Charging module for charging electrical storage media of electrically powered motor vehicles

Abstract

Charging module (1) for charging electrical storage media of at least temporarily electrically powered motor vehicles, comprising a plug connection for an external power supply, an electrically movable locking element (5) between a locking position and an unlocking position for securing the plug connection in the locked position, and an emergency release device (6) manually actuated by means of an actuating element (7) for moving the locking element (5) into its unlocking position, wherein the charging module (1) comprises a cover on the outside of the vehicle that provides a recess for the plug connection, the actuating element (7) of the emergency release device (6) is positioned on the side of the cover facing the inside of the vehicle, and the cover has a guide (9) through the cover directed towards this actuating element (7) for a defined translational movement of a tool (8).by which a manual actuating force can be transmitted to the actuating element (7) of the emergency release device (6).

Description

[0001] The invention relates to a charging module for charging electrical storage media of at least temporarily electrically powered motor vehicles, comprising a plug connection for an external power supply, an electrically movable locking element between a locked and an unlocked position for securing the plug connection in the locked position, and an emergency release device manually actuated by means of an actuating element for moving the locking element into its unlocked position, in which the plug connection can be disconnected. The invention further relates to a motor vehicle equipped with such a charging module.

[0002] In times of dwindling resources and climate change, electric and hybrid electric vehicles are seen as a promising solution for personal transportation. In a typical charging scenario, the electric or hybrid electric vehicle is connected to a local power grid, and its onboard storage system is charged from this grid. It is also desirable to be able to charge the vehicle at locations other than its base station, such as a charging station in a parking lot or at a business location. At these remote charging points, it is often advisable to protect the charging cable from unauthorized access during the charging process.

[0003] For this purpose, it is already known to use charging modules with a locking element for a charging cable equipped with a plug connection in electric and hybrid electric vehicles, in order to establish a safe and secure connection between the electrical power supply and the vehicle during charging of the storage media. In particular, this also secures the charging cable against unintentional disconnection of the plug connection during the charging process.

[0004] For this purpose, a corresponding charging socket or plug connection is provided on the vehicle, into which the charging cable carried with the vehicle or provided at a charging station can be plugged in, in order to then connect the vehicle to the external power supply.

[0005] This is intended to prevent the charging cable from being disconnected without authorization, the cable from being stolen, or the charging process from being interrupted by third parties. The locking mechanism also serves as protection against unauthorized power extraction for other vehicles or other purposes.

[0006] For this purpose, locking elements are provided between the charging cable plug and the corresponding charging socket on the vehicle. These elements together form the plug connection and are controlled, in particular, by the vehicle's electronics. The vehicle's security systems, such as the central locking system or the immobilizer, can be used for this purpose.

[0007] However, it cannot be reliably ruled out that a fault, such as a failure of the control unit or the vehicle's electrical system, could impair the function of the locking device, preventing the connector from being disconnected via the control unit. This would preclude further driving or towing of the vehicle. Therefore, it is desirable to provide a manually operated emergency release device that allows the user to manually move the locking element into the unlocked position.

[0008] Such an emergency release is known, for example, from DE 10 2011 050 783 A1. The locking device serves to lock and unlock a charging cable connector and has a movable locking element in the form of a longitudinally displaceable locking bolt or a locking lever and an electromechanical drive that actuates the locking element. With the emergency release, the authorized operator can move the locking element from its locked position to its unlocked position. For this purpose, the emergency release can be operated from inside the vehicle or interacts with a secured actuating element, which can be operated via a locking device, in particular a mechanical locking cylinder with a corresponding key or via a pull cord. For this purpose, the locking device, in particular the locking cylinder, is accessible to the user from outside the vehicle.In order to create a particularly secure mechanical connection between the locking device and the moving part, it must be arranged in such a way that the connection is not accessible from the outside, thus preventing external manipulation.

[0009] German patent application DE 10 2012 208 661 A1 already discloses a locking device for locking and unlocking a charging cable for electric vehicles or hybrid electric vehicles and features a locking bolt designed to lock the charging cable in the charging port during charging. The vehicle also has a hood lock that is kinematically coupled to the locking bolt by means of a pull rod.

[0010] DE 10 2010 029 446 A1 relates to an actuator with a bolt movable by means of an electric motor. The actuator may also include a lever with which the bolt can be mechanically retracted from its extended position. If the electrical or electronic components responsible for locking malfunction, the driver can manually operate the actuator lever from inside the vehicle. A charging plug can then be disconnected from a charging socket. In a simple embodiment, the lever consists of a bolt with an attached handle or eyelet for attaching a Bowden cable.

[0011] German patent DE 102 59 465 A1 discloses an actuator for a fuel filler flap lock of a motor vehicle, comprising an electric motor capable of rotating a spindle. A rotational movement of the spindle causes a linear displacement of a bolt. The bolt is sealed to the outside by a bellows to protect the actuator from moisture and contamination.

[0012] From DE 196 42 687 A1, an actuator is known with which the connection of a charging plug and a charging socket of an electric vehicle is locked.

[0013] JP 2011-238533A showcases a wireless power transfer system for electric vehicles. The aim is to make charging more convenient and safer by utilizing inductive coupling between a primary coil in a stationary charging unit and a secondary coil in the vehicle. The system includes features for precise coil positioning and orientation to minimize energy loss and increase charging efficiency. Additionally, a communication interface enables data exchange between the vehicle and the charging unit for monitoring and controlling the charging process. Safety mechanisms such as foreign object detection and temperature monitoring are integrated to prevent risks like overheating or malfunctions. The solution is specifically designed for electric vehicles and plug-in hybrids, aiming to make the charging process user-friendly and reliable.

[0014] US Patent 2013 / 0260597A1 describes a locking device comprising a helical gear driven by a motor. The helical gear is connected to a control shaft via a gearbox. Furthermore, the helical gear is connected to a lid locking lever via a connecting rod. A coil spring permanently presses the lid locking lever into the lid locking position.

[0015] A disadvantage of the described state of the art is that manually operating the emergency release is comparatively cumbersome and, in particular, requires relatively precise knowledge of its operation. Thus, it is often impossible for someone unfamiliar with its function to operate the emergency release intuitively. Furthermore, known systems are often designed so that operation of the emergency release device is restricted to a person with access to the interior, meaning that, for example, rescue workers cannot quickly activate the emergency release.

[0016] Against this background, the invention aims to design a charging module of the type mentioned above in such a way that the emergency release can be activated quickly, easily, and without requiring individual access authorization tied to a key or transponder. Furthermore, the invention aims to create a motor vehicle equipped with such a charging module.

[0017] The first problem is solved with a charging module according to the features of claim 1. The dependent claims relate to particularly advantageous further developments of the invention.

[0018] According to the invention, a charging module is provided in which the charging module comprises a cover on the outside of the vehicle that has a recess for the plug connection, the actuating element of the emergency release device is positioned on the side of the cover facing the inside of the vehicle, and the cover has a guide through the cover directed towards this actuating element for a defined translational movement of a tool by which a manual actuating force can be transmitted to the actuating element of the emergency release device. This enables a surprisingly simple and more intuitive operation of the emergency release, which is readily understandable not only to persons familiar with the vehicle or vehicle type, but also to rescue workers or first responders. In particular, the time-consuming and, in extreme cases, fruitless search for the operating unit of the emergency release device, as required by the prior art, is eliminated.Furthermore, the manufacturing effort for the emergency release device is significantly reduced by eliminating power transmission components such as Bowden cables. This also results in a considerable increase in the operational reliability of the emergency release, which functions flawlessly even in the event of significant accident-related damage to the vehicle body. Impairment of functionality due to environmental influences is also not a concern, as the tool guide is designed to prevent, or at least minimize, the ingress of dirt particles or moisture during normal operation. To achieve this, the guide is adapted to the tool's dimensions, allowing the free cross-sectional area to be limited to just a few millimeters.

[0019] The charging module could be designed as a separate functional module that can be detached from the vehicle. However, it is particularly advantageous if the charging module is permanently connected to the vehicle, especially during normal use, and inseparably so.

[0020] The locking element could be actuated externally by a rotary movement of the tool. For this purpose, the guide can accommodate the tool rotatably or itself be pivotally movable to transmit the movement and be equipped with a shape suitable for transmitting torque. It is particularly advantageous, however, if the actuating element of the emergency release device has a pivoting lever connected to the locking element, which can be deflected by a translational movement of the tool. This results in a particularly simple design. In particular, the actuation of the emergency release device is not limited to a specific tool, but can be operated, for example, with a standard screwdriver or, if necessary, with a broken antenna.The pivoting axis of the swivel lever is not parallel to the axis of the translational actuation axis, but rather orthogonal to it. To prevent the tool from slipping, the swivel lever preferably has a concave contact surface for the tool.

[0021] A particularly advantageous embodiment of the present invention is also achieved by making the tool translationally movable within the guide, so that, unlike a rotary movement, a specific angular position of the tool relative to its longitudinal axis is not required. This virtually eliminates the possibility of incorrect operation. Naturally, the actuating element can also be designed to be actuated by both a rotary and / or a translational movement.

[0022] It is particularly practical if the tool can be positively engaged in or inserted through the guide, so that the tool has a predetermined orientation determined by the guide and the operator only needs to perform the translational movement. Operation is further simplified by limiting the movement to a maximum of two degrees of freedom. If the tool and the corresponding guide are not rotationally symmetrical, thus precluding rotation around the longitudinal axis, the movement can alternatively be limited to a single degree of freedom.

[0023] Naturally, the actuating element can be directly connected to the locking element, for example, even as a single unit. However, an embodiment of the invention in which the actuating element of the emergency release device is connected to the locking element via a tension element proves particularly advantageous. This reduces the required force by appropriately selecting the transmission ratios and thus increasing the actuating travel. Furthermore, it allows for a flexible arrangement of the emergency release device, spatially separated from the locking element, so that the charging module created according to the invention can be easily installed in different vehicle types and variants.

[0024] In another, equally advantageous embodiment of the present invention, the guide defines a passage opening which is closed by a separating layer, in particular a plastic film, through which the tool acts on the actuating element. Considering that the emergency release device is only used in extremely rare exceptional situations, a separating layer, for example with a predetermined breaking point or perforation, proves advantageous for protection against external influences. In particular, this reliably prevents the ingress of moisture. The separating surface runs in the same plane as the outer surface of the cover or offset from it towards the vehicle interior. Furthermore, the use of the emergency release device can be easily recognized and, if necessary, verified.Naturally, it may be possible to cover the separating layer with a repair patch or to join the separating surfaces using an adhesive bond. Furthermore, it may also be possible to ensure that the separating layer has sufficient flexibility or elasticity to allow the actuation of the actuator without damaging the separating layer.

[0025] It is particularly practical if the sealed guide and / or the separating layer is marked with an indicator to enable faster and more intuitive operation.

[0026] Another, equally practical embodiment of the invention is achieved when the cover is made of a plastic, in particular a polymer, elastomer, or composite material. The cover can be designed as a molded part and carrier for further functional components and can be fixed as a single unit in a designated recess in the vehicle body. This also makes the cover inexpensive to manufacture.

[0027] Furthermore, the cover and / or the separating layer can consist, at least in sections, of a translucent plastic. This allows the components relevant to the emergency release device, as well as other components, to be visible from the outside, so that the operator can visually check the operating position of the actuator using the tool.

[0028] The tool could be taken from the existing on-board toolkit. If, according to another promising variation, the tool is detachably fixed to the cover, then it is always readily accessible and available for use. In this case, the tool could also be positioned, for example, in a clearly recognizable spatial proximity to or in relation to the guide.

[0029] Preferably, the tool consists at least partially of a thermally and / or electrically insulating material. This prevents, for example, unintentional electrical discharge when inserting the tool, thus improving overall operational safety.

[0030] Furthermore, the problem according to the invention is solved with a motor vehicle with a charging module for charging the electrical storage medium of the motor vehicle, wherein the charging module is equipped with a plug connection for an external power supply, a locking element movable between a locking position and an unlocking position for securing the plug connection in the locking position, and with a manually operable emergency release device for moving the locking element into its unlocking position, in which the plug connection can be released, wherein the charging module comprises a cover on the outside of the vehicle which provides a recess for the plug connection.The actuating element of the emergency release device is positioned on the side of the cover facing the vehicle interior, and the cover has a guide through the cover that directs a defined translational movement of a tool, allowing a manual actuating force to be transmitted to the actuating element of the emergency release device. This enables a simple and quick disconnection of the plug connection, even for individuals without individual access authorization, such as a key or transponder, to the vehicle. Instead, only a tool, preferably a screwdriver, is required, which is moved translationally along an axis predetermined by the guide. This movement brings the tool into contact with the actuating element, thus activating the emergency release device and disconnecting the plug connection.

[0031] By enabling intuitive operation and supplemented by features such as markings for quick location, even in darkness, the guide allows for rapid operation by bystanders in an emergency. A separating layer, which must be clearly identifiable as requiring the user to cut and whose damage is readily apparent, prevents the user from routinely disconnecting the plug connection using the emergency release mechanism.

[0032] The invention allows for numerous embodiments. To further illustrate its basic principle, one of these is shown in the drawing and described below. This shows in Fig. 1. An electrically powered motor vehicle in a side view; Fig. 2 a body area of ​​the motor vehicle that includes a charging module; Fig. 3 an enlarged view of the charging module during the operation of an emergency release device; Fig. 4. A rear view of the charging module during the process. Fig. 2 shown actuation of the emergency release device; Fig. 5 an enlarged representation of the emergency release device accordingly Fig. 4.

[0033] The charging module 1 according to the invention is described below with reference to the Fig. 1, Fig. 2, Fig. 3, Fig. 4 to Fig. 5 described in more detail. These each show a body section 2 of a Fig.Figure 1 shows a side view of an electrically powered vehicle, which houses the charging module 1 for the vehicle's electrical supply and is closed by a conventional flap 3 during operation. Accordingly, the charging module 1 serves to charge an electrical storage medium designed as a battery. For this purpose, an electrical connection for an external power supply is established via a charging cable (not shown) to a charging socket 4 of the charging module 1. Due to the comparatively high current flow, it must be ensured that the connection is not unintentionally disconnected, as this could otherwise lead to an unwanted electrical discharge, which would be harmful to the vehicle's electronics.The charging process is therefore controlled such that an electrically actuated locking element 5 is first moved from an unlocked position to a locked position that mechanically blocks the plug connection. The plug connection is thus secured throughout the entire charging process. However, a fault in the control system cannot be completely ruled out during operation, so the locking element 5 is additionally equipped with an emergency release device 6 for manually moving the locking element 5 to its unlocked position, in which the plug connection can be disconnected. For this purpose, an actuating element of the emergency release device 6 has an actuating element 7, designed as a pivot lever, which is connected to the locking element 5 and can be deflected by a translational movement of a manually operated, movable tool 8. The orientation of this translational movement is predetermined by a guide 9.This allows the emergency release device 6 to be actuated using a standard screwdriver, which in the illustrated example is equipped with an electrically insulated handle. The guide 9 thus defines a passage opening 10, which is matched to the cross-section of the tool 8 and is sealed by a thin separating layer 11 made of a plastic film. The tool 8 can easily be pushed through this separating layer 11 and act on the pivot lever 7 of the emergency release device 6. Reference symbol list 1 charging module 2 Body section 3 flap 4 charging ports 5 locking element 6 Emergency release device 7 Actuating element 8 tools 9 Leadership 10 Passage opening 11 Separation layer

Claims

Charging module (1) for charging electrical storage media of at least temporarily electrically powered motor vehicles, comprising a plug connection for an external power supply, an electrically movable locking element (5) between a locking position and an unlocking position for securing the plug connection in the locked position, and an emergency release device (6) manually actuated by means of an actuating element (7) for moving the locking element (5) into its unlocking position, wherein the charging module (1) comprises a cover on the outside of the vehicle which provides a recess for the plug connection, the actuating element (7) of the emergency release device (6) is positioned on the side of the cover facing the inside of the vehicle, and the cover has a guide (9) through the cover directed towards this actuating element (7) for a defined translational movement of a tool (8).by which a manual actuating force can be transmitted to the actuating element (7) of the emergency release device (6). Charging module (1) according to claim 1, characterized in that the actuating element (7) of the emergency release device (6) has a pivot lever connected to the locking element (5). Charging module (1) according to claims 1 or 2, characterized in that the tool (8) is translationally movable in the guide (9). Charging module (1) according to at least one of the preceding claims, characterized in that the tool (8) is held in the guide (9) in a form-fitting manner so as to be movable. Charging module (1) according to at least one of the preceding claims, characterized in that the actuating element (7) of the emergency release device (6) is connected to the locking element (5) via a traction element. Charging module (1) according to at least one of the preceding claims, characterized in that the guide (9) defines a passage opening which is closed by a separating layer (11) through which the tool (8) acts on the actuating element (7). Charging module (1) according to at least one of the preceding claims, characterized in that the guide (9) and / or the separating layer (11) is provided with a warning marking. Charging module (1) according to at least one of the preceding claims, characterized in that the cover and / or the separating layer (11) consists at least partially of a translucent plastic. Charging module (1) according to at least one of the preceding claims, characterized in that the tool (8) is detachably fixed to the charging module (1), in particular to the cover. Motor vehicle with a charging module (1) according to at least one of the preceding claims for charging an electrical storage medium of the motor vehicle.

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