WO2024182841A1

WO2024182841A1 - A cable exit assembly

Info

Publication number: WO2024182841A1
Application number: PCT/AU2024/050175
Authority: WO
Inventors: Aaron Jarvis Palm; Nathan David van der Heide; Shelley Ellen Farrell
Original assignee: Tritium Holdings Pty Ltd
Current assignee: Tritium Holdings Pty Ltd
Priority date: 2023-03-03
Filing date: 2024-03-04
Publication date: 2024-09-12
Anticipated expiration: 2025-09-03

Abstract

The present invention relates to a cable exit assembly for use in establishing one or more electrical connections between at least one point internal to the housing and at least one point external the housing. The present invention allows alleviates some of the prior art issues associated with accessing terminations in present housing.

Description

A CABLE EXIT ASSEMBLY

TECHNICAL FIELD

The present invention relates to a cable exit assembly for use in establishing one or more electrical connections between at least one point internal to a housing and at least one point external to the housing.

BACKGROUND

Any references to methods, apparatus or documents of the prior art are not to be taken as constituting any evidence or admission that they formed, or form part of, the common general knowledge in the art.

Cable exit assemblies according to embodiments described herein are explained in the context of their use with electric vehicle charging stations. However, it will be realized that such cable exit assemblies may be used in other situations where it is necessary to establish one or more electrical connections between at least one point on a first side of a divider, such as a wall of a housing, and at least one point on a second side of the divider.

Figure 1 depicts prior art front and left-hand sides of an electrical vehicle charging station 1 . Charging station 1 comprises a housing 2. As can be seen in Figure 2, which shows rear and left-hand sides of the charging station 1 , the charging station 1 includes cables 3a, 3b, which are electrically coupled to internal electrical circuitry of the charging station 1 .

Figure 3 depicts an enlarged view of the rear of the charging station showing a portion of a cable exit assembly 5 which acts to facilitate passage of cable 3a through a divider in the form of rear wall 7 of housing 2 of the electrical vehicle charging station 1 . Various views of cable exit assembly 5 appear in Hgures 3 to b. cable exit assembly 5 is configured to provide an IP67 level sealed conduit for cable 3a to pass through with integrated strain relief. IP ratings are “ingress protection” ratings that are set by the International Electrotechnical Commission (IEC). An “IP65” rating is an ingress protection rating that specifies that the cable exit assembly 5 is dust tight (i.e., does not allow ingress of dust into the housing) and also provides protection against the ingress of water into the housing at a level equivalent to exposure to water for 30 minutes at a depth of up to 1 m.

Cable exit assembly 5 includes integrated strain relief, provided by strain relief member 9, which is located around the cable and fastened into grommet opening 1 1 . The cable exit assembly 5 was able to accept an off-the-shelf cable grommet that was cost efficient, with the added ability of interchangeable strain reliefs to accommodate a range of cable diameters. The cable exit assembly 5 then incorporated pads, concentric with the fastening studs, to control the compressive force of the IP65 gasket and a conductive earth path from the cable exit to the chassis to mitigate electromagnetic interference (EMI).

A problem that became evident with use of the cable exit assembly 5 was that in order to establish terminations of ends of cable 3a, 3b with termination points within the housing 2, it was necessary to open a door of the housing and make the terminations in an internal space of the housing. Consequently, if a cable had to be replaced then the housing door would have to be opened and the ends of the cable unfastened from termination points within the cabinet. It would then be necessary to pull the cable through the cable exit assembly grommet opening 1 1 in order to remove it.

It would be advantageous to address one or more of the above issues and/or to provide the consumer with a useful or commercial alternative.

SUMMARY In a first aspect, although it need not be the only aspect or the broadest aspect, the invention resides in a cable exit assembly for establishing one or more electrical connections between at least one point on a first side of a divider and at least one point on a second side of the divider.

In an aspect, there is provided a cable exit assembly (100) for establishing one or more electrical connections between at least one point on an inside of a divider (1000) and at least one point on an outside of the divider (1000), comprising: a cable exit base (1 10) for attachment to the outside of the divider (1000); a busbar assembly (120) dimensioned to extend away from an inner side of the cable exit base (1 10) for extending through an opening in the divider (1000) upon attachment of the cable exit base (1 10) to the outside of the divider (1000); at least one outer end termination portion (90) coupled to, or integrally formed with, an outer end of a busbar of the busbar assembly (120); and at least one inner end termination portion (92) coupled to, or integrally formed with, an inner end of a busbar of the busbar assembly (120).

In an embodiment, the cable exit base (110) includes points (11 1 ) for attachment to the divider (1000).

In an embodiment, the cable exit base (1 10) includes a cable securement member (1 12) for securing a cable (113) to be coupled to the outer end termination portion (90).

In an embodiment, the cable securement member (1 12) is formed with an opening therethrough for passage of a portion of the cable (113).

In an embodiment, a cable fastening arrangement (114) is fastened with the cable securement member (1 12) for fastening the cable (1 13) to the cable exit base (110). In an embodiment, the cable exit assembly (100) includes a strain-relief clamping member (115) for clamping the cable fast with the cable exit base (1 10).

In an embodiment, one or more triangular gussets (1 16) are provided between the cable securement member (1 12) and a portion of the cable exit base (1 10) parallel with a divider attachment plane.

In an embodiment, the busbar assembly (120) comprises a first busbar (121 a) and a second busbar (121 b).

In an embodiment, the busbar assembly (120) includes an insulating member (122) that locates between the first busbar (121 a) and the second busbar (121 b).

In an embodiment, the busbar assembly (120) includes a dampener assembly comprising a ferrite ring (123) and ferrite clip (124) surrounding at least a portion of the first busbar (121 a) and the second busbar (121 b).

In an embodiment, the ferrite ring (123) is cylindrical.

In an embodiment, the ferrite ring (123) is formed of two longitudinally extending parts that cooperate to locate around the portion of the at least one busbar.

In an embodiment, the dampener assembly further includes a choke (125) located around a portion of the at least one busbar, insulating member (122), ferrite ring (123) and/or ferrite clip (124). In an embodiment, the choke (125) is a choke ferrite.

In an embodiment, the cable exit assembly (100) further comprises a cover (130) for attachment to the cable exit base (1 10). In embodiments, the cable exit assembly is iHbb rated.

In particular embodiments, the cable exit assembly for use with charging stations. In certain embodiments, the cable exit assembly when used with charging stations. In an embodiment, the charging station is an electric vehicle charging station.

In an aspect, there is provided a method for establishing one or more electrical connections between at least one point on an inside of a divider (1000) and at least one point on an outside of the divider (1000), comprising: attaching a cable exit base (1 10) of a cable exit assembly (100) to the outside of the divider (1000); assembling a busbar assembly (120) to extend away from an inner side of the cable exit base (1 10) and extending through an opening in the divider (1000); wherein at least one outer end termination portion (90) is coupled to, or integrally formed with, an outer end of a busbar of the busbar assembly (120); and at least one inner end termination portion (92) is coupled to, or integrally formed with, an inner end of a busbar of the busbar assembly (120).

The cable exit assembly and components thereof may be as substantially described hereinabove.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to understand and implement the subject matter disclosed herein. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary in any way. The Detailed Description will make reference to a number of drawings as follows: Figure 1 shows a front and left-hand side of a prior art electrical vehicle charging station;

Figure 2 shows rear and left-hand side of the charging station of FIG 1 ;

Figures 3 to 6 show various views of a prior art cable exit assembly;

Figure 7 shows an embodiment of the present cable exit assembly;

Figure 8 shows an exploded view of an embodiment of the present cable exit assembly;

FIG 9 shows a further exploded view of an embodiment of the present cable exit assembly; and

FIG 10 shows an exploded view of an embodiment of the busbar assembly.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Embodiments of the present invention reside primarily in a method and/or assembly for passage of a cable through a divider such as a wall of a housing. Accordingly, the apparatus, assembly or method steps have been illustrated in concise schematic form in the drawings, showing only those specific details that are necessary for understanding the embodiments of the present invention, but so as not to obscure the disclosure with excessive detail that will be readily apparent to those of ordinary skill in the art having the benefit of the present description.

Figures 7 to 9 show various views of a cable exit assembly 100. The cable exit assembly 100 is for establishing one or more electrical connections between at least one point on an inside of a divider 1000 and at least one point on an outside of the divider 1000. In one embodiment, a wall of a housing comprises the divider. In an embodiment, the housing is suitably a housing for an electrical vehicle charging station. The cable exit assembly 100 suitably comprises a cable exit base 1 10. The cable exit base 1 10 is adapted to attach to the outside surface of the divider 1000. In this regard, the cable exit base 1 10 comprises points 11 1 adapted for attachment to the divider 1000. The divider 1000 suitably defines a divider attachment plane. In an embodiment, the cable exit base 1 10 comprises an aperture 1 19 therethrough that accommodates the busbar assembly 120. The divider 1000 suitably comprises an aperture that is alignable with the aperture 1 19.

The cable exit base 110 suitably comprises a wall abutting portion 1 17a and an offset portion 117b. The offset portion 1 17b is in a substantially parallel plane to a plane of the wall abutting portion 1 17a. In other embodiments, the offset portion 1 17b may be angled relative to the plane of the wall abutting portion 1 17a. The offset portion 1 17b is securely attached, connected, integrally formed with, or secured, to the wall abutting portion 1 17a.

The cable exit base 1 10 comprises a cable securement member 1 12 for securing a cable 1 13 to be coupled to the outer end terminal formation. The cable securement member 1 12 extends outwardly from the offset portion 1 17b at a substantially right angle thereto (in the present embodiment). The cable securement member 1 12 is suitably securely attached to the wall abutting portion 1 17a. In an embodiment, the cable securement member 1 12 is securely attached to a lower end of the wall abutting portion 117a.

The cable securement member 112 suitably comprises an opening or aperture therethrough for passage of a portion of the cable 1 13. A cable fastening arrangement 1 14 is suitably provided or fastened with the cable securement member 1 12 for fastening the cable 113 to the cable exit base 110. The cable fastening arrangement may suitably comprise a cable gland 114’ which is fastened with nut 94. The cable gland 114’ provides an ingress protection seal. The cable exit base 1 10 suitably comprises one or more gusset(s) between tne cable securement member 1 12, the offset portion 1 17b and/or the wall abutting portion 117a. In an embodiment, the one or more gusset(s) are triangular gussets 116. The one or more gusset(s) provide further strength and structure to the cable exit assembly 100.

The cable exit base 110 further comprises one or more engagement portions 1 18 for securing a cover thereto (mentioned in more detail hereinafter). In one embodiment, the one or more engagement portions 1 18 are threaded elongate members extending away from the cable exit base 1 10. The one or more engagement members 1 18 are adapted to receive a fastening device. In one embodiment, the fastening device is a nut. In an embodiment, the cable exit base 1 10 is suitably integrally formed.

The cable exit assembly 100 further comprises a busbar assembly 120. The busbar assembly 120 is dimensioned to extend away from an inner side of the cable exit base 1 10 for extending through an opening in the divider 1000 upon attachment of the cable exit base 1 10 to the outside of the divider 1000.

The busbar assembly 120 suitably comprises a first busbar 121 a and a second busbar 121 b. In an embodiment, the first busbar 121 a is a negative busbar. In one embodiment, the second busbar 121 b is a positive busbar. The busbar assembly 120 further comprises an insulating member 122. The insulating member 122 locates between the first busbar 121 a and the second busbar 121 b. The insulating member 122 prevents electrical connection between the first busbar 121 a and the second busbar 121 b. The insulating member 122 suitably comprises an insulating material.

The first busbar 121 a and the second busbar 121 b suitable comprise an attachment portion adapted to attach to electrical components of the housing. In one embodiment, an inner end of a busbar of the busbar assembly 120 is provided with an inner end termination portion 92. That is, at least one inner end termination portion 92 coupled to, or integrally tormed witn, an inner end ot a busbar of the busbar assembly 120. The inner end termination portion 92 is adapted to be coupled to internal circuitry in the housing.

In an embodiment, an outer end of a busbar of the busbar assembly 120 is provided with an outer end termination portion 90. That is, at least one outer end termination portion 90 coupled to, or integrally formed with, an outer end of a busbar of the busbar assembly 120. The outer end termination portion 90 is adapted to be coupled to the cable 1 13.

The busbar assembly 120 further comprises a dampener assembly comprising a ferrite ring(s) 123 and ferrite clip 124. The ferrite ring(s) 123 suitably surround at least a portion of the first busbar 121 a, second busbar 121 b and the insulating member 122. The ferrite clip 124 suitably holds and secures the ferrite ring(s) 123, the first busbar 121 a, second busbar 121 b and the insulating member 122 together. It will be appreciated that the ferrite ring(s), first busbar, second busbar and/or insulating member may receive the ferrite clip or a portion thereof. In this regard, the first busbar 121 a, second busbar 121 b, insulating member 122, ferrite ring(s) 123 may comprise aligned apertures to receive an elongate locking member 124a of the ferrite clip 124. The ferrite clip may suitably be arcuate. In one embodiment, the ferrite clip suitably has a ‘C’ shape. In an embodiment, the ferrite clip comprises an elongate locking member 124a extending therefrom. The elongate locking member 124a suitably holds the assembly together. Suitably, the ferrite clip is contoured to be reciprocal to the ferrite ring(s). Suitably the ferrite ring(s) are contoured to be reciprocal to the first busbar, second busbar and insulating member.

In an embodiment, the ferrite ring(s) is/are cylindrical. In an embodiment, the ferrite ring(s) 123 are formed of two longitudinally extending parts that cooperate to locate around at least a portion of the first busbar 121 a, second busbar 121 b, and the insulating member 122. The dampener assembly suitably further comprises a choKe 1 5 located about at least a portion of the first busbar 121 a, second busbar 121 b, the ferrite ring(s) and/or ferrite clip 124. In an embodiment, the choke is cylindrical. In an embodiment, the choke is a choke ferrite. In an embodiment, the choke 125 also or further attenuates high frequency conducted emission. Suitably, the ferrite clip 124 further secures the choke 125, ferrite ring(s) 123, the first busbar 121 a, second busbar 121 b and the insulating member 122 together.

It will be appreciated that the busbar assembly 120 can move independently to the cable exit base 1 10. Furthermore, since the outer end termination portion 90 of the busbar assembly 120 locates on an outer surface of the housing wall, cables may be readily terminated thereon simply by removing an exit assembly cover 130 (mentioned in more detail hereinafter). This allows for the terminations to be more readily accessible for servicing. This alleviates the problem of having to open the housing to gain access to terminal points.

The cable exit assembly 100 further comprises a cable strain relief assembly. The cable strain relief assembly suitably comprises a cable clamp platform 126, a cable strain relief clamp base 127, a strain-relief clamping member 1 15 cooperating with a cable strain relief clamp cap 128, and a cable strain relief clamp nut(s) 129.

The strain-relief clamping member 1 15 is adapted to clamp the cable 1 13. The cable 1 13 is suitably fastened with the cable exit base 110. In an embodiment, the cable 1 13 is fastened to the cable securement member 1 12. The cable strain relief assembly provides a transition from a flexible cable to a rigid connector or connection point.

The cable exit assembly 100 may further comprise a charge cable 113’. The charge cable 113’ is suitably a passively cooled charge cable. It will be appreciated that the present cable exit assembly can utilize both ‘dry’ and ‘liquid cooled’ charge cables to interface with the cable exit. The cable 1 13 is suitably in electrical connection with the busbar assembly 120. The cable 1 13 is suitably in electrical connection with the first busbar 121 a and/or second busbar 121 b. As shown in Figure 8, the cable 1 13 is suitably in electrical connection with the first busbar 121 a and the second busbar 121 b by a respective electrical connection. In one embodiment, the busbar assembly 120 extends substantially perpendicular to the divider attachment plane. In an embodiment, the cable 1 13 is connected in a substantially perpendicular orientation to the busbar assembly 120. That is, the cable 1 13 is connected in a generally parallel plane to the divider attachment plane. One or more busbars can be connected to the first busbar 121 a and second busbar 121 b to connect the cable 1 13. In one embodiment, the one or more busbars are adapter busbars. The adapter busbars are suitably in electrical communication with one of the first busbar and second busbar. This allows for a direct conductive path from the charge cable to the output circuitry whilst offering maximum accessibility which assists in servicing. Furthermore, different adapter busbars for different styles of cables enables maximum cable compatibility. The adapter busbars are suitably accessible by removing the cover. The adapter busbars can be easily exchanged for different styles of cables, and this enables further cable compatibility. As mentioned hereinabove, the termination points are easily accessible by simply removing the cover and this is a significant advantage over prior art cable exit assemblies.

The cable exit assembly 100 suitably further comprises a cover 130. The cover 130 suitably forms a watertight seal with the cable exit base 1 10. The cable exit base 1 10 suitably forms a watertight seal with the divider 1000. It will be appreciated that the internal volume of the housing and the enclosed components of the cable exit assembly 100 are protected from the external environment, such as rain, dust and water. In one embodiment, the cable exit assembly is IP65 rated. The cover 130 suitably comprises one or more apertures 131 adapted to receive the one or more engagement portions 1 18 of the cable exit base 1 10. The cover 130 can then be secured to the cable exit base 1 10 by the fixing member 132 that secures to a respective engagement portion of the one of the one or more engagement portions 118 over a respective aperture of the one or more apertures 131 .

The cable exit assembly 1 10 may suitably comprise an emergency power off (EPO) switch. The EPO switch is a safety measure for quickly disconnecting electrical power to a unit. The EPO switch ensures that the upstream power feed is disconnected while operating on terminals.

In use, a busbar assembly 120 of a cable exit assembly 100 is assembled such an inner end termination portion 92 thereof is coupled to internal circuitry in a housing. The busbar assembly 120 suitably extends through an opening in the housing.

The cable exit base 1 10 of the cable exit assembly 120 is then attached to an outer surface of the housing. The cable exit base 1 10 comprises an aperture therethrough that accommodates the busbar assembly 120. The cable exit base 1 10 is attached such that the busbar assembly 120 extends through the aperture.

As mentioned above, the cable securement member 1 12 suitably comprises an opening or aperture therethrough for passage of a portion of a cable 1 13. A portion of a cable 113 is suitably passed through the opening or aperture and connected to outer end termination portion(s) 90 of the busbar assembly 120.

A cover 130 is then secured to the cable exit base 1 10. The busbar assembly 120 and a portion of the cable 1 13 is enclosed by the cable exit base 1 10 and cover 130. The outer end termination portion(s) 90 is/are suitably enclosed by the cable exit base 1 10 and cover 130. The busbar assembly 120 may suitably be assembled by assembling a first busbar 121 a and a second busbar 121 b with an insulating member 122 located therebetween.

A dampener assembly may suitably be assembled about the busbar assembly 120. The dampener assembly may be assembled by surrounding the busbar assembly 120 with ferrite rings 123. The ferrite rings 123 are suitably secured to the busbar assembly 120 by ferrite clip 124.

A choke 125 may suitably be assembled and located about at least a portion of the first busbar 121 a, second busbar 121 b, the ferrite ring(s) 123 and/or ferrite clip 124.

Adapter busbar(s) are suitably assembled to be in electrical communication with one of the first busbar 121 a and second busbar 121 b. The cable 1 13 is suitably assembled to be in electrical communication with the first busbar 121 a and/or the second busbar 121 b.

The cover 130 is releasably secured to the cable exit base 110 such that the termination points within the cable exit assembly 100 can be easily accessed. The cover 130 is suitably secured and sealed to the cable exit base 1 10. The cover 130 can suitably be removed from the cable exit base 110.

Removal of the cover allows for complete access to the termination points of the cable and busbar assembly. This allows for more efficient cable change which is critical for serviceability of a charge station. The cable exit assembly can also accommodate cables with and without an integrated strain relief assembly. Additionally, liquid cooled cable coolant tubes can be utilized with the present invention as the termination of the cables can be easily accessed. These cooled cable coolant tubes can also be readily interchangeable. This is assisted by the orientation of the busbar assembly as mentioned hereinabove. The output busbar assembly can suitably accommodate different cable termination combinations more readily.

In this specification, adjectives such as first and second, left and right, and the like may be used solely to distinguish one element or action from another element or action without necessarily requiring or implying any actual such relationship or order.

Words such as “comprises” or “includes” are intended to define a non-exclusive inclusion, such that an assembly, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed, including elements that are inherent to such an assembly, method, article, or apparatus.

As used herein, the term ‘about’ means the amount is nominally the number following the term ‘about’ but the actual amount may vary from this precise number to an unimportant degree.

Throughout the specification and claims (if present), unless the context requires otherwise, the term "substantially" or "about" will be understood to not be limited to the value for the range qualified by the terms.

Any embodiment of the invention is meant to be illustrative only and is not meant to be limiting to the invention. Therefore, it should be appreciated that various other changes and modifications can be made to any embodiment described without departing from the spirit and scope of the invention.

Claims

The claims defining the invention are as follows:

1 . A cable exit assembly for establishing one or more electrical connections between at least one point on an inside of a divider and at least one point on an outside of the divider, comprising: a cable exit base for attachment to the outside of the divider; a busbar assembly dimensioned to extend away from an inner side of the cable exit base for extending through an opening in the divider upon attachment of the cable exit base to the outside of the divider; at least one outer end termination portion coupled to, or integrally formed with, an outer end of a busbar of the busbar assembly; and at least one inner end termination portion coupled to, or integrally formed with, an inner end of a busbar of the busbar assembly.

2. The cable exit assembly of claim 1 , wherein the cable exit base includes points for attachment to the divider.

3. The cable exit assembly of claim 1 or claim 2, wherein the cable exit base includes a cable securement member for securing a cable to be coupled to the outer end termination portion.

4. The cable exit assembly of claim 3, wherein the cable securement member is formed with an opening therethrough for passage of a portion of the cable.

5. The cable exit assembly of claim 3 or claim 4, wherein a cable fastening arrangement is fastened with the cable securement member for fastening the cable to the cable exit base.

6. The cable exit assembly of any one of claims 3 to 5 further including a strain-relief clamping member for clamping the cable fast with the cable exit base.

7. The cable exit assembly of any one of claim 3 to claim 6, wherein one or more triangular gussets are provided between the cable securement member and a portion of the cable exit base parallel with a divider attachment plane.

8. The cable exit assembly of any one of the preceding claims, wherein the busbar assembly comprises a first busbar and a second busbar.

9. The cable exit assembly of claim 9, wherein the busbar assembly includes an insulating member that locates between the first busbar and the second busbar.

10. The cable exit assembly of claim 8 or claim 9, wherein the busbar assembly further includes a dampener assembly comprising a ferrite ring and ferrite clip surrounding at least a portion of the first busbar and the second busbar.

1 1 . The cable exit assembly of claim 10, wherein the ferrite ring is cylindrical.

12. The cable exit assembly of claim 10 or claim 11 , the ferrite ring is formed of two longitudinally extending parts that cooperate to locate around the portion of the at least one busbar.

13. The cable exit assembly of any one of claims 10 to 12, wherein the dampener assembly further includes a choke located around a portion of the at least one busbar, insulating member, ferrite ring and/or ferrite clip.

14. The cable exit assembly of claim 13, wherein the choke is a choke ferrite.

15. The cable exit assembly of any one of the preceding claims, wherein the cable exit assembly further comprises a cover for attachment to the cable exit base.

16. The cable exit assembly of any one of the preceding claims, wherein the cable exit assembly is IP65 rated.

17. The cable exit assembly of any one of the preceding claims for use with electric vehicle charging stations.

18. The cable exit assembly of any one of the preceding claims when used with electric vehicle charging stations.

19. A method for establishing one or more electrical connections between at least one point on an inside of a divider and at least one point on an outside of the divider, comprising: attaching a cable exit base of a cable exit assembly to the outside of the divider; assembling a busbar assembly to extend away from an inner side of the cable exit base and extending through an opening in the divider; wherein at least one outer end termination portion is coupled to, or integrally formed with, an outer end of a busbar of the busbar assembly; and at least one inner end termination portion is coupled to, or integrally formed with, an inner end of a busbar of the busbar assembly.