Splash-proof charging port housing for an electrically powered vehicle

Abstract

Charging port housing (12) for optionally connecting a charging cable intended for charging an electrically powered motor vehicle, with a lower shell (10) that can be positioned at a charging opening of a motor vehicle body, wherein the lower shell (10) has a socket opening (14) for receiving a plug socket for the charging cable, and an upper shell (18) attached to the lower shell (10), wherein the upper shell (18) has a through-opening (24) for passing the charging cable to the connector socket, characterized by the fact that at least one drain opening (26) is provided for gravity-driven drainage of liquid (28), which is bounded by both the lower shell (10) and the upper shell (18), wherein the drain opening (26) is bounded partly by the lower shell (10) and partly by the upper shell (18), wherein a space for receiving components (20) in the form of electrically connected current-carrying conductors is formed between the lower shell (10) and the upper shell (18), wherein the at least one drain opening (26) communicates with the space.

Description

[0001] The invention relates to a charging port housing for an electrically powered motor vehicle, through which a charging cable can be connected and which cost-effectively protects electrical components against dust and splashing water.

[0002] From EP 2 899 048 A1 a charging port housing for an electrically powered motor vehicle is known, in which a lower floor in the Z direction slopes towards the center of the vehicle, in which collection pockets spaced apart from each other are formed over a ridge of the lower floor projecting upwards in the Z direction, in each of which a drainage opening for the removal of splash water is provided in the center.

[0003] From DE 10 2016 206 002 A1 it is known to mount a charging socket for charging an electrically powered motor vehicle in a suspension of a pot unit attached to an outer skin of the motor vehicle, wherein the pot unit is inserted in an opening of the outer skin and can be closed with a flap.

[0004] From DE 10 2012 102 419 A1, a charging device for charging an electrically powered motor vehicle is known, in which a charging socket is attached in an opening of an adapter device, which in turn is mounted with a charging cradle attached to an outer surface of the motor vehicle. A reinforcing element has an opening and the adapter device has a recess adjoining the opening, through which a hose for draining the charging cradle is passed.

[0005] DE 10 2008 020 538 A1 discloses a fuel filler neck housing in the form of a fuel filler flap module housing for the optional insertion of a fuel nozzle intended for refueling a motor vehicle. The fuel filler neck housing has a lower shell that can be indirectly positioned on a fuel tank opening of a motor vehicle body and which has a nozzle opening for receiving a nozzle for the fuel nozzle. An upper shell is bonded to the lower shell and has a through-opening for inserting the fuel nozzle into the filler neck. A drain opening for the gravity-driven removal of liquid in the form of water or fuel is partially bordered by both the lower and upper shells.

[0006] From DE 10 2013 222 686 A1 a two-part flap module for a motor vehicle, having a drainage edge for liquids, is known, which can be used for a filling nozzle of a fuel nozzle but also for a charging plug of a charging cable.

[0007] There is a constant need to protect the electrical components of a motor vehicle against dust and splashing water in a cost-effective manner.

[0008] The object of the invention is to demonstrate measures that enable cost-effective protection of electrical components of a motor vehicle against dust and splashing water.

[0009] The problem is solved according to the invention by a charging port housing with the features of claim 1. Preferred embodiments of the invention are specified in the dependent claims and the following description, each of which can individually or in combination represent an aspect of the invention.

[0010] One embodiment relates to a charging port housing for optionally connecting a charging cable intended for charging an electrically powered motor vehicle, comprising a lower shell that can be positioned at a charging port of a motor vehicle body, wherein the lower shell has a socket opening for receiving a plug socket for the charging cable, and an upper shell attached to the lower shell, wherein the upper shell has a through-opening for guiding the charging cable to the plug socket, wherein at least one drain opening is provided for gravity-driven drainage of liquid, bounded in part by the lower shell and in part by the upper shell, wherein a space is formed between the lower shell and the upper shell for receiving components in the form of current-carrying conductors electrically connected to the plug socket.where at least one drainage opening communicates with the space between.

[0011] The lower and / or upper shell of the charging port housing already provides sufficient protection against contact with electrical components that would otherwise be accessible when connecting the charging cable to the socket. The upper shell can also keep a significant amount of splashing water and / or rainwater away from the electrical components.If water should nevertheless enter the charging port housing through the opening in the upper shell, particularly during a period when the opening is open due to a charging cover but the charging cable is not yet plugged into the socket, the water can be channeled away from electrical components in a space maintained between the lower and upper shells. This channeling is achieved through a suitable three-dimensional geometry of the opposing surfaces of the lower and upper shells, and under the influence of gravity, it will eventually reach the at least one drain opening and be discharged, particularly to the surrounding environment. For example, the lower and / or upper shell can have ribs projecting into the space, which block contact between splashing water and electrical components and preferably deflect and / or drip off the splashing water arriving at these ribs towards the drain opening.

[0012] The lower and upper shells are primarily made of a plastic material, allowing for easy production of their three-dimensional shapes using injection molding. Since the drain opening is not designed as an opening solely in the lower shell or a separate opening in the upper shell, but rather is partially bounded by the lower shell and partially by the upper shell, it is unnecessary to create the drain opening with a core during injection molding or subsequently through machining. Instead, the drain opening can be provided by appropriately shaping an edge region of the lower and / or upper shell, so that the drain opening automatically forms as a recess between the lower and upper shells when the charging port housing is assembled.By forming the drainage opening as a recess between the lower shell and the upper shell of the charging port housing, a cost-effective drainage system can be created for splash water entering through the through-opening, thus enabling cost-effective protection of electrical components of a motor vehicle against dust and splash water.

[0013] The socket, into which a charging cable plug can be inserted, can be mounted in the opening of the lower shell. The socket can be positioned at a distance from the opening in the upper shell, as well as from any charging cover that may be provided to close the opening, towards the center of the vehicle. This allows splash water and / or rainwater to enter a gap between the lower and upper shells, specifically in the area of ​​the opening, and into a space formed between the two shells. The opening is dimensioned such that a charging cable plug can be inserted through the opening into the socket.Even when the charging cable is plugged in, a gap remains between the cable (or its connector) and the inner edge of the through-hole. This gap allows dust and splashing water to enter and drain away through the drain opening. Since the drainage of splashing water is gravity-driven, no external conveying system is required. The drain opening can be positioned at a low point (in the direction of gravity) to direct any splashing water that has entered the space between the lower and upper shells. In particular, the upper shell, apart from the through-hole provided in it, can largely or even completely cover the lower shell.

[0014] The charging port housing, through its upper shell which is connected to the lower shell in a liquid-tight manner (except for at least one drainage opening), can provide a protection rating of IP54 according to ISO 20653:2013. Specifically, all drainage openings are exclusively limited by the lower and upper shells. Therefore, no additional components are required to dissipate splashing water. Instead, the at least one drainage opening can be integrated into the housing as an integral part of the charging port housing.

[0015] Electrical components are provided in the space between the socket and the charging cable that interact electrically with the socket and / or the charging cable. For example, a protective conductor electrically coupled to the socket is provided in the space to offer additional protection against electric shock. Additionally or alternatively, an electrically powered sensor can be provided in the space, which can, for example, indicate charging readiness via a warning light and / or detect relevant measurements at the interface between the socket and the charging cable. Any water that enters the space is kept away from the electrical components by gravity and drained away through at least one opening that communicates with the space.

[0016] Preferably, an edge piece forming the edge of the drain opening, spaced particularly in the Z-direction from the drain opening, forms a drain ramp that is beveled in the Z-direction and leads away from the drain opening. This allows the splash water to first be guided out of the gap via the drain opening and then, outside the gap, away from the vehicle's center via the drain ramp to an outer surface of the vehicle body in which the charging port housing can be installed. The splash water can, in particular, be directed to an inner surface of the vehicle body and drip down the inside of the vehicle body into the surrounding environment. This eliminates the need to provide a defined path inside the vehicle for the splash water to be drained from the charging port housing.The edge piece is formed integrally with the lower shell, thus enabling a small number of components. The edge piece can, in particular, have a tab projecting downwards from the edge of the drain opening, essentially in the Z-direction, from which the drain ramp can project downwards at an angle, spaced away from the drain opening in the Z-direction. Specifically, the upper shell, apart from the through-opening provided in the upper shell and the edge piece projecting from the drain opening, can cover a large part or even the entire lower shell.

[0017] The X-direction refers to a coordinate direction along a longitudinal axis of a motor vehicle when the charging port housing is installed in the vehicle. The X-direction is essentially horizontal when the vehicle is parked on a level, horizontal surface. The Y-direction refers to a coordinate direction along a transverse axis of a motor vehicle when the charging port housing is installed in the vehicle. The Y-direction is essentially horizontal when the vehicle is parked on a level, horizontal surface. The Z-direction refers to a coordinate direction along a vertical axis of a motor vehicle when the charging port housing is installed in the vehicle. The Z-direction is essentially vertical when the vehicle is parked on a level, horizontal surface.The X-direction, the Y-direction, and the Z-direction are orthogonally aligned with each other.

[0018] Particularly preferably, at least one rib is provided extending upwards from the drain ramp with a portion in the Z-direction. This at least one rib is preferably formed integrally with the edge piece. The at least one rib preferably extends from both the tab of the edge piece and the drain ramp, with the rib bearing continuously and thus liquid-tight against both the tab and the drain ramp along its entire length. The rib, formed integrally with the lower shell, for example, can rest at its free end pointing away from the lower shell against the edge of the drain opening formed by the upper shell.

[0019] In particular, the at least one rib forms a side wall that defines a flow cross-section and / or a stabilizing rib spaced from an edge of the discharge ramp, thereby stiffening the discharge ramp. The discharge ramp can thus be part of, for example, a U-shaped discharge channel. Furthermore, the discharge ramp is torsionally stiffened by the at least one rib.

[0020] Preferably, the at least one rib forms a drainage ramp for liquid runoff when the charging port housing is tilted relative to the direction of gravity. This allows the vehicle, into which the charging port housing can be installed, to be parked not necessarily on a horizontal surface, but rather at an angle to the horizontal. The at least one rib creates a V-shaped drainage channel between the drainage ramp and the rib, preventing splash water discharged through the drain opening from immediately running down the sides of the ramp after passing through it. This ensures that the splash water drips off the upper shell even when the vehicle is tilted relative to the horizontal.

[0021] Particularly preferred are at least two drainage openings spaced apart from each other in one direction transverse to the Z-direction. Regardless of the direction in which the vehicle is inclined relative to the horizontal with the charging port housing, the splash water from the space between the lower shell and the upper shell can be drained away via one of the drainage openings.

[0022] In particular, at least one drain opening is arranged in a corner of the gap, with the drain opening being positioned at the lowest point of the gap in the direction of gravity when the charging port housing is tilted relative to gravity. When the vehicle is tilted, the corner of the gap can act like a funnel, directing any splash water arriving in that corner to the corresponding drain opening. This ensures that virtually any angle of the vehicle relative to the horizontal allows all splash water entering the gap to be drained away.

[0023] Preferably, a charging flap is provided that pivots between a closed and an open position. The charging flap is hinged to the lower shell and, in the closed position, seals the through-opening of the upper shell, particularly in a liquid-tight manner. If no charging cable is connected to the connector socket, the through-opening can be sealed by the charging flap, thus preventing unnecessary ingress of splashing water and dust. The charging flap can be hinged to the lower shell through the upper shell and / or through a U-shaped recess in the upper shell. Since the socket opening of the lower shell must already accommodate and mechanically support the connector socket, the lower shell is designed to be sufficiently robust to also withstand the hinge forces and weight of the charging flap.This allows the upper shell to be designed for lower loads and, for example, to be manufactured more cost-effectively due to a reduced material thickness.

[0024] Another embodiment relates to an electrically powered motor vehicle comprising an electric machine for propelling the motor vehicle, a rechargeable traction battery connected to the electric machine for storing and supplying electrical energy, a plug socket connected to the traction battery for charging the traction battery with external electrical energy, a motor vehicle body and a charging port housing provided at a charging opening of the motor vehicle body, which can be designed and further developed as described above, wherein the plug socket is attached in the socket opening of the lower shell.By forming the drainage opening as a recess between the lower shell and the upper shell of the charging port housing, a cost-effective drainage system can be created for splash water entering through the through-opening, thus enabling cost-effective protection of electrical components of a motor vehicle against dust and splash water.

[0025] The invention is explained below by way of example with reference to the accompanying drawings and preferred embodiments, wherein the features shown below can represent an aspect of the invention, either individually or in combination. The drawings show: Fig. 1: A schematic top view of a partially cut-away charging port housing, Fig. 2: a schematic top view of the charging port housing made of Fig. 1 in a first tilting position, Fig. 3: a schematic top view of the charging port housing made of Fig. 1 in a second tilting position and Fig. 4: A schematic detail view of the charging port housing made of Fig. 1.

[0026] The in Fig. The lower shell 10 of a charging port housing 12, as shown in Figure 1, can be provided at a charging port in the body of an electrically powered vehicle, allowing a plug of a charging cable connected to an external power source to be connected through the vehicle body to a socket in the vehicle to charge a traction battery connected to an electric motor for powering the vehicle. The lower shell 10 has a socket opening 14 in which the socket can be provided and connected to the lower shell 10. Furthermore, at least one hinge element 16 can be provided on the lower shell 10, to which a charging flap can be pivotally attached. The forces and weight forces occurring when the charging flap is actuated can be supported by the hinge element 16 on the lower shell 10.

[0027] The lower shell 10 can be attached to an upper shell 18, creating a hollow space between the lower shell 10 and the upper shell 18, in which, for example, an electrical component 20 can be provided. The electrical component 20 can be, for example, a grounding conductor, particularly one that is grounded and / or floating, which can be connected at one end to the connector socket and at the other end to, in particular, the metallic vehicle body. The lower shell 10 can be connected to the upper shell 18 by means of fasteners 22, for example, screw connections, particularly in a common flange area.

[0028] As in Fig. As shown in Figure 2, the upper shell 18 can cover at least one electrical component 20. The upper shell 18 has a through-opening 24, which can be closed by the charging flap, through which a plug of the charging cable can be connected to the plug socket in the socket opening 14 of the lower shell 10. However, this also makes the space formed between the lower shell 10 and the upper shell 18 accessible to splash water. For this purpose, at least one drain opening 26 is provided in each of the lower corner areas of the space, through which liquid 28 accumulating in the space can be drained. Due to the arrangement in the corner areas, the respective drain opening 26 can also be opened when the vehicle and the charging port housing 12 are tilted in a first tilting direction, as shown in Figure 2. Fig. 2 shown, or in the event of a tilting position of the motor vehicle and the charging port housing 12 in a second tilting direction opposite to the first tilting direction, as shown in Fig. 2 shown, positioned at the lowest point in the direction of gravity.

[0029] As in Fig.As shown in Figure 4, the respective drain opening 26 is bounded exclusively by the lower shell 10 and the upper shell 18. The lower shell 10 has a downwardly projecting edge piece 30 in the Z-direction, which has a tab 32 projecting from the drain opening 26 in the Z-direction and a drain ramp 34 projecting from the lower free end of the tab 32 at an angle to the Z-direction. First ribs 36 and second ribs 38 are connected to both the tab 32 and the drain ramp 34. The first ribs 36 are located on a lateral edge of the drain ramp 34 and prevent the liquid 28 from dripping laterally from the drain ramp 34. The drain ramp 34 and the lateral first ribs 36 can form a U-shaped drain channel for removing the liquid 28 exiting the drain opening 26.The second ribs 38 extend into the drain opening 26 and can bear against the upper shell 18 with sufficient pressure to provide a sealing force and reinforce the edge piece 30 torsionally. In a tilted position, the ribs 36, 38 can also act like a drain ramp and, together with the drain ramp 34, form a V-shaped drain channel.

Claims

[1] Charging port housing (12) for optionally connecting a charging cable intended for charging an electrically powered motor vehicle, with a lower shell (10) that can be positioned at a charging opening of a motor vehicle body, wherein the lower shell (10) has a socket opening (14) for receiving a plug socket for the charging cable, and an upper shell (18) attached to the lower shell (10), wherein the upper shell (18) has a through-opening (24) for passing the charging cable to the connector socket, characterized by , that at least one drain opening (26) is provided for gravity-driven drainage of liquid (28), which is bounded by both the lower shell (10) and the upper shell (18), wherein the drain opening (26) is bounded partly by the lower shell (10) and partly by the upper shell (18), wherein a space for receiving components (20) in the form of electrically connected current-carrying conductors is formed between the lower shell (10) and the upper shell (18), wherein the at least one drain opening (26) communicates with the space. [2] Charging port housing (12) according to claim 1 characterized by , that an electrical component (20) is provided in the space which is a protective conductor electrically coupled to the plug socket in order to provide additional protection against contact, and / or an electrical component (20) is provided in the space which is a sensor supplied with electrical energy. [3] Charging port housing (12) according to claim 1 or 2 characterized by, that an edge piece (30) forming an edge of the drain opening (26), in particular spaced apart in the Z direction from the drain opening (26), forms a drain ramp (34) which is beveled in the Z direction and leads away from the drain opening (26). [4] Charging port housing (12) according to claim 3 characterized by , that at least one rib (36, 38) is provided from the discharge ramp (34) with a portion projecting upwards in the Z-direction. [5] Charging port housing (12) according to claim 4 characterized by , that the at least one rib (36, 38) forms a side wall (36) limiting a flow cross-section and / or a stabilizing rib (38) spaced apart from an edge of the discharge ramp (34), in particular stiffening the discharge ramp (34). [6] Charging port housing (12) according to claim 4 or 5 characterized by, that the at least one rib (36, 38) forms a drainage ramp for the removal of liquid (28) when the charging port housing (12) is inclined to the direction of gravity. [7] Charging port housing (12) according to one of claims 1 to 6 characterized by , that at least two drainage openings (26) are formed that are spaced apart from each other in one direction transverse to the Z-direction. [8] Charging port housing (12) according to one of claims 1 to 7 characterized by , that the at least one drain opening (26) is arranged in a corner area of ​​the space, wherein the drain opening (26) is positioned at a point in the space that is lowest in the direction of gravity when the charging port housing (12) is inclined to the direction of gravity. [9] Charging port housing (12) according to any one of claims 1 to 8 characterized by, that a loading flap is provided which can pivot between a closed position and an open position, wherein the loading flap is hinged to the lower shell (10) and in the closed position closes the passage opening (24) of the upper shell (18), in particular in a liquid-tight manner. [10] Electrically powered motor vehicle comprising an electric machine for propelling the motor vehicle, a rechargeable traction battery connected to the electric machine for storing and supplying electrical energy, a plug socket connected to the traction battery for charging the traction battery with external electrical energy, a motor vehicle body and a charging port housing (12) provided at a charging opening of the motor vehicle body according to one of claims 1 to 9, wherein the plug socket is attached in the socket opening (14) of the lower shell (10).

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