Charging cable plug
The two-part cup housing design with a standardized base body and adaptable charging cable connection body addresses the issue of varying cable diameters and assembly complexity, offering a cost-effective, secure, and easy-to-assemble solution for charging cable plugs.
Patent Information
- Application Number
- DE102013019882
- Authority / Receiving Office
- DE · DE
- Patent Type
- Patents
- Current Assignee / Owner
- Filing Date
- 2013-11-28
- Publication Date
- 2025-10-02
- Estimated Expiration
- 2033-11-28
AI Technical Summary
Existing charging cable plugs with cup housings are not adaptable to varying cable diameters and require complex assembly processes, leading to increased costs and potential misuse.
A two-part cup housing design with a standardized housing base body and a variable charging cable connection body, featuring a frustoconical inner surface for securing elements, allows for easy assembly and adaptation to different cable diameters, and includes a clip connection and bayonet lock for secure attachment.
The solution provides a cost-effective, secure, and easy-to-assemble charging cable plug that adapts to various cable diameters while preventing misuse through a one-time clip connection and bayonet lock mechanism.
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Abstract
Description
[0001] The invention relates to a charging cable plug comprising a charging cable and an electrically contacted plug-in unit designed for connection to a mating plug-in unit, comprising a cup housing which at least partially encompasses the plug-in unit and has a connection opening via which the plug-in unit is accessible and / or led out of the cup housing, and with a charging cable connection opening provided at a distance from the connection opening, and comprising a strain relief for a charging cable which is led into the cup housing via the charging cable connection opening and is in contact with the plug-in unit.The cup housing is constructed in several parts and in any case has a housing base body which is closed on the shell side and a charging cable connection body, wherein the housing base body serves to receive the plug-in unit and has the connection opening, and wherein the charging cable connection body has the charging cable connection opening and is constructed to receive the charging cable. To implement strain relief for the charging cable, a securing body can be attached to the charging cable connection body. At least one securing element is provided on the securing body such that the securing element, in an assembled position of the securing body in which the securing body is secured to the charging cable connection body, is supported against the charging cable connection body and / or is braced against the charging cable and secures the charging cable in the cup housing with strain relief.In the assembly position, the securing body is secured to the charging cable connection body and / or to the housing base body via a clip connection, wherein the clip connection has an elastically deformable holding arm with a hook-shaped formation and a locking edge encompassed by the hook-shaped formation in the assembly position.
[0002] There are various standardized charging interfaces for charging an electric vehicle. Depending on the respective interface specification, the electric vehicle can be charged with different currents or at different voltages. To charge, the electric vehicle is connected to a charging station that provides electrical energy via a charging cable. The charging cable, which has at least one charging cable plug at one end, is designed with different cable cross-sections depending on the current or voltage. As a result, the outer diameters of the charging cables vary considerably due to the different cable cross-sections. To ensure that the charging cable is routed precisely from the charging cable plug, the contour of the charging cable plug and in particular the charging cable connection opening provided on the plug housing are adapted to the respective outer diameter.For this reason, there is a wide variety of different connector housings for the various specified charging cables.
[0003] Although housings for charging cable plugs consisting of two half-shells are known in practice, cup-shaped housings have proven particularly effective for charging cable plugs. Since the cup-shaped housing is closed on the shell side, the charging cable must be routed into the cup-shaped housing via the charging cable connection opening before installing the electrically contacted plug-in unit.
[0004] DE 10 2012 209 907 A1 discloses a charging cable plug with a housing formed from two interconnectable half-shells, each extending over the entire length of the charging cable plug. The housing has a connection opening at one end, in which the plug-in unit is arranged, and a charging cable connection opening at its other, opposite end, through which the charging cable can be inserted into the charging cable plug.
[0005] Furthermore, DE 10 2011 002 024 A1 discloses a charging cable connector having a housing formed from two half-shells, each extending over the entire length of the charging cable connector and connected to each other via a connecting seam. The same applies to DE 10 2012 016 641 A1, in which the housing is formed from two half-shells, each extending over the entire length of the charging cable connector.
[0006] From DE 20 2010 011 857 U1 a photovoltaic connector is known with a housing into which a contact element can be inserted, with a receiving area open at the end, into which a cable sealing ring and a clamping ring can be inserted and to which a screw nut can be fastened.
[0007] DE 10 2012 202 368 A1 shows a charging plug which has a cable connecting element through which the cable harness is guided into the charging plug in a predetermined cable direction and the plugging direction and the cable direction are essentially spatially perpendicular to one another.
[0008] Further charging plugs are known from JP 2000-113934 A and JP H06-231832 A.
[0009] Furthermore, DE 32 09 734 A1 shows a circular connector consisting of several assembled components, wherein a circular arrangement of teeth running in the direction of the connector axis (ratchet ring) is provided on the first component for the screw connection of a first and a second component in a manner that prevents them from loosening, while locking means are provided on the second component which, when the two components are screwed together, engage with the ratchet ring of the first component.
[0010] The object of the invention is to further develop a charging cable plug with a cup housing in such a way that the cable outlet is designed to be variable for different cable diameters and the assembly of the housing is simplified.
[0011] To achieve the object, the invention in conjunction with the preamble of patent claim 1 is characterized in that a frustoconical inner surface is formed on the charging cable connection body in the region of the charging cable connection opening, against which the securing element of the securing body leans in the assembly position.
[0012] The particular advantage of the invention is that by providing a cup housing consisting of at least two parts, a housing base body that is always identical and matched to the plug-in unit is connected to a charging cable connector body. The charging cable connector body can be matched to the respective charging cable diameter. The housing base body is thus designed as a common component for all charging cable connectors. Only the charging cable connector body is designed for each configuration.
[0013] In particular, cost advantages arise from the use of the same housing base. These cost advantages are particularly evident when the charging cable connector body has a simple geometric design and essential functional features of the charging cable plug, independent of the electrical operating parameters, are implemented in the same housing base. For example, a handle or a handle recess of the charging cable plug can be implemented as part of the housing base. Likewise, means for securing the charging cable plug to a mating connector unit of an electric vehicle or a charging station can be provided on the housing base.
[0014] According to the invention, the connection opening of the cup housing associated with the plug-in unit is provided on the housing base body. The housing base body is thus designed in the manner of a cup housing, closed on the shell side, and constructed in one piece. The charging cable connection opening, which must be designed differently for charging cables of different dimensions, is implemented as part of the charging cable connection body.
[0015] For connecting the housing base body to the charging cable connector body, conventional fasteners such as screws or clamps can be used. Precise positioning of the bodies relative to one another can be ensured, in particular, by positioning elements molded onto the housing base body or the charging cable connector body. The housing base body and the charging cable connector body can, for example, be realized as plastic parts and manufactured using an injection molding process.
[0016] According to a preferred embodiment of the invention, connecting means can be provided that allow tool-free assembly of the charging cable connector body to the housing base body. For example, the housing base body can be screwed to the charging cable connector body. For this purpose, corresponding threads can be formed directly on the housing base body and on the charging cable connector body. For example, a clip connection can be provided to connect the charging cable connector body to the housing base body.
[0017] In particular, the charging cable connector body and the housing base body can be releasably secured to one another. For example, quick-connection means can be provided to simplify the assembly of the cup housing. For example, a bayonet lock with an engagement groove on the charging cable connector body and a correspondingly designed recess on the housing base body can be provided as the quick-connection means, which allows the charging cable connector body to be secured to the housing base body through a combined feed and rotation movement.
[0018] According to a further development of the invention, a securing body is attached to the charging cable connection body to provide strain relief for the charging cable. For this purpose, the securing body can have at least one elastically deformable securing element which, in an assembled position of the securing body in which the securing body is secured to the charging cable connection body, is braced against the charging cable and thus fixes the charging cable in the cup housing with no strain on it. In particular, it can be provided that when the securing body is attached to the charging cable connection body, the securing element or a sheath of the charging cable is elastically deformed and, as a result of the elastic deformation, fixes the charging cable in the charging cable connection body. The elastic deformation of the securing element can be achieved, for example, via an inclined plane or a wedge surface.
[0019] According to the invention, the securing body is secured to the charging cable connector body or the housing base body via a clip connection. As part of the clip connection, an elastically deformable retaining arm with a hook-shaped protrusion at its free end and a locking edge encompassed by the hook-shaped protrusion in the assembled position of the securing body are provided. The elastically deformable retaining arm with the hook-shaped protrusion can be implemented, for example, as part of the charging cable connector body or the securing body. Accordingly, the locking edge will be provided on the securing body or the charging cable connector body.
[0020] According to a further development of the invention, a closure body with at least one locking element for the clip connection can be provided as a further component of the cup housing. The closure body is secured to the securing body or the charging cable connector body in such a way that the locking element of the closure body engages in a mounting opening for the clip connection formed between the securing body and the charging cable connector body. The locking element is dimensioned with respect to the mounting opening such that the elastically deformable retaining arm of the clip connection of the securing body is blocked when the securing body is mounted and secured. Disassembly or loosening of the securing body is then impossible. This advantageously effectively prevents misuse or tampering with the charging cable plug.
[0021] The entire cup housing can be designed to prevent disassembly by providing an additional clip connection for the safety body and the closure body. For this purpose, the additional clip connection, for example, between the closure body and the safety body, is designed in such a way that once the connection between the bodies has been clipped together once, it can no longer be removed. For example, the additional clip connection can be arranged in an inaccessible manner in the cup housing after the closure body has been secured to the safety body.
[0022] According to a further development of the invention, a guide element is provided on the fuse body and / or on the closure body, which, when the fuse body is in the assembled position, engages into a mounting recess in the housing base body. This advantageously simplifies the positioning of the fuse body relative to the housing base body. At the same time, the correct assembly of the bodies can be easily verified. Assembly is correct when the guide element is inserted into the mounting recess as intended.
[0023] According to a further development of the invention, the mounting recess on the housing base body is elongated or groove-shaped. Advantageously, the guide element provided on the securing body can be guided in the groove-shaped mounting recess during assembly. This ensures a relative positional alignment of the securing body and the housing base body throughout the entire assembly process. This prevents incorrect assembly. The securing body can be positioned and secured on the charging cable connector body or the housing base body, in particular, by means of a linear feed movement.
[0024] According to a further development of the invention, a contact surface for a charging cable seal is provided on an inner recess of the charging cable connector body. The provision of the charging cable seal advantageously prevents the ingress of moisture into the cup housing. In addition, the provision of the charging cable seal on the charging cable connector body results in a functional separation. The charging cable connector body defines the mechanical-structural interfaces for receiving the charging cable. In particular, the charging cable is fixed and sealed in the charging cable connector body. An annular seal, for example, is provided as the charging cable seal. In contrast, the electrical functional elements and in particular the plug-in unit are enclosed by the housing base body and electrically contacted in the housing base body.
[0025] Further advantages, features, and details of the invention can be gathered from the further subclaims and the following description. The features mentioned therein may be essential to the invention individually or in any combination. The drawings serve merely as examples to clarify the invention and are not limiting in nature.
[0026] They show: Fig. 1 a side view of a charging cable plug with a multi-part cup housing according to the invention in an exploded view, Fig. 2 a perspective view of the charging cable plug, Fig. 3 a perspective detailed view of a charging cable connection body of the charging cable plug, Fig. 4 a perspective detailed view of a fuse body of the charging cable plug, Fig. 5 a perspective detailed view of a closure body of the charging cable plug, Fig. 6 a first assembly step of the charging cable plug according to the invention in a sectional view, Fig. 7 shows a second assembly step of the charging cable plug according to the invention in a sectional view, Fig. 8 shows a third assembly step of the charging cable plug according to the invention in a sectional view, Fig. 9 a fourth assembly step of the charging cable plug according to the invention in a sectional view and Fig. 10 an assembly drawing of the charging cable plug according to the invention in a sectional view.
[0027] An inventive charging cable plug according to the Fig. 1 and Fig. 2 has as essential components a multi-part can housing, a charging cable 1 and an electrically contacted plug element provided in sections in the can housing. The plug element comprises a plug face 2 and electrical contacts (not shown) held in the plug face 2 for electrically connecting the charging cable plug to a mating plug unit (not shown) of an electric vehicle or a charging station. According to the invention, the can housing is designed as a multi-part can housing. It comprises a housing base body 3 receiving the plug unit with the plug face 2 and the electrical contacts, a charging cable connection body 4 that can be secured to the housing base body 3, as well as a securing body 5 and a closure body 6. The housing base body 3, which is designed like a can housing with its shell side closed, has a connection opening 7 for the plug unit.The plug-in face 2 of the plug-in unit protrudes from the housing base body 3 beyond the connection opening 7 in such a way that it can be inserted into the mating plug-in unit for mechanical and electrical connection. Furthermore, a charging cable connection opening 8 for the charging cable 1 is provided on the charging cable connection body 4.
[0028] In the embodiment shown here, a grip recess 9 and a handle 10 are formed on the housing base body 3 as a means for handling the charging cable plug. Furthermore, a fastening lug 11 and an actuating element 12 associated with the fastening lug 11 for unlocking the fastening lug 11 are provided on the housing base body 3. The fastening lug 11 serves to mechanically connect and secure the charging cable plug to the mating plug unit. For this purpose, the fastening lug 11 engages around a locking element of the mating plug unit and can be lifted off the locking element via the actuating element 12 to release the fastening.
[0029] A charging cable seal 13 is also provided as part of the charging cable connector. The charging cable seal 13 encloses the charging cable 1 and is held in the charging cable connector body 4. Additional seals, which are not shown here for reasons of clarity, can be provided, for example, between the plug face 2 and the housing base body 3 in the region of the connection opening 7 and between the housing base body 3 and the charging cable connector body 4. An annular contact surface 18 is provided for the charging cable seal 13 on an inner recess 36 of the charging cable connector body 4 designed to receive the seal 13. The contact surface 18 facilitates simple and precise installation of the charging cable seal 13 in the charging cable connector body 4.
[0030] The charging cable connector body 4 can be secured to the housing base body 3 via a bayonet lock with a combined feed and rotation movement. For this purpose, thread-like engagement grooves 14 are provided on the casing side of the charging cable connector body 4. Correspondingly, the housing base body 3 has thread-segment-like protrusions 15 that are inserted into the engagement grooves 14 of the charging cable connector body 4 to secure the charging cable connector body 4 to the housing base body 3. The securing body 5 is secured to the charging cable connector body 4 via a clip connection. Furthermore, the closure body 6 is fastened to the securing body 5 via another clip connection.
[0031] Details of the charging cable connector body 4, the fuse body 5 and the locking body 6 are shown in the Fig. 3 to 5 and in the following assembly drawings. The charging cable connection body 4 has the charging cable connection opening 8 on a front side opposite the engagement grooves 14. In the area of the charging cable connection opening 8, a truncated cone-shaped or conical inner surface 32 is formed, which serves to apply and support the securing body 5 on the charging cable connection body 4. At the same time, the truncated conical taper of the charging cable connection opening 8 allows for particularly simple passage of the charging cable 1. Due to its essentially cylindrical outer geometry, the charging cable connection body 4 can be secured to the housing base body 3 in a particularly simple manner via the bayonet lock through the combined feeding and rotating movement. The charging cable connection opening 8 is surrounded by a total of four longitudinal recesses 16 provided for the installation of the securing body 5.In the area of the longitudinal recesses 16, a locking edge 17 is provided inside the charging cable connection body 4 as part of the clip connection.
[0032] The securing body 5, which can be attached to and secured to the charging cable connection body 4, together with the charging cable connection body 4 provides strain relief for the charging cable 1. As a shaping component, the securing body 5 has an annular disc element 21 with a cylindrical through-opening 25 for the charging cable 1. To fasten the securing body 5 to the charging cable connection body 4, four elastically deformable holding arms 19 are provided, distributed around the circumference. Hook-shaped projections 20 are provided at a free end of the holding arms 19. The hook-shaped projections 20 are designed such that, when the securing body 5 is in the assembled position, they engage around the locking edge 17 provided on the charging cable connection body 4. Secondly, securing elements 22 are provided, projecting from the end face of the disc element 21.The securing elements 22 are also provided circumferentially distributed on the disc element 21 of the securing body 5. A radially outwardly oriented rear side 23 of the securing elements 22 is inclined according to the conical shape of the charging cable connection opening 8. At a free end facing away from the disc element 21, the securing elements 22 provide contact formations 24, via which the securing elements 22 engage the charging cable 1.
[0033] Furthermore, a guide element 26 protruding radially from the disc element 21 is provided on the securing body 5. The guide element 26 is positioned and shaped such that it is inserted and guided in a dovetail-like mounting recess 27 formed on the housing base body 3 in the region of the handle recess 9.
[0034] The closure body 6 is designed symmetrically with respect to a central axis. It comprises a centrally provided retaining ring 28 with a passage opening 35 for the charging cable 1, as well as four slender locking elements 29 protruding axially from the retaining ring 28. The locking elements 29 are evenly distributed around the circumference of the retaining ring 28. Between each two adjacent locking elements 29, a holding arm 30 of the further clip connection designed to connect the closure body 6 to the securing body 5 is provided. A total of four holding arms 30 are evenly distributed on the retaining ring 28, alternating with the locking elements 29. The locking elements 29 and the holding arms 30 protrude from the retaining ring 28 of the closure body 6 to the same end face.
[0035] Opposite the locking elements 29 and the retaining arms 30, an anti-kink section 31 for the charging cable 1 is formed on the retaining ring 28. The anti-kink section 31 is formed from a spirally wound plastic body. The retaining ring 28, the locking elements 29, the retaining arms 30, and the anti-kink section 31 are formed as a single piece.
[0036] To assemble the charging cable plug, first the locking body 6, the securing body 5, the charging cable connection body 4, the charging cable seal 13 as well as the housing base body 3 and any other seals not shown are placed on the charging cable 1 and the plug-in unit is electrically contacted with the charging cable 1. Then the plug-in unit is fixed in the housing base body 3. Subsequently, as shown in the Fig. 6 and Fig. 7, the charging cable connection body 4 with the charging cable seal 13 located therein is fixed to the housing base body 3 via the bayonet lock.
[0037] In the next assembly step, which is Fig. As shown in Figure 8, the securing body 5 is attached to the charging cable connector body 4. For this purpose, the guide element 16 of the securing body 5 is inserted into the mounting recess 27 of the housing base body 3 and attached to the charging cable connector body 4 along the mounting recess 27. During assembly, the retaining arms 19 engage in the longitudinal recess 16 of the charging cable connector body 4.
[0038] An assembly position of the securing body 5 is reached when the hook-shaped formations 20 of the holding arms 19 engage around the locking edge 17 provided on the charging cable connection body 4. In this Fig. In the assembly position shown in Figure 9, the elastically designed securing elements 22 of the securing bodies 5 are supported with the rear side 23 on the conical inner surface 32 of the charging cable connection opening 8. The contact formations 24 rest against the charging cable 1 (not shown) on the sheath side and press into the elastic sheath of the charging cable 1 in such a way that the charging cable 1 is secured in the charging cable connection body 4 with strain relief.
[0039] As also in Fig. 9, in the assembly position of the fuse body 5, a mounting opening 33 is formed between the fuse body 5 and the charging cable connection body 4. The closure body 6 is then inserted into the mounting opening 33 with the locking elements 29 facing forward. The holding arms 30 of the closure body 6 engage around the disc element 21 of the fuse body 5 and rest against a flat side 34 facing the charging cable connection body 4. By inserting the locking elements 29 into the mounting opening 33, the holding arm 19 of the fuse body 5, as shown in Fig. 10. The clip connection formed between the charging cable connector body 4 and the securing body 5 cannot be released after the locking body 6 has been secured.
[0040] Since the flat side 34 of the disc element 21 facing the charging cable connector body 4, as well as the retaining arms 30, are arranged inaccessibly in the cup housing of the charging cable connector when the closure body 6 is assembled, the charging cable connector can be installed once and then cannot be removed again. This ensures that the charging cable connector can be installed quickly and easily, and that the installed charging cable connector cannot be removed without causing damage. This prevents misuse and tampering with the charging cable connector. List of reference symbols 1 charging cable 2 mating face 3 Housing base body 4 charging cable connector bodies 5 fuse bodies 6 locking bodies 7 Connection opening 8 Charging cable connection opening 9 Handle recess 10 Grab handle 11 Mounting lug 12 Actuating element 13 Charging cable seal 14 engagement groove 15 Forming 16 Longitudinal recess 17 locking edge 18 contact surface 19 Holding arm 20 hook-shaped recess 21 Disc element 22 Securing element 23 Back 24 Investment design 25 passage opening 26 Guide element 27 Mounting recess 28 Retaining ring 29 Locking element 30 holding arm 31 Anti-kink section 32 conical inner surface 33 Mounting opening 34 Flat side 35 passage opening 36 inner recess
Claims
[1] Charging cable plug comprising a charging cable (1) and an electrically contacted plug-in unit, comprising a cup housing which at least partially encompasses the plug-in unit and has a connection opening (7) through which the plug-in unit is accessible and / or led out of the cup housing, and with a charging cable connection opening (8) provided at a distance from the connection opening (7), and comprising a strain relief for a charging cable (1) which is led into the cup housing via the charging cable connection opening (8) and is contacted with the plug-in unit, wherein the cup housing is designed in several parts and in any case has a housing base body (3) which is closed on the shell side and a charging cable connection body (4), wherein the housing base body (3) serves to receive the plug-in unit and has the connection opening (7), and wherein the charging cable connection body (4) has the charging cable connection opening (8) and is designed to receive the charging cable (1),wherein, to realize the strain relief for the charging cable (1), a securing body (5) can be attached to the charging cable connection body (4), and wherein at least one securing element (22) is provided on the securing body (5) such that the securing element (22), in an assembly position of the securing body (5), in which the securing body (5) is fixed to the charging cable connection body (4), is supported against the charging cable connection body (4) and / or is braced against the charging cable (1) and fixes the charging cable (1) in the cup housing in a strain-relieved manner, wherein the securing body (5) is fixed in the assembly position thereof via a clip connection to the charging cable connection body (4) and / or to the housing base body (3), wherein the clip connection comprises an elastically deformable holding arm (19) with a hook-shaped formation (20) and a locking edge encompassed by the hook-shaped formation (20) in the assembly position (17) has, characterized bythat a frustoconical inner surface (32) is formed on the charging cable connection body (4) in the region of the charging cable connection opening (8), against which the securing element (22) of the securing body (5) leans in the assembly position. [2] Charging cable plug according to claim 1, characterized by that the charging cable connection body (4) can be fixed to the housing base body (3) using connecting means without tools. [3] Charging cable plug according to claim 1 or 2, characterized by that quick-connection means are provided for detachably connecting the charging cable connection body (4) to the housing base body (3). [4] Charging cable plug according to one of claims 1 to 3, characterized by that the charging cable connection body (4) is connected to the housing base body (3) via a thread or a bayonet lock. [5] Charging cable plug according to one of claims 1 to 4, characterized bythat a closure body (6) with at least one locking element (29) is provided and can be attached to the securing body (5) and / or the charging cable connection body (4) in such a way that the locking element (29) of the closure body (6) engages in a mounting opening (33) formed between the securing body (5) and the charging cable connection body (4) for the clip connection and blocks the elastically deformable holding arm (19) of the clip connection in the mounting position of the securing body (5). [6] Charging cable plug according to claim 5, characterized by that the closure body (6) can be permanently fixed to the securing body (5) and / or to the charging cable connection body (4) via a further clip connection, wherein the further clip connection is provided in the assembled state of the closure body (6) in the cup housing. [7] Charging cable plug according to claim 5 or 6, characterized bythat a passage opening (25, 35) for the charging cable (1) is provided on the securing body (5) and on the closure body (6). [8] Charging cable plug according to one of claims 1 to 7, characterized by that a guide element (20) is provided on the securing body (5) which, in the mounting position of the securing body (5), engages in a mounting recess (27) formed on the housing base body (3). [9] Charging cable plug according to claim 8, characterized by that the mounting recess (27) on the housing base body (3) is elongated and groove-shaped. [10] Charging cable plug according to one of claims 1 to 9, characterized by that a contact surface (18) is formed on an inner recess (36) of the charging cable connection body (4) for a charging cable seal (13) fixed in the charging cable connection body (4). [11] Charging cable plug according to claim 7 or one of claims 8 to 10 dependent on claim 7, characterized bythat the charging cable connection opening (8) of the charging cable connection body (4) on the one hand and the passage opening (25) provided on the securing body (5) for the charging cable (1) and the passage opening (35) provided on the closure body (6) on the other hand have a circular cross-sectional geometry in the manner of a bore and are arranged coaxially to one another in the assembled state.
Citation Information
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