Charging connector for an electric or hybrid vehicle

Abstract

The invention relates to a charging connector (1) for electric and hybrid vehicles, having a housing (2), two charging contacts (3), a temperature sensor element (4) and a sealing mounting element (5), wherein the two charging contacts (3) lead out of the housing (2) through at least one opening (6) formed in the housing (2), the sealing mounting element (5) is electrically insulating and thermally conductive, is shaped and arranged in the opening (6) such that it circumferentially surrounds the charging contacts (3) and seals the area of the opening (6) between the housing (2) and the charging contacts (3), has a mounting recess (7) in which the temperature sensor element (4) is mounted in order to be able to detect the temperature of the charging contacts (3). In this way, a charging connector is provided which is easy to manufacture, which is able to withstand the ingress of environmental dirt and which reliably detects the temperature of the charging contacts.

Description

Technical Field

[0001] The present invention relates to a charging connector for electric vehicles and hybrid vehicles, the charging connector having a housing and two charging contacts extending out of the housing through at least one opening formed in the housing. Background Technology

[0002] Electric and hybrid vehicles are key components in the development of sustainable mobility solutions because they reduce reliance on fossil fuels and help lower greenhouse gas emissions. A crucial part of these vehicles is their high-voltage batteries—rechargeable energy storage devices that supply the electric drive system with the energy needed to operate. These high-voltage batteries—mostly lithium-ion batteries—offer limited storage capacity and require regular charging to maximize the vehicle's range.

[0003] The charging process for these batteries is achieved through a connection between the vehicle and the charging station via a specially designed charging cable. This cable is constructed according to the European standard IEC 62196 Typ 2 and enables efficient and safe power transmission. It consists of a charging plug that connects to the charging station and a charging connector that connects to the vehicle's built-in charging plug. All these components used for vehicle connection and charging are collectively referred to as "charging connectors." The construction of these connectors ensures that the contact pins and contact sleeves establish a safe and efficient electrical connection.

[0004] In charging, especially when using direct current (DC) at very high current levels (potentially exceeding 500 A), a challenge is the heating of current-carrying components. Increased temperature can affect component performance and lifespan, and in worst-case scenarios, may lead to safety risks. Therefore, the construction and monitoring of charging connectors must meet legal and user-specific temperature monitoring requirements. This typically involves using temperature sensors, such as NTC thermistors, positioned close to the charging contacts to achieve accurate and real-time temperature monitoring. This monitoring is crucial for maximizing charging efficiency while ensuring safety. If the temperature exceeds a critical threshold, the charging process will automatically interrupt to prevent damage to the vehicle or infrastructure.

[0005] To prevent overheating and ensure a fast, efficient charging process, advanced technologies and materials are employed in the charging connector. This includes an integrated thermal management system that effectively dissipates heat and ensures a uniform temperature distribution during charging. Continuous improvements to these technologies aim to reduce charging time and enhance the safety and reliability of the charging process, which is crucial for the acceptance and adoption of electric and hybrid vehicles.

[0006] A charging plug for a motor vehicle is known from DE 10 2017 108 526 A1, which has a connection module and a load contact module, wherein the connection module is capable of being connected to a power supply line for power supply, wherein the load contact module has load contacts for transmitting charging power, and wherein the load contact module is fixed to the connection module in a detachable and replaceable manner, and wherein the load contact module has a temperature sensor.

[0007] A connector assembly for electrical connection with a mating connector assembly is known from DE 10 2019 120 470 A1. The connector assembly includes a housing, at least two load contacts, a protective conductor contact, and a grounding element disposed in the housing and electrically connected to the protective conductor contact, wherein the grounding element extends in an electrically contactable manner along a creepage path between the two load contacts. Summary of the Invention

[0008] The purpose of this invention is to provide an easy-to-manufacture charging connector that is resistant to environmental contaminants and can reliably detect the temperature of the charging contacts.

[0009] This objective is achieved by the subject matter of claim 1. Preferred improvements of the invention are described in the dependent claims.

[0010] Therefore, according to the present invention, a charging connector for electric vehicles and hybrid vehicles is provided, having a housing, two charging contacts, a temperature sensor element, and a sealing mounting element, wherein the two charging contacts are led out from the housing through at least one opening formed in the housing, the sealing mounting element is electrically insulating and thermally conductive, and is shaped and arranged in the opening such that the sealing mounting element circumferentially surrounds the charging contacts and seals the area of ​​the opening between the housing and the charging contacts, the sealing mounting element having a mounting groove in which the temperature sensor element is mounted so as to be able to detect the temperature of the charging contacts.

[0011] Therefore, an important aspect of this invention is that the charging connector has a sealing mounting element, which effectively functions as a multi-functional component, performing a sealing function on one hand and mounting a temperature sensor element on the other. The sealing function is particularly important when the charging connector is not plugged into a corresponding charging connector. On the other hand, the temperature sensor is used when the charging connector is plugged in, enabling monitoring of the temperature of the charging contacts during charging.

[0012] When "corresponding charging connector" is mentioned herein, it refers, on the one hand, to a charging connector having the same mating surfaces as the charging connector according to the invention, but with one mating surface having contact pins and the other having contact sleeves, or vice versa. Therefore, a kit consisting of the charging connector according to the invention and a corresponding charging connector can be mated together. On the other hand, even if the mating surfaces only partially match in the above sense, it can still be referred to as a corresponding charging connector, i.e., the corresponding charging connector, for example, does not have all the contacts present in the charging connector according to the invention, but the existing contacts of the corresponding charging connector match the charging connector according to the invention in terms of mating surfaces. Thus, in this case, the charging connector according to the invention and the corresponding charging connector can also be mated together. Furthermore, it should be noted that a charging connector can of course have more than two charging contacts.

[0013] The sealing mounting element can be constructed in different ways. However, according to a preferred improvement, the sealing mounting element is designed as a one-piece plastic component. This simplifies the manufacture of the charging connector and allows for easy installation into the housing.

[0014] Due to the thermal conductivity of the sealed mounting element, the temperature sensor element can be mounted in the mounting recess in different arrangements, and the mounting recess can have different shapes and arrangements. However, it is preferred that the mounting recess extends to within 1 mm of the charging contact area surrounded by the sealed mounting element. It is also preferred that the temperature sensor element is mounted in the mounting recess such that the distance between the temperature sensor element and the charging contact is less than 1 mm. In this way, the temperature of the corresponding charging contact can be determined virtually directly.

[0015] In principle, the temperatures of the two charging contacts can be determined jointly using the temperature sensor element, thereby effectively measuring an average temperature. However, according to a preferred improvement of the invention, the temperature sensor element has two temperature sensors, each used to measure the temperature of a corresponding charging contact. Preferably, the temperature sensors are located on a circuit board arranged in a mounting opening. Particularly preferably, the distance between the temperature sensors and the corresponding charging contacts whose temperatures are to be measured is less than 1 mm.

[0016] Preferably, the charging contacts are designed in a pin shape, and the sealing mounting element has two spaced-apart cylindrical openings through which the charging contacts sealably pass. Furthermore, preferably, the sealing mounting element has two tapered outer regions that sealably abut against the inner wall region of an opening formed in the housing.

[0017] According to a preferred embodiment of the invention, a transition region is constructed between the two charging contacts, the transition region having a rib-like structure for suppressing creepage current between the charging contacts. Thus, the sealing mounting element assumes a third function in the sense of a multifunctional element, wherein the desired short-circuit withstand strength is achieved through the rib height and number of ribs in the rib-like structure.

[0018] Creepage current in charging connectors, as it can occur in energy transfer systems, particularly in electric and hybrid vehicles, is a significant safety and efficiency issue. Creepage current is an unintended current that flows along the surface of an insulating material instead of following a predetermined path through a conductor. It can be caused by a variety of factors, including moisture, dirt, salt, chemical contaminants, or the inherent properties of the material surface itself. In the context of charging connectors, this can lead to specific problems, such as certain safety risks: creepage current may cause heating, increasing the risk of fire, or it may cause electric shock if a person comes into contact with affected components. The safety of users and the system can be seriously compromised as a result.

[0019] The heat generated by creepage current can also lead to the degradation or corrosion of insulating materials. This can affect component lifespan and ultimately cause charging connector failure. Furthermore, creepage current represents undesirable energy loss. It reduces the efficiency of the charging process because a portion of the energy is lost as heat instead of being used for battery charging. Additionally, creepage current can affect the measurement and monitoring of actual current flow. This can lead to malfunctions in control electronics or cause safety systems to issue false alarms.

[0020] To minimize or avoid creepage currents, this paper employs a special construction element in the form of a ribbed structure, which extends the path that creepage current must take, thereby reducing its likelihood of occurrence. Furthermore, clean and dry surfaces contribute to reducing the risk of creepage currents. This clean and dry surface is achieved through the sealing function of the sealed mounting element.

[0021] This invention can, in principle, be applied to any charging contact of a charging connector for charging electric or hybrid vehicles. According to a preferred embodiment of the invention, the charging contact is a DC charging contact. The advantages provided by this invention are particularly significant in DC charging contacts, as there is a risk that the DC charging contact will heat up beyond a critical temperature due to the high charging current during DC charging. Attached Figure Description

[0022] The present invention will now be described in further detail with reference to the accompanying drawings and preferred embodiments.

[0023] As shown in the attached figure:

[0024] Figure 1 A perspective front view of a charging connector according to a preferred embodiment of the present invention is shown.

[0025] Figure 2 Show Figure 1 A perspective front view of the charging connector in the middle.

[0026] Figure 3 Show Figure 2 A perspective detail view of the charging connector without charging contacts.

[0027] Figure 4 Show Figure 3 Perspective view of the sealing mounting element in the middle.

[0028] Figure 5 Show Figure 4 A perspective view of the sealed mounting element before the temperature sensor element is installed.

[0029] Figure 6 Show Figure 5 A perspective view of the sealed mounting element after the temperature sensor element has been installed, and...

[0030] Figure 7 This shows a cross-sectional perspective detail view of the installed temperature sensor element. Detailed Implementation

[0031] from Figure 1 The image shows a front perspective view of a charging connector 1 for electric and hybrid vehicles according to a preferred embodiment of the present invention. The charging connector 1 has a housing 2 and two charging contacts 3. The charging contacts 3 extend forward from the housing 2 through an opening 6 formed in the housing 2. The charging contacts 3 are DC charging contacts. Above these DC contacts are additional contacts, which are AC charging contacts and signal contacts, but these will not be further described for the purposes of this invention.

[0032] from Figure 2 (It shows) Figure 1 The temperature sensor element 4 can be seen in the front perspective view of the charging connector. The temperature sensor element is mounted in the sealing mounting element 5. The sealing mounting element 5 is electrically insulating and thermally conductive, and is further shaped and arranged in the opening 6 such that the sealing mounting element circumferentially surrounds the charging contact 3 and seals the area of ​​the opening 6 between the housing 2 and the charging contact 3.

[0033] like Figure 3 and Figure 4As can be seen, the sealing mounting element 5 is designed as a one-piece plastic component with two spaced-apart cylindrical openings 10 through which the charging contacts 3 can be sealed. Furthermore, the sealing mounting element 5 has two tapered outer regions 11 that, in the installed state, are sealed against the inner wall region of the opening 6 formed in the housing 2. A transition region 13 is constructed between the two tapered outer regions 11 of the sealing mounting element 5, and this transition region is provided with a rib-like structure 14 that suppresses creepage current between the charging contacts 3.

[0034] For mounting the temperature sensor element 4, a mounting groove 7 is provided in the sealed mounting element 5. Figure 5 and Figure 6 The image shows the mounting of the sealing element 5 in the mounting recess 7 of the temperature sensor element 4. Here, the sealing element 5 is arranged in the mounting recess 7 such that the temperature of the charging contact 3 can be detected. For this purpose, the temperature sensor element 4 is provided with two temperature sensors 8, each used to measure the temperature of its corresponding charging contact 3. The temperature sensors 8 are positioned on a circuit board 9 arranged in the mounting recess 7 such that the distance between the temperature sensor and the corresponding charging contact 3 whose temperature is to be measured is less than 1 mm. Figure 7 As shown, therefore, only a corresponding thin wall area 12 is provided between the temperature sensor 8 and the charging contact.

[0035] According to the present invention, a charging connector 1 for electric vehicles and hybrid vehicles is provided, comprising a housing 2, two charging contacts 3, a temperature sensor element 4, and a sealing mounting element 5, wherein the charging contacts 3 extend from the housing 2 through at least one opening 6 formed in the housing 2. The sealing mounting element 5 is electrically insulating and thermally conductive, and is shaped and arranged in the opening 6 such that the sealing mounting element circumferentially surrounds the charging contacts 3 and seals the area of ​​the opening 6 between the housing 2 and the charging contacts 3. Furthermore, the sealing mounting element has a mounting groove 7 in which the temperature sensor element 4 is mounted to detect the temperature of the charging contacts 3.

[0036] The main aspect of the invention is that the charging connector 1 has a sealing mounting element 5, which functions almost as a multifunctional element. It not only performs a sealing function but also serves to mount the temperature sensor element 4. The sealing function becomes particularly important when the charging connector 1 is not connected to a corresponding charging connector. In the plugged-in state, the temperature sensor element 4 is activated to monitor the temperature of the charging contacts 3 during charging.

[0037] When referring to a corresponding charging connector, this means a charging connector having the same mating surfaces as the charging connector 1 according to the invention. Here, one mating surface has contact pins, while the other has a contact sleeve, and vice versa. Therefore, a kit consisting of the charging connector 1 according to the invention and a corresponding charging connector can be plugged together. Furthermore, even if the mating surfaces only partially match, it can still be called a corresponding charging connector, meaning the corresponding charging connector may not have all the contacts present in the charging connector 1 according to the invention. However, the existing contacts of the corresponding charging connector match the charging connector 1 according to the invention in terms of the mating surfaces, so that the two connectors can also be plugged together in this case.

[0038] This configuration offers several advantages. First, integrating the temperature sensor element 4 into the hermetically sealed mounting element 5 enables near-direct temperature monitoring, which is crucial for safe and efficient charging. Second, the multifunctional hermetically sealed mounting element 5 simplifies the construction and assembly of the charging connector 1 by reducing the number of required components and assembly steps. Third, the sealing function of the element 5 provides protection against environmental influences such as moisture and dust, thereby improving the reliability and lifespan of the charging connector 1.

[0039] List of reference numerals in the attached diagram:

[0040] 1. Charging Plug

[0041] 2. Shell

[0042] 3 Charging contacts

[0043] 4 Temperature sensor components

[0044] 5 Sealing mounting elements

[0045] 6. Openings in the casing

[0046] 7. Mounting groove

[0047] 8 Temperature Sensor

[0048] 9 Circuit Boards

[0049] 10 cylindrical openings

[0050] 11. Conical extended outer region

[0051] 12 Thin-walled regions

[0052] 13 Transition Zone

[0053] 14 Rib structure

Claims

1. A charging connector (1) for electric vehicles and hybrid vehicles, said charging connector having: Shell (2); Two charging contacts (3); Temperature sensor element (4); and Sealing mounting element (5); wherein, The two charging contacts (3) are led out from the housing (2) through at least one opening (6) formed in the housing (2). The sealing mounting element (5) is electrically insulating and thermally conductive. The sealing mounting element is shaped and arranged in the opening (6) such that it circumferentially surrounds the charging contact (3) and seals the area of ​​the opening (6) between the housing (2) and the charging contact (3). The sealing mounting element has a mounting groove (7) in which a temperature sensor element (4) is mounted so as to detect the temperature of the charging contact (3).

2. The charging connector (1) according to claim 1, wherein, The sealing mounting element (5) is designed as a one-piece plastic component.

3. The charging connector (1) according to claim 1 or 2, wherein, The mounting groove (7) extends to a distance of less than 1 mm from the area of ​​the charging contact (3) surrounded by the sealing mounting element (5).

4. The charging connector (1) according to claim 3, wherein, The temperature sensor element (4) is mounted in the mounting groove (7) such that the distance between the temperature sensor element and the charging contact (3) is less than 1 mm.

5. The charging connector (1) according to any one of the preceding claims, wherein, The temperature sensor element (4) has two temperature sensors (8), which are used to measure the temperature of the corresponding charging contact (3).

6. The charging connector (1) according to claim 5, wherein, The temperature sensor (8) is located on the circuit board (9) arranged in the mounting groove (7).

7. The charging connector (1) according to claim 5 or 6, wherein, The distance between the temperature sensor (8) and the corresponding charging contact (3) of the temperature to be measured is less than 1 mm.

8. The charging connector (1) according to any one of the preceding claims, wherein, The sealing mounting element (5) has two cylindrical openings (10) arranged spaced apart from each other, through which the charging contacts (3) pass in a sealed manner.

9. The charging connector (1) according to any one of the preceding claims, wherein, The sealing mounting element (5) has two tapered outer regions (11) that are respectively sealed against the inner wall region (12) of the opening (6) formed in the housing (2).

10. The charging connector (1) according to any one of the preceding claims, wherein, The sealing mounting element (5) has a transition region (13) extending between the charging contacts (3), which is provided with a rib-like structure (14) for suppressing creepage current between the charging contacts (3).

11. The charging connector (1) according to any one of the preceding claims, wherein, The charging contact (3) is a DC charging contact.

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