Patent Description:
With the advent of high fuel prices, the automotive industry has reacted with a selection of Electric Vehicles (EVs). Such EVs are propelled by an electric motor (or motors) that are powered by rechargeable power sources (e.g., battery packs). EVs include both full electric and hybrid electric vehicles. Electric motors have several advantages over internal combustion engines. For example, electric motors may convert about <NUM>% of the chemical energy from the batteries to power the wheels, whereas internal combustion engines are considerably less efficient. EVs emit no tailpipe pollutants when operating in battery mode. Electric motors provide quiet, smooth operation, strong acceleration and require relatively low maintenance.

However, most current EVs can only go about <NUM>-<NUM> miles before requiring electrical recharging. Fully recharging an EV's battery pack may take about <NUM> to <NUM> hours. Even a quick charge to about <NUM>% capacity can take about <NUM> minutes. Furthermore, as battery pack size increases, so does the corresponding charging time. EV charging may take place at the owner's residence using an electric vehicle charging station, sometimes referred to as electric vehicle supply equipment (EVSE).

Such electric vehicle charging stations may be installed at the residence (e.g., in a garage), on an outside wall, or on a post or other structure, and may be electrically coupled to an electrical load center of the residence. Existing EVSEs may be generally quite difficult to install. Furthermore, charging the EV using existing EVSEs may take a long time. Moreover, existing EVSEs may not be readily adapted to outside usage. Document <CIT> discloses an EVSE enclosure that may be mounted to a wall or other surface directly over a receptable.

Therefore, there is a need for simple, cost effective, and high performance EVSEs, as well as improved methods for installing and operating such electric vehicle charging stations.

According to a first aspect, an electric vehicle charging apparatus is provided. The electric vehicle charging apparatus includes second a housing having a body with a first front cavity, a first rear cavity, a second rear cavity configured and adapted to receive a charging cable and a through connector, and at least one electrical terminal in the first front cavity, the body having a first wiring entry and a second wiring entry being configured to provide a plurality of electrical power connection options to the at least one electrical terminal, wherein the first writing entry is provided on the periphery of the body and connects directly into the first cavity, wherein the second wiring entry is a hole and provides a path between the first front cavity and the second front cavity, and wherein the plurality of electrical power connection options comprises:.

According to a second aspect, a method of configuring an electric vehicle charging apparatus is provided. The method comprises providing a housing having a body with a first front cavity, a first rear cavity, a second rear cavity configured and adapted to receive a charging cable and a through connector, and at least one electrical terminal in the first front cavity, the body having a first wiring entry and a second wiring entry, wherein the first writing entry is provided on the periphery of the body and connects directly into the first cavity, wherein the second wiring entry is a hole and provides a path between the first front cavity and the second front cavity; configuring an electrical connection to the at least one electrical terminal of the electric vehicle charging apparatus in one of a plurality of electrical power connection options, the plurality of electrical power connection options comprising: an outside cord option wherein an outside cord and coupled outside electrical plug are adapted to electrically connect to an electrical receptacle located outside of a footprint of the body, and the outside electrical cord is received through the first wiring entry; and a rear receptacle mount option wherein a rear cord and coupled rear electrical plug are received in the first rear cavity and adapted to electrically connect to an electrical receptacle located inside of the footprint of the body wherein the rear electrical cord is received through the second wiring entry.

Still other aspects, features, and advantages of the present invention may be readily apparent from the following detailed description by illustrating a number of exemplary embodiments and implementations, including the best mode contemplated for carrying out the present invention. The present invention may also be capable of other and different embodiments, and its several details may be modified in various respects, all without departing from the scope of the present invention. Accordingly, the drawings and descriptions are to be regarded as illustrative in nature, and not as restrictive. The drawings are not necessarily drawn to scale.

Reference will now be made in detail to the example embodiments of which are illustrated in the accompanying drawings. The drawings are not necessarily drawn to scale.

One or more of the aforementioned problems of difficulty of installing the electric vehicle charging apparatus or slow charging rates are overcome by one or more embodiments of the present invention. In addition or alternatively, aspects of the invention allow enhanced user functionality and feedback. In particular, in a first aspect, mechanical and packaging considerations that make the product easier to mechanically and electrically install in the field are provided. According to one aspect of the present invention, up to four different electrical wiring options are enabled in a common housing configuration. Accordingly, a manufacturer or installer may easily configure the electric vehicle charging apparatus in one of up to four options by using the common housing configuration. In another aspect, an installer can readily adapt the installation in the field to the electrical wiring platform that is present at the installation location.

In one or more embodiments, the electric vehicle charging apparatus includes housing structural features and an outside cable and outside electrical plug allowing the electric vehicle charging apparatus to be installed as an "outside direct wire option" to a panel (e.g., a load center) or sub-panel box. In another embodiment, the electric vehicle charging apparatus includes housing structural features allowing the electric vehicle charging apparatus to be installed with an "outside cord option" having an outside cord and outside electrical plug and wherein the outside electrical plug is plugged into an electric outlet that is located adjacent to an exterior of the electric vehicle charging apparatus. In a third embodiment, the electric vehicle charging system includes housing structural features allowing the electric vehicle charging apparatus to be connected using a "rear direct wire option" wherein the electric vehicle charging apparatus is wired into and through a gang box located behind the electric vehicle charging apparatus. In yet another embodiment, the electric vehicle charging system includes housing structural features enabling a "rear receptacle mount option" wherein the electric vehicle charging apparatus is plugged into an electrical receptacle located behind the electric vehicle charging apparatus, such that it is able to hide the cord. Removable wire trough connectors and/or knockouts offer wire routing flexibility and allow for wire entrance from the bottom (or even the side or top), or at the rear of (e.g., behind) the electric vehicle charging apparatus. These flexible electrical wiring options offer a homeowner and/or installer more flexibility when installing or retrofitting an electric vehicle charging apparatus.

In another aspect, embodiments of the present invention enable various mechanical mounting styles that allow for flexibility in the mechanical connections to a structure, such as a stud, wall, post, pedestal, or the like. One or more embodiments provide a fast mounting bracket that allows the installer to mount the electric vehicle charging apparatus while allowing free hands for making electrical connections.

In another aspect, embodiments of the present invention enable improved feedback of a status of the electric vehicle charging apparatus. For example, light guide assembly may generate and display one or more colors and/or flashing lights on a light exit region that indicate a status of the electric vehicle charging apparatus to the user at a distance. Status such as charge status, charge completeness, readiness to charge, fault, fault condition/type, charge time delay, pause, indicating remote access, or the like may be displayed.

Embodiments of the invention will be explained in greater detail with reference to <FIG> below.

<FIG> illustrates an embodiment of an electric vehicle charging apparatus <NUM> being mounted to a structure <NUM>, such as a wall. The electric vehicle charging apparatus <NUM> receives electrical power from an electrical power supply system or component by electrically connecting to a residential panel box, sub-panel box, electrical gang box, or electrical receptacle (e.g., an electrical outlet) or the like and electric vehicle charging apparatus <NUM> is adapted to charge an electric vehicle <NUM> (<FIG>). The electric vehicle charging apparatus <NUM> includes a housing <NUM>, which may be a multi-piece housing, and which may be configured and adapted to allow multiple electrical connection options, as well as multiple mechanical fastening options (e.g., mounting options). The housing <NUM> may be mounted to any suitable structure <NUM> such as a wall, stud, post, pedestal, or the like. Multiple mounting methods and electrical connection method options may be used, as will be described herein.

The housing <NUM> may have a body <NUM> and a lid <NUM> coupled to the body <NUM>. The lid <NUM> may be removable or hinged by one or more hinges 104A to the body <NUM>, such as at a top thereof. The lid <NUM> may include a latch or other securing features, such as one or more fasteners 105F (e.g., screws) to fasten the lid <NUM> to the body <NUM>. The electric vehicle charging apparatus <NUM> includes a charging cable <NUM> and an electrical connector 103C that is adapted to couple to a mating connector located on the electric vehicle <NUM> (<FIG>). In the depicted embodiment, the electrical connector 103C may be mounted for easy access on a front mounting post 105P (<FIG>) formed on the housing <NUM>, such as on lid <NUM>. The housing <NUM> may have a suitable shape such that the charging cable <NUM> may be wrapped about a periphery of the housing <NUM> one or more times and may include a housing lip that is adapted to provide a channel in conjunction with the structure <NUM> to retain the charging cable <NUM> within bounds, much like a hose reel. The body <NUM> may be made of a plastic material, such as a highly flame-retardant plastic material (e.g., a glass-filled, highly flame-retardant polyester material). Other suitable highly flame-retardant materials may be used. However, in one or more embodiments, the lid <NUM> may be made from a more attractive plastic, such as a non-flame retardant or mildly flame-retardant plastic (e.g., colorable plastic such as a polycarbonate plastic). Other suitable materials may be used.

The one or more hinges 104A may allow relatively free rotation of the lid <NUM> relative to the body <NUM>, and may include a suitable mechanism (not shown) for locking the lid <NUM> in an opened position. A suitable flexible seal may be provided around the periphery or the body <NUM> or lid <NUM> and located at the intersection thereof in order to seal the internal portions and cavities of the electric vehicle charging apparatus100 such that outside use, i.e., exposure to rain and weather is possible.

The electric vehicle charging apparatus <NUM> may include a control panel 105C that may be located on the lid <NUM>. The control panel 105C allows the user to select various items, such as pause and delay time via pressing one or more buttons on the control panel 105C. Additionally, status indicator lights may be displayed on the front of the lid <NUM> next to indicia (e.g., Power Available, Ready, Charging, Fault, Delay Time, or the like). Other indicia may be used. Additionally or alternatively, the electric vehicle charging apparatus <NUM> may include a light guide assembly that is adapted to display one or more colors, one or more flashing lights, or combinations at one or more light exit regions <NUM> (e.g., at one or more halos). These halos are large enough so that they may be readily viewed from across a room (say at <NUM> feet or more). The halos may extend about some or all of the housing <NUM>.

Various electrical installations of the electric vehicle charging apparatus <NUM> may be achieved according to one or more embodiments of the invention. Several installation embodiments are shown in <FIG>. As installed, the electric vehicle charging apparatus <NUM> comprises at least one of the electrical loads that are electrically connected to the electrical supply system 500A-500C. The number of loads may be as many as allowed by the load center <NUM>, and/or any sub-panel electrically coupled thereto. Each electrical load may be protected by its own circuit breaker, and such circuit breakers may have amperage ratings of between about <NUM> A and about <NUM> A, for example. One of the electrical circuit branches may include an electrical load, which is the electric vehicle charging apparatus <NUM>.

The electric vehicle charging apparatus <NUM> is adapted to supply an electrical current output to charge an electrical power source <NUM> (e.g., a battery pack) of an electric vehicle (EV) <NUM>. In the depicted embodiments herein, the charge may be at about 220V. Accordingly, a much more rapid charge may be achieved. The power may be supplied to the EV <NUM> by the charging cable <NUM> having the electrical connector 103C electrically coupling to a receiving connector on the EV <NUM>. The electric vehicle charging apparatus <NUM>, as shown in <FIG> may include an "outside direct wired option" and may be wired directly to a circuit breaker <NUM> in a main load center <NUM>, or to a sub-panel (not shown) electrically coupled to the main load center <NUM>, such as through a conduit <NUM> (See <FIG>), shown as a bottom feed conduit. The conduit <NUM> may be a typical metal or PVC conduit and may protrude out of a lower or other portion of the electric vehicle charging apparatus <NUM>. To complete this installation, an electrical cable <NUM> (e.g., <NUM>-<NUM> cable) runs through the conduit <NUM> and through a first wiring entry <NUM>. The first wiring entry <NUM> may be formed by removing a knock out or a replacement plug. In the case of a replacement plug, which may be a sealed plug, the replacement plug can be swapped to another location within the electric vehicle charging apparatus <NUM> when reconfiguring the electrical connection (e.g., in the field). The wires of the outside electrical cable <NUM> may be run up to the one or more electrical terminals <NUM> on the inside of a first front cavity <NUM> and connected to the at least one electrical terminal <NUM>. The at least one electrical terminal <NUM> is a common end point for all the wiring options discussed herein.

In another embodiment, as shown in <FIG>, the electric vehicle charging apparatus <NUM> may be plugged directly into an electrical receptacle <NUM> that is electrically coupled to the circuit breaker <NUM>. The electric vehicle charging apparatus <NUM> may include an outside electrical cord <NUM> and a suitable outside electrical plug <NUM>, such as a <NUM> V NEMA plug. Other plugs may be used. Thus, in this embodiment, the electric vehicle charging system <NUM> is wired with an outside cord option and powered through the outside electrical cord <NUM> and outside electrical plug <NUM> which provides excellent flexibility regarding installation location of the electric vehicle charging apparatus <NUM>. The term "outside" as used herein denotes a position outside of a footprint of the electric vehicle charging apparatus <NUM>, i.e., external to, but not behind the electric vehicle charging apparatus <NUM>.

In another embodiment, shown in <FIG>, the electric vehicle charging apparatus <NUM> is shown wired to a rear electrical receptacle <NUM> via a rear receptacle mount option or to a gang box <NUM> (both shown dotted) located behind the electric vehicle charging system <NUM>, i.e., each within the footprint of the electric vehicle charging apparatus <NUM>. These electrical configurations and installations and the details of the electric vehicle charging apparatus <NUM> enabling these various electrical power installations will now be described with reference to <FIG>.

<FIG> illustrate the components and several different installation embodiments of an electric vehicle charging apparatus <NUM>. Referring to <FIG>, the body <NUM> may include a number of internal cavities. A first front cavity <NUM> of the body <NUM> (e.g., at a lower section of the electric vehicle charging apparatus <NUM>) may contain at least one electrical terminal <NUM>. The at least one electrical terminal <NUM> may be a lug, lug assembly, quick connect, terminal block, or the like. In the depicted embodiment, a line terminal block 107A and a grounding terminal block 107B are shown. Other electrical terminal options may be used.

The lower section of the electric vehicle charging apparatus <NUM> has been designed to properly route and terminate the various electrical connection options. <FIG> and <FIG> illustrate an interior flexible wiring compartment as a first front cavity <NUM> easily assessable by removing or rotating the lid <NUM> out of the way. This first front cavity <NUM> may be appropriately sized to house either a single phase or a three phase wiring system, such as with an earth ground. <FIG> illustrates one of the flexibility features, and illustrates an interchangeable lug interface or terminal <NUM>. The electrical terminal <NUM> (providing an electrical connection between the incoming wires and electrical components of the electric vehicle charging apparatus <NUM>) may be mounted on threaded inserts in the plastic molding, for example. This lug interface or terminal <NUM> may be fastened to the threaded inserts by one or more suitable fasteners. Various alternative lug interfaces or terminal designs or types can be selected and utilized on a common mounting platform within the first front cavity <NUM>. Some examples include lug or terminal designs intended for US application, and an alternative lug or terminal design for IEC application. In a similar manner, these lug interface or terminals <NUM> can be swapped between single and <NUM> phase setups by adding additional modules into the lug interface.

The body <NUM> may also include a second front cavity <NUM> (e.g., at an upper portion) that is adapted to house and contain high voltage components, such as a contactor <NUM> and one or more printed circuit boards. The contactor <NUM> in the second front cavity <NUM> may be electrically coupled to the at least one electrical terminal <NUM>, and also to the charging cable <NUM>. The contactor <NUM> may have a rating of <NUM>-<NUM> amperes. The printed circuit board may receive a low voltage (e.g., less than about <NUM> V) from a low voltage supply electrically coupled to the contactor <NUM>.

Furthermore, various signal or data line inputs/outputs may be provided to and/or from the printed circuit board via one or more low voltage terminal blocks <NUM> located in the first front cavity <NUM>. Optionally, an Ethernet terminal <NUM> (shown dotted in <FIG>) may be provided in the first front cavity <NUM> and may be adapted to connect an Ethernet cable to the printed circuit board. In this way, access to low voltage components is through the first front cavity <NUM> via removing or opening the lid <NUM>. A removable plug <NUM> in the first front cavity <NUM> may be used to receive a hard wired connection from the rear of the unit to the one or more low voltage terminal blocks <NUM> and/or the Ethernet terminal <NUM>. In this manner data communication with a home network cable (e.g., a CAT5e or similar cable), a utility service communication cable, other communication cable, or the like may be provided. For example, in one or more embodiments, a status of the electric vehicle charging apparatus <NUM> (e.g., powered, faulted, charging, charged, delayed, or the like) may be remotely monitored. In one or more embodiments, the utility service may monitor and/or remotely shut down the electric vehicle charging apparatus <NUM> during periods of high electrical demand. Furthermore, the electric vehicle charging apparatus <NUM> may be locked via a remote signal through the one or more low voltage terminal blocks <NUM> or the Ethernet terminal <NUM>.

In more detail, the first front cavity <NUM> and second front cavity <NUM> may be separated by dividing wall <NUM>. The dividing wall may extend between the sides of the body <NUM>. Hot(s), neutral, and ground conductors pass through a small opening in the dividing wall <NUM> and may be connected to the contactor <NUM>. A filter <NUM> may function to reduce the transmission of specific signal frequencies (e.g., RF) from the home and to prevent the transmission of signals from the car to the home, for example. The filter <NUM> may be positioned so as to physically block and/or partially fill the small opening between the cavities <NUM>, <NUM>. As shown, a first wiring entry <NUM> is provided on the periphery of the body <NUM>, such as at a bottom thereon. This first wiring entry <NUM> connects directly into the first front cavity <NUM>, and may be a circular hole as shown in <FIG>. The first wiring entry <NUM> may have a diameter of between about <NUM> and <NUM>, or even between <NUM> and <NUM>, for example. Other sizes may be used.

As shown in <FIG>, the body <NUM> of the housing <NUM> includes a first rear cavity <NUM>, and a second rear cavity <NUM>. The body <NUM> may include mounting features adapted to mount the electric vehicle charging system <NUM> to a structure <NUM>. The mounting features may include an upper housing mounting feature <NUM> and a lower housing mounting feature <NUM>, which may be molded tabs, for example. The first rear cavity <NUM> may be positioned on one side of the body <NUM> and may extend from a top to a bottom of the body <NUM>, for example. Other configurations are possible. The first rear cavity <NUM> may be at least partially formed by an outer sidewall <NUM>, an inner sidewall <NUM>, and an intermediate wall <NUM>. The other side of the intermediate wall <NUM> forms part of the first front cavity <NUM> and second front cavity <NUM>. As shown in <FIG>, the second rear cavity <NUM> is configured and adapted to receive the charging cable <NUM> and a through connector <NUM>. The through connector <NUM> may be a sealed through connector.

In one outside direct wired option, as shown in <FIG>, a conduit <NUM> (e.g., PVC or metal tubing) may be used to carry a conductor <NUM> (e.g., standard <NUM>-<NUM> electrical conductor or the like) to a panel box or sub-panel box. In another embodiment, the conduit <NUM> may extend to an underground location (e.g., where the conductor <NUM> may be a direct-burial conductor). In other embodiment, the conduit may pass through a wall, and then to a panel box, or the like. The first wiring entry <NUM> is located on a peripheral side of the body <NUM>, but still for direct connection into the first front cavity <NUM>.

Optionally, as shown in <FIG>, first wiring entry <NUM> may receive an outside electrical cord <NUM> with coupled outside electrical plug <NUM> (e.g., a NEMA plug) that is adapted to plug into a nearby electrical receptacle <NUM> (See <FIG>). The electrical receptacle <NUM> may be protected by a suitable ground fault circuit interrupter (GFCI). The outside electrical cord <NUM> and outside electrical plug <NUM> may be adapted to carry 220V, for example. The outside electrical plug <NUM> may be an external <NUM> V dryer plug in some embodiments. As shown in <FIG>, any suitable connector 128C may be used to rigidly secure and pass the outside cord <NUM> into and through the first wiring entry <NUM>. In particular, the connection through the first wiring entry <NUM> may be a sealed connection.

Again referring to <FIG>, a second wiring entry <NUM> may be provided. The second wiring entry <NUM> is a hole and provides a path between the first rear cavity <NUM> and the first front cavity <NUM> containing the one or more electrical terminals <NUM>. The second wiring entry <NUM> may be the same size the first wiring entry <NUM> in some embodiments, so that the sealed plugs <NUM> may be interchangeable therein. In one rear receptacle mount installation option embodiment, as shown in <FIG>, a suitable rear cord <NUM> with attached rear electrical plug <NUM> (e.g., a NEMA plug) may be received in the first rear cavity <NUM> and the rear plug <NUM> may be configured and adapted to be plugged into a receptacle <NUM> (e.g., a wall receptacle <NUM>) that is hidden behind the body <NUM> and within its footprint (see <FIG>, for example). Within the footprint means that the receptacle <NUM> is entirely hidden when looking from a front view orientation. The second wiring entry <NUM> may receive a through connector <NUM> that passes the rear cord <NUM> through the second wiring entry <NUM> and into the first front cavity <NUM> for electrical connection to the at least one electrical terminal <NUM>. The through connector <NUM> may be a sealed connector so that the rear wiring entry <NUM> into the front cavity <NUM> is entirely sealed. The first wiring entry <NUM> may be closed with plug <NUM> in this embodiment. Plug <NUM> may be a removable plug, and may also be a sealed plug, for example. Optionally, the rear cord <NUM> may simply pass through the second wiring entry <NUM> and be connected to the at least one terminal <NUM> in the first front cavity <NUM>, if a sealed environment is not needed. Optionally, a simple elastomer sealing grommet may be used. Also shown in <FIG>, is the charging cable <NUM> and the connection from the second rear cavity <NUM> through into the second front cavity <NUM> via connector <NUM>. The components in the second front cavity <NUM> are removed and the cable <NUM> is shown terminated for clarity.

In another installation option embodiment, as shown in <FIG> and <FIG>, a short length (e.g., <NUM>-<NUM> inches) of electrical conduit <NUM> (e.g., <NUM>-<NUM>) from a gang box <NUM> that is mounted to a structure <NUM> may pass through the second wiring entry <NUM> and connect to the at least one electrical terminal <NUM> in the first front cavity <NUM>. In this manner, the electric vehicle charging apparatus <NUM> may be direct wired into a rear located gang box <NUM> and the gang box may be entirely hidden behind the footprint of the electric vehicle charging system <NUM>. Again, a sealed through connector <NUM> may be used to pass through the second wiring entry <NUM>.

Thus, in all the embodiments described herein, the body <NUM> is structurally configured with a first wiring entry <NUM> and second wiring entry <NUM>, the first front cavity, and the second front cavity <NUM> to provide a plurality of electrical power connection options for electrical connection of electrical power to the at least one electrical terminal <NUM>. The plurality of electrical power connection options include, in summary:.

<FIG> illustrates another embodiment of an electric vehicle charging system <NUM>. In this embodiment, the electric vehicle charging system <NUM> may include either a rear receptacle mount configuration or a rear direct wired configuration. The charging cable <NUM> has been removed for clarity. The electric vehicle charging system <NUM> may include light exit regions <NUM> positioned on opposite sides of the housing <NUM> (See also <FIG>, <FIG> and <FIG>) that may light up to indicate a status of the electric vehicle charging system <NUM>, such as a charge or other operating condition.

<FIG> illustrates various example mounting embodiments utilizing a mounting bracket <NUM> for installation of an electric vehicle charging apparatus <NUM> to a structure <NUM>. The mounting bracket <NUM> has a location feature <NUM> adapted to locate relative to an electrical receptacle <NUM>, for example. The location feature <NUM> may be a cutout portion that may fit over and locate (e.g., register) on the cover <NUM> as shown in <FIG>, such as when the electric vehicle charging apparatus <NUM> is mounted to a structure <NUM> such as a wall or stud shown. Optionally, the location feature <NUM> may be a one or more marks on the bracket. Optionally, the location feature <NUM> may be adapted in use to be lined up with the cover <NUM>, the gang box <NUM>, the receptacle <NUM>, or other geometrical feature. The mounting bracket <NUM> may have one or more installation features <NUM> adapted to install the mounting bracket <NUM> to the structure <NUM> (e.g., a wall, stud, pole, pedestal, or the like) such that the mounting bracket <NUM> may be mounted directly adjacent to the electrical receptacle <NUM>. The installation features <NUM> may be apertures, slots, holes or other geometrical features formed in the mounting bracket <NUM> to accept fasteners, for example. Other types of mounting features <NUM> may be used.

The mounting bracket <NUM> may be made from a suitably rigid material, such as a Polyphenylene ether/polystyrene (PPE/PS) plastic. Other materials may be used. The mounting bracket <NUM> may be about <NUM> long and about <NUM> wide, for example. Other sizes may be used. Furthermore, the mounting bracket <NUM> may have an upper bracket mounting feature 356U adapted to receive and engage the upper housing mounting feature <NUM> of the housing <NUM> (See <FIG> and <FIG>), and an lower bracket mounting feature <NUM> that is adapted to receive and engage the lower housing mounting feature <NUM>. The upper bracket mounting feature 356U may be spaced a distance from a back surface of the mounting bracket <NUM> abutting the structure <NUM> so that the upper housing mounting feature <NUM> may slide between the upper bracket mounting feature 356U and the structure <NUM>. Likewise, the lower mounting feature <NUM> is spaced from a back surface of the mounting bracket <NUM> so that the lower housing mounting feature <NUM> may slide between the lower mounting feature <NUM> and the structure <NUM>.

As installed, as shown in cross section in <FIG>, the mounting bracket <NUM> may first be mounted to the structure <NUM> via fasteners <NUM> such as with lag bolts, screws, nails, or the like. The electric vehicle charging apparatus <NUM> may then be hung on the mounting bracket <NUM> by offsetting the body <NUM> above the bracket <NUM> and sliding the housing mounting features <NUM>, <NUM> behind the upper and lower bracket mounting features 356U, <NUM>. A suitable clearance space 104C may be provided in the back of the body <NUM> to allow clearance for the sliding.

For the rear receptacle mount option, the rear electrical plug <NUM> may be connected to the receptacle <NUM> and then the electric vehicle charging apparatus <NUM> may be hung on the mounting bracket <NUM>. For the rear direct wire option, the electrical cable <NUM> (e.g., a <NUM>-<NUM> cable) may be passed through the second wire entry <NUM>, such as by using a sealed through connector <NUM> (See <FIG>), and then the electric vehicle charging apparatus <NUM> may be hung on the mounting bracket <NUM> so that the installer may have both hands free to strip, prepare and connect the conductors of the electrical cable <NUM> to the at least one electrical terminal <NUM>.

In the outside cord option, the electric vehicle charging apparatus <NUM> may be hung on the mounting bracket <NUM> and the outside electrical plug <NUM> on the outside cord <NUM> may be plugged into an adjacent receptacle <NUM> (<FIG>). For the outside direct wire option, the electric vehicle charging apparatus <NUM> may be hung on the mounting bracket <NUM>, the conduit <NUM> mechanically connected to the body <NUM> by a coupling (e.g., a sealed coupling) and then the electrical cable <NUM> may be passed through the first wire entry <NUM>. Also, in this option, the installer may have both hands free to connect the conduit <NUM> to the body <NUM>, and the conductors of the outside electrical cable <NUM> to the at least one electrical terminal <NUM>.

Once installed on the mounting bracket <NUM>, the electric vehicle charging apparatus <NUM> may be secured to the bracket <NUM>, or both the bracket <NUM> and structure <NUM> by suitable fasteners <NUM>. For example, fasteners <NUM> such as long sheet rock screws may pass through the apertures <NUM>, <NUM> (<FIG>) in the mounting bracket <NUM> and the apertures <NUM>, <NUM> in the upper and lower mounting features <NUM>, <NUM> (<FIG>) and into the structure <NUM>. Optionally, the electric vehicle charging apparatus <NUM> may mount directly to the structure <NUM> by fasteners received through the upper and lower mounting features <NUM>, <NUM> (<FIG>).

<FIG> illustrates an isometric view of a body <NUM> of the housing <NUM> with a first inner cover <NUM> shown removed. The first inner cover <NUM> may be secured to and close the front of the second front cavity <NUM>. A first printed circuit board <NUM> may reside on a rear side of the first inner cover <NUM> and may be connected thereto. The first inner cover <NUM> may be a suitable flame-rated plastic, such as described above. A second printed circuit board <NUM> (<FIG>) is connected to the printed circuit board <NUM> by a suitable cable, such as ribbon cable <NUM>. The second circuit board <NUM> may be a low voltage circuit board. Also shown in <FIG> is a safety cover <NUM> that is adapted to be received in the first cavity <NUM> and covers the one or more electrical terminals <NUM> and protects the user from possible contact with high voltage shock hazards. The safety cover <NUM> may be manufactured from a highly flame-retardant plastic such as described herein, and may be fastened by screws or the like.

<FIG> illustrates an exploded view of a light guide assembly <NUM>. The light guide assembly <NUM> mounts to the body <NUM> (See <FIG> and <FIG>) and may mount over the first inner cover <NUM>. The light guide assembly <NUM> may include at least a light guide <NUM> and one or more light sources <NUM>. In the depicted embodiment, the light guide assembly <NUM> includes a shield <NUM>, and the second printed circuit board <NUM>. The second printed circuit board <NUM> may include one or more light sources <NUM> mounted thereon or otherwise coupled thereto. The light sources <NUM> may be one or more LEDs, for example. The light sources <NUM> may emit light one or more colored light emissions. For example, the one or more light sources <NUM> may comprise white, green, red, blue, yellow, or any other color. The colors may be used to display a status of the electric vehicle charging apparatus <NUM>.

For example, the colors may be used to convey at least one of ready to charge, a fault, a fault condition, an override condition (e.g., an override mode), an operational mode, a communication taking place, charging, charge status, charge completed, or the like. In one or more embodiments, green may indicate a ready to charge status. In one or more other embodiment, one or more colors may flash on and off to indicate a status, such as any one of the colors above. For example, a flashing green may signify a charging status, whereas continuous green may signify a completion of charging of the electric vehicle charging apparatus <NUM>. Yellow may signify a <NUM>% charge, for example. Red may indicate a fault mode. Blue may indicate an override condition, such as where the residential power service provider (e.g., utility company) shuts down the electric vehicle charging apparatus <NUM>. Lights may flash in unison, or out of synchronism. Any combination of flashing lights and/or color emissions may be used.

Light from the one or more light sources <NUM> may be emitted and travel in the light guide <NUM>. The light guide <NUM> receives the light at one or more light receiving areas <NUM> located adjacent to the one or more light sources <NUM>, conveys the light along one or more light guiding regions <NUM>, to one or more light exit regions <NUM>. The one or more light exit regions <NUM> may include an expansion zone, and may include a surface that is other than parallel with a direction of travel of the light emissions in the light guiding region <NUM>.

In the depicted embodiment, as best shown in <FIG>, the printed circuit board <NUM> is located and secured in a pocket just below the under surface of a shield <NUM>. This PCB <NUM> may house the microcontroller <NUM> (<FIG>), light sources <NUM> such as side emitting light sources (LEDs) and front emitting LEDs. The light sources <NUM> (e.g., side emitting LEDSs) may emit light through one or more restrictive side apertures <NUM> formed in the shield <NUM>. The restrictive side apertures <NUM> may be slots that may be vertically oriented (as installed). Light emissions are generated by the one or more light sources <NUM>, may pass into the light guide <NUM> at the light receiving regions <NUM>, channel light into the one or more light guiding regions <NUM>, and emit light at the one or more light exit regions <NUM>. The light exit regions <NUM> may be positioned on one or more portions of the electric vehicle charging apparatus <NUM> so that they are viewable by a user.

In the depicted embodiment, the light exit regions <NUM> are positioned on opposite sides of the housing <NUM>. The light exit regions <NUM> may include a roughened surface or other surface discontinuity that functions to scatter the light delivered thereat. The surface roughening may provide a frosted surface on some or all of the light exit regions <NUM>. The surface may be rougher than a surface of the light guiding region <NUM>, for example. The surface roughening may be provided by bead blasting the mold used to make the light guide <NUM> at the locations of the mold that form the light exit regions <NUM>. The light guide <NUM> may be made from a clear material, such as clear plastic. The plastic may be a polycarbonate resin thermoplastic, a polyacrylate, or other suitable clear plastic material, for example. The light guide <NUM> may include a center portion <NUM> that is adapted to fasten to the shield <NUM> such that the light sources <NUM> are properly aligned with the light receiving regions <NUM>.

<FIG> illustrates a block diagram of an example embodiment of an electric vehicle charging apparatus <NUM>. The electric vehicle charging apparatus <NUM> may include a maximum amperage set switch <NUM> that functions to limit the maximum amperage that the EV <NUM> can request from the electric vehicle charging apparatus <NUM>. The amperage adjustment feature offers a mechanical means of limiting the current to the EV <NUM>. This limit may be desirable either due to existing limitations of the electrical infrastructure of the residential electrical delivery system (e.g., load center), or a charging methodology that may "load shift" the energy demands of the electric vehicle charging apparatus <NUM> across a wider time of the day.

One embodiment of the maximum amperage set switch <NUM> is illustrated in <FIG>. In this embodiment, the printed circuit board <NUM> is located and secured in a pocket just below the surface of a shield <NUM>. This printed circuit board <NUM> houses the microprocessor <NUM> (<FIG>) of the electric vehicle charging apparatus <NUM> and includes a maximum amperage set switch <NUM>. In this embodiment, the maximum amperage set switch <NUM> may be a multi-position rotary switch. Optionally, the maximum amperage set switch <NUM> may be a dip switch or a series of <NUM> or <NUM> position switches. When the user rotates the switch, such as with a screwdriver (<FIG>), the maximum amperage set switch <NUM> signals an EVSE state machine located on the printed circuit board <NUM> to adjust a parameter of the charging. This data is then communicated to the EV <NUM> via industry standard protocol SAE J1772, for example, and the electronics inside the EV <NUM> limit the amperage delivered through the electric vehicle charging apparatus <NUM>. The maximum charge amperage setting for the maximum amperage set switch may be between about <NUM> A and about <NUM> A, or even between about <NUM> A and about <NUM> A in some embodiments. By using a design wherein the access is recessed behind a surface of the center section <NUM> so that it requires a small screwdriver, a probability that the switch <NUM> will be accidently adjusted is reduced. This switch <NUM> can also easily be covered by a small piece of plastic or epoxy to reduce the likelihood that it is adjusted in the field by unqualified end users. In some embodiments, a small knob (e.g., plastic knob) may be molded on the top of switch <NUM> to allow rotation by hand. In any event, adjustment may not take place in the depicted embodiment without removing the lid <NUM> to gain access.

Again referring to <FIG>, the contactor <NUM> is connected to charge cable <NUM>, which terminates at the electrical connector 103C. The electrical connector 103C may be a SAE J1772 connector and is adapted to couple to a receiving connector on the EV <NUM> (<FIG>). Other suitable connector may be used. The electric vehicle charging apparatus <NUM> may further include a communication terminal <NUM>, such as a serial port (e.g., a differential serial port RS485 for data communication), which may be provided in the first inner cavity <NUM>, for example. Other types of communication terminal connections may be used. Suitable power supply and conditioning <NUM> may be provided on the printed circuit board <NUM> or on the printed circuit board <NUM>. In the depicted embodiment, a two board configuration is shown. However, it should be recognized that the various components may be combined on one board or separated into two or more boards. In the depicted embodiment, the printed circuit board <NUM> may be a low voltage board, carrying less than <NUM> V, for example. A user interface <NUM>, such as one or more push buttons may be adapted to allow a user to input into the electric vehicle charging apparatus <NUM>. A Charging Circuit Interrupting Device (CCID) <NUM> may be provided to monitor the differential current among the current carrying conductors and indicate the presence of a ground-fault to the microprocessor <NUM> as needed to provide personnel protection, such as per UL <NUM>, for example. A separate pause button <NUM> may be provided to start/stop the charging operation, as well as a delay input button <NUM> to enable input of delayed charging for an amount of delay time (e.g., <NUM>, <NUM>, <NUM> or <NUM> hours). Other visual indicators <NUM> may be provided that may be adapted to indicate whether the electric vehicle charging apparatus <NUM> is powered, ready, in a fault condition, or is charging. Visual indicators <NUM> may indicate the delay time. Visual indicators <NUM>, <NUM> may be provided on the control panel 105C (see <FIG>).

The configuration of the visual indicators <NUM>, <NUM> and the various inputs to the electric vehicle charging apparatus <NUM> will now be described in detail with reference to <FIG>. These visual indicators <NUM>, <NUM> may be provided by a plurality of LEDs, for example. The visual indicators <NUM>, <NUM> may be provided by forward-projecting colored light sources, for example. The light sources may be forward firing LEDs that may be mounted on the printed circuit board <NUM>. The light sources may project light forward through a plurality of channeling elements <NUM>, <NUM> formed in the shield <NUM>, and through the lid <NUM> so that status information can be displayed on the control panel 105C on a surface of the lid <NUM>. Accordingly, the status may be displayed on the front lid <NUM> such that it may be readily viewable by the user. Various lights may be lit based upon the detected status.

In <FIG>, the shield <NUM> may include a first plurality of channeling elements <NUM> that may indicate a status of the electric vehicle charging apparatus <NUM>. Displayed status may include power available (e.g., orange), charging (e.g., green), ready (e.g., green), or fault (e.g., red), or pause (e.g., blue). Similarly, the second plurality of channeling elements <NUM> may indicate a delay of the electric vehicle charging apparatus <NUM>, such as <NUM>, <NUM>, <NUM>, or <NUM> hours, or the like. Nine channels are shown in <FIG> for each of the groups of channeling elements <NUM>, <NUM>. Some or all of the channels may be used. At a location relative to the shield <NUM>, such as at a center of one or both of the plurality of channeling elements <NUM>, <NUM>, one or more switches <NUM>, <NUM>, such as a domed micro-switch may be provided. The switches <NUM>, <NUM> may be mounted on the printed circuit board <NUM>, for example. The switches <NUM>, <NUM> may be operable by buttons <NUM>, <NUM> mounted to the lid <NUM>.

As shown in <FIG>, as the button <NUM> is depressed, a post <NUM> coupled to the button <NUM> may make contact with the switch <NUM>. This toggles the switch <NUM> (<FIG>). For example, as shown in <FIG>, pressing the pause button <NUM> may pause the charging by the electric vehicle charging apparatus <NUM>. A light may be projected to indicate the pause status next to the word "pause" on a thin film adhered to the cover and in contact with the front of the button <NUM>. As depicted, four other lights may be projected through various ones of the plurality of channeling elements <NUM>, depending upon the status (ready, power available, charge, or fault). Other numbers of lights and statuses may be displayed. Similarly, depressing button <NUM> may likewise toggle the switch <NUM> (<FIG>) and may be used to set the delay. Depending on the condition of the switch <NUM>, one of the lights corresponding to one of the plurality of channeling elements <NUM> will be it. Thus, the delay time may be indicated on the lid <NUM> next to the indicia (e.g., <NUM>, <NUM>, <NUM>, <NUM>, or the like).

As shown in <FIG>, toggling of the pausing operation and the delay operation may take place through the lid <NUM>. Likewise, status indications may be displayed on the lid <NUM>. This is accomplished while still allowing the lid <NUM> to be removed or hinged such that it may rotate out of the way. Contact with the switches <NUM>, <NUM> on the printed circuit board <NUM> is provided by posts <NUM> flexibly mounted to the lid <NUM> and coupled to the buttons <NUM>, <NUM>. The posts <NUM> may be part of a button and indicator assembly <NUM> wherein the buttons <NUM>, <NUM> are flexibly mounted to the lid <NUM> by small beams <NUM> (FIG. Other flexible means for supporting the buttons <NUM>, <NUM> may be used. Light passing through the light channels <NUM>, <NUM> is received in the guiding elements <NUM> of the button and indicator assembly <NUM> and is displayed on the control panel 105C at locations <NUM>, which may be clear portions in the control panel 105C. The control panel may be a thin film adhered to the lid <NUM> and buttons <NUM>, <NUM>.

In some embodiments, the electric vehicle charging apparatus <NUM> may include a communication module <NUM> that is adapted to wirelessly communicate with other devices or systems. The EVSE communication module <NUM> may have an antenna <NUM> connected to the communication module <NUM> and adapted to send and receive wireless signals <NUM> according to a suitable protocol from a device or system. For example, the communication module <NUM> may be used to communicate with a smart grid node of a utility, a smart meter of a utility, a home computer network, an electrical load panel, an internet portal so as to link to a service provider, such as to perform diagnostics, software updates, or the like. Any suitable digital communication protocol may be used, such as Wi-Fi, Wi-MAX, Bluetooth, ZigBee, Dash <NUM>, EnOcean, or the like.

A method of the invention will now be described with reference to <FIG>. The method <NUM> of configuring an electric vehicle charging apparatus (e.g., electric vehicle charging apparatus <NUM>) includes, in <NUM>, providing a housing having a body (e.g., <NUM>) with a first front cavity (e.g., <NUM>), a first rear cavity (e.g., <NUM>), and at least one electrical terminal (e.g., <NUM>) in the first front cavity (e.g., <NUM>), the body (e.g., <NUM>) having a first wiring entry (e.g., <NUM>) and a second wiring entry (e.g., <NUM>), and, in <NUM>, configuring an electrical connection to the at least one electrical terminal (e.g., <NUM>) of the electric vehicle charging apparatus (e.g., <NUM>) in one of a plurality of electrical power connection options, the plurality of electrical power connection options comprising: an outside cord option (<FIG>) wherein an outside cord (e.g., <NUM>) and coupled outside electrical plug (e.g., <NUM>) are adapted to electrically connect to an electrical receptacle (e.g., <NUM>) located outside of a footprint of the body (e.g., <NUM>), and the outside electrical cord (e.g., <NUM>) is received through the first wiring entry (e.g., <NUM>), and a rear receptacle mount option (<FIG>) wherein a rear cord (e.g., <NUM>) and coupled rear electrical plug (e.g., <NUM>) are received in the first rear cavity (e.g., <NUM>) and adapted to electrically connect to an electrical receptacle (e.g., <NUM>) located inside of the footprint of the body (e.g., <NUM>) wherein the rear electrical cord (e.g., <NUM>) is received through the second wiring entry (e.g., <NUM>).

Claim 1:
An electric vehicle charging apparatus (<NUM>), comprising:
a housing (<NUM>) having a body (<NUM>) with a first front cavity (<NUM>), a first rear cavity (<NUM>), and at least one electrical terminal (<NUM>) in the first front cavity (<NUM>), the body (<NUM>) having a first wiring entry (<NUM>) and a second wiring entry (<NUM>) being configured to provide a plurality of electrical power connection options to the at least one electrical terminal (<NUM>), wherein the first wiring entry (<NUM>) is provided on the periphery of the body (<NUM>) and connects directly into the first cavity (<NUM>), wherein the second wiring entry (<NUM>)is a hole and provides a path between the first rear cavity (<NUM>) and the first front cavity (<NUM>), and wherein the plurality of electrical power connection options comprises:
- an outside cord option wherein an outside cord (<NUM>) and coupled outside electrical plug (<NUM>) are adapted to electrically connect to an electrical receptacle (<NUM>) located outside of a footprint of the body (<NUM>), and the electrical cord (<NUM>) is received through the first wiring entry (<NUM>);
- a rear receptacle mount option wherein a rear cord (<NUM>) and coupled rear electrical plug (<NUM>) are received in the first rear cavity (<NUM>) and adapted to electrically connect to an electrical receptacle (<NUM>) located inside of the footprint of the body (<NUM>) wherein the rear electrical cord (<NUM>) is received through the second wiring entry (<NUM>);
- an outside direct wire option wherein an outside electrical cable (<NUM>) is adapted to electrically connect to a panel (<NUM>), and the electrical cable (<NUM>) is received through the first wiring entry (<NUM>); and
- a rear direct wire option wherein a rear electrical cable (<NUM>) is adapted to electrically connect through a gang box (<NUM>), and the rear electrical cable (<NUM>)is adapted to pass through the second wiring entry (<NUM>);
characterised in that the electric vehicle charging apparatus comprises a second rear cavity (<NUM>) configured and adapted to receive a charging cable (<NUM>) and a through connector (<NUM>).