an extent of less than <NUM>%. By this means the release of the locking mechanism and thus, the release of the flap from the open position, occurs automatically when the plug is inserted in the socket. Also, a misuse or an unintended handling of the flap by the user is prevented, particularly if the user applies additional movement of the flap during plug removal and rotates the flap back into the open position. In such a case, the flap does not retain in the open position again, since the activation pin is still in the release position. Only when the flap has been closed to an extent of at least <NUM>%, the activation pin shifts to the activation position and the flap can be locked again in the open position.

The activation pin may be shiftable in a plane that may be perpendicular to a plane where a plug is inserted into the socket. The activation pin may be linearly movable between the activation position and the release position. The activation position of the activation pin may be a position where the activation pin may extend into a part of the socket that receives the plug. The activation pin may be in the activation position if there is no plug received by the socket and the locking mechanism may be activated by the activation pin if the activation pin is in the activation position. The release position of the activation pin may be a position where the activation pin may not extend into a part of the socket that receives a plug. Particularly, the activation pin may be in the release position if a plug is completely inserted in the socket.

According to an embodiment, the activation pin may comprise a tilted surface to contact a plug, wherein the tilted surface may be contacted by the plug when the plug is inserted in the socket, wherein the activation pin may be shifted from the activation position into the release position when the plug is inserted in the socket. It has been found, that due to the tilted surface of the activation pin the plug may slide over the tilted surface and pushes the activation pin backwards without any interruptions during insertion of the plug in the socket.

The activation pin may be of a cuboid structure, wherein one side of the activation pin may be sloped to build the tilted surface of the activation pin. The tilted surface of the activation pin may extend into a part of the socket that receives a plug. The activation pin may be extended into the part of the socket such that the tilted surface of the activation pin may be in the direction to where a plug can be inserted in the socket. When a plug is inserted into the socket, the plug may contact the tilted surface of the activation pin and pushes back the activation pin. The activation pin may not extend into the part of the socket that receives the plug after the plug is inserted into the socket completely. In other words, inserting the plug into the socket may move the activation pin from the activation position into the release position of the activation pin by sliding the plug over the tilted surface of the activation pin.

According to an embodiment, the release mechanism may comprise a spring hook that may lock the activation pin in the release position. The spring hook may be of a double bended form wherein a bended part at one end of the spring hook may form a hook structure. The hook structure may lock the activation pin in the release position of the activation pin by retaining the activation pin such that the activation pin may not be moveable from the release position into the activation position. This leads to the effect that a further activation of the mechanism of the socket assembly as described herein, is only possible after the activation pin has been released from its release position.

According to an embodiment, the release mechanism may comprise a return spring that may shift the activation pin from the release position into the activation position. The return spring may be a coil spring or may be made up of a metal plate that has a bended form. The return spring may be tensioned when the activation pin shifts from the activation position into the release position. If the activation pin is released from the release position, the activation pin may be shifted from the release position into the activation position by means of the return spring. This means that the mechanism of the socket assembly as described herein returns to an initial condition after the activation pin has been shifted in the activation position.

According to an embodiment, the locking mechanism may comprise a spring hook that may lock the flap in the open position. It has been found, that locking the flap in the open position may guarantee a more comfortable handling for the user during the charging process. The spring hook may be of a double bended form wherein a bended part at one end of the spring hook may form a hook structure. The hook structure may lock the flap in the open position by retaining the flap such that the flap may not be moveable from the open position into the closed position. The locking mechanism may comprise the spring hook that locks the flap in the open position.

According to an embodiment, the socket assembly may further comprise a connector, wherein the connector may accommodate the shaft and may comprise a protrusion, wherein the protrusion may release the activation pin from the release position. The connector may be a connecting element that connects the flap with a base member. The connector may comprise a cylindrical retainer accommodating the shaft and the connector may be rotatable about the shaft when the flap rotates from the open position into the closed position or from the closed position into the open position. The connector may also accommodate the spring that is tensioned when the flap rotates from the closed position into the open position and the flap may close to the closed position by the spring if the flap is released from the open position. The spring may be a coil spring, wherein the spring may be hold by the shaft. The protrusion may be arranged at the cylindrical retainer and may be of a cuboid structure. The protrusion may release the activation pin from the release position of the activation pin. Besides the main function of the connector to connect the flap with a base member it may be possible with the connector to steer the position where the flap is locked in the open position and at which position the activation pin is released from its release position. Depending on the position of the protrusion on the connector, the protrusion may release sooner or later the activation pin from its release position and let the socket assembly return to its initial condition. Also, there is a cavity on the connector that receives the spring hook that locks the flap in the open position. Depending on the position of that cavity, the open position of the flap is determined.

According to an embodiment, the socket assembly may further comprise a base member, wherein the base member may accommodate the connector, the locking mechanism and the release mechanism, and wherein the base member may snap-fit in the socket. The base member may have a cuboid shape and may have cavities to accommodate the connector, the locking mechanism and the release mechanism. The base member may comprise a snap-fit, wherein the base member may snap or click in the socket by means of the snap-fit. It has to be found, that by means of the snap-fit an easy replacement of the base member from the socket may be possible.

According to an embodiment, the connector may couple the flap and the base member by means of the shaft. The connector may be hold by the shaft that is clamped in the base member into two circular cavities. The flap may be connected to the connector by means of pins on the connector that are plugged in appropriate retainers on the flap. The connection between the connector and the flap may be releasable. Therefore, for example, a replacement of a broken flap is possible without disassembling the socket assembly. Another benefit is to mount a disconnected flap to the connector again after the flap has been disconnected from the connector. This may happen after a misuse of the flap, for example, if the flap has been rotated beyond the open position.

According to an embodiment, the socket assembly may further comprise a spring member, wherein the spring member may comprise the spring hook that may lock the flap in the open position, the spring hook that may lock the activation pin in the release position, and the return spring, wherein the spring member may be of a cuboid structure, wherein the spring hooks and the return spring are dedicated to respectively one side of the cuboid structure. The spring member may be accommodated in a cavity of the base member. It has turned out, that assembling the spring hooks and the return spring by means of the spring member may lead to a simultaneous operation by means of the activation pin. It may also be possible that the return spring is an additional component, i.e. the spring member may not comprise the return spring. In this case, the return spring may be a compression spring that operates as described above. That means, the return spring may be tensioned when the activation pin shifts from the activation position into the release position. If the activation pin is released from the release position, the activation pin may be shifted from the release position into the activation position by means of the return spring. Thus, the production of the spring member may be simplified.

According to an embodiment, the spring member may enclose the activation pin. The activation pin may activate or move or push the spring member if the activation pin is shifted from the activation position into the release mechanism. The spring hook that locks the flap in the open position may be pushed back and release the flap from the open position if the activation pin pushes the spring member when the activation pin is pushed back by means of a plug from the activation position into the release position. Simultaneously, the spring hook that locks the activation pin in the release position may be pushed back and retain the activation pin in the release position if the activation pin pushes the spring member when the activation pin is pushed back by means of a plug from the activation position into the release position. Also, the return spring that shifts the activation pin from the release position into the activation position may be pushed back corresponding to the spring hooks and the return spring may be prestressed if the activation pin pushes the spring member when the activation pin is pushed back by means of a plug from the activation position into the release position.

According to an embodiment, the flap and the connector may be releasably connected. This results in an easy replacement of the flap as described above.

According to an embodiment, the flap and the connector may be disconnected if the flap has been rotated from the closed position to the open position to an extent of at least <NUM>%. A rotation beyond the open position, i.e. for example to an extent of at least <NUM>%, may lead to a damage of the flap. The disconnection of the flap and the connector may preserve the flap to be damaged. The flap may be insertable into the connector after a disconnection. Neither the connector, nor the flap may be damaged if the flap has been disconnected from the connector. The angle of rotation about the shaft from the closed position into the open position of the flap may be about <NUM>° and may be defined as <NUM>%. The flap and the connector may be disconnected if the angle of rotation about the shaft may be at least <NUM>%, i.e. if the flap has been rotated from the closed position to the open position to an extent of at least <NUM>%.

According to an embodiment, the locking mechanism may be activated only after the flap has been rotated from the open position to the closed position to an extent of at least <NUM>%, or at least <NUM>%, or at least <NUM>%.

<FIG> depicts a perspective view of a charging terminal <NUM> comprising a socket assembly <NUM> with a flap <NUM> in an open position according to an embodiment of the present disclosure. The socket assembly <NUM> comprises a direct current (DC) charging socket <NUM> for charging with direct current and an alternating current (AC) charging socket <NUM> for charging with alternating current. <FIG> shows the flap <NUM> in an open position, prepared to receive a plug (not shown in <FIG>).

The flap <NUM> covers the charging socket <NUM> in the closed position to protect the charging socket <NUM> against external influences, such as moisture or dirt. In contrast to that, an alternating current (AC) charging socket <NUM> is not provided with a flap <NUM>. However, it is to be understood, that the AC charging socket <NUM> may also be provided with a correspondingly configured flap <NUM>, or both, the DC charging socket <NUM> and the AC charging socket <NUM> may be covered with a correspondingly configured single flap.

<FIG> shows a perspective view of the flap <NUM> in an open position according to the above embodiment of the present disclosure. The flap <NUM> is connected to a base member <NUM> by means of a connector <NUM>. The connector <NUM> accommodates a shaft <NUM>, wherein the shaft <NUM> retains the connector <NUM> at the base member <NUM>. For this, the shaft <NUM> is pivotably mounted in circular cavities of the base member <NUM>. The flap <NUM> is rotatable about the shaft <NUM> between a closed position and an open position. The flap <NUM> is biased into the closed position by means of a spring <NUM>, wherein the spring <NUM> encloses the shaft <NUM>. One end of the spring <NUM> is fixed with a part of the connector <NUM> that connects the flap <NUM> with the connector <NUM>. The other end of the spring <NUM> is supported on the base member <NUM>. The spring <NUM> is prestressed when the flap <NUM> rotates from the closed position into the open position and the flap <NUM> may move to the closed position by means of the spring <NUM> if the flap <NUM> is released from the open position. The base member comprises a snap-fit <NUM>, wherein the base member <NUM> snaps into the socket assembly <NUM> by means of the snap-fit <NUM>.

The base member <NUM> further accommodates a spring member <NUM> and a shiftable activation pin <NUM>, wherein the spring member <NUM> encloses the activation pin <NUM>. The spring member <NUM> and the activation pin <NUM> are described in detail in the subsequent paragraphs.

<FIG> shows a perspective exploded view of the socket assembly <NUM> according to the above embodiment of the present disclosure. The spring member <NUM> comprises a spring hook <NUM> that locks the flap <NUM> in the open position, a spring hook <NUM> that locks the activation pin <NUM> in a release position, and a return spring <NUM> (see <FIG>). The spring member <NUM> has a cuboid shape, wherein the spring hooks <NUM>, <NUM> and the return spring <NUM> are located at respectively one side of the cuboid shape as shown in <FIG>. The activation pin <NUM> also is of a cuboid structure, wherein one side of the activation pin <NUM> is sloped to build a tilted surface <NUM> of the activation pin <NUM>. The tilted surface <NUM> contacts a plug <NUM> (see <FIG>) when the plug <NUM> is inserted into the socket assembly <NUM> and the plug pushes the activation pin <NUM> back from an activation position (<FIG>) into a release position (<FIG>) of the activation pin <NUM>. The activation pin <NUM> comprises a hook with a snap-fit <NUM>, wherein the activation pin <NUM> snaps into the base member <NUM> by means of the snap-fit <NUM>, as can be seen in <FIG>. The connector <NUM> further comprises a cylindrical retainer <NUM> that accommodates the shaft <NUM> and a protrusion <NUM> that releases the activation pin <NUM> from a release position (see <FIG>).

<FIG> illustrate the process of opening and closing the flap <NUM> of the socket assembly <NUM> in more detail. <FIG> shows a cross-sectional side view of the socket assembly <NUM> with the flap <NUM> in an open position. The flap <NUM> has to be opened manually from a user, i.e. the user has to rotate the flap <NUM> about the shaft <NUM> from the closed position into the open position. Once the flap <NUM> is in the open position, the flap <NUM> is locked by the spring hook <NUM> in the open position. Therefor, the spring hook <NUM> grabs into a cavity of the connector <NUM> (see <FIG>). A rotation about the shaft <NUM> is prevented in the direction of the closed position by the spring hook <NUM>. The activation pin <NUM> is in the activation position if there is no plug <NUM> inserted into the socket assembly <NUM>. The activation position of the activation pin <NUM> is a position where the activation pin <NUM>, particularly the tilted surface <NUM> of the activation pin <NUM>, extends into a channel <NUM> of the socket assembly <NUM> that receives the plug <NUM>. As described above, the activation pin <NUM> is hold by means of the snap-fit <NUM> in the base member <NUM> in the activation position and the return spring <NUM> is unstressed.

In a next step, the plug <NUM> is inserted in the socket assembly <NUM>. <FIG> shows a cross-sectional side view of the socket assembly <NUM> with an inserted plug <NUM>. When the plug <NUM> is inserted into the socket assembly <NUM>, the plug <NUM> contacts the tilted surface <NUM> of the activation pin <NUM> and there is an overlapping between the plug <NUM> and the activation pin <NUM>. The activation pin <NUM> is pushed back by means of the plug <NUM> such that the activation pin <NUM> does no longer extend into the channel <NUM> of the socket assembly <NUM> that receives the plug <NUM>. If the plug <NUM> is completely inserted into the socket assembly <NUM>, the activation pin <NUM> has been shifted from the activation position into the release position. The activation pin <NUM> pushes the spring hook <NUM> in the same direction as the activation pin <NUM> is shifted by means of the plug <NUM>. In the release position of the activation pin <NUM> the spring hook <NUM> that locks the flap <NUM> in the open position releases the flap <NUM> since the activation pin <NUM> has moved the spring hook <NUM> to an extent that the spring hook <NUM> is disconnected from the connector <NUM>. The flap <NUM> is no longer hold by the spring hook <NUM>, i.e. the spring hook <NUM> no longer grabs in the cavity of the connector <NUM>. The flap <NUM> rotates by means of the biased spring <NUM> in the direction of the closed position and strikes against an outer wall of the plug <NUM> which is inserted in the socket assembly <NUM>. The flap <NUM> rotates about the shaft <NUM> from the open position in the direction of the closed position to an extend of more than <NUM>%, only if the plug <NUM> is unplugged from the socket assembly <NUM>. The return spring <NUM> is compressed or prestressed in the release position of the activation pin <NUM>, as shown in <FIG>.

<FIG> shows a cross-sectional top view of an activation pin <NUM> in the release position. The plug <NUM> is inserted in the socket assembly <NUM> and the plug <NUM> shifts the activation pin <NUM> from the activation position into the release position. The activation pin <NUM> pushes the spring member <NUM> in the same direction as the activation pin <NUM> is shifted by the plug <NUM>. If the activation pin <NUM> is in the release position, the spring hook <NUM> locks the activation pin <NUM> in the release position as one end of the spring hook <NUM> hooks in a clamp <NUM> of the base member <NUM>. The activation pin <NUM> is not shiftable any more into the activation position as long as the activation pin <NUM> is locked in the release position by means of the spring hook <NUM>.

If the plug <NUM> is unplugged from the socket assembly <NUM>, the flap <NUM> that was hold by the plug <NUM> moves into the closed position by means of the spring <NUM>. The activation pin <NUM> still rests in the release position until the activation pin <NUM> has been released by the protrusion <NUM> of the connector <NUM>. <FIG> shows a cross-sectional top view of the activation pin <NUM>, that has been released from the release position by means of the protrusion <NUM>. The protrusion <NUM> releases the spring hook <NUM> of the activation pin <NUM> from the release position, if the flap <NUM> rotates about the shaft <NUM> from the open position into the closed position. Since the flap <NUM> and the connector <NUM> are connected to each other, the connector <NUM> also rotates about the shaft <NUM>, if the flap <NUM> rotates about the shaft <NUM>. The protrusion <NUM> enters a cavity <NUM> of the base member <NUM>, interferes with the spring hook <NUM> and pushes back the spring hook <NUM> as shown in <FIG>. Thereby, the connection between the spring hook <NUM> and the clamp <NUM> is released and the activation pin <NUM> is unlocked from the release position. This allows the biased return spring <NUM> to push back the activation pin <NUM> from the release position into the activation position. If the flap <NUM> is fully locked, i.e. the flap <NUM> is in the closed position, the socket assembly <NUM> returned to its initial position wherein the activation pin <NUM> is in the activation position.

One additional aspect of the present disclosure is, that the flap <NUM> and the connector <NUM> are disconnected if the flap <NUM> rotates from the closed position to the open position to an extent of e.g. at least <NUM>%, i.e. beyond the open position. The flap <NUM> and the connector <NUM> are not damaged due to a disconnection of the flap <NUM> from the connector <NUM> such that the flap <NUM> can be inserted into the connector <NUM> after the disconnection, and the socket assembly <NUM> operates as described herein.

Claim 1:
A socket assembly (<NUM>), comprising:
a socket (<NUM>) for receiving a plug (<NUM>),
a flap (<NUM>) for covering the socket (<NUM>), wherein said flap (<NUM>) is rotatable about a shaft (<NUM>) between a closed position and an open position and is biased into the closed position,
a locking mechanism that locks the flap (<NUM>) in the open position,
a release mechanism that releases the locking mechanism, when a plug (<NUM>) is inserted in the socket (<NUM>),
characterized in that, after a release of the locking mechanism, the locking mechanism can be activated to lock the flap (<NUM>) in the open position again only after the flap (<NUM>) has been rotated from the open position to the closed position to an extent of at least <NUM>%.