Curb charging device having a sealed charging socket

Abstract

The invention relates to a curb charging device (10) for electrically charging a traction battery of a battery electric vehicle, comprising a charging socket (20) arranged in such a manner that a charging socket insertion opening (22) of the charging socket (20) faces upward when the curb charging device (10) is in its installed position, so that a charging plug (80) of the vehicle can be inserted into the charging socket (20) from above in the vertical direction, wherein the charging socket (20) comprises a plurality of electrically conductive contact sleeves (30) which have a slot (32) and which are associated with one electrical line (50) each and into which one contact pin (82) each, of a charging plug (80) of the vehicle, can be inserted. The charging socket (20) also comprises a charging socket housing (40), which has a charging socket housing base (42), and a plurality of contact sleeve casings (44, 45), which radially enclose one contact sleeve (30) each, wherein at least one axially acting seal (60) is arranged between the contact sleeve casing (44, 45) and the contact sleeve (30), and wherein, according to the invention, each contact sleeve casing (44, 45) has a water drain opening (46, 48) which extends radially through the contact sleeve casing (44, 45) and which is arranged at a distance from the charging socket housing base (42).

Description

[0001] PI. P.24041.WO / EBFS August 27, 2024

[0002] - 1 -

[0003] Curbside charging device with sealed charging socket

[0004] Description

[0005] The present invention relates to a curb charging device for electrically charging a traction battery of a battery-electrically powered vehicle, in particular a sealed charging socket for a curb charging device.

[0006] A curbside charging device is a charging system integrated into a curb, kerbstone, or paving stone for charging the traction battery of a battery-electric vehicle (BEV). These devices are installed at the roadside, for example, at the edge of sidewalks or parking bays. Their power electronics, as part of an electronic unit, are fully or partially integrated into the curb, kerbstone, or paving stone, or otherwise embedded in the ground, such as a sidewalk or parking area. The curbside charging device can, for example, replace a conventional curb bordering the sidewalk, allowing it to blend relatively unobtrusively into the urban landscape and be used in locations where space is limited.This allows the curb charging device to be installed, for example, in urban areas with relatively narrow sidewalks, where conventional charging stations cannot be used due to their large space requirements.

[0007] Sealed charging sockets are already known and are used, for example, in conventional charging devices, namely so-called charging stations, which are installed on sidewalks or parking lots and by means of which a traction battery of a battery-electrically powered vehicle, namely a so-called electric vehicle, can be electrically charged.

[0008] Such a charging socket is known, for example, from CN 113270731 A. The charging socket disclosed therein is typically installed in a horizontal orientation, so that a vehicle-side charging plug is inserted horizontally into the socket. PI. P.24041.WO / EBFS 27.08.2024

[0009] - 2 -

[0010] The charging socket can be plugged in. By means of two axially spaced seals that completely enclose the contact sleeves, water is prevented from flowing past the contact sleeves and into the interior of the charging station, especially to the electrical cables.

[0011] In a curbside charging station, which typically replaces a conventional curb at the edge of a sidewalk and is therefore installed close to the ground, the charging socket is mounted vertically on the top of the device. This allows a vehicle-side charging plug to be inserted vertically from above. This design presents the problem that the charging socket housing, due to its tray-like shape, can fill with water. Similarly, water can also collect in the vertically oriented contact sleeves, which are connected to the electrical wiring and into which the charging plug's contact pins are inserted. This can unintentionally create an electrical connection between adjacent live contact sleeves, potentially leading to fault currents and thus posing a safety risk.

[0012] Against this background, the task arises to create a curb loading device that does not have the aforementioned disadvantages.

[0013] This problem is solved according to the invention by a curb-loading device with the features of claim 1.

[0014] The curb charging device according to the invention for charging a traction battery of a battery-electrically powered vehicle has a charging socket which is arranged such that a charging socket insertion opening of the charging socket points upwards in the installation position of the curb charging device, so that a vehicle-side charging plug can be inserted vertically from above into the charging socket.

[0015] The terms "top", "top side", "bottom side", "under side", etc. generally refer to the horizontal installation position of the curb-mounted loading device, which replaces a PI. P.24041 .WO / EBFS 27.08.2024

[0016] - 3 - conventional kerbstone at the edge of a sidewalk, for example in the area of ​​parking bays.

[0017] The charging socket is preferably a female connector into which a charging plug, usually vehicle-side and designed as a male connector, can be inserted, thereby establishing an electrical connection between the curb charging device and the traction battery of the battery-electric vehicle. Either an alternating current or a direct current can be transmitted from the curb charging device to the vehicle's traction battery. Signals can also be transmitted via dedicated lines. Preferably, the charging socket is designed as a Type 2 charging socket for a Type 2 charging plug.

[0018] The charging socket comprises several electrically conductive contact sleeves, each with a slot, which are assigned to an electrical conductor and into which a contact pin of a vehicle-side charging plug can be inserted. The contact sleeves are made of an electrically conductive material and are preferably hollow cylindrical. Each contact sleeve is electrically connected to a single electrical conductor, which in turn is electrically connected to the electronics of the curb charging device. The curb charging device can have several current-carrying conductors that are routed to and electrically connected to the contact sleeves of the charging socket. In the case of the Type 2 charging socket, for example, it can have three electrical phases L1, L2, and L3. The Type 2 charging socket also has a protective earth conductor PE, a neutral conductor N, and two signal conductors CP and PP.

[0019] The slots in the contact sleeves extend axially to a free end of the contact sleeve in the area of ​​the charging socket's insertion opening. Preferably, the contact sleeve has several separate axial slots distributed around its circumference. Due to the slots, the contact sleeves spread open at their free end as soon as a contact pin of a charging plug inserted into the charging socket penetrates the contact sleeve. This ensures that the PI. P.24041.WO / EBFS 27.08.2024

[0020] - 4 -

[0021] The contact sleeve is pre-tensioned against the contact pin of the charging plug, thus creating a reliable electrical connection.

[0022] Furthermore, the slots are designed such that water penetrating the contact sleeves from above can drain radially outwards through the slots and does not collect in the contact sleeves. The width of the slots should therefore be large enough to allow the water to drain freely and not be hindered from draining away, for example, by capillary action.

[0023] Furthermore, the charging socket has a charging socket housing, preferably made of plastic and formed in one piece. The charging socket housing has several contact sleeve casings, each of which radially encloses a contact sleeve. The contact sleeve casing protects the contact sleeve and prevents a person from coming into contact with the contact sleeves, for example, when inserting the charging plug. The contact sleeve casing also guides the charging plug and / or the contact pin of the charging plug. At their free end in the area of ​​the insertion opening, the contact sleeve casings each have a contact pin opening through which the preferably cylindrical contact pin of the charging plug can be passed, allowing it to penetrate the contact sleeve enclosed by the contact sleeve casing.

[0024] The charging socket housing further comprises a preferably horizontal base from which the contact sleeve sheaths extend preferably vertically towards the insertion opening. The base and the wall radially surrounding the charging socket form a kind of basin in which water penetrating the charging socket from above can collect.

[0025] At least one axially acting seal is arranged between the contact sleeve and the contact sleeve casing, which prevents water penetrating the contact sleeve casing or the contact sleeve itself from entering the interior of the curb-loading device through the gap formed between the contact sleeve and the contact sleeve casing. The seal is preferably of the type PI. P.24041.WO / EBFS 27.08.2024

[0026] - 5 - a separate sealing element is provided. The sealing element is particularly preferably designed as a seal that completely encloses the contact sleeve. For this purpose, for example, a circumferential groove can be provided in the contact sleeve in which the sealing element sits in a sealing manner. In addition, the sealing element rests against the radial inner wall of the contact sleeve casing in a sealing manner. Furthermore, the seal can also be formed by the contact sleeve being enclosed by the contact sleeve casing in a sealing manner, for example by overmolding or casting the contact sleeve. This protects the interior of the curb charging device, in particular the electrical lines leading to the charging socket, from contact with water.

[0027] Furthermore, each contact sleeve casing has a water drainage opening that extends radially through the casing and is positioned at a distance from the charging port housing base. The drainage opening is located above the seal, so that the majority of the water entering the contact sleeve casing drains away directly and does not accumulate in front of the seal.

[0028] Preferably, the water drainage openings of different contact sleeve sheaths have different distances to the base of the charging socket housing. For example, the water drainage openings of the contact sleeve sheaths enclosing the contact sleeves connected to the live phases can be located further away from the base of the charging socket housing than the contact sleeve sheaths of the other conductors. Should water collect in the trough-shaped charging socket housing and the level rise to the point where it reaches the water drainage openings, fault currents will initially flow away via the conductor whose water drainage opening is located closest to the base of the charging socket housing.

[0029] Preferably, the distance between the water drainage opening of the contact sleeve sheath, which is associated with the contact sleeve of a return conductor, and the charging socket housing base is smaller than the respective distance between the PI. P.24041.WO / EBFS 27.08.2024

[0030] - 6 - remaining water drainage openings and the base of the charging socket housing. The return conductor is, in particular, a ground or earthing conductor, in Germany, for example, the protective conductor PE, through which fault currents can flow away. Due to the smaller distance, the water collecting in the charging socket housing will first come into contact with the contact sleeve of the return conductor or the protective conductor PE, so that when fault currents occur, they flow directly via the return conductor and trip the residual current device, which then de-energizes the entire curbside charging device. This distance is particularly preferably at least 1.5 mm less than the distance between the other contact sleeve sheaths and the base of the charging socket housing. This ensures a particularly high level of electrical safety.Alternatively, the water drainage opening of the contact sleeve sheath of a signal conductor, for example, the water drainage opening of the contact sleeve sheath of signal conductor CP, can be positioned at the smallest distance to the base of the charging socket housing. This allows the charging process to be immediately interrupted by the control unit in the event of a fault current in the signal conductor, without tripping the residual current device (RCD). The signal conductor would thus serve as a water level detector for the charging socket.

[0031] The water drainage opening is particularly preferably located at the lower end or below the lower end of the slot of the associated contact sleeve. This ensures that the water flowing out of the contact sleeve drains directly out of the contact sleeve casing and thus cannot accumulate excessively in the contact sleeve casing above the seal.

[0032] In a further preferred embodiment of the invention, the contact sleeve casing is designed as a contact sleeve sleeve. The contact sleeve sleeve is preferably hollow cylindrical and extends from the charging socket housing base substantially perpendicularly towards the insertion opening of the charging socket. At its free end, the contact sleeve sleeve has a radially inwardly projecting collar that extends at least partially over the end face of the enclosed contact sleeve. Furthermore, the contact sleeve sleeve has a contact pin opening enclosed by the collar, through which the PI. P.24041.WO / EBFS 27.08.2024

[0033] - 7 -

[0034] The contact pin of the vehicle's charging plug is guided through it when plugged in, so that the contact pin can penetrate into its associated contact sleeve and make electrical contact with it.

[0035] In a further particularly advantageous embodiment of the invention, the water drainage opening is formed by a water drainage slot in the radial wall of the contact sleeve casing, which is advantageous with regard to manufacturing.

[0036] Preferably, the water drainage slot extends axially to the free end of the contact sleeve casing. The bottom of the water drainage slot facing the charging socket housing base forms the water drainage opening and is accordingly spaced apart from the charging socket housing base. The distance between the bottom of the water drainage slot and the charging socket housing base is equal to or less than the distance between the slots in the contact sleeve and the charging socket housing base.

[0037] Consequently, the distance between the lower edge of the water drainage slot and the charging port housing base is equal to or less than the distance between the lower edge of the slots in the contact sleeve and the charging port housing base. By designing the water drainage opening as a drainage slot, the charging port housing is relatively lightweight and therefore inexpensive to manufacture, since the drainage slot can be incorporated during the injection molding process and demolded from the mold in the same direction as the rest of the charging port housing geometry.

[0038] Preferably, the distance between the water drainage opening nearest to the base of the charging socket housing and the base of the charging socket housing is at least 10 mm. This ensures that a certain amount of water can collect in the charging socket housing before reaching the drainage opening. It also allows a certain amount of dirt to accumulate without impairing the insertion of the charging plug. Furthermore, it compensates for angled charging sockets where the base of the charging socket housing is inclined relative to the horizontal, for example, when installing the curb charger on an incline. PI. P.24041.WO / EBFS 27.08.2024

[0039] - 8 -

[0040] In a further advantageous embodiment of the invention, the slotting has several slots with a width of at least 1 mm. When no vehicle-side charging plug is inserted into the charging socket and the contact sleeve is therefore not spread open by a contact pin, the slot tapers towards the free end of the contact sleeve. At the free end, each slot of the contact sleeve is completely closed, whereas at the end of the slotting facing the base of the charging socket housing, each slot has a width of at least 1 mm, so that even in the unspread state, water that penetrates the contact sleeve from above can easily drain away.

[0041] In a particularly advantageous embodiment of the invention, at least two seals are arranged axially spaced apart from each other in each contact sleeve. This achieves a particularly high level of sealing, even if one of the two seals should fail.

[0042] Preferably, the seal is designed as a sealing element, and particularly preferably as a gasket. This allows the use of a standard part such as an O-ring, which is particularly cost-effective. Two sealing rings are preferably arranged axially spaced apart from each other.

[0043] In a further advantageous embodiment of the invention, the charging socket housing has a water drainage channel in the area of ​​the base of the charging socket housing. Water penetrating the trough-shaped charging socket housing can drain away through this drainage channel, preventing it from accumulating permanently within the housing. The drainage channel is particularly preferably located at the lowest point of the trough-shaped charging socket housing. The drainage channel preferably extends horizontally through the radial wall of the charging socket housing, with the water drained out preferably downwards or towards the street side of the curbside charging device. Alternatively, the drainage channel can also extend downwards through the base of the charging socket housing. PI. P.24041.WO / EBFS 27.08.2024

[0044] - 9 -

[0045] Furthermore, the water drainage openings of adjacent contact sleeve casings can be arranged in such a way that they have the largest possible horizontal distance to each other, so that relatively long creepage distances are created, which makes the risk of unwanted creepage currents relatively low.

[0046] An embodiment of the present invention is described below with reference to the accompanying schematic figures. These show:

[0047] Figure 1 A curb-loading device according to the invention in a perspective view,

[0048] Figure 2 shows the charging socket of the curbside charging device of Figure 1 according to the invention in a perspective view.

[0049] Figure 3 shows the charging socket of the curbside charging device of Figure 1 according to the invention in a longitudinal section view,

[0050] Figure 4 shows the charging socket of the curbside charging device of Figure 1 according to the invention with a vehicle-side charging plug inserted in a longitudinal section view,

[0051] Figure 5 shows the charging socket of the curbside charging device of Figure 1 according to the invention in a cross-sectional view, and

[0052] Figure 6 shows a single contact sleeve of the charging socket of the curbside charging device of Figure 1 according to the invention in the spread-open state in a perspective view.

[0053] Figure 1 shows a curb charging device 10 for electrically charging a traction battery of a battery-electric vehicle. The curb-

[0054] Charging device 10 includes a charging socket 20, which, with regard to the installation position of the PI. P.24041.WO / EBFS 27.08.2024

[0055] - 10 -

[0056] The curb charging device 10 is arranged vertically on its upper side, such that a charging socket insertion opening 22 of the charging socket 20 points upwards. This allows a vehicle-side charging plug 80, which is shown in Figure 4 in the inserted state in the charging socket 20, to be inserted vertically from above into the charging socket 20 by a user.

[0057] Figure 2 shows the charging socket 20 in a perspective view, and Figure 3 shows the charging socket 20 in a longitudinal section. The charging socket 20 has a one-piece charging socket housing 40 made of plastic, which is shaped like a trough and is bounded on the underside by a horizontal charging socket housing base 42. Furthermore, the charging socket housing 40 has a water drainage channel 70 that extends horizontally through the wall 41 radially enclosing the charging socket 20 in the area of ​​the charging socket housing base 42, and through which water, such as rainwater, entering the charging socket 20 from above can drain away. A hose, for example, can be connected to the water drainage channel 70, through which the water is discharged downwards into the ground or towards the street.

[0058] The charging socket 20 further comprises several electrically conductive, hollow cylindrical contact sleeves 30, each with a slot 32, which extend vertically upwards through the charging socket housing base 42 towards the charging socket insertion opening 22. Each contact sleeve 30 is associated with an electrical conductor 50, 52 and is electrically connected at its lower end 39 below the charging socket housing base 42 to its respective conductor 50, 52. A heat-shrink tube 54 provides additional insulation to each conductor end 56. The charging socket 20 shown is a type 2 charging socket, which has three electrical phases L1, L2, and L3. Furthermore, such a type 2 charging socket 20 has a neutral conductor N, a protective conductor PE, and two signal lines CP and PP. The arrangement of the contact sleeves 30 connected to the conductors L1, L2, L3, N, PE, CP, PP is shown in Figure 5.PI. P.24041 .WO / EBFS 08 / 27 / 2024.

[0059] - 11 -

[0060] When a vehicle-side charging plug 80 is inserted, a contact pin 82 is inserted into its associated contact sleeve 30, as shown in Figure 4, so that an electrical connection can be established between the electronics of the battery-electrically powered vehicle and the electronics of the curb charging device 10, via which energy and signals can then be transmitted.

[0061] The slot 32 of each contact sleeve 30 has six individual slots 33 distributed around its circumference, extending axially to a free end 31 of the contact sleeve 30, as can be clearly seen in Figure 6. Due to the slot 32, the contact sleeve 30 expands when the contact pin 82 of the vehicle-side charging plug 80 is inserted, so that the contact sleeve 30 bears against the contact pin 82 under preload evenly around its circumference, thereby creating a large-area electrical connection for energy signal transmission. The contact sleeve is shown in the expanded state in Figure 6, but without the contact pin 82 of the vehicle-side charging plug 80.In the unspread state, i.e., with the charging plug 80 not inserted, the two inner walls, each defining a single slot 33 in the circumferential direction, lie against each other at the free end 31 of the contact sleeve 30. At the opposite axial end of the slot 33, a gap 331 with a width D of approximately 1 mm is formed, which serves as a water drain and allows water entering the contact sleeve 30 from above to flow away. With the charging plug 80 not inserted, the width D of each slot 33 thus decreases towards the free end 31 of the contact sleeve 30.

[0062] The charging socket housing 40 further comprises several contact sleeve casings 44, 45, each of which radially encloses a contact sleeve 30. Each contact sleeve casing 44, 45 extends vertically from the charging socket housing base 42 to the charging socket insertion opening 22. The contact sleeve casing 44, 45 is designed as a hollow cylindrical contact sleeve sleeve 43, which axially projects beyond the contact sleeve 30 and has a radially inwardly extending collar 49 at its free end 442 in the region of the insertion opening 22. The collar 49 projects at least partially beyond the end face of the respective enclosed contact sleeve 30, forming a contact pin opening 444 through which PI. P.24041.WO / EBFS 27.08.2024

[0063] - 12 - the respective contact pin 82 of the vehicle-side charging plug 80 is passed through in the plugged-in state to contact the contact sleeve 30.

[0064] Each contact sleeve casing 44, 45 has a single water drainage opening 46, 48, which is designed as a water drainage slot 47, 47' extending axially from the charging socket housing base 42 to the free end 442 of the contact sleeve casing 44. The water drainage slot 47, 47' is thus arranged at a distance from the charging socket housing base 42, with the water drainage openings 46, 48 and the respective ends of the water drainage slots 47, 47' facing the charging socket housing base 42 of different contact sleeve casings 44 having differently dimensioned distances A, B to the charging socket housing base 42. The distance of the slots 33 of the contact sleeves 30 to the charging socket housing base 42 corresponds approximately to the distance of the water drainage slot 47, 47' of the respective contact sleeve sheath 44, 45 enclosing the contact sleeve 30.

[0065] In particular, the distance B between the water drainage opening 48 of the contact sleeve sheath 45, which is assigned to the contact sleeve 38 of the return conductor 52, i.e., the protective conductor PE, and the charging socket housing base 42 is smaller than the respective distance A between the other water drainage openings 46 and the charging socket housing base 42. If water should collect in the charging socket 20, for example, if more water enters the charging socket 20 from above than can drain out through the water drainage channel 70, the water collecting in the charging socket 20 first comes into contact with the contact sleeve 30 of the protective conductor PE, so that fault currents can be discharged directly via the protective conductor PE, whereby the residual current device that subsequently trips then disconnects the entire electronics of the curbside charging device 10 from the power supply.For this purpose, the distance B between the water drainage slot 47' of the contact sleeve sheath 45 enclosing the protective conductor PE and the charging socket housing base 42 is at least 1.5 mm less than the distance between the other contact sleeve sheaths 44 and the charging socket housing base 42. PI. P.24041.WO / EBFS 27.08.2024.

[0066] - 13 -

[0067] Nevertheless, the distance B should be at least 10 mm to allow a certain amount of water to collect in the charging socket 20 without tripping the residual current device. This also allows a certain amount of dirt or grime to collect in the charging socket 20 without affecting the insertion of the charging plug 80.

[0068] Furthermore, each contact sleeve 30 has two seals 60 designed as sealing elements 61, which are arranged axially spaced apart from each other and each completely encloses the contact sleeve 30 and radially seals against it, with each sealing element 61 being designed as a seal 62, for example as an O-ring. The seals 60 bear radially against the inside of the respective contact sleeve casing 44, 45, so that the gap between the contact sleeve 30 and the contact sleeve casing 44, 45 is closed and sealed, and the curb-loading device 10 is thus protected from the ingress of water through the charging socket 20 past the contact sleeves 30.

Claims

PI. P.24041 .WO / EBFS 27.08.2024 - 14 - Patentanspriiche 1. Curb charging device (10) for electrically charging a traction battery of a battery-electric vehicle, with a charging socket (20) arranged such that a charging socket insertion opening (22) of the charging socket (20) points upwards in the installation position of the curb charging device (10), so that a vehicle-side charging plug (80) can be inserted vertically from above into the charging socket (20), the charging socket (20) comprising: several electrically conductive contact sleeves (30, 38) having a slot (32), each associated with an electrical line (50, 52) and into each of which a contact pin (82) of a vehicle-side charging plug (80) can be inserted, a charging socket housing (40) with a charging socket housing base (42), and several contact sleeve sheaths (44, 45), each of which radially encloses a contact sleeve (30, 38), wherein between the Contact sleeve sheathing (44,45) and the contact sleeve (30) at least one axially acting seal (60) is arranged, wherein each contact sleeve casing (44, 45) has a water drainage opening (46) which extends radially through the contact sleeve casing (44, 45) and which is spaced apart from the charging socket housing base (42).

2. Curbside charging device (10) according to claim 1, wherein the water drainage openings (46, 48) of different contact sleeve sheaths (44, 45) have differently dimensioned distances (A, B) to the charging socket housing base (42).

3. Curbside loading device (10) according to claim 2, wherein the distance (B) between the water drainage opening (48) of the contact sleeve sheath (45) associated with the contact sleeve (38) of a return conductor (52) and the PI. P.24041.WO / EBFS August 27, 2024 - 15 - The base of the charging socket housing (42) is smaller than the respective distance between the other water drainage openings (46) and the base of the charging socket housing (42).

4. Curbside loading device (10) according to one of the preceding claims, wherein the water drainage opening (46, 48) is arranged with respect to the installation position at the lower end or below the lower end (34) of the slot (32) of the associated contact sleeve (30).

5. Curbside loading device (10) according to one of the preceding claims, wherein the contact sleeve sheathing (44, 45) is designed as a contact sleeve sleeve (43).

6. Curbside loading device (10) according to one of the preceding claims, wherein the water drainage opening (46, 48) is formed by a water drainage slot (47, 47') in the radial wall (41 ) of the contact sleeve casing (44).

7. Curbside loading device (10) according to claim 6, wherein the water drainage slot (47, 47') extends axially to the free end (442) of the contact sleeve sheathing (44, 45).

8. Curbside charging device (10) according to one of the preceding claims, wherein the distance (B) between the water drain opening (46) nearest to the charging socket housing base (42) and the charging socket housing base (42) is at least 10 mm.

9. Curb loading device (10) according to one of the preceding claims, wherein each slot (32) has several separate slots (33), each slot (33) having a width (D) of at least 1 mm. PI. P.24041.WO / EBFS August 27, 2024 - 16 - 10. Curb-loading device (10) according to one of the preceding claims, wherein at least two seals (60) per contact sleeve (30) are arranged axially spaced apart from each other.

11. Curb-loading device (10) according to one of the preceding claims, wherein the seal (60) is designed as a sealing element (61), particularly preferably as a seal (62).

12. Curbside charging device (10) according to one of the preceding claims, wherein the charging socket housing (40) has a water drainage channel (70) in the area of ​​the charging socket housing base (42).

Images