Charging connectors for electric and hybrid vehicles

Abstract

The invention relates to a charging connector (1) for electric and hybrid vehicles (2), comprising a housing (3), charging contacts (4) arranged in the housing (3) which can be contacted through an opening (5) of the housing (3) with corresponding charging contacts (6) of a corresponding charging connector (7), a movable, galvanically insulating cover (8) which, in a closed position, closes the opening (5) and, in an open position, releases the opening (5) for contact with the corresponding charging contacts (6), and a spring (9) connected to the cover (8), wherein the cover (8) and the spring (9) are designed and arranged such that, when the charging connector (1) is plugged together with the corresponding charging connector (7), the cover (8) is displaced by the corresponding charging connector (7) in the plugging direction, thereby compressing the spring (9).

Description

[0001] The invention relates to a charging connector for electric and hybrid vehicles with a housing and charging contacts arranged in the housing, which can be contacted with corresponding charging contacts of a corresponding charging connector through an opening in the housing.

[0002] Electric and hybrid vehicles have a rechargeable energy storage device, usually a high-voltage battery, which supplies energy to an electric drive motor when the vehicle is in operation. The storage capacity of these high-voltage batteries is limited, so they must be recharged regularly at a charging station. The battery is charged via a charging cable provided between the charging station and the vehicle. The charging cable, for example, in accordance with the European standard IEC 62196 Type 2, is equipped with a charging plug on one end that can be plugged into a charging socket provided on the charging station, and a charging coupling on the other end that can be connected to a charging plug installed in the electric or hybrid vehicle. For the purposes of this article, charging sockets, charging plugs, charging couplings and charging plugs are all referred to as “charging connectors”.Charging sockets and charging couplings have contact sleeves as charging contacts, and charging plugs as well as charging plugs that can be installed in electric and hybrid vehicles have contact pins as charging contacts that can be inserted into the contact sleeves.

[0003] Charging connectors in general can be provided with a cover to prevent contaminants such as dirt and liquids from the environment from entering the charging connector. Due to the exposed position in which the vehicle-side charging connector in particular is located, such covers are of increased importance for maintaining the functionality of the charging connector. This applies even more to the DC charging contacts, which are intended for DC charging on the vehicle side. Here, it is particularly important to exclude external environmental influences from interacting with the DC charging contacts as far as possible. Any contamination will undoubtedly increase the resistance when plugged into the corresponding charging connector. Corrosion and dirt particles increase the charging resistance, which in turn causes an increase in temperature in the charging connector and thus a reduction in the charging current.The charging process takes longer the more contaminants are introduced. Therefore, it is especially important to protect the DC charging contacts of the charging connector during AC charging to prevent environmental contaminants from entering the area of ​​the DC charging contacts.

[0004] One such case is a charging connector connected to a charging cable for AC charging according to the European standard IEC 62196 Type 2. Such a charging connector can be plugged into a charging connector installed in the body of an electric or hybrid vehicle and suitable for both AC and DC charging. The AC connector face of the AC charging connector contains the communication contacts, the protective contact, and the contacts for the outer conductor and a center conductor for AC charging. However, this AC charging connector does not have any DC charging contacts for DC charging, so the DC charging contacts of the charging connector are freely accessible to external environmental influences.

[0005] An outer conductor (also colloquially referred to as a phase conductor) is a conductor that is live during normal operation and can contribute to the transmission or distribution of electrical energy, but is not a neutral conductor. A neutral conductor is a conductor that is electrically connected to the neutral point and is capable of contributing to the distribution of electrical energy. In the European standard IEC 62196 Type 2, the contacts, which are referred to here as AC charging contacts, are designated L1, L2 and L3 (outer conductor) and N (neutral conductor), and the DC charging contacts are designated DC+ and DC. This understanding should not be contradicted by the fact that the European standard IEC 62196 Type 2 also recognizes an operating mode according to which direct current charging takes place via contacts L1, L2, L3 and N.

[0006] At the same time, there is a general drive toward increased automation in vehicle technology, particularly with regard to autonomous charging processes. Manually removable covers designed to prevent the entry of contaminants run counter to this fundamental drive toward automation. They block the charging contacts and must be removed manually to expose the corresponding charging contacts.

[0007] DE 10 2018 200 596 A1 shows a control device for an electric vehicle comprising a locking device which is configured to block and / or permit insertion of a first plug into a first plug opening and / or unplugging of the first plug from the first plug opening by means of a locking device, a flap control device which is configured to open and / or close a second plug opening by means of at least one flap, and a control circuit which is designed such that control by means of the control circuit effects operation of both the locking device and the flap control device.

[0008] According to DE 10 2022 109 654 A1, a charging inlet for an electric vehicle is provided, comprising a body defining an opening having a conductive terminal disposed therein. A sealing cover is pivotally mounted on the body and is movable between an open position, in which the opening and the conductive terminal are exposed, and a closed position, in which the opening and the conductive terminal are sealed from an external environment. A sealing element of the cover defines a sealing plug, which includes an angled sealing rib defined around an outer periphery thereof. The sealing plug and the sealing rib are configured to engage the opening of the inlet body to seal the opening with the cover in the closed position.

[0009] DE 10 2017 209 444 A1 describes a charging interface for a vehicle. The charging interface comprises a housing with a front side. Furthermore, the charging interface comprises at least two power contact parts arranged on the front side of the housing, via which electrical energy can be transmitted to charge an electrical energy storage device of the vehicle. The charging interface further comprises a channel-shaped opening extending from the front side of the housing into the interior of the housing, as well as a pin movably arranged in the opening, which pin can be moved from a base position into a second position by a force coming from the front side. Furthermore, the charging interface comprises at least one means for determining position information that indicates whether the pin is in the base position or in the second position.Furthermore, the charging interface comprises a control unit which is configured to determine an operating state of the charging interface on the basis of the position information.

[0010] Based on this, the object of the present invention is to provide a charging connector for electric and hybrid vehicles that is well suited for automated autonomous charging processes.

[0011] This object is achieved by the subject matter of the independent claims. Preferred developments of the invention are described in the subclaims.

[0012] According to the invention, a charging connector for electric and hybrid vehicles is provided with a housing, charging contacts arranged in the housing, which can be contacted through an opening in the housing with corresponding charging contacts of a corresponding charging connector, a movable, galvanically insulating cover which closes the opening in a closed position and releases the opening in an open position for contact with the corresponding charging contacts, and a spring connected to the cover, wherein the cover and the spring are designed and arranged such that when the charging plug connector is plugged together with the corresponding charging plug connector, the cover is displaced by the corresponding charging plug connector in the plugging direction, whereby the spring is compressed and the cover is transferred from the closed position to the open position, so that the charging contacts are released and can thus be contacted with the corresponding charging contacts of the corresponding charging plug connector.

[0013] To ensure that the charging connectors can be plugged together, the charging contacts extend, as usual, in the plug-in direction. Incidentally, when reference is made here to a corresponding charging connector, this refers, on the one hand, to a charging connector that has the same plug-in face as the charging connector according to the invention, whereby one plug-in face has contact pins while the other plug-in face has contact sleeves, and vice versa. The set comprising the charging connector according to the invention and the corresponding charging connector can therefore be plugged together.

[0014] On the other hand, in the present case, a corresponding charging connector is also referred to when the plug faces in the aforementioned sense only partially correspond, i.e. the corresponding charging connector, for example, does not have all the contacts that are present in the charging connector according to the invention, but the existing contacts of the corresponding charging connector correspond to the charging connector according to the invention in terms of the plug face, so that the charging connector according to the invention and the corresponding charging connector can also be plugged together in this case.

[0015] In principle, it is possible for the cover to be completely closed, at least when closed. However, according to a preferred development of the invention, the cover is provided with openings whose outer circumference corresponds to the outer circumference of a respective charging contact, and the charging contacts protrude through the openings when the charging connectors are plugged together. If it is stated here that the cover is provided with openings whose outer circumference corresponds to the outer circumference of a respective charging contact, this does not mean, of course, that the outer circumferences are exactly the same size. Rather, it means that the outer circumferences are dimensioned such that the cover can move along the longitudinal axes of the charging contacts and yet a certain degree of sealing can still be achieved between the charging contacts and the cover.

[0016] With regard to such a seal, a direct seal can in principle be provided between the cover and a respective charging contact. According to a preferred development of the invention, however, the cover is provided with a sealing element in each of its openings, which seals off the respective charging contact. Additionally or alternatively, according to a preferred embodiment of the invention, the cover is provided on its outer circumference with a sealing element, which seals off a wall of the housing surrounding the charging contacts. The sealing elements are preferably designed as O-ring seals. In this way, the penetration of moisture and dirt into the area behind the cover can be effectively counteracted.In the event that moisture should nevertheless penetrate into this area, according to a preferred development of the invention, a wall of the housing surrounding the charging contacts is provided with a water drainage opening in order to be able to drain the moisture away again.

[0017] The spring can be used to move the cover in various ways. Preferably, however, the spring presses against the cover with one end and against a housing wall with its other end, which acts as a counterforce for the spring to move the cover toward a corresponding charging connector to be plugged in. The spring can be applied directly to the cover or the housing wall, or indirectly, i.e., via an intermediate element.

[0018] According to a further preferred embodiment of the invention, the charging contacts are provided with galvanic insulation at their front end regions, and the cover is pushed forward by the spring when the charging connectors are not plugged together, so that the charging contacts are completely protected against contact, both by their galvanic insulation in their end regions and by the galvanically isolating cover. In this embodiment, the charging contacts can only be galvanically contacted outside their galvanically insulated end regions, where they pose a danger if touched by a person. However, since this area is inaccessible due to the cover when the charging connectors are not plugged together, any danger due to people touching live surfaces is avoided.

[0019] In this context, it is particularly preferred that the front end region be defined by a region running perpendicular to the plug-in direction. This achieves a maximum area of ​​the charging contacts that can be used for contacting the corresponding charging contacts without the risk of a person touching live surfaces. When the charging connectors are not connected, they are completely protected from external contact by the insulated end regions of the charging contacts on the one hand and the galvanically insulating cover on the other. Preferably, the cover and the galvanic insulation of the end regions of the charging contacts are made of a plastic material.

[0020] The invention also relates to a system comprising a charging connector as described above and a charging connector corresponding thereto, wherein the corresponding charging connector has charging contacts corresponding to the charging contacts of the charging connector, which are surrounded by housing walls which press on the cover when the charging connectors are plugged together, so that the cover is displaced in the plugging direction, whereby the spring is compressed.

[0021] Furthermore, according to a preferred development of the invention, it is provided that the charging connector is a charging plug and the corresponding charging connector is a charging coupling.

[0022] Finally, the invention also relates to the use of a previously described charging connector or a previously described system on the vehicle body of an electric or hybrid vehicle.

[0023] The invention is described in more detail below with reference to the drawings using preferred embodiments.

[0024] The drawings show Fig. 1 shows a charging connector in the form of a charging plug according to a preferred embodiment of the invention in a perspective view, wherein no cover is shown here, Fig. 2 a corresponding charging connector in the form of a charging coupling for direct current charging according to a preferred embodiment of the invention in a perspective view, Fig. 3 schematically shows a sectional view of a portion of a charging connector according to a preferred embodiment of the invention and Fig. 4 the use of a charging connector according to a preferred embodiment of the invention on the body of an electric vehicle.

[0025] Out of Fig. 1 shows a perspective view of a charging connector 1 according to a preferred embodiment of the invention. The charging connector 1 is a charging plug, which, as shown in Fig. 4, for example, can be installed on the body 19 of an electric vehicle 2. For the sake of clarity, Fig. 1 no cover is shown yet. A representation of the cover will follow in Fig. 3.

[0026] The Fig. 1 shows a charging connector 1 according to the preferred embodiment of the invention, comprising a housing 3 and charging contacts 4 arranged in the housing 3, which can be contacted through an opening 5 of the housing 3 with corresponding charging contacts 6 of a corresponding charging connector 7. Such a corresponding charging connector 7 is made of Fig. 2. This is a charging connector for direct current charging with two corresponding charging contacts 6 and housing walls 17 surrounding each charging contact 6. The charging contacts 4 of the charging connector 1 are contact pins, as is usual for a plug, while the charging contacts 6 of the corresponding charging connector 7 are contact sleeves, as is usual for connectors.

[0027] What is now decisive is how Fig.3, which schematically shows in a sectional view a portion of a charging plug connector 1 according to a preferred embodiment of the invention, that the charging plug connector 1 according to the preferred embodiment of the invention has a movable, galvanically insulating cover 8. This movable, galvanically insulating cover 8 closes the opening 5 in a closed position and releases the opening 5 in an open position for contact with the corresponding charging contacts 6. For this purpose, a spring 9 is connected to the cover 8, which presses with one end against the cover 8 and with its other end against a wall 14 of the housing 3 running parallel to the cover 8, which wall thus acts as an abutment for the spring 9.

[0028] Specifically, the cover 8 and the spring 9 are designed such that when the charging connector 1 is plugged together with the corresponding charging connector 7, the cover 8 is displaced by the corresponding charging connector 7 in the plugging direction, thereby compressing the spring 9. For this purpose, the corresponding charging connector 7 has charging contacts 6 corresponding to the charging contacts 4 of the charging connector 1, which are surrounded by housing walls 17. When the charging connectors 1, 7 are plugged together, these walls press against the cover 8, causing it to be displaced in the plugging direction, resulting in the compression of the spring 9.

[0029] To achieve effective contact protection, the charging contacts 4 are provided with galvanic insulation 16 made of a plastic material at their front end regions 15. The front end region 15 of each charging contact is formed by a region of each charging contact 4 running perpendicular to the plug-in direction, which means that only the forward-facing surface of each charging contact 4 is galvanically insulated, but not the perpendicular side surfaces of the charging contacts 4, so that the side surfaces are completely available for contacting the corresponding charging contacts 6 of the corresponding charging connector 6.

[0030] In addition, the cover 8 is pushed forward by the spring 9 when the charging connectors 1, 7 are not connected together, so far that the charging contacts 4, due to their galvanic insulation 16 in their front end regions 15, and the galvanically insulating cover 8 are not accessible from outside the charging connector 1. This prevents an operator from accidentally coming into contact with the live charging contacts 4 when handling the charging connector 1.

[0031] In accordance with the preferred embodiment of the invention described here, the charging contacts 4 of the charging connector 1 are released in that the cover 8 is provided with openings 10, the outer circumference of which corresponds to the outer circumference of a respective charging contact 4, and the charging contacts 4 protrude through the openings 10 when the charging connectors 1, 7 are plugged together. Thus, when the two charging connectors 1, 7 are plugged together, the cover 8 is practically displaced along the charging contacts 4, so that they become accessible from the side of the corresponding charging connector 7.

[0032] To achieve the best possible protection of the charging contacts 4 of the charging connector 1 against moisture and dirt when covered by the cover 8, a sealing element 11 is arranged in each of the openings 10 of the cover 8, which seals off the respective charging contact 4 assigned to the corresponding opening 10. Furthermore, the cover 8 has a sealing element 12 on its outer circumference, which seals off a wall 18 of the housing 3 surrounding the charging contacts 4. In this case, the sealing elements 11, 12 are designed as O-ring seals made of a rubber material.

[0033] In the event that moisture nevertheless gets behind the cover 8, a wall 18 of the housing 3 surrounding the charging contacts 4 is provided with a water drainage opening 13.

[0034] As already explained above, there is a general effort toward increased automation in vehicle technology, particularly with regard to autonomous charging processes. According to the invention, manually removable covers intended to prevent the entry of contaminants are now avoided. Instead, a charging connector 1 for electric and hybrid vehicles 2 is provided, which is excellently suited for automated autonomous charging processes, since the cover 8 is automatically moved when the charging connectors 1, 7 are plugged together, so that the charging contacts 4 can be contacted by the corresponding charging contacts 6. List of reference symbols 1 charging connector 2 electric or hybrid vehicles 3 housings 4 charging contacts 5 Opening in the housing 6 corresponding charging contacts 7 corresponding charging connector 8 Cover 9 spring 10 openings in the cover 11 Sealing elements in the openings of the cover 12 Sealing element on the outer circumference of the cover 13 Water drain opening 14 wall of the housing acting as abutment 15 front end areas 16 galvanic insulation 17 corresponding charging contacts surrounding housing walls 18 wall of the housing surrounding the charging contacts 19 Vehicle body QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] DE 10 2018 200 596 A1

[0007] DE 10 2022 109 654 A1

[0008] DE 10 2017 209 444 A1

[0009]

Claims

[1] Charging connector (1) for electric and hybrid vehicles (2), with a housing (3), charging contacts (4) arranged in the housing (3), which can be contacted through an opening (5) in the housing (3) with corresponding charging contacts (6) of a corresponding charging connector (7), a movable, galvanically insulating cover (8) which closes the opening (5) in a closed position and releases the opening (5) in an open position for contacting the charging contacts (4) with the corresponding charging contacts (6), and a spring (9) connected to the cover (8), wherein the cover (8) and the spring (9) are designed and arranged in such a way that when the charging plug connector (1) is plugged together with the corresponding charging plug connector (7), the cover (8) is displaced by the corresponding charging plug connector (7) in the plugging direction, whereby the spring (9) is compressed and the cover (8) is transferred from the closed position to the open position, so that the charging contacts (4) are released and can thus be contacted with the corresponding charging contacts (6) of the corresponding charging plug connector (7). [2] Charging connector according to claim 1, wherein the cover (8) is provided with openings (10) whose outer circumference corresponds to the outer circumference of a respective charging contact (4), and the charging contacts (4) protrude through the openings (10) when the charging connectors (1, 7) are plugged together. [3] Charging connector (1) according to claim 2, wherein the cover (8) is provided in its openings (10) with a sealing element (11) each, which effects a seal with respect to the respective charging contact (4) associated with the corresponding opening (10). [4] Charging connector (1) according to claim 2 or 3, wherein the cover (8) is provided on its outer circumference with a sealing element (12) which effects a seal with respect to a wall (18) of the housing (3) surrounding the charging contacts (4). [5] Charging connector (1) according to claim 3 or 4, wherein the sealing elements (11, 12) are designed as O-ring seals. [6] Charging connector (1) according to one of the preceding claims, wherein a wall (18) of the housing (3) surrounding the charging contacts (4) is provided with a water drainage opening (13). [7] Charging connector (1) according to one of the preceding claims, wherein the spring (9) presses with one end against the cover (8) and with its other end against a wall (14) of the housing (3), which thus acts as an abutment for the spring (9). [8] Charging plug connector (1) according to one of the preceding claims, wherein the charging contacts (4) are provided with galvanic insulation (16) at their front end regions (15), and the cover (8) is pressed forward by the spring (9) in the unplugged state of the charging plug connectors (1, 7) so far that complete contact protection is provided for the charging contacts (4) by their galvanic insulation (16) in their front end regions (15) and the galvanically insulating cover (8). [9] Charging connector (1) according to claim 8, wherein the front end region (15) is defined by a region of a respective charging contact (4) extending perpendicular to the plugging direction. [10] Charging connector (1) according to claim 8 or 9, wherein the cover (8) and the galvanic insulation (16) of the front end regions (15) of the charging contacts (4) are made of a plastic material. [11] Charging connector (1) according to one of the preceding claims, wherein the charging connector (1) is a charging plug and the corresponding charging connector (7) is a charging coupling. [12] System comprising a charging connector (1) according to one of claims 1 to 11 and a charging connector (7) corresponding thereto, wherein the corresponding charging connector (7) has charging contacts (6) corresponding to the charging contacts (4) of the charging connector (1), which are surrounded by housing walls (17) which, when the charging connectors (1, 7) are plugged together, press on the cover (8) so that the cover is displaced in the plugging direction, whereby the spring (9) is compressed. [13] Use of a charging connector (1) according to one of claims 1 to 11 or a system according to claim 12 on the vehicle body (19) of an electric or hybrid vehicle (2).

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