Panel-mounted charging plug for attaching to the body of an electric or hybrid vehicle

Abstract

The invention relates to a panel-mounted charging plug (1) for attaching to the body (3) of an electric or hybrid vehicle (4), said plug having two charging contacts (5) for a galvanically conductive plug-in connection to two corresponding charging contacts of a corresponding charging coupling (6), and two electrical bushings (7) which are guided through the panel-mounted charging plug (1), are each connected at one end in a galvanically conductive manner to a charging contact (5) and lead at their other end in a galvanically conductive manner to two battery terminals (8, 13) which are spatially separated from one another. In this manner, a panel-mounted charging plug for electric or hybrid vehicles is provided that can be used universally.

Description

[0001] Charging plug for mounting on the vehicle body

[0002] an electric or hybrid vehicle

[0003] The invention relates to a charging plug for mounting on the body of an electric or hybrid vehicle, with two charging contacts for a galvanically conductive plug connection with two corresponding charging contacts of a corresponding charging coupling and two electrical feedthroughs through the charging plug, which are each galvanically connected at one end to a charging contact.

[0004] Electric and hybrid vehicles have a rechargeable energy storage system, usually a high-voltage battery, which provides energy to an electric drive motor during 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 located between the charging station and the vehicle. This charging cable, conforming to, for example, the European standard IEC 62196 Type 2, has a charging plug on one end that can be inserted into a charging socket on the charging station, and a charging coupler on the other end that can be connected to a charging connector installed in the electric or hybrid vehicle. For the purposes of this text, charging sockets, charging plugs, charging couplers, and charging connectors are collectively referred to as "charging connectors."Charging sockets and charging couplers have contact sockets as charging contacts, while charging plugs and charging plugs that can be installed in electric or hybrid vehicles have contact pins as charging contacts. These pins can be inserted into the contact sockets or removed from them. Therefore, a set always consists of a charging connector and a corresponding charging connector, which can be plugged together. When we refer to a charging connector and a corresponding charging connector, this means, on the one hand, that the charging connectors have the same mating face, but one mating face has contact pins, while the other mating face has contact sockets. On the other hand, the term "corresponding charging connector" is also used when the mating faces only partially correspond in the aforementioned sense, for example, if the corresponding charging connector...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-in face, so that the charging connector and the corresponding charging connector can also be plugged together in this case.

[0005] One such case is a DC charging connector attached to a charging cable, conforming to the European standard IEC 62196 Type 2. This type of connector can be plugged into a charging plug integrated into the body of an electric or hybrid vehicle, suitable for both AC and DC charging. However, the DC charging connector only has communication contacts and a protective earth contact on the AC connector side; it lacks contacts for live conductors and a neutral conductor for AC charging. A live conductor (also commonly referred to as a phase) 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 capable of contributing to the distribution of electrical energy.In the European standard IEC 62196 Type 2, the contacts referred to here as AC charging contacts are designated LI, L2, and L3 (live conductors) and N (neutral conductor), and the DC charging contacts are designated DC+ and DC-. This understanding is not contradicted by the fact that the European standard IEC 62196 Type 2 also recognizes an operating mode in which DC charging takes place via the contacts LI, L2, L3, and N.

[0006] The Combined Charging System (CCS) is a charging system for electric vehicles designed for both AC and DC charging and offers a standardized interface. It exists in two versions, CCS1 and CCS2, each based on different regional standards. CCS1 is primarily used in North America and is an evolution of the Type I connector. It combines the Type I connector (J1772) for AC charging with additional pins for DC charging. The additional DC charging option enables fast charging, making CCS1 a preferred choice in North America. CCS2 is mainly used in Europe and other regions. This version is based on the IEC 62196 Type 2 standard, which uses a round socket for AC charging that is additionally equipped with two DC pins.The Type 2 connector is widely used in the European market and, in addition to single-phase and two-phase charging, also allows three-phase charging, enabling higher charging capacities and being frequently used in charging stations in Europe. Unlike CCS1, CCS2 thus supports three-phase charging and is designed for European power grids. In North America, however, three-phase charging is mainly limited to the commercial vehicle sector, which is why CCS1 does not include this feature.

[0007] In North America, the North American Charging System (NACS) is used, which describes charging connectors designed for both AC and DC charging via the same connection. A characteristic feature of the NACS standard is the linear arrangement of the charging contacts through the connector, enabling a compact and space-saving design. With AC charging, the current in the vehicle is converted into a form usable by the battery system, whereas DC charging directly supplies the battery system with a charging power of up to 250 kW. This allows for rapid energy transfer, which is particularly useful at fast-charging stations.

[0008] The NACS standard uses a two-pole configuration for power transmission and also includes a communication module that enables data exchange between the vehicle and the charging station. This communication serves to monitor the charging process and dynamically adjust the charging power to the requirements. For use with alternating current, NACS is designed for a current of up to 80 A at a maximum of 277 V, which corresponds to the upper power range for households with three-phase connections in the USA. With a split-phase connection (single-phase, three-wire system) widely used in North America, typical values ​​are 48 A at 240 V.

[0009] Since NACS uses the two main contacts in the vehicle to transmit both direct current (DC) and single-phase alternating current (AC), a special technology for detection and wiring is required. This technology is integrated either in the vehicle itself or in an adapter and ensures that the correct current type is used. Unlike the Combined Charging System (CCS), where these contacts are galvanically isolated, NACS achieves this adaptation without additional insulation. Neither the NACS nor the CCS1 standard permits three-phase charging, as provided for in CCS2 and the US commercial vehicle standard SAE J3068, which is based on IEC 62196 Type 2. Three-phase charging at 480 V is common in the US, particularly in the commercial vehicle sector, but is not supported in standard passenger car charging systems.

[0010] The differences between the charging port standards NACS, CCS1, and CCS2 present various challenges affecting both the technical and practical aspects of electric vehicle charging. A key issue arises from the different connector interfaces used by the standards at the charging station, as well as the differences in how the charging contacts are used for direct current (DC) and alternating current (AC). Because the connector interfaces of NACS, CCS1, and CCS2 are designed differently, electric vehicles require specific connector types or adapters for each system to ensure compatibility. Another important difference lies in how the charging contacts for DC and AC are routed through the charging connector. With NACS, the same feedthroughs are used for both DC and AC charging, and these then lead to a common cable to the battery.This standardized contact configuration saves space and allows for a compact design, but requires additional technology in the vehicle for detection and switching between the two current types. In contrast, CCS2 uses separate feedthroughs for DC and AC current with subsequent separate leads to the battery, enabling galvanic isolation of the systems and offering potential safety advantages. However, this also increases the complexity of the connector and the wiring requirements.

[0011] These differences lead to practical challenges in the design of charging infrastructure and vehicles. Vehicles with NACS connectors may require special adapters or be limited to charging stations that support the standard, particularly in regions where CCS2 is more prevalent. At the same time, the galvanic isolation of CCS2 offers additional safety advantages, but these come at the cost of increased complexity and space requirements within the connector. This creates challenges both for the expansion of charging infrastructure and for vehicle manufacturers, who must adapt their models to the prevailing standards in different regions. The object of the invention is to provide a charging connector for electric and hybrid vehicles that is universally applicable, taking into account the aspects described above.

[0012] This problem is solved by the subject matter of the independent claims. Further developments of the invention are described in the dependent claims.

[0013] According to the invention, a charging plug is provided for attachment to the body of an electric or hybrid vehicle, with two charging contacts for a galvanically conductive plug connection with two corresponding charging contacts of a corresponding charging coupling and two electrical feedthroughs through the charging plug, which at one end are each galvanically connected to a charging contact and at their other end are each galvanically connected to two spatially separated battery terminals.

[0014] The charging connector according to the invention is characterized by its universal compatibility with various standards, such as NAGS, CCS1, and CCS2, which are used for electric and hybrid vehicles in different regions. Its special design makes it possible to meet existing, country-specific requirements for AC and DC interfaces without requiring any further modifications within the vehicle. The division of the electrical connection into at least two separate battery terminals allows for the transmission of direct current and alternating current to the vehicle battery via spatially separate lines. This arrangement ensures compliance with the specific requirements of both AC and DC charging for the vehicle battery, thus facilitating the use of the connector in various charging environments.This solution offers the advantage that the charging connector provides galvanically isolated paths for AC and DC, which offers safety benefits because the AC and DC current paths can be routed to the battery in isolation. Detection and switching between the current types is handled by a vehicle-side control unit, which selects and adjusts the current type based on the requirements of the respective charging situation.

[0015] According to a further development of the invention, the two charging contacts for the plug connection transition directly into the bushings with the two corresponding charging contacts of the corresponding charging coupling. The two charging contacts for the plug connection with the two corresponding charging contacts of the corresponding charging coupling can be formed integrally with the bushings.

[0016] This further development of the invention, in which the two charging contacts for the plug connection transition directly and immediately into the feedthroughs, offers several technical advantages. First, the one-piece design of the charging contacts and feedthroughs reduces the number of components, simplifying the manufacturing and assembly of the charging plug. This not only lowers production costs but also eliminates potential weak points caused by transition connections, resulting in greater reliability and robustness of the charging plug.

[0017] Another advantage of this one-piece design lies in the improved electrical conductivity. Since there are no transitions or contact points between the charging contacts and the feedthroughs, electrical resistance is reduced, making energy transfer more efficient. This helps minimize energy losses and reduce heat generation during the charging process, which is particularly important at high charging power levels and can shorten charging time.

[0018] Additionally, the one-piece design increases the mechanical stability of the charging connector. Since no mechanical connections between charging contacts and feedthroughs are necessary, the connector can better withstand stresses and mechanical strains. This stability is particularly advantageous in vehicle environments, where the charging connector is subjected to repeated insertion and removal cycles.

[0019] According to a further development of the invention, a connecting component is attached to each of the two electrical feedthroughs, which provides at least one battery connection that is galvanically connected to the respective electrical feedthrough. In one embodiment, the connecting component provides exactly two galvanically connected battery connections.

[0020] This further development of the invention, in which a connection component is attached to each of the two electrical feedthroughs, providing at least one galvanically connected battery terminal, offers several advantages in terms of flexibility, safety, and efficiency of energy transmission. By attaching such a connection component, additional connection options can be created, enabling flexible adaptation of the electrical lines and their configuration within the vehicle. This is particularly advantageous when different battery architectures need to be supported, as the galvanically connected battery terminals allow for different conduction paths for AC and DC.

[0021] If the connection component, as described in one embodiment, provides exactly two galvanically interconnected battery terminals, this can further enhance safety. This configuration allows for a stable current distribution and ensures optimal use of the conductor capacity by distributing the current through multiple connection points. This reduces the stress on individual connection points and helps extend the service life of the electrical bushings. The galvanic connection between the two battery terminals also ensures that the connected battery is charged continuously and efficiently, regardless of whether it is an AC or DC connection.

[0022] Furthermore, this arrangement simplifies the installation and maintenance of the charging plug, as the connection components can be designed to be compatible with both AC and DC currents, allowing for easy connection to various chargers. The galvanic isolation and structural separation of the AC and DC connections ensure a high level of safety, which is particularly important in high-voltage applications to prevent electrical arcing and short circuits.

[0023] According to a further development of the invention, the connecting components are designed as stamped and bent parts with a recess by which they are slid onto the respective electrical bushing. The recess can be provided with a collar. The stamped and bent parts can each be attached to the respective electrical bushing by means of a contact spring. The stamped and bent parts can be made of copper or aluminum. The battery terminals can be attached to the stamped and bent parts as separate components.

[0024] This further development of the invention, in which the connecting components are designed as stamped and bent parts that are slid onto the electrical bushings and provided with a recess, offers several technical advantages, particularly with regard to manufacturing, assembly, and electrical properties. The use of stamped and bent parts made of materials such as copper or aluminum offers the advantage of high conductivity, which contributes to efficient energy transfer. Copper and aluminum are also cost-effective and easy to process, making production economical and efficient. The recess in the stamped and bent parts allows the components to be quickly and easily slid onto the electrical bushings, reducing assembly time and simplifying the design of the charging plug.The optional collar pull around the recess ensures a stable and firm connection, securing the component against unwanted movements and increasing mechanical stability.

[0025] Securing the stamped and bent parts to the respective electrical bushing using a contact spring offers additional advantages in terms of electrical contact quality and vibration resistance. The spring action of the contact spring ensures a reliable and permanent connection to the electrical bushing, which does not lose conductivity even under mechanical vibrations such as those encountered during vehicle operation. This flexible contact connection minimizes the risk of contact interruptions and ensures constant current transmission, thus increasing operational reliability.

[0026] The ability to attach the battery terminals as separate components to the stamped and bent parts increases the system's flexibility and modularity. This allows for easy replacement or adaptation of the battery terminals to meet specific vehicle or battery architecture requirements without requiring modification of the entire terminal assembly. Furthermore, separating the battery terminals from the stamped and bent parts reduces thermal stress and prevents potential material wear, further improving the service life and ease of maintenance of the charging connector.

[0027] According to a further development of the invention, the end of each electrical feedthrough facing away from the respective charging contact provides a battery connection. This battery connection can be cylindrical and provided with an internal thread.

[0028] This further development of the invention, in which the end of an electrical bushing opposite the charging contact provides a battery connection that is cylindrical and equipped with an internal thread, offers several functional and practical advantages, particularly with regard to mounting flexibility, electrical connection reliability, and adaptability. The cylindrical battery connection with internal thread enables secure and stable attachment to the vehicle's battery terminal. The internal thread allows for a tightly screwed connection, ensuring high mechanical stability and remaining reliable even under the vibrations and shocks typical in vehicles. This type of connection ensures that the contact remains permanently established and no loose connections occur, thus increasing the overall reliability of the charging connector.This design is advantageous during initial assembly as well as maintenance or repair work, as it allows for quick and easy handling. The internal thread also enables the use of standardized screws and fasteners, increasing compatibility with various battery connections and simplifying the procurement of spare parts.

[0029] Electrically, the cylindrical battery connector offers a large contact area, minimizing contact resistance and ensuring efficient current transfer. The larger contact area also contributes to better heat dissipation, reducing heat generation at high currents. This thermal stability is particularly advantageous in fast-charging applications, as it prevents contact overheating, thus promoting both the safety and longevity of the charging connector. Overall, this cylindrical, internally threaded design of the battery connector provides a robust, efficient, and flexible interface to the vehicle battery, meeting the demands of high-current charging as well as the practical requirements of installation and maintenance.

[0030] According to a further development of the invention, the electrical feedthroughs are each offset so that the longitudinal axis of the respective charging contact runs parallel to and at a distance from the longitudinal axis of the respective battery connection. The battery connections can be formed by plug and / or screw connectors.

[0031] The further development of the invention, in which the electrical feedthroughs are each angled so that the longitudinal axis of the respective charging contact runs parallel to and at a distance from the longitudinal axis of the battery connection, offers several significant advantages in terms of space saving, design flexibility, and connection options, particularly with regard to providing multiple battery connections. The angled design, i.e., the targeted redirection of the feedthroughs, creates the necessary space. Overall, the angled feedthrough thus offers better space utilization. The option of designing the battery connections as plug-in and / or screw connections significantly increases the connection flexibility of the charging plug. Plug-in connections allow for quick and easy assembly and disassembly, which is advantageous during maintenance and service work.Screw connections offer a stable and stronger mechanical connection that ensures permanent current transmission and has proven particularly effective under high current loads.

[0032] The invention is described in more detail below with reference to the drawings and preferred embodiments.

[0033] In the drawings, Fig. 1 schematically shows a charging plug according to an embodiment of the invention and a corresponding charging coupling in a side view.

[0034] Fig. 2 schematically shows a routing of the charging plug from Fig. 1 in a perspective view,

[0035] Fig. 3 schematically shows the implementation from Fig. 2 in an exploded view,

[0036] Fig. 4 schematically shows the implementation from Fig. 2 together with the side of the charging plug facing the vehicle battery and

[0037] Fig. 5 schematically shows the use of the charging plug from Fig. 1 on the body of an electric or hybrid vehicle.

[0038] Figure 1 shows a side view of a charging connector 1 according to an embodiment of the invention in conjunction with a corresponding charging coupling 6. This charging connector 1 is intended for mounting on the body 3 of an electric or hybrid vehicle 4, as shown schematically in Figure 5. The charging coupling 6 is designed to be connected to a charging cable of a charging station. As is common with charging connectors for electric or hybrid vehicles, the charging connector 1 also has two charging contacts 5, which establish a galvanically conductive connection with the corresponding charging contacts of the charging coupling 6.

[0039] The electrical feedthroughs 7 are designed to completely pass through the charging connector 1. The charging contacts 5 transition directly into the electrical feedthroughs 7, thus forming a single unit with them, thereby reducing the number of components required. This direct connection, shown in Figures 2 and 3, minimizes contact resistance and ensures more efficient energy transfer. This one-piece design also increases mechanical stability and reduces the risk of contact problems that could arise from wear or vibration.

[0040] At their other end, the electrical bushings 7 lead to spatially separated battery terminals 8 and 13. This arrangement allows for the separation of the AC and DC lines, each leading to the vehicle battery, thus ensuring a clear separation of the current paths, as shown in Fig. 4. Four AC battery terminals 8 are located in the upper area of ​​the vehicle battery side, while two DC battery terminals 13 are located in the lower area. This separation not only ensures safe current flow but also optimizes heat distribution, as the lines are physically separated, thus preventing overheating at high charging rates.

[0041] Electrical bushings 7 are fitted with connection components 9, each providing two galvanically connected battery terminals 8. The connection components 9, which are stamped and bent parts, have a recess 10 equipped with a collar 11. This design allows the components to be easily slid onto the bushings 7, with the contact spring 12 ensuring a reliable mechanical connection. The spring action of the contact spring 12 ensures that the connection remains stable even under vibrations and mechanical stresses during ferry operation, thus increasing the long-term reliability of the system.

[0042] The separate mounting of the battery terminals 8 on the stamped and bent parts allows for a modular design and facilitates maintenance. Should a battery terminal become defective or require replacement, this can be done without replacing the entire housing, reducing maintenance costs and minimizing vehicle downtime. The materials copper or aluminum, from which the stamped and bent parts can be manufactured, offer high conductivity and robustness. Copper is known for its excellent electrical conductivity, while aluminum is preferred due to its lighter weight and good corrosion resistance.

[0043] The end of the electrical bushings 7 opposite the charging contact 5 provides a DC battery connection 13 and is cylindrical in shape with an internal thread 14. This design enables a secure and firm connection of the battery terminals 8 to the corresponding cables in the vehicle. The internal thread 14 allows the use of standardized screw connections, ensuring simple and stable installation. Furthermore, the cylindrical shape contributes to the even distribution of mechanical loads, thereby increasing the durability of the battery connection 13.

[0044] The electrical bushings 7 are also offset, meaning that the longitudinal axis of the charging contacts 5 runs parallel to, but at a certain distance from, the longitudinal axis of the battery terminals 8 and 13. This offset ensures a compact design and optimizes space utilization in the vehicle, which is particularly advantageous where installation space is limited. The offset also allows for flexible cable routing in the vehicle, as the position of the battery terminals can be better adapted to the specific requirements of the vehicle architecture. This contributes to the easy integration of the charging plug into various vehicle models. Reference numeral list

[0045] 1 charging plug

[0046] 3 Bodywork

[0047] 4 Electric or hybrid vehicle 5 Charging contact

[0048] 6 Charging coupling

[0049] 7 electrical feedthrough 8 AC battery connection

[0050] 9 Connecting component

[0051] 10 Exclusion

[0052] 11 Collar pull

[0053] 12 Contact spring

[0054] 13 DC battery connection

[0055] 14 internal threads

Claims

Patent claims 1. Charging plug (1) for mounting on the body (3) of an electric or hybrid vehicle (4), with two charging contacts (5) for a galvanically conductive plug connection with two corresponding charging contacts of a corresponding charging coupling (6) and two electrical feedthroughs (7) passing through the charging plug (1), each of which is galvanically connected at one end to a charging contact (5) and at the other end of which each leads galvanically to two spatially separated battery terminals (8, 13).

2. Charging plug (1) according to claim 1, wherein the two charging contacts (5) for the plug connection with the two corresponding charging contacts of the corresponding charging coupling (6) transition directly into the feedthroughs (7).

3. Charging plug (1) according to claim 2, wherein the two charging contacts (5) for the plug connection with the two corresponding charging contacts of the corresponding charging coupling (6) are formed in one piece with the feedthroughs (7).

4. Charging plug (1) according to one of the preceding claims, wherein a connecting component (9) is attached to each of the two electrical feedthroughs (7), which provides at least one battery connection (8) galvanically connected to the respective electrical feedthrough (7).

5. Charging plug (1) according to claim 4, wherein the connecting components (9) are designed as stamped and bent parts with a recess (10) with which they are pushed onto the respective electrical feedthrough (7).

6. Charging plug (1) according to claim 5, wherein the recess (10) is provided with a collar pull (11).

7. Charging plug (1) according to one of claims 4 to 6, wherein the stamped and bent parts are each attached to the respective electrical feedthrough (7) by means of a contact spring (12).

8. Charging plug (1) according to one of the preceding claims, wherein the end of a respective electrical feedthrough (7) facing away from the respective charging contact (5) provides a battery connection (13).

9. Charging plug (1) according to one of the preceding claims, wherein the electrical feedthroughs (7) are each bent so that the longitudinal axis of the respective charging contact (5) runs parallel to and at a distance from the longitudinal axis of the respective battery connection (8).

10. Use of a charging plug (1) according to one of the preceding claims on the body (3) of an electric or hybrid vehicle (4).

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