High-performance charging socket and charging socket kit with such a high-performance charging socket
Patent Information
- Authority / Receiving Office
- DE · DE
- Patent Type
- Patents
- Current Assignee / Owner
- EUGEN FORSCHNER
- Filing Date
- 2024-05-08
- Publication Date
- 2026-07-23
Smart Images
Figure 00000000_0000_ABST
Abstract
Description
Technical field
[0001] The invention relates to a high-performance charging socket for megawatt charging, particularly for an electric vehicle. The high-performance charging socket has a connection element with a plurality of contact pin receptacles and a circumferential collar that is formed around the connection element and surrounds it laterally. The invention further relates to a modular charging socket system comprising such a high-performance charging socket. State of the art
[0002] Charging ports for electric vehicles are known in the state of the art. The transformation from combustion engine vehicles to electric vehicles, aimed at reducing dependence on fossil fuels and promoting sustainability in the transport sector, has also made the provision of efficient and versatile charging options crucial. This is especially true for vehicles used in industrial and commercial applications, where time and power are critical.
[0003] Against this backdrop, efforts have been made to provide high-performance charging sockets that allow charging capacities in the megawatt range. A standard connector specification, or charging socket specification, has also been developed within the framework of the Megawatt Charging System (MCS). With its higher charging capacity, the new Megawatt Charging System (MCS) opens up the possibility of electromobility for a wide variety of vehicles. This includes the conversion of heavy commercial vehicles, special-purpose vehicles, marine vessels, and aircraft into electric vehicles.
[0004] However, the charging sockets known from the state of the art are currently not suitable for such a diverse range of applications. Description of the invention
[0005] The invention is therefore based on the objective of providing a high-performance charging socket for megawatt charging that eliminates the aforementioned problems and disadvantages of the prior art. Furthermore, it is an objective of the present invention to provide a corresponding modular charging socket system.
[0006] These problems are solved by the subject matter of the independent claims. Further possible embodiments of the invention are specified in particular in the dependent claims.
[0007] The solution according to the invention consists in particular of providing a high-performance charging socket for megawatt charging, especially for an electric vehicle. The high-performance charging socket has a connection element with a plurality of contact pin receptacles, preferably shaped and formed therein. Furthermore, the high-performance charging socket has a circumferential collar formed around the connection element. In particular, the circumferential collar and the connection element are spaced apart from each other, so that a gap is provided between the connection element and the collar. The circumferential collar surrounds the connection element laterally. Preferably, the collar is formed completely around the connection element.
[0008] According to the invention, the circumferential collar is arranged to be replaceable on the connecting element.
[0009] The high-performance charging socket is designed to receive charging power in the megawatt range. Specifically, the high-performance charging socket is suitable for charging powers between 0.3 and 4.5 megawatts, preferably between 1 and 4 megawatts. It is particularly preferred that the high-performance charging socket is suitable for charging powers of at least 0.3 megawatts, preferably 0.5 megawatts, preferably 1 megawatt, preferably 2 megawatts, and preferably 3 megawatts. Furthermore, the high-performance charging socket is preferably suitable for a rated current of up to 3000 amperes and a rated voltage of up to 1500 volts DC.
[0010] The connection element is preferably a one-piece, and in particular a one-piece, molded element in which all contact pin receptacles of the high-performance charging socket are centrally arranged. The contact pin receptacles are designed to receive contact pins for establishing an electrical contact. The contact pin receptacles preferably comprise two DC contact pin receptacles, a protective conductor receptacle, a communication line receptacle, a PP (proximity pilot) contact pin receptacle, and a CP (control pilot) contact pin receptacle.
[0011] Regardless, the contact pin receptacles extend axially through the connecting element. The collar is preferably an essentially annular rim formed around the connecting element. The collar is designed to protect the connecting element from lateral impacts. Furthermore, the collar can generally protect the connecting element, or the contact pins that can be arranged in the connecting element, from external influences such as dust, moisture, or mechanical stress. The essentially annular rim of the collar is formed by means of a circumferential wall. The circumferential wall is preferably designed to be complementary to a shell of the connecting element. For example, the shell of the connecting element has three rounded corners. Correspondingly, the circumferential wall also has three rounded corners.
[0012] The surrounding collar is replaceable and attached to the connecting element. Therefore, the collar can be removed from the connecting element without damage.
[0013] This has the advantage that the collar can be replaced if damaged. This means that if the collar is damaged, the entire high-performance charging port does not need to be replaced.
[0014] Furthermore, there is flexibility in selecting different materials for the collar, depending on the application. For example, in particularly stressed areas, the collar can be made of a particularly robust, especially hard, material. Depending on the use, it may also be necessary to make the collar from an electrically conductive material. Another advantage is that the high-performance charging port can be used both directly on a PDU and as a remote inlet.
[0015] The collar preferably has a coating. Particularly preferably, the collar has a coating in the area of a connector receptacle, especially a charging connector receptacle, to minimize abrasion and wear during insertion. The coating can generally be a sliding coating, a rubber coating, a paint finish, or similar.
[0016] According to an advantageous embodiment of the invention, the collar projects axially beyond the connecting element in the assembled state. In other words, the collar extends axially, i.e., parallel to the extent of the contact pin receptacles, beyond the connecting element.
[0017] This design protects the connector not only from the sides but also from the front. It also prevents accidental damage or contamination during charging. Furthermore, the collar makes inserting the charging plug into the charging socket easier, as it centers the plug before it comes into contact with the connector.
[0018] In an advantageous embodiment of the invention, the collar is detachably attached, in particular by screws, to the connecting element. The collar can thus be fastened by means of one or more screw connections. However, this does not mean that the collar itself is screwed to the connecting element. Preferably, the collar is screwed to a wall to which the connecting element is also connected, in particular by screws.
[0019] In general terms, the wall can refer to the housing of a high-voltage system. More specifically, the wall can be the wall of a high-voltage distribution unit (HDU), also known as a power distribution unit. In this case, the overarching system is a high-voltage system with a wall and a high-power charging socket mounted on the wall. If the high-voltage system is a PDU, the high-power charging socket is located directly on the PDU. With this configuration, high charging capacities of, for example, at least 1 megawatt, preferably at least 2 megawatts, and preferably at least 3 megawatts are possible. The high-power charging socket can be any of the high-power charging sockets described here.
[0020] The PDU (Power Distribution Unit) is a device for distributing, converting, and / or protecting power within a vehicle. It contains high-voltage components that operate using high voltage (HV). These high-voltage components must be protected from the environment. The PDU is therefore housed in a suitable enclosure with walls.
[0021] As an alternative to the PDU, the wall can also be the wall of a separate charging port housing. In this case, the charging port housing is separate from the PDU. Accordingly, it is a high-performance charging port located remotely from the PDU. Such a charging port is also referred to as a remote inlet. With such a remote inlet, the charging power can also be lower, for example, 0.3 megawatts, preferably 0.5 megawatts, preferably 1 megawatt.
[0022] The charging socket is preferably designed such that it can be attached to both a PDU and a separate charging socket housing. More precisely, the charging socket is designed such that it can be mounted on either a wall of the PDU or a wall of the separate charging socket housing.
[0023] In an advantageous embodiment of the invention, the collar is made of a different, in particular harder, material than the connecting element. Preferably, the collar is made of aluminum or a fiber-reinforced plastic. For example, the fiber-reinforced plastic is glass fiber-reinforced or carbon fiber-reinforced plastic.
[0024] This results in improved durability and resistance of the collar to environmental influences, leading to an overall longer lifespan for the high-performance charging socket.
[0025] The connecting element is particularly preferably designed to electrically insulate the contact pins from the surrounding collar. The connecting element is, for example, made of a non-electrically conductive material and prevents contact between the contact pins and the collar.
[0026] Preferably, the material of the collar can be an electrically conductive material, in particular an electrically conductive plastic or a metal.
[0027] According to an advantageous embodiment of the invention, the connecting element has a, in particular circumferential, fastening flange for preferably detachable fastening to a wall.
[0028] Particularly preferred is the detachable fastening by means of a screw connection. The fastening flange preferably extends laterally around a lower end of the connecting element. In other words, the surface of the connecting element extends axially upwards from the fastening flange.
[0029] The mounting flange allows for simple and secure installation of the connecting element on a wall. This wall can be the same wall described above. Preferably, an opening is formed in the wall, and the connecting element can be attached to the wall in a way that covers the opening. Consequently, the mounting flange of the connecting element is larger than the opening in the wall.
[0030] In an advantageous embodiment of the invention, the collar has a, in particular circumferential, fastening flange for detachable fastening to the connecting element or to the wall.
[0031] Preferably, the collar or the collar's mounting flange is also attached to the wall and not to the connecting element. The mounting flange preferably extends circumferentially outwards at a lower end of the collar. In other words, the collar's edge, which is particularly annular, extends vertically upwards from the mounting flange in an axial direction.
[0032] The collar's mounting flange provides a separate mounting option for the collar, which is designed to be independent and separate from the mounting of the connecting element.
[0033] In an advantageous embodiment of the invention, the mounting flange of the collar has mounting holes. The mounting holes of the collar are preferably arranged offset from the mounting holes of the mounting flange of the connecting element.
[0034] In particular, the collar's mounting flange spans the mounting flange of the connecting element. Preferably, the collar's mounting holes are arranged in the areas of the collar's mounting flange that span the mounting flange of the connecting element. The collar's mounting flange is specifically positioned on the mounting flange of the connecting element.
[0035] This allows the collar to be removed from the wall independently of the connecting element.
[0036] Regardless, the mounting flange of the collar is preferably aligned parallel to the mounting flange of the connecting element. Particularly preferably, the mounting flange of the collar and the mounting flange of the connecting element are in full contact. Alternatively, the mounting flange of the collar and the mounting flange of the connecting element can be axially spaced apart with an axial gap between them.
[0037] According to an advantageous embodiment of the invention, a sealing device is arranged between the connecting element and the wall. A flat sealing device is particularly preferred, clamped between the connecting element and the wall. Alternatively, a profile seal, for example an O-ring seal, is also conceivable.
[0038] In particular, the sealing device is located on the mounting flange of the connecting element. The sealing device generally ensures a reliable seal of the opening in the wall against moisture and dirt. Because the sealing device is positioned between the connecting element and the wall, removing the collar does not require any intervention in the sealing system. In other words, the collar can be removed without affecting the sealing system of the entire component.
[0039] According to an advantageous embodiment of the invention, the high-performance charging socket has a drainage device, in particular for draining water from a space between the collar and the connection element.
[0040] For example, the drainage device can be designed as an axial gap between the collar and the connecting element. In particular, the drainage device can be designed as an axial gap between the mounting flange of the collar and the mounting flange of the connecting element.
[0041] Furthermore, the task is solved by means of a charging socket kit. The charging socket kit comprises one of the aforementioned high-performance charging sockets and at least one additional interchangeable collar. In other words, the charging socket kit includes a connector element with a plurality of contact pin receptacles and at least two circumferential collars that can be arranged interchangeably on the connector element such that the circumferential collar is formed around the connector element and surrounds the connector element laterally.
[0042] The two collars can be made of the same material and be identical in shape. Alternatively, the two collars can be made of different materials but be identical in shape. Another alternative is that the collars can differ in shape.
[0043] The modular charging socket system allows for flexible adaptation to different requirements and applications, as various collars can be combined with a single high-performance charging socket. Brief description of the drawings
[0044] The above-described, different, and exemplary features can be combined with one another according to the invention, insofar as this is technically sensible and suitable. Further features, advantages, and embodiments of the invention will become apparent from the following description of exemplary embodiments and with reference to the figures.
[0045] The figures used to illustrate the exemplary embodiments show: Fig. 1 A top view of a high-performance charging socket; Fig. 2 a perspective representation of the in Fig. 1 high-performance charging socket shown; Fig. 3 an exploded view of the in Fig. 1 high-performance charging socket shown; Fig. 4 a sectional view of an embodiment of the high-performance charging socket with drainage device; Fig. 5 a perspective view of a wall to which the high-performance charging socket is designed to be attached; Fig. 6 a perspective view of a connecting element of the in Fig. 1 high-performance charging socket shown; and Fig. 7 a perspective view of a collar that is in Fig. 1 high-performance charging socket shown. Ways to implement the invention
[0046] Fig. Figure 1 shows a top view of a high-performance charging socket 100. It is located in Fig. 1 The high-performance charging socket 100 is shown in an axial direction, along which a high-performance charging plug can be inserted into the high-performance charging socket 100.
[0047] In Fig. Figure 1 shows individual contact pin receptacles 111 to 115 of a connection element of the high-performance charging socket 100 particularly well. The connection element 110 comprises two DC contact pin receptacles 111, one protective conductor contact pin receptacle 112, one communication line contact pin receptacle 113, one PP contact pin receptacle 114 and one CP contact pin receptacle 115.
[0048] The high-performance charging socket 100 is designed in the plug specification shown with a charging power of up to at least 4.5 megawatts.
[0049] In Fig. Figure 2 shows the structure of the high-performance charging socket 100 more clearly. The high-performance charging socket 100 has a connection element 110 and a collar 120. The connection element 110 and the collar 120 are independently connected to a wall 130. The wall 130 can be a part, in particular a charging socket housing, of the high-performance charging socket 100. The wall 130 can also be part of a housing of a high-voltage system, in particular an HV distribution unit.
[0050] As in Fig. As can be seen in Figure 2, the collar 120 surrounds the connecting element 110. In particular, the collar 120 is at least substantially ring-shaped, with the connecting element 110 arranged inside the ring. Thus, the collar 120 surrounds the connecting element 110 laterally. The collar 120 is open on an axial front face to receive a high-performance charging plug. This allows the high-performance charging plug to be axially connected to the high-performance charging socket 100.
[0051] In Fig. 3 is an exploded view of the in Fig. 1 and Fig. The high-performance charging socket shown in the 2 images is shown. It is located in Fig. Figure 3 clearly shows that the connecting element 110 has a mounting flange 116. The mounting flange 116 is arranged around the entire circumference of the connecting element 110. The mounting flange 116 has a plurality of mounting holes 117. The mounting holes 117 can be aligned with threaded holes 133 of a connecting element mounting structure 132 in the wall 130. This allows the connecting element 110 to be detachably screwed to the wall 130.
[0052] A sealing device 140 (not shown) can be arranged between the connecting element 110 and the wall 130 or its connecting element fastening structure 132. The sealing device 140 serves in particular to prevent a Fig. 5 to seal the opening 135 shown in the wall 130, so that the connecting element 110 and the wall 130 form a closed sealing system.
[0053] The in Fig. 2 and Fig. The collar 120 shown in Figure 3 also has a mounting flange 121. The mounting flange 121 has a plurality of mounting holes 122. The mounting holes 122 can be aligned with further threaded holes 133 of a collar mounting structure 131 of the wall 130. Thus, the collar 120 can be screwed to the wall 130 or its collar mounting structure 131.
[0054] As particularly in Fig. As can be seen in Figure 2, the mounting flange 121 of the collar 120 projects beyond the mounting flange 116 of the connecting element 110 in certain areas. In other words, the mounting flange 121 spans the mounting flange 116 in certain areas. The mounting holes 122 of the mounting flange 121 are located in areas that span the mounting flange 116. This makes it easy to remove the collar 120 from the wall 130 independently of the connecting element 110. The collar 120 is therefore replaceable and attached to the connecting element 110 on the wall 130.
[0055] In Fig. 2 It can also be seen that the fastening holes 122 are offset from the fastening holes 117.
[0056] In Fig. Figure 4 shows a sectional view of an embodiment of the high-performance charging socket 100 with a drainage device 150. The high-performance charging socket 100 can be the one described in the Fig. Figures 1-3 show a high-performance charging socket 100. The drainage device 150 is formed by a gap S between the collar 120 and the connection element 110. In particular, the gap S is formed between the mounting flange 121 and the mounting flange 116. Water can drain through the gap S from a space 160 between the collar 120 and the connection element 110.
[0057] The gap S arises because the mounting flange 121 does not rest fully on the mounting flange 116. This can be explained by the height in the axial direction of the Fig. The collar fastening structure 131 shown in Figure 5 can be adjusted relative to the height of the connecting element fastening structure 132.
[0058] In another embodiment, not shown in a sectional view, the mounting flange 121 is flush with the mounting flange 116. Thus, there is no gap S between the mounting flange 116 and the mounting flange 121, and therefore no drainage device 150 is formed.
[0059] As an alternative to the design as a gap S, the drainage device 150 can also be designed as an opening, in particular a bore, in the collar 120. For example, several bores can also be formed in the collar 120.
[0060] Fig. Figure 5 shows a more detailed perspective view of wall 130. Wall 130 has opening 135, which forms a passage through wall 130. Wall 130 can be part of a housing for a high-voltage system, in particular an HV distribution unit.
[0061] The connecting element fastening structure 132 is at least substantially ring-shaped. The connecting element fastening structure 132 rises above the remaining wall 130. Alternatively, however, it would also be conceivable that the threaded bores 133 of the connecting element fastening structure 132 are arranged directly in the wall 130 without any protrusion. In that case, the wall 130 would be at least substantially flat.
[0062] The collar fastening structure 131 has a plurality of fastening elements 136, which are at least substantially cylindrical. The fastening elements 136 are arranged distributed around the connecting element fastening structure 132. Each of the cylindrical fastening elements 136 has a corresponding threaded bore 133.
[0063] The collar fastening structure 131 is designed to be higher in the axial direction than the connecting element fastening structure 132.
[0064] Preferably, the collar mounting structure 131 is designed to center the connecting element 110. This is made possible in particular by the fact that the collar mounting structure 131 is higher than the connecting element mounting structure 132 and preferably adjacent to the connecting element mounting structure 132.
[0065] In Fig. Figure 6 shows a more detailed perspective view of a connection element 110. The connection element 110 has a mounting flange 116, which has a plurality of mounting holes 117. The mounting holes 117 are distributed along the circumference of the mounting flange 116. For example, five mounting holes 117 are provided. A sleeve 118 of the connection element 110 extends axially from the mounting flange 116.
[0066] The sheath 118 of the connecting element 110 is in particular complementary to one in Fig. The edge 123 of the collar 120 is formed as shown in Figure 7. The coat 118 has a cross-section that is at least substantially triangular in shape. Accordingly, the edge 123 of the collar 120 is not exactly ring-shaped, but also formed in a rounded triangular shape.
[0067] The in Fig. The collar 120 shown in Figure 7 has the mounting flange 121 with the plurality of mounting holes 122. In particular, six mounting holes 122 are arranged on the mounting flange 121. The edge 123 extends axially from the mounting flange 121. Reference sign 100 high-performance charging sockets 110 connection element 111 - 115 Contact pin receptacles 116 Mounting flange (of the connecting element) 117 mounting holes (of the connecting element) 118 coat 120 collars 121 Mounting flange (of the collar) 122 mounting holes (of the collar) 123 Rand 130 wall thickness 131 Collar fastening structure 132 Connection element fastening structure 133 threaded holes 135 Opening 136 fasteners 150 drainage system 160 space S gap
Claims
[1] High-performance charging socket (100) for megawatt charging, especially for an electric vehicle, comprising the following: a connecting element (110) with a plurality of contact pin receptacles (111, 112, 113, 114, 115); a circumferential collar (120) that is formed around the connecting element (110) and surrounds the connecting element (110) laterally, characterized by , that the circumferential collar (120) is interchangeably arranged on the connecting element (110). [2] High-performance charging socket (100) according to claim 1, characterized by , that the collar (120) protrudes axially beyond the connecting element (110) in the assembled state. [3] High-performance charging socket (100) according to claim 1 or 2, characterized by , that the collar (120) is detachably fastened, in particular screwed, to the connecting element (110). [4] High-performance charging socket (100) according to any one of the preceding claims, characterized bythat the collar (120) is made of a different, in particular harder, material than the connecting element (110), wherein the collar (120) is preferably made of aluminium or fiber reinforced plastic. [5] High-performance charging socket (100) according to any one of the preceding claims, characterized by , that the connecting element (110) has a, in particular circumferential, fastening flange (116) for preferably detachable fastening to a wall (130). [6] High-performance charging socket (100) according to any one of the preceding claims, characterized by that the collar (120) has a, in particular circumferential, fastening flange (121) for detachable fastening to the connecting element (110) or to a wall (130) respectively. [7] High-performance charging socket (100) according to claims 5 and 6, characterized by, that the mounting flange (121) of the collar (120) has mounting holes (122) which are offset from the mounting holes (117) of the mounting flange (116) of the connecting element (110). [8] High-performance charging socket (100) according to any one of the preceding claims, characterized by , that a sealing device (140) is arranged between the connecting element (110) and a wall (130). [9] High-performance charging socket (100) according to any one of the preceding claims, characterized by , that the high-performance charging socket (100) has a drainage device (150) for draining water from a space (160) between the collar (120) and the connection element (110). [10] Charging socket kit comprising a high-performance charging socket (100) according to one of the preceding claims and several interchangeable collars (120).