Charging plug with cable entry

Abstract

The invention relates to a charging plug with contact elements for a detachable, electrically conductive connection of a battery-electric vehicle to a charging station, comprising a charging plug housing with at least one cable entry, wherein at least one sensor of the charging plug is arranged adjacent to the contact elements and in the plugging direction in the front area of ​​the charging plug, wherein sensor cables of the at least one sensor are passed through the at least one cable entry and sealed against the charging plug housing with at least one sealing element, wherein the at least one sensor comprises two temperature sensors and one voltage sensor and the charging plug housing has two cable entries, each with a sealing element.

Description

[0001] The invention relates to a charging plug with contact elements for a detachable, electrically conductive connection of a battery-electric vehicle to a charging station, comprising a charging plug housing with at least one cable entry.

[0002] Documents US 2023 / 0396028 A1, CN 219610909 U and CN 220253609 U deal with connectors with a cable entry having a sealing element according to the preamble of claim 1.

[0003] US Patent 6,071,146 A relates to a sealing element designed to be placed between a plug and a cable.

[0004] Document US 2013 / 0201641 A1 deals with a charging cable with a sensor for temperature and voltage measurement.

[0005] Contacts generally have at least one electrically conductive contact section for detachable, temporary, or plug-in connection with a corresponding mating contact element and a shaft section adjoining the contact section for attaching an electrical conductor to the contact. Such a contact, plug-in contact, or high-current contact can be used, for example, on a charging plug or socket for charging an electric vehicle. In this case, a cable is connected to a charging station on one side and carries a connector part in the form of a charging plug on the other, which can be inserted into a corresponding mating connector part in the form of a charging socket on a vehicle to establish an electrical connection between the charging station and the vehicle.Other uses for high-current contacts arise in a variety of other high-current applications, such as for operating a high-current household appliance or for supplying power to a welding machine, compressor, water heater, etc.

[0006] Supply and charging currents can generally be transmitted as direct currents or as alternating currents, whereby charging currents and high-current ranges in the form of direct current have a high current intensity, for example greater than 200 A or even greater than 300 A or even 350 A, and can lead to heating of the cable as well as of a high-current contact connected to the cable.

[0007] To charge battery-electric trucks quickly and efficiently, even higher charging capacities are generally required. A so-called Megawatt Charging System Standard (MCS) is intended to be used as a fast-charging system in the future and should enable a charging capacity of up to 3.75 megawatts, with a voltage of up to 1,250 V and a charging current of up to 3,000 A.

[0008] Regardless of the specification of the charging plug or charging socket (for example according to the standard IEC 62196-2 or IEC 62196-3 or CHAdeMO standard or according to the Megawatt Charging System Standard), it is particularly important, especially at higher and high charging capacities, that charging plugs and / or charging sockets are sealed very carefully and reliably.

[0009] To prevent the ingress of moisture, water, or other conductive liquids, charging plug housings are often sealed. This means that seals are used on the components that lead into and / or out of the charging plug housing. The connection between the charging cable and the vehicle's charging socket is also sealed when plugged in. In addition to the actual power supply cables and contact elements, sensor cables are often routed into and / or out of the plug housings because sensors for measuring various physical quantities are integrated inside charging plugs and sockets.

[0010] Utility model DE 20 2016 102 392 U1 describes a solution for cable feedthroughs in charging plugs in the form of a sealed overmolded adapter sleeve, having an end thread for connection to a mating thread of the connector housing, and the overmolded adapter sleeve having an internal channel for routing a cable, wherein several ribs and / or grooves are provided on the outer shell of the overmolded adapter sleeve, and the area with the ribs and / or grooves is designed for joint overmolding with a plastic in an overmolding tool with a cable.

[0011] However, this state-of-the-art solution has the disadvantage, in addition to its complex design and the need for plastic overmolding, that the cable routing within the connector housing has a longer distance when the sensors are positioned in the desired proximity to the plug contacts.

[0012] The object of the invention is to further develop a sensor arrangement with cable routing and sealed cable entry in a charging plug and to at least partially reduce the disadvantages of known solutions.

[0013] To solve this problem, the invention proposes a charging plug with the features of claim 1. Advantageous embodiments of the invention are found in the dependent claims. In particular, it is provided that a sensor arrangement (comprising two temperature sensors and one voltage sensor) is located directly adjacent to the contact elements of the charging plug, so that the aforementioned sensors are positioned in the front area in the direction of insertion. Due to this positioning, it is necessary that the respective sensor wiring be routed through the interior of the charging plug, with the cable routing passing through the insert.

[0014] According to the invention, positioning the sensors for measuring temperature and voltage directly adjacent to the contact elements of the charging plug is particularly advantageous for measurement data acquisition and measurement accuracy.

[0015] The invention recognizes that, particularly in charging plugs for transmitting high electrical power, the sealing of the cable glands must be reliably hermetically sealed to prevent water ingress. If there is no plug-in face, no water may pass through the insert.

[0016] To ensure the tightness requirements of the cable penetration, the invention provides a sealing element that guides and seals at least two sensor cables. The sealing of the at least two sensor cables is carried out individually, meaning that a sealing and through-hole is provided within the sealing element for each sensor cable to be sealed.

[0017] The sealing element, preferably made of a silicone material, has essentially an outer cross-sectional contour comparable to a regular oval, with cross-sectional areas that change in the longitudinal direction.

[0018] The sealing element is functionally divided into two areas along its longitudinal axis: the sealing area and the position-locking area. The sealing area has at least two sealing lips to seal the cable entry point of the sealing element against the charging plug housing. The position-locking area, located on the longitudinal axis of the sealing element opposite the sealing area, has a smaller cross-section than the sealing area and features a circumferential raised section for positioning the sealing element.

[0019] The invention is explained in more detail below with reference to an exemplary embodiment in conjunction with the figures. These show: Fig. 1. A side view of the charging plug with sealing elements on the plug side; Fig. 2 a side view of the charging plug with sealing elements on the back of the plug; Fig. 3 the three-dimensional view of the sealing element; Fig. 4. The representation of the sealing element in three views.

[0020] Fig. Figure 1 shows a side view of the charging plug 1 with sealing elements 5 on the plug side, i.e., on the side of the charging plug 1 that first makes contact during the contact movement into the charging socket.

[0021] The insert 3 is received on the inside of the charging plug housing 2, and at least one cable gland 4 is formed in an inwardly extending projection, into which a sealing element 5 is inserted. Depending on the number of sensor wires, two cable glands 4, each with a sealing element 5, are provided in this embodiment. In this view, the sealing elements 5 are seen from their end face on the side of the sealing area 7.

[0022] Fig. Figure 2 shows a side view of the charging plug 1 with sealing elements 5 on the side opposite the insertion direction. In this view, the sealing elements 5 can be seen from their end face on the side of the position securing area 9.

[0023] Fig. Figure 3 shows the three-dimensional view of the sealing element 5. A first receiving bore 11 and at least a second receiving bore 11 are provided, which are designed as through bores.

[0024] The receiving bores 11 serve to guide the sensor cables axially through the sealing element 5 in a sealing manner, in the direction of the longitudinal extent of the sealing element 5 and largely parallel to the longitudinal center axis. The sealing function is achieved by the respective inner surface of the receiving bore 11 clamping and sealing against the inserted sensor cable.

[0025] Since the sealing function of the sealing element 5 is designed as a single-wire seal against the sensor cables, a receiving bore 11 is provided in the sealing element 5 for each sensor cable to be routed through it. In the illustrated embodiment, the sealing element 5 is designed for use in a charging plug with two temperature sensors and one voltage sensor. Since each of these sensors has two sensor cables, two sealing elements 5 are provided, each with three receiving bores 11. Depending on the outer diameter of the sensor cables to be routed through it, the receiving bores 11 are adapted accordingly with respect to their bore diameters. The illustrated embodiment of Fig. Figure 3 shows a larger inner diameter of the receiving bore 11 for the voltage sensor cable and two smaller inner diameters for the temperature sensor cables. To facilitate insertion of the sensor cables into the receiving bores 11, the receiving bores may have a chamfer.

[0026] The outer contour of the sealing element 5 in the section planes transverse to the longitudinal center axis is oval-shaped, in which in Fig. In the embodiment shown in Figure 3, the shape of a regular oval 6 was chosen. The oval cross-sectional area optimizes the possibility of positioning a first and at least one second receiving bore 11 within the sealing element 5 as a single-wire seal.

[0027] Fig.Figure 4 shows the sealing element 5 in three views. Along its longitudinal extent, and thus in the direction of the receiving bores 11 of the sealing element 5, there is a sealing area 7 and a position securing area 9.

[0028] The sealing area 7 has a first sealing lip 8 and at least one second sealing lip 8 to seal the cable entry 4 of the sealing element 5 against the charging plug housing 2. The use of at least two sealing lips 8 achieves a particularly reliable sealing effect.

[0029] The position-locking area 9 of the sealing element 5 has at least one circumferential elevation 10 in its end section and opposite the sealing area 7. At the same time, the cross-sectional area of ​​the position-locking area 9 is preferably smaller than the cross-sectional area of ​​the sealing area 7, viewed at the axial height of the sealing lips 8 and the circumferential elevation 10. In this way, the position-locking area 9 has increased deformability relative to the sealing area, which allows the position of the sealing element 5 to be elastically retained in the cable gland 4. Reference symbol list 1 charging plug 2 charging plug housings 3 insert 4 cable feedthrough 5 sealing element 6 regular oval 7 Sealing area 8 Sealing lip 9 Position securing area 10 per-circulation increase 11. Mounting hole

Claims

[1] Charging plug (1) with contact elements for a detachable, electrically conductive connection of a battery electric vehicle to a charging station, comprising a charging plug housing (2) with at least one cable entry (4), characterized by , that at least one sensor of the charging plug (1) is arranged adjacent to the contact elements and in the plugging direction in the front area of ​​the charging plug (1), wherein sensor cables of the at least one sensor are passed through the at least one cable entry (4) and are sealed with at least one sealing element (5) against the charging plug housing (2), characterized by , that at least one sensor comprises two temperature sensors and one voltage sensor and the charging plug housing (2) has two cable glands (4) each with a sealing element (5). [2] Charging plug (1) according to claim 1, characterized by, that the outer contour of the at least one sealing element (5) is oval-shaped in the section planes transverse to the longitudinal center axis. [3] Charging plug (1) according to claim 1, characterized by , that the at least one sealing element (5) has in the longitudinal direction a first and at least one second receiving bore (11) for passing the sensor cables through the at least one cable passage (4). [4] Charging plug (1) according to claim 3, characterized by that the receiving bores (11) are designed as single-wire seals. [5] Charging plug (1) according to claim 3, characterized by , that the receiving holes (11) each have a threading slope. [6] Charging plug (1) according to claim 1, characterized by , that the at least one sealing element (5) has a sealing area (7) and a position securing area (9). [7] Charging plug (1) according to claim 6, characterized by, that in the sealing area (7) a first sealing lip (8) of the at least one sealing element (5) and at least a second sealing lip (8) of the at least one sealing element (5) are arranged. [8] Charging plug (1) according to claim 6, characterized by , that in the position securing area (9) at least one circumferential elevation (10) of the at least one sealing element (5) is arranged. [9] Charging plug (1) according to claim 1, characterized by that the sealing elements (5) each have three receiving bores (11) for passing the sensor cables through the respective cable entry (4).

Images