Electric vehicle supply equipment power supply cord
View Patent ↗An electrical power supply cord includes a wire cable comprising a plurality of separate conductors, a plurality of plug terminals connected to the plurality of separate conductors, a molded inner plug encasing a connection between the plurality of plug terminals and the plurality of separate conductors, and an in-mold bonding adhesive disposed intermediate the connection between the plurality of plug terminals and the plurality of separate conductors and the molded inner plug.
1. An electrical power supply cord, comprising:
a wire cable comprising a plurality of separate conductors;
a plurality of plug terminals connected to the plurality of separate conductors;
a molded inner plug encasing a connection between the plurality of plug terminals and the plurality of separate conductors;
in-mold bonding adhesive disposed intermediate the connection between the plurality of plug terminals and the plurality of separate conductors and the molded inner plug; and
a molded outer plug encasing the molded inner plug and a portion of the wire cable.
2. The electrical power supply cord in accordance with claim 1 , wherein the molded inner plug is formed of an injection moldable polymer.
3. The electrical power supply cord in accordance with claim 2 , wherein the molded inner plug is formed of polybutylene terephthalate.
4. The electrical power supply cord in accordance with claim 1 , wherein the molded outer plug is formed of a thermoplastic elastomer.
5. The electrical power supply cord in accordance with claim 1 , wherein the molded outer plug is shaped to provide strain relief between the molded inner plug and the wire cable.
6. An electrical power supply cord, comprising:
a wire cable comprising a plurality of separate conductors;
a plurality of plug terminals connected to the plurality of separate conductors;
a molded inner plug encasing a connection between the plurality of plug terminals and the plurality of separate conductors;
in-mold bonding adhesive disposed intermediate the connection between the plurality of plug terminals and the plurality of separate conductors and the molded inner plug;
a plurality of socket terminals connected to the plurality of separate conductors;
a molded inner socket encasing a connection between the plurality of socket terminals and the plurality of separate conductors;
a molded outer socket encasing the molded inner socket and a portion of the wire cable; and
in-mold bonding adhesive disposed intermediate the molded inner socket and the molded outer socket.
7. The electrical power supply cord in accordance with claim 6 , wherein the molded inner socket is formed of an injection moldable polymer.
8. The electrical power supply cord in accordance with claim 7 , wherein the molded inner socket is formed of polybutylene terephthalate.
9. The electrical power supply cord in accordance with claim 6 , wherein the molded outer socket is formed of a thermoplastic elastomer.
10. The electrical power supply cord in accordance with claim 6 , wherein the molded outer socket is shaped to provide strain relief between the molded inner socket and the wire cable.
11. A method of assembling an electrical power supply cord, comprising:
connecting a plurality of plug terminals, a plurality of separate conductors in a wire cable;
depositing an in-mold bonding adhesive on the plurality of plug terminals and the plurality of separate conductors;
forming a molded inner plug encasing a connection between the plurality of plug terminals and the plurality of separate conductors using an injection molding process;
connecting a plurality of socket terminals to the plurality of separate conductors;
forming a molded inner socket encasing a connection between the plurality of socket terminals and the plurality of separate conductors using an injection molding process;
deposing the in-mold bonding adhesive on the molded inner socket; and
forming a molded outer socket encasing the molded inner socket and a portion of the wire cable using an injection molding process, such that the in-mold bonding adhesive is deposited intermediate the molded inner socket and the molded outer socket.
12. The method in accordance with claim 11 , wherein the molded inner plug is formed of polybutylene terephthalate.
13. The method in accordance with claim 11 , further comprising forming a molded outer plug encasing the molded inner plug and a portion of the wire cable using the injection molding process.
14. The method in accordance with claim 13 , wherein the molded outer plug is formed of a thermoplastic elastomer.
15. The method in accordance with claim 13 , further comprising shaping the molded outer plug to provide strain relief between the molded inner plug and the wire cable.
16. The method in accordance with claim 11 , wherein the molded inner socket is formed of polybutylene terephthalate.
17. The method in accordance with claim 11 , wherein the molded outer socket is formed of a thermoplastic elastomer.
18. The method in accordance with claim 11 , further comprising shaping the molded outer socket to provide strain relief between the molded inner socket and the wire cable.