Vehicle charger, service kit for replacing at least one fuse in a charger, and cover element for a charger

Abstract

Charger for vehicles, in particular for electric vehicles or plug-in hybrids, comprising a housing, at least one circuit board and fuses arranged on the circuit board, wherein the circuit board with the fuses is arranged inside the housing and is connected to the housing by means of a force-fit and / or form-fit connection via at least one fastening element (2), and a cover element (1) connected to the circuit board via at least one fastening means (3), in particular via a fastening point, which covers the circuit board and the fastening element (2) at least partially, and wherein inserting or removing the fuses on or from the circuit board is only possible by removing the circuit board from inside the housing, characterized in that the cover element (1) must be damaged at least partially to remove the circuit board, wherein the cover element (1) is to be damaged in the area where it covers the fastening elements (2).

Description

[0001] The present invention relates to a charger for vehicles, in particular for electric vehicles or plug-in hybrids according to claim 1, and to a service kit for replacing at least one fuse in a charger, in particular in the charger according to claim 8. Furthermore, the present invention relates to a cover element for a charger, in particular for the charger according to the invention and / or as a spare part for the service kit according to the invention, according to claim 9.

[0002] Vehicles, such as motor vehicles, and especially electric vehicles or plug-in hybrids, can be equipped with an onboard charger (AL). In addition to its charging function, the onboard charger can also act as a power distributor, for which purpose it integrates additional power outlets. These outlets allow the charger to distribute high-voltage power. Examples of high-voltage components that can be supplied via these outlets include an electric air conditioning compressor or a high-voltage heater. To ensure adequate protection of these components connected to the charger via these outlets, the charger must also contain high-voltage fuses that will trip in the event of a short circuit.Since the fuses are designed to be replaceable after a short circuit, allowing the charger to continue operating afterward, they must be accessible and replaceable, for example, via a service hatch. However, the fuses must not be directly touchable after the service hatch is opened or unscrewed, as high voltage could still be present at the fuses in a still-active system. For this reason, there is usually an additional service cover in front of the fuses, marked with a warning label, which can only be intentionally removed. Currently, due to the design of this service cover, it can be removed, the fuses replaced, and then the same service cover reinstalled.Because the same service cover can be reused, a service technician working on the charger cannot determine whether the fuses behind the cover have been tampered with. This makes it difficult for both the manufacturer and the customer to prove, for example, in a warranty claim, whether a defect in the charger or in high-voltage components connected to the charger was caused by, for instance, the incorrect replacement of a fuse – i.e., by tampering.

[0003] Further cover elements are known from document US 5 973 399 A.

[0004] The present invention is therefore based on the objective of providing a charger that can detect tampering with the fuses.

[0005] The foregoing problem is solved by a charger for vehicles, in particular for electric vehicles or plug-in hybrids, having the features of claim 1, by a service set having the features of claim 8, and by a cover element having the features of claim 9. Further advantages, features, and details of the invention will become apparent from the dependent claims, the description, and the drawings. Features and details described in connection with the charger according to the invention naturally also apply in connection with the service set according to the invention for replacing at least one fuse in a charger and the cover element according to the invention, and vice versa, so that the disclosure regarding the individual aspects of the invention always refers to, or can refer to, each other.

[0006] The charger according to the invention for vehicles, in particular for electric vehicles or plug-in hybrids, comprising a housing, at least one circuit board and fuses arranged on the circuit board, wherein the circuit board with the fuses is arranged inside the housing and is connected to the housing by means of force and / or form locking via at least one fastening element, and a cover element connected to the circuit board via at least one fastening means, in particular via a fastening point, which covers the circuit board and the fastening element at least partially, and wherein inserting or removing the fuses on or from the circuit board is only possible by removing the circuit board from inside the housing, the technical teaching includes the fact that the cover element must be damaged at least partially in order to remove the circuit board.

[0007] This solution offers the advantage that, due to the design of the cover element, i.e., the service cover, which allows access to the fuses arranged on the circuit board, and due to the fact that replacing, i.e., removing or adding fuses to or from the circuit board, is only possible by removing the circuit board from inside the housing, the cover element or service cover inevitably becomes damaged according to the invention. Because the cover element, i.e., the service cover, must be damaged before access to the circuit board, tampering or attempted tampering with the fuses or the circuit board can be clearly demonstrated.

[0008] In order for the cover element, i.e., the service cover, to function as an indicator of tampering or attempted tampering with the fuses located on the circuit board, the assembly of the charger components involves the following steps: Before the circuit board is inserted into the charger housing and, if necessary, secured using fasteners such as screws that engage in corresponding counter-retaining elements, such as threaded holes in the charger housing or self-tapping screws, the fuses must be positioned on the circuit board, i.e., attached to it. After the fuses have been attached to the circuit board, the board can be inserted into the charger housing and screwed to the housing as described. Only after the circuit board has been screwed to the charger housing are the circuit board and the fuses attached to it protected by the cover element, i.e., the service cover.The cover element, i.e., the service cover, is advantageously and irreversibly attached to the circuit board, for example, via a corresponding opening in the circuit board using fasteners, which can be designed as attachment points. The attachment of the cover element to the circuit board can be force-fit, form-fit, and / or material-fit. For example, one or more clips formed on the cover element can engage in the openings provided on the circuit board, forming clip connections. However, it is also conceivable that the service cover is material-fitted to the circuit board via attachment points or fasteners designed as adhesive points.The only limitation to the functionality of the charger according to the invention, and in particular to the functionality of the cover element according to the invention, is that in the event of servicing or tampering with the fuses, the cover element must be detachable from the circuit board, at least in the area of ​​the fastening means, i.e., for example, by destroying the clip connections or the fastening points designed as adhesive dots. If the fastening means or the fastening points are designed as adhesive dots, it must be ensured that the material bond between the cover element, i.e., the service cover, and the circuit board is designed in such a way that detaching the cover element from the circuit board results in material damage, i.e., partial destruction of the service cover, which is visible from the outside.To ensure this, for example, the material thickness of the service cover can be selected so that the force required to break the material bond between the circuit board and the cover element is so great that the cover element, i.e. the service cover, is damaged at least in the area of ​​the material bond.

[0009] As previously described, in order to insert or remove fuses from the circuit board during servicing or manipulation, the circuit board must first be removed from inside the charger housing. To remove the circuit board from the housing, the preferably force-fit and / or form-fit connection between the circuit board and the housing, preferably created by a screw-type fastener, must first be released. This is achieved by destroying, i.e., damaging, the cover element in the area of ​​the fastener(s) in order to, for example, use a screwdriver to operate the screws.

[0010] To allow the fasteners to be operated, for example, with a screwdriver, the cover element in the area of ​​the fasteners is advantageously designed, either materially or structurally, so that the cover element can be pierced by a tool, preferably a screwdriver. This can advantageously be achieved by making the cover element from a plastic material and, for example, reducing the wall thickness in the area of ​​the fasteners, i.e., above them, as is known, for example, in junction boxes or canopies for mounting lamps.

[0011] Advantageously, the cover element can already incorporate an access opening to the fasteners. To prevent manipulation of the fasteners located beneath the cover element, the access opening is closed in its undamaged state by a structural element. This structural element must be destroyed or damaged before the fasteners beneath the access opening can be accessed. The structural element can, for example, be a grid, the mesh size of which must be designed to prevent the tool used to access the fasteners. Only by destroying the grid, i.e., by destroying the structural element, preferably with the tool, can the fastener beneath the access opening be accessed.

[0012] Firstly, the access opening created by destroying the structural element is necessary to allow the underlying fastening elements to be operated with a tool. Secondly, the destroyed structural element serves as an indicator to signal tampering or attempted tampering with the charger's fuses. Therefore, in the context of the present invention, the damaged structural element is to be understood as at least partial damage to the cover element.

[0013] Furthermore, the object of the present invention is solved by a service set for replacing at least one fuse for a charger, in particular for the charger according to the invention, which comprises at least one fuse and a cover element, wherein in the event of service the cover element from the service set replaces a cover element damaged during the replacement of the fuse.

[0014] The service set according to the invention ensures that any manipulation of the fuses located under the cover element according to the invention can only be carried out by a person skilled in the art, namely when the service set is only accessible to such persons. Accordingly, the service set according to the invention, which can also be referred to as a spare parts set, is primarily made available only to service partners who, for example, replace a fuse destroyed by a short circuit in the vehicle's on-board charger and who are generally responsible for servicing the charger.

[0015] Finally, the object of the present invention is achieved by a cover element for a charger, in particular for the charger according to the invention and / or as a spare part for the service set according to the invention, which, as a service cover, blocks direct access to fuses of the charger in an undamaged state.

[0016] The cover element advantageously serves as an indicator, showing access to the fuses through at least partial damage to the cover element.

[0017] In order to avoid repetition regarding the advantages of the service set and the cover element according to the invention, reference is made to the description of the advantageous embodiment of the charger for vehicles according to the invention, and full use is made of this description.

[0018] Further measures improving the invention are described in more detail below with reference to the figures and a preferred embodiment of the invention. The features mentioned in the claims and in the description can be essential to the invention individually or in any combination. It should be noted that the figures are for descriptive purposes only and are not intended to limit the invention in any way.

[0019] They show: Fig. 1 a schematic sketch of a cover element for a charger according to the invention or as a spare part for the service set according to the invention in an undamaged state and Fig. 2 the cover element from the Fig. 1 in a damaged condition.

[0020] In the different figures, identical parts are always marked with the same reference symbols, which is why they are usually only described once.

[0021] In Fig. Figure 1 schematically depicts a cover element 1 according to the invention. The cover element 1 serves as a service cover for a charger for vehicles, in particular for motor vehicles designed as electric vehicles or plug-in hybrids. In order to explain the function of the illustrated cover element 1, the structure of the charger must first be explained. The charger comprises a housing into which a circuit board (not shown in the figures) with fuses arranged on it can be inserted. The circuit board arranged inside the housing and the fuses arranged on it are secured by at least one fastening element 2, as shown in Fig. 2 shown via two fastening elements 2, connected to the charger housing (not shown) by means of a force-fit and / or form-fit connection. In addition to the force-fit and / or form-fit connection of the circuit board to the housing via the fastening elements 2, the circuit board is also connected by at least one fastening means 3, which is shown here in Fig. The mounting point 1 is connected to the cover element 1. The mounting element 3 can be a force-fit and / or form-fit connection, for example, a clip connection between the cover element 1 and at least one opening in the circuit board. Alternatively, the mounting element 3 can be an adhesive point, in which case the circuit board and the cover element 1 are bonded together. The adhesive force formed between the circuit board and the cover element 1 via the mounting element 3, which is designed as an adhesive point, must be sufficient so that when the cover element 1 is removed from the circuit board, the cover element 1 is either completely destroyed or at least damaged in the area of ​​the mounting element 3.

[0022] Above the fastening elements 2, an access opening 4, here two parallel access openings 4, is provided in the cover element 1. The access openings 4 are covered by structural elements 5. The structural elements 5 can be configured as shown in Fig. 1. It is depicted in the form of a cross with a central indentation element. In the Fig. In the undamaged state of the cover element 1 shown in Figure 1, namely in the undamaged state of the structural elements 5 that lie above the access openings 4, wherein the access openings 4 and the structural elements 5 arranged above and / or in the access openings 4 are arranged above and preferably at a distance from the fastening elements 2, the structural elements are a central element held by four struts, which can be detached from the struts with a screwdriver by pressing it in with the screwdriver or by levering it off. If, in the event of a service call, the cover element 1, i.e., the service cover, is found in the undamaged state shown, a service technician can assume that no unauthorized manipulation of the circuit board fuses has taken place. If one wants to replace fuses on the circuit board, the circuit board must first be removed from inside the housing, i.e.,to remove the circuit board from inside the charger housing. This requires damaging, i.e., irreversibly destroying, the structural elements 5 in order to access the fastening elements 2 located beneath them, which connect the circuit board to the charger housing by force and / or form. Since the structural elements 5 are firmly connected to the cover element 1, or may be integrally formed with it, the cover element 1 must therefore be damaged, i.e., irreversibly destroyed, at least partially by damaging the structural elements 5 in order to gain access to the fastening elements 2 via the access opening 4.

[0023] Fig.Figure 2 shows a damaged cover element 1, in which the structural elements 5 have been irreversibly destroyed by pressing in or prying out the central element. The destruction of the structural elements 5 exposes the fastening elements 2 located beneath them, in this case, Phillips head screws. The access openings 4 allow the fastening elements 2 to be accessed with a tool, preferably a Phillips head screwdriver, to turn or loosen the screws and decouple the circuit board from the charger housing. Once the screws are loosened, the circuit board, along with the cover element 1, can be pulled out of the charger housing.While it might be possible to replace fuses on the circuit board removed from the charger, the damaged structural elements 5 would indicate that the fuses have been replaced or tampered with, or attempted to be tampered with. Therefore, the cover element 1 according to the invention is doubly secured by the fastening means 3 and the structural elements 5, which close the access opening 4. Regardless of whether the cover element 1 was detached from the circuit board via the fastening means 3, or whether the structural elements 5 were destroyed to detach the fastening means 2, it can be assumed in any case that at least an attempt to tamper with the fuses has occurred. Of course, it is also conceivable that the fastening means 3 also serve to connect the cover element 1, i.e., the service cover, to the inner wall of the charger housing.In such a design of the cover element 1, in order to detach the circuit board from the housing of the charger, firstly the structural elements 5 would have to be destroyed so that the fastening elements 2 located underneath at least at a distance from the cover element 1 could be operated, and secondly the fastening means 3 that connect the cover element 1 to the housing of the charger would have to be removed, i.e. destroyed or damaged, whereby the cover element 1 is preferably irreversibly destroyed at least in the area of ​​the fastening means 3. Reference symbol list 1 cover element 2 fastening elements 3 Fasteners 4 Access opening 5 structural element

Claims

[1] Charger for vehicles, in particular for electric vehicles or plug-in hybrids, comprising a housing, at least one circuit board and fuses arranged on the circuit board, wherein the circuit board with the fuses is arranged inside the housing and is connected to the housing by means of a force-fit and / or form-fit connection via at least one fastening element (2), and a cover element (1) connected to the circuit board via at least one fastening means (3), in particular via a fastening point, which covers the circuit board and the fastening element (2) at least partially, and wherein inserting or removing the fuses on or from the circuit board is only possible by removing the circuit board from inside the housing, characterized by , that in order to remove the circuit board the cover element (1) must be damaged at least in sections, whereby the cover element (1) is to be damaged in the area of ​​the cover of the fastening elements (2). [2] Charger according to claim 1, characterized by , that the cover element (1) is damaged at the fastening means (3). [3] Charger according to any of the preceding claims, characterized by , that reuse of the cover element (1) is precluded by its complete damage. [4] Charger according to any of the preceding claims, characterized by , that the cover element (1) has an access opening (4) in the area of ​​the cover of the fastening element (2), which is closed by a damageable structural element (5) in the undamaged state of the cover element (1). [5] Charger according to claim 4, characterized by , that the structural element (5) must be damaged in order to open the access opening (4). [6] Charger according to claim 4 or 5, characterized by, that the fastening element (2) covered by the cover element (1) can be operated through the opened access opening (4) to release the force-fit and / or form-fit connection between the circuit board and the housing. [7] Service set for replacing at least one fuse in a charger, in particular in a charger according to one of claims 1 to 6, comprising at least one fuse and a cover element (1), wherein in the event of service the cover element (1) from the service set replaces a cover element (1) that is damaged for the replacement of the fuse. [8] Cover element (1) for a charger, in particular for the charger according to one of claims 1 to 6 and / or as a spare part for the service set according to claim 7, which as a service cover in an undamaged state blocks direct access to fuses of the charger. [9] Cover element (1) according to claim 8, which is designed as an indicator that shows access to the fuses by at least partial damage to the cover element (1).

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