Portable Charge Coupler. One end of the portable Charge Coupler Cordset mates the charge port coupler to a vehicle–side receptacle and the other plugs into any standard 15 Amp wall outlet. The portable Charge Coupler Cordset will be targeted to all EV and PHEV automakers, giving them the option to provide a charging system in the trunk of every plug-in vehicle on the road.

We expect this system to provide one of the safest, most innovative charging solutions to the rapidly growing EV market, allowing consumers to plug into existing electrical infrastructure.

—Randy Sumner, director, global hybrid vehicle development, Delphi Packard Electrical/Electronic Architecture

In the research and development phase of its portable Charge Coupler Cordset, Delphi held focus groups to better understand consumer preferences for the shape and size of the charger handle and its overall design in terms of material, shape, and ergonomic features. The focus groups were comprised of current hybrid vehicle owners interested in purchasing an EV or PHEV as their next vehicle. Participants were shown various Delphi interconnect prototypes and design renderings and provided feedback on the styling and functionality they preferred and found to be most comfortable and convenient.

Components for CODA. CODA’s electric vehicle is powered by a 33.8 kWh lithium-ion battery which provides a range of 90-120 miles. CODA anticipates it can deliver more than 14,000 vehicles to customers in California by the end of 2011.

Delphi is supplying the direct current to direct current (DC/DC) converter which converts 300-volt power from the CODA’s battery pack to 12-volt power needed for the vehicle’s low-voltage systems including the audio/navigation systems, LED driving lights and other accessories. The design is currently in use on hybrid vehicles offered by a number of manufacturers.

Delphi engineers in North America and China worked together to develop the ten high-power, high-voltage wiring harnesses and two power distribution boxes that will stand up to the vehicle’s power requirements to route power and signal distribution. Delphi’s battery service disconnect provides manual disengagement of the high-voltage system, allowing it to be safely disabled by pulling the service plug from the battery pack.

Delphi is also providing CODA’s multi-service antenna. Its small, modular design enables CODA to maximize functionality while minimizing mass. The antenna system not only provides high-quality AM, FM and satellite radio reception, but also includes cellular and GPS antennas that enable cellular connectivity and in-vehicle navigation.