[0001] The present disclosure relates to electrical wire or cable handling systems, and more particularly, to a pass-through cable guide and cable seal.

[0002] In order to achieve reliable operation of electrical systems, it is often desired to seal associated electrical components from harsh operating environments. By way of non-limiting example, electric vehicles (EVs) are increasing in popularity as their practicality and usability improves. Such improvements in performance for both personal and commercial applications require ongoing optimization to extract maximum performance and reliability. One critical aspect of EV performance includes the ability to consistently charge the batteries of an EV as quickly as possible. In this way, it is desired to minimize any degradation in charging performance over the life of the vehicle.

[0003] Charging performance can be negatively affected by any number of factors, including water, dirt and other debris contaminating and/or degrading the electrical terminals or contacts of a vehicle’s charging inlet or socket housing. Accordingly, it is desired to prevent the ingress of contaminants into the inlet. Further, wire or cable routing in and around these devices is often space constrained. As a result, wiring paths implementing tight bends immediately before and/or after a cable enters an inlet housing may be required.

[0004] According to the prior art, pass-through cable guides may be used to guide and seal a cable as it enters into a housing of an electronic device, such as a charging inlet of an EV. However, the presence of tight bends in the cable before and/or after entering the housing often results in stress or strain being applied to the cable. This may cause the cable to pull away from a sealing surface (e.g., glands or sidewalls) of a sealing element of the guide or deflect the guide from a sealing surface of the housing, thereby preventing its ability to provide an effective seal. [0005] Accordingly, there is a need for improved systems and methods for preventing ingress of contaminants into an electrical device housing.

[0006] In one embodiment of the present disclosure, a wire guide assembly includes a seal cover having at least one cover opening defined therethrough and at least one fixation element. A seal is fitted to a face of the seal cover and defines at least one seal opening aligned with the at least one cover opening in an axial direction. A strain relief guide of the assembly is sized to be fitted to a side of the seal opposite the seal cover and defines at least one guide opening aligned with the at least one seal opening and the at least one cover opening in the axial direction.

[0007] The invention will now be described by way of example with reference to the accompanying Figures, of which:

[0008] Figure 1 is a perspective view of a charging inlet assembly useful for describing embodiments of the present disclosure;

[0009] Figure 2A is an exploded view of a cable strain relief guide according to an embodiment of the present disclosure;

[0010] Figure 2B is another exploded view of the cable strain relief guide of Figure 2A;

[0011] Figure 2C is a perspective view of the strain relief guide of Figures 2A and 2B in an assembled state;

[0012] Figure 3 is a cross-sectional view of the strain relief guide of Figure 2C in an installed state on a charging inlet;

[0013] Figure 4 is a cross-sectional view of the strain relief guide of Figure 3 with wires or cables installed therethrough;

[0014] Figure 5 is an exploded view of a strain relief guide according to another embodiment of the present disclosure;

[0015] Figure 6 is a cross-sectional view of the strain relief guide of Figure 5 in an installed state on a charging inlet; and

[0016] Figure 7 is a cross-sectional view of a strain relief guide according to another embodiment of the present disclosure.

[0017] Referring generally to Figure 1, embodiments of the present disclosure will be described in use with an exemplary charging inlet 10, such as that used for charging an electric vehicle. The inlet 10 includes a multi-component body or housing 12 adapted to receive a charging plug in an inlet socket 14 thereof. As understood by one of ordinary skill in the art, the inlet socket 14 includes at least one conductive charging terminal adapted to engage with a corresponding terminal of the charging plug. The inlet 10 further includes at least one opening 16 adapted to receive one or more wires or cables therethrough for electrically connecting conductive components of the inlet to external electrical devices. In the embodiment shown, a seal 18 may be provided between the opening 16 and a removable cover or cap 20. More specifically, the seal 18 may be arranged within the cap 20 for retaining the seal relative to the body 12 of the inlet 10. The seal 18 includes a plurality of apertures 19 defined therethrough for receiving respective wires of a multi-wire cable in a sealing manner. As set forth above, however, inadequate strain relief provided for a cable passing through this seal 16 often prevents the establishment of a reliable seal between the apertures 19 and the wires of the cable, or between an exterior surface of the seal and an internal surface of the opening 16.

[0018] Referring generally to Figures 2A-2C, embodiments of the present disclosure include an improved wire guide assembly 100. The assembly 100 comprises a seal cover 110 having a generally cylindrical central body 111 defining at least one cover opening 112. The cover opening(s) 112 extend through the body 111 and are sized to receive a wire or cable therethrough. At least one fixation element 115 is formed integrally with the body 111 for securing the seal cover 110 to a mating component, such as to the body 12 of the charging inlet 10 of Figure 1. See also Figures 3 and 4. In the exemplary embodiment, the fixation element(s) 115 comprise latches sized and positioned to engage with corresponding catches formed on the mating component. Each fixation element 115 extends integrally from a rear end of the body 111, and defines a free end positioned proximate a front end of the body.

[0019] The assembly 100 further comprises a seal 120 sized to be fitted to or abut a face 113 of the seal cover 110. The seal 120 may be formed from an elastic, polymer material, and defines at least one seal opening 122 extending therethrough. In the exemplary embodiment, a plurality of seal openings 122 are provided, and aligned with a respective one of the plurality of cover openings 112 in an axial direction of the assembly 100 (i.e., an insertion direction of a cable or wire to be inserted through the assembly). The seal 120 further comprises a ribbed exterior surface, including a plurality of circumferential ribs 121. The ribs 121 are adapted to form a seal between the seal 120 and a corresponding internal surface (e.g., a cylindrical bore) defined in a mating component.

[0020] Still referring to Figures 2A-2C, the assembly 100 includes a strain relief guide 130 sized to be fitted to or abut a side of the seal 120 opposite the seal cover 110. The strain relief guide 130 comprises a generally cylindrical body 131 defining at least one, or in the illustrated embodiment, a plurality of guide opening 132 aligned with the plurality of seal openings 122 and cover openings 112 in the axial direction. The strain relief guide 130 may further comprise an alignment feature or protrusion 136 extending from an end thereof opposite the seal 120. The alignment feature 136 is operative to engage with a complementary recess defined in the mating component (e.g., the body 12 of the charging inlet 10) for fixing the orientation of the assembly 100 relative thereto in its installed state. A flange 138 may be formed circumferentially about the strain relief guide 130 for limiting an insertion depth of the assembly 100 into the mating component, as shown in Figures 3 and 4. The flange 138 may be keyed, or formed discontinuously about its circumference. In this way, the flange 138 may more securely engage with a secondary seal 139 arranged within the opening or bore of the inlet body 12.

[0021] As shown in Figures 2A and 2B, the seal cover 110 further comprises a plurality of retainment or alignment protrusions 114 extending from the first face 113 thereof in the axial direction. In the exemplary embodiment, the retaining protrusions 114 are uniformly cylindrical in shape. Likewise, the seal 120 defines a plurality of correspondingly shaped retaining openings 124 aligned with the plurality of retaining protrusions 114. In the assembled state shown in Figure 2C, the retaining protrusions 114 are received within the retaining openings 124, fixing the position of the seal 120 relative to the cover 110 and preventing its rotation during use. Likewise, as shown in Figure 2B, the strain relief guide 130 may include a plurality of retaining or alignment protrusions 134 received within corresponding ones of the retaining openings 124 of the seal 120. In some embodiments, the same retaining opening 124 may receive retaining protrusions 114,134 of both the seal cover 110 and the strain relief guide 130.

[0022] Referring again to Figures 3 and 4, the assembly 100 is shown in the installed position and fixed to the inlet body 12, or an exemplary mating component housing. As shown, two fixation elements or latches 115 of the seal cover 110 receive corresponding catches 15 of the body 12. With the assembly fixed to the inlet body 12, the seal cover 110 and seal 120 apply a seating pressure on the strain relief guide 130 in the axial direction. A corresponding axial compression of the seal 120 may result in its radial expansion, urging the sealing ribs 121 thereof into an internal sealing surface of the opening 16 of the inlet body 12.

[0023] As shown in Figures 3 and 4, the seal openings 122 each comprise a varying diameter moving in the axial direction. More specifically, each seal opening 122 may comprise a plurality of internal sealing ribs 124, with each rib sized to sealingly engage with an outer insulation of a wire 30 passing therethrough. In one embodiment, at least three sealing ribs 124 are formed within each seal opening 122. The diameter of the seal opening 122 widens one each side of each sealing rib 124. The diameters of each seal opening 122 at respective ends of the seal 120 correspond to a diameters of each of the openings 112,134 of the cover 110 and the strain relief guide 130, at least in the areas where the cover and strain relief guide abut the seal in the assembled state. In this way, the wire 30 is permitted to more freely pass therethrough.

Moreover, the seal cover 110 and guide 130 and their respective openings 112,132 provide strain relief to either side of a cable or wire inserted through the assembly 100, as shown in Figure 4. In this way, excess strain on the wires 30 as well as the seal 120 is prevented. By reducing strain or tension on the seal 120, deformation thereof is reduced, and a water-tight seal can be more reliably ensured.

[0024] Referring now to Figures 5 and 6, according to another embodiment of the present disclosure, a seal cover 210 comprises a plurality of hollow posts 218 extending from each of a plurality of cover openings 212 in a direction of the seal 120. As shown in Figure 6, in an assembled state, the posts 218 extend partially through respective seal openings 122 of the seal 120. Preferably, at least one sealing rib 124 of the seal 120 remains exposed by the cover 210 in the assembled state, In this way, a wire inserted through the post 218 may still sealing engage directly with the seal 120. The remaining sealing ribs 124 of each seal opening 122 engage with an external surface of each post 218. The embodiment of Figures 5 and 6 may be advantageous in that insertion of a cable or wire (e.g., a wire 30 as shown in Figure 4) through each of the openings 122 of the seal 120 is made easier by the presence of the posts 218. Likewise, the posts 218 provide additional strain relief for each of the wires inserted therethrough, limiting any deflection of the seal 120 and further improving the sealing characteristics of the resulting assembly. [0025] Referring now to Figure 7, a seal 220 according to another embodiment of the present disclosure includes internal flashing 224 temporarily blocking each seal opening 222. More specifically, each seal opening 222 may initially be discontinuous in the axial direction, or the insertion direction of a wire or cable, with the flashing 224 blocking a respective seal opening 222. Either via a force applied on the flashing 224 by a cable or wire, or via the insertion of a cover having the protruding posts 218 of the embodiment of Figures 5 and 6, the flashing 224 may be broken, and the wire or cable permitted to pass through the opening(s) 222 in a sealed manner. The flashing 224 may be formed by a molding process in conjunction with the formation of a remainder of the seal 220.

[0026] It should be understood that the embodiments of Figures 5-7 share numerous additional features similar to those described with respect to the embodiments of Figures 2A-4, unless otherwise indicated. However, a detailed description of these features has been omitted herein in the interest of brevity.