Emergency unlocking apparatus for an electric connection device for electric or hybrid vehicles

Abstract

The invention relates to a locking device (1), in particular a connection device having a locking apparatus (1) for an electric or hybrid vehicle having a charging socket and a charging-column-side charging plug or vice versa, a locking element (6), which can be moved in a motor-driven manner by a drive (3) and at least one gear stage (17, 18, 19), for releasably locking the charging plug in the charging socket, a flexible actuating element (6), which is wound at least in some regions, for manually moving the locking element (6), wherein the actuating means (5) is formed from a traction cable (12) made of plastic.

Description

[0001] STRICTLY CONFIDENTIAL

[0002] P25019WO 1 23 March 2026

[0003] Description

[0004] Emergency release device for an electrical connection device for electric or hybrid vehicles

[0005] The invention relates to an emergency release device, in particular an electrical connection device with a locking device for electric or hybrid vehicles with a vehicle-side charging socket and a charging column-side charging plug, or vice versa, and a locking element that can be moved by a motor via a drive and at least one gear stage for releasable locking of the charging plug in the charging socket and a flexible actuating element that is wound at least in some areas for manually moving the locking element.

[0006] The batteries of electric or hybrid vehicles need to be regularly supplied with electrical energy. This is done using a charging infrastructure, which typically includes one or more charging stations. For the charging process, the charging station's plug is generally connected to the vehicle's charging socket. However, the reverse is also possible. In this case, the charging station is equipped with the charging socket, while the vehicle has its own charging plug.

[0007] Locking the charging plug against the charging socket is necessary to prevent health hazards to users, for example. This is because high voltage, which can reach several hundred volts, is generally used at this point. Furthermore, the locking mechanism ensures STRICTLY CONFIDENTIAL operation.

[0008] P25019WO 2 23 March 2026

[0009] This ensures that only previously identified users can lawfully draw the energy provided by the charging station and that misuse is prevented. For this purpose, operator identification and authorization verification using an identification signal usually take place before such a charging process, as described in principle in WO 2010 / 149426 Al.

[0010] In the prior art, according to CN 2029695855 U, the adjustment of the locking element is typically carried out using an electric motor drive. The electric motor drive itself consists of an electric motor and a downstream, often multi-stage, gearbox. The multi-stage gearbox, in turn, acts on the locking element via a cam.

[0011] Another locking device, particularly for a charging plug, is known from the generic patent DE 10 2011 050 783 A1. In this case, too, an electromechanical drive is provided for the locking element, which allows switching between a locked and unlocked position of the locking element. Furthermore, an emergency release for emergencies is already mentioned. During the emergency release, the locking device or locking element is moved from its locked position to its unlocked position.

[0012] Such an emergency occurs, or an emergency release is required, among other things, when the vehicle electronics or the drive for the locking element or locking device fails. As a result, the charging plug can no longer be removed from the vehicle. This makes further driving or STRICTLY CONFIDENTIAL

[0013] P25019WO 3 23 March 2026

[0014] Towing the vehicle is hardly possible, or only with increased effort and additional costs.

[0015] In the case of DE 10 2011 050 783 Al, a pull-out mechanism is used for emergency release, with which at least part of the locking element can be moved in an emergency. This pull-out mechanism can be a rope, a Bowden cable, a rod, or a lever that terminates inside the vehicle, allowing it to be operated by a user in an emergency. In this respect, the pull-out mechanism, for example in conjunction with a lever, constitutes a tool for the manually actuated actuating element. Such a solution is structurally complex. Furthermore, in the described case, the emergency release can practically only be performed from inside the vehicle—and not from the outside. This becomes problematic if the vehicle can no longer be opened.

[0016] For this purpose, the further prior art according to DE 10 2013 222 509 A proposes a charging module for charging electrical storage media of electrically powered motor vehicles. This module includes an emergency release device that can be manually operated by means of an actuating element, with which the locking element can be moved into its unlocked position. Furthermore, a tool is mentioned with which a manual actuating force can be transmitted to the actuating element of the emergency release device.

[0017] The well-known emergency release is generally accessible from the outside when the flap covering the charging socket is open. STRICTLY CONFIDENTIAL

[0018] P25019WO 4 23 March 2026

[0019] Accessible. However, the actuating element is a pivot lever connected to the locking element, which is mounted externally on a housing that accommodates the drive and the locking element. Additionally, a passage opening for the tool is provided, sealed by a thin separating layer of plastic film. The separating layer or passage opening temporarily closes an additional guide. The guide is directed towards the actuating element or the pivot lever and serves for the defined translational movement of the tool. This again results in a high degree of design complexity. Furthermore, in the known invention according to DE 10 2013 222 509 A1, the guide must be adapted to the tool to be used, as well as to the vehicle itself, which complicates a universal emergency release. The invention aims to remedy this overall.

[0020] The generic prior art is formed by DE 10 2019 129 887 A1. This document discloses a locking device for an electric or hybrid vehicle with an electric drive and multiple gear stages for moving a control element. The control element can be used for releasably locking a charging plug in the charging socket. In order to return the locking element to its initial position, i.e., an unlocked position, in the event of a power failure or interruption, the document proposes moving the locking element back to its initial position by means of a cable. For this purpose, the cable is wound around a winding drum, the winding drum interacting with a helical spring, which interacts with a drive shaft in such a way that a clutch formed by the spring element is strictly confidential.

[0021] P25019WO March 23, 2026

[0022] The mechanism is activated. When the rope is pulled, the diameter of the spring element is reduced, causing it to clamp between the spring element and the drive shaft. This clamping action allows the drive shaft to be moved by means of the rope. The movement of the drive shaft can then be used to operate the locking element.

[0023] The object of the invention is to provide an improved emergency release for a locking device and, in particular, to further develop such an emergency release device in such a way that it uses the fewest possible components, provides permanently stable actuation, reduces the space required for the emergency release to a minimum, and provides a structurally simple solution.

[0024] This problem is solved by the features of independent claim 1. Advantageous embodiments of the invention are specified in the dependent claims. It should be noted that the exemplary embodiments described below are not limiting; rather, any number of variations of the features described in the description, the dependent claims, and the drawings are possible.

[0025] According to claim 1, the object of the invention is achieved by providing an emergency release device for an electrical connection device for electric or hybrid vehicles, with a vehicle-side charging socket and a charging station-side charging plug, or vice versa, and a motor-driven, drive unit with at least one gear stage.

[0026] P25019WO 6 23 March 2026

[0027] A locking element for the releasable locking of the charging plug in the charging socket, wherein an actuating element for manually operating the locking element is provided, and a flexible actuating element, at least partially wound, for manually operating the locking element, wherein the actuating means is formed from a pull cable made of plastic. The inventive design of the emergency release device now makes it possible to provide an emergency release using the simplest possible structural means, which enables emergency release with sufficiently high long-term stability.

[0028] By using a synthetic rope, a groove release mechanism can be implemented in the locking device with the simplest design features and, in particular, at low cost. Synthetic materials offer sufficient tensile strength while also providing the advantage of flexibility, allowing for adequate movement of the locking element. This provides a cost-effective, sufficiently stable, and flexible means of moving the locking element. For movement, the pull rope is wound at least partially within the locking device and can be grasped and moved manually. Unwinding the pull rope then returns the locking element from an extended position to its initial position.

[0029] The emergency release device is an emergency release device in which a locking element can be moved or extended from the emergency release device, so that a positive locking connection is STRICTLY CONFIDENTIAL

[0030] P25019WO 7 23 March 2026

[0031] a connection can be established between a charging socket and a charging plug. Typically, a charging socket is provided on the motor vehicle, into which a charging plug can be inserted, with the charging plug being located at a charging station or, for example, a suitable socket, such as in a garage. Of course, a reverse arrangement of charging socket and charging plug is also conceivable according to the invention.

[0032] To increase operator convenience, the charging plug is locked using an electric motor. A locking element is moved, particularly linearly, by the electric motor and a gearbox located between the electric motor and the plug, so that the locking element engages with the charging socket or plug. The arrangement of the emergency release mechanism is freely selectable. Preferably, the emergency release mechanism is located inside the vehicle, so that it is associated with the charging socket. Consequently, when the charging plug is inserted into the vehicle's charging socket, the locking element is then engaged by the electric motor. The charging plug is then fixed in the charging socket and secured by the locking element.Securing the charging plug is absolutely essential, as very high currents flow during charging, especially short-term charging, which can endanger the user. In the event of a power failure and / or a defect in the electric drive of the emergency release device, the locking element must be removable from the charging plug so that the vehicle can be put back into operation or, for example, STRICTLY CONFIDENTIALLY.

[0033] P25019WO 8 23 March 2026

[0034] It is towable. The manual unlocking mechanism proposed according to the invention, using a wound plastic rope, allows for the emergency unlocking of the charging plug in the simplest way possible, with minimal design effort and sufficient long-term stability.

[0035] If the locking element can be moved from a locking position to an unlocking position by means of the pull cable, a further embodiment of the invention can be achieved. The pull cable is arranged in the locking device or is wound up in such a way that the locking element can be moved from the locking position to the unlocking position by manually pulling on the pull cable. The locking position is defined as when the locking element is extended from the locking device and locks, i.e., holds the charging plug in the vehicle. In the extended state, the locking element holds the charging plug in the charging position, preferably by engaging in a recess in the charging plug. Once the charging process is complete or the vehicle operator interrupts the charging process, the locking element is released from the extended position.The locking position is engaged, and the locking element is moved back into the locking device, thus returning it to its initial or unlocked position. The pull cable can then be manually grasped and moved until the cable unwinds and returns the locking element to its initial position.

[0036] It has proven advantageous if the plastic-made pull rope is at least partially surrounded by STRICTLY CONFIDENTIAL

[0037] P25019WO 9 23 March 2026

[0038] A drive shaft for the locking element can be wound. To achieve a structurally simple solution, the pull cable can act directly on a drive shaft for the locking element. Preferably, the locking element is moved by means of an electric drive and one, two, or more gear stages. By selecting the appropriate number of gear ratios, the speed during locking or moving of the locking element can be adjusted, and sufficient force can be provided to move the locking element even in extreme situations. An extreme situation could occur, for example, due to jamming or contamination in the movement area of ​​the locking element. Gear stages can also be used to enable a compact, for example, very flat design of the locking device; so-called crown gear stages can be used for this purpose.Advantageously, a drive shaft in the gearbox, in particular a drive shaft of a spindle drive, can be used to actuate the locking element. When a gear stage is mentioned in this context, this also refers to different types of gearboxes, such as a spur gear, a worm gear, a spindle drive, a crown gear, or similar. The locking device is therefore not limited to a specific type of gearbox or a particular gear ratio; rather, any gear stages, such as a worm gear with a spur gear and a spindle drive, can be combined. Preferably, the pull cable is wound around a drive shaft of a spindle gear stage. STRICTLY CONFIDENTIAL.

[0039] P25019WO 10 23 . March 2026

[0040] It has proven advantageous to have the pull rope wound on a cable drum. Winding the pull rope on a drum offers the advantage of guiding the rope and simultaneously ensuring a uniform force transmission to the control element. Furthermore, the torque applied to the drive shaft can be varied and adjusted to the requirements of the locking device by selecting the appropriate diameter of the cable drum or a corresponding winding radius. In addition, a cable drum provides a structurally simple way to ensure secure guidance of the pull rope within the locking device.

[0041] The pull cable is wound around the cable drum, at least partially, so that it can be unwound from the drum by manually pulling on it. It has proven particularly advantageous if the pull cable is formed integrally with the cable drum. This integral manufacturing process allows for extremely cost-effective production of the actuating element, as the entire assembly, consisting of the pull cable and the winding drum, can be manufactured in a single injection molding process. This results not only in a design advantage but also in a cost advantage for the locking device as a whole. The integral construction also offers the advantage of eliminating stress concentrations at the transition between the pull cable and the cable drum, since the actuating element is manufactured in one piece and is therefore made of a single material.Consequently, if a power outage occurs during the charging process or after the vehicle has been parked for an extended period, the actuating element may be damaged by STRICTLY CONFIDENTIALLY.

[0042] P25019WO 11 23 . March 2026

[0043] Manual engagement is required, causing the portion of the cable wound on the cable drum to unwind from the drum and engage the drive shaft in the locking device. Preferably, there is a positive connection between the cable drum and the output shaft.

[0044] The cable drum carries the traction cable and can also have a drive contour, which can engage with the locking device's gearbox. Preferably, the cable drum can engage with a drive shaft on a gearbox stage. For this purpose, the cable drum has a drive contour that enables a positive fit between the cable drum and a gearbox stage and / or a drive shaft. The drive contour can extend from a planar portion of the drum towards the gearbox axis, thus enabling a positive fit with, for example, a gear of the gearbox stage. The drive contour is preferably also integrally manufactured with the cable drum and the traction cable. It has proven advantageous if a freewheel is formed between the cable drum and the drive shaft and / or the gearbox component.On the one hand, the formation of a drive contour on the cable drum allows force to be transmitted into the gearbox and / or the drive shaft, and on the other hand, the freewheel provides sufficient clearance to move the locking element independently of the groove actuation, i.e., the actuating means. Thus, it is possible to move the locking element from the locked position to the unlocked position. STRICTLY CONFIDENTIAL.

[0045] P25019WO 12 23 . March 2026

[0046] For example, a recess may be present in a drive gear of the transmission into which a drive contour of the actuating element engages. The arrangement of the recess and the drive contour is designed such that, in the locked position of the locking element, the actuating element, when manually actuated, moves the locking element back into the unlocked position. Simultaneously, sufficient free play exists in conjunction with the drive contour and the gear element, allowing the locking element to move independently of the actuating element. Only in emergency operation does the actuating element engage the drive shaft or gear. A positive fit can be established between the gear and / or the drive shaft and the actuating element. A protrusion on the gear and / or the drive shaft may also be present, which interacts with a protrusion and / or recess on the actuating element.In any case, a suitable freewheel must be provided between the actuating element and the output, i.e. a drive shaft and / or a gear, which allows the locking element to be actuated independently of the actuating element.

[0047] If the pull cable is led out of a housing of the locking device and has an external coupling point, a further advantageous embodiment of the invention results. The overall one-piece construction of the actuating element offers the aforementioned advantages, such as the absence of stress peaks in connection areas; a further design advantage can be achieved by additionally molding a coupling point onto the pull cable. The pull cable extends from the housing of the locking device and can be manually STRICTLY CONFIDENTIAL

[0048] P25019WO 13 23 . March 2026

[0049] The manual actuation mechanism must be mounted on the pull cable. Since a manual actuation device is required on the pull cable, it has proven advantageous to have a coupling element or coupling point molded onto the pull cable itself. A handle or loop, for example, can then be mounted at the coupling point, allowing an operator to grip it with their hand or fingers to actuate the groove in the locking device.

[0050] Polyamide plastics, preferably polyamide plastics with a tensile strength of >40 mPa / mm², have proven to be the preferred materials for the pull rope. 2It has been highlighted that polyamides, such as PA6 or PA66, exhibit high strength combined with high elasticity. In other words, the material used provides sufficient tensile strength for transmitting the emergency actuation force while simultaneously allowing the pull rope to be wound onto the drum. Winding or bearing the rope against the drum offers the aforementioned advantages, such as guiding the pull rope and simultaneously introducing a torque corresponding to the winding radius of the pull rope on the drum.

[0051] In one embodiment of the invention, the pull rope has a diameter of >1.5 mm, preferably >2 mm, and even more preferably >2.5 mm. With the aforementioned materials, a tensile strength of at least 150 Newtons (N), preferably >170 N, can be achieved. The aforementioned materials and material specifications offer sufficient flexibility for the pull rope and can simultaneously meet the high requirements of STRICTLY CONFIDENTIAL

[0052] P25019WO 14 23 . March 2026

[0053] Tensile strength, also in relation to the temperature ranges encountered in use from -40 to +80 degrees, is stable.

[0054] The design according to the invention provides a structurally simple and cost-effective solution for actuating the groove in the locking device. An emergency actuation can be provided with just one component in conjunction with the gearbox in the locking device.

[0055] The invention is explained in more detail below with reference to the accompanying drawings and a preferred embodiment. However, it is important to note that this embodiment does not limit the invention but merely represents an advantageous configuration. The features shown can be implemented individually or in combination with other features described in the description and claims.

[0056] It shows:

[0057] Fig. 1 shows a three-dimensional top view of a locking device designed according to the invention in a top view and a representation without a housing cover.

[0058] Fig. 2 shows an actuating element shown separately from the locking device. STRICTLY CONFIDENTIAL

[0059] P25019WO 15 23 . March 2026

[0060] Fig. 3 shows a three-dimensional view of an actuating element, with an electric drive and downstream gearbox as well as a locking element.

[0061] Fig. 4 shows a detailed view of a gear stage with a freewheel implemented in a gear for the engagement of the actuating element and

[0062] Fig. 5 shows a top view of the actuating element and a drive contour arranged on the actuating element or a rope drum.

[0063] Fig. 1 shows a locking device 1 in a three-dimensional view and in a top view of the open housing 2, i.e., without a housing cover. The locking device comprises an electric drive 3, a multi-stage gearbox 4, an actuating element 5, and a locking element 6. Also visible are an electrical component carrier 7, fastening means 8, 9, a connector socket 10, and a guide 11 for a pull cable 12 of the actuating element 5. A coupling point 13 is integrally formed at one outer end of the pull cable 12.

[0064] The drive 3 comprises an electric motor 14, on whose output shaft 15 a wear gear 16 and a first gear stage 17 are mounted in a rotationally fixed manner. The first gear stage 17 engages with an intermediate gear stage 18, which in turn acts on a further gear stage 19. The further gear stage engages with the locking element 6 and moves the locking element 6 into a locking position or an unlocking position. In this embodiment - STRICTLY CONFIDENTIAL

[0065] P25019WO 16 23 . March 2026

[0066] For example, the drive 3 is formed from the motor 14 and several gear stages 17, 18, 19.

[0067] The position of the locking element 6 can be detected by means of contacts 20 on the electrical component carrier 7 in conjunction with the locking element 6. Furthermore, the electrical component carrier 7 is in electrical contact with the connector socket 10, thus enabling control of the locking device 1.

[0068] In Fig. 2, the actuating element 5 is shown in a three-dimensional representation, detached from the locking device 1. The actuating element comprises a cable drum 21, a drive contour 22, a pull cable 12, and the coupling element 13. In this embodiment, the cable drum 21 is freely rotatable on an axis 23, for which purpose the cable drum 21 has an arc 24. The actuating element 5 is a single piece and is made of a plastic, preferably a polyamide. The pull cable 12 is partially wound around the cable drum 21 and engages with the guide contour 25 on the cable drum 21, the wound area of ​​the cable drum 21 being designed such that a winding area of ​​<270° is achieved. Preferably, a winding area of ​​approximately 180° is present on the cable drum 21.The one-piece construction of the actuating element 5 allows for a cost-effective and structurally simple actuating element for emergency opening of the locking device 1.

[0069] Figure 3 shows a fundamentally identical design of the drive 3 for moving the locking element 6, with only an alternative embodiment of a STRICTLY CONFIDENTIAL

[0070] P25019WO 17 23 . March 2026

[0071] The coupling element 26 is integrally connected to the pull cable 12. It can be seen that the actuating element 5, together with the gear stage 19, is freely pivotable on the axis 23. The gear stage 19 has two gears 27, 28, which in this embodiment are integrally formed. The gear 27 engages directly with the locking element 6 and moves the locking element 6 in the direction of arrow P into or out of the housing 2. Fig. 3 shows the locked position, so that a travel distance S can be achieved by means of the locking element 6. If the position shown in Fig. 3 is reached, the locking element 6 is locked in the position shown in Fig. 3. If the position of the locking element 6 shown in 3 is such that no current is available for the drive 3, a force F can be introduced into the pull rope 12 by a pulling movement Z, causing a rotational movement in the direction of the arrow PI into the actuating element 5 or .The cable drum 21 is engaged, causing the gears 27 and 28 to also pivot clockwise around the axis 23. The movement of the gears 27 and 28, in turn, causes the control element 6 to move into the housing 2 of the locking device 1.

[0072] The interaction between the gear 28 and the cable drum 21, or rather the drive contour 22 on the cable drum 21, is illustrated in Figures 4 and 5. In this embodiment, the drive contour 22 engages in a recess 29 in the gear 28 and engages with a strut-like stop 30. A drive surface 31 on the drive contour 22 engages with the strut-like stop 30 and thus moves the gear 28, as well as the gear 27, in the direction of arrow PI, thereby moving the locking element 6. STRICTLY CONFIDENTIAL

[0073] P25019WO 18 23 . March 2026

[0074] The recess 29 in the gear forms the freewheel 29 for the gear 28, thus enabling independent movement from the actuating element 5. Only in the extended position of the locking element 9 is the gear 28 in a position such that the stop 30 engages with the drive surface 31 of the drive contour 22. The drive contour 22 and the recess 29 are thus aligned. The winding area 25 is also aligned, with the winding area 25 simultaneously serving as the guide contour 25. In this embodiment, the guide contour 24 forms an angle α of <180 degrees, with the guide contour 25 corresponding, for example, to a circumference of approximately 25 mm on the cable drum 21.Thus, a pulling motion Z on the pull cable 12 can initiate sufficient movement in the gear 28 to move the locking element 6 over the travel path S and thereby move the locking element 6 back into the housing 2 of the locking device 1. The selected gear ratio between the gears 27 and 28 can influence the travel path S, so that, in conjunction with the actuating element 5, sufficient pulling force can be provided and movement can be initiated in the locking element 6 to enable the safe unlocking of a charging plug. STRICTLY CONFIDENTIAL.

[0075] P25019WO 19 23 March 2026

[0076] Reference symbol list

[0077] 1 Locking device 2 Housing

[0078] 3 Drive

[0079] 4 gearboxes

[0080] 5 Actuating element

[0081] 6 bar element

[0082] 7 Electrical component carriers 8, 9 Fasteners

[0083] 10 sockets

[0084] 11 Management tools

[0085] 12 tow rope

[0086] 13, 26 Coupling element

[0087] 14 Electric motor

[0088] 15 Output shaft

[0089] 16, 27, 28 gear

[0090] 17, 19 gear stage

[0091] 18 Intermediate gear stage

[0092] 20 contacts

[0093] 21 Rope drum

[0094] 22 Carrying contour

[0095] 23 axle

[0096] 24 bore, opening

[0097] 25 Leadership contour

[0098] 29 Recess, free run

[0099] 30 strikes

[0100] 31 Drive area

[0101] P, P1 Arrow

[0102] S travel path

[0103] Z train movement

Claims

STRICTLY CONFIDENTIAL P2501 9WO 20 23 . March 2026 Patent claims 1. Locking device (1), in particular a connection device with a locking device (1) for an electric or hybrid vehicle with a charging socket or a column-side charging plug, or vice versa, a locking element (6) movable by a motor by a drive (3) and at least one gear stage (17, 18, 19) for releasably locking the charging plug in the charging socket, a flexible actuating element (5) wound at least in part for manually moving the locking element (6), characterized in that the actuating means (5) is formed from a pull rope (12) made of plastic.

2. Locking device (1) according to claim 1, characterized in that the locking element (6) can be moved from a locking position to an unlocking position by means of the pull cable (12).

3. Locking device (1) according to one of claims 1 or 2, characterized in that the pull rope (12) can be wound at least partially around a drive shaft of a gearbox (4) for the locking element (6).

4. Locking device ( 1 ) according to one of claims 1 to 3 , characterized in that the pull rope ( 12 ) can be wound on a rope drum .

5. Locking device (1) according to claim 4, characterized in that the pull rope (12) is formed integrally with the rope drum (21). STRICTLY CONFIDENTIAL P2501 9WO 21 23 . March 2026 6. Locking device (1) according to one of claims 4 or 5, characterized in that the cable drum (21) has a drive contour (22), wherein the drive contour (22) can be engaged with the transmission (4), in particular with a gear (16, 27, 28) of the transmission (4).

7. Locking device ( 1 ) according to one of claims 4 to 6 , characterized in that a free wheel ( 2 9 ) is formed between the rope drum ( 21 ) and the gearbox ( 4 ).

8. Locking device (1) according to one of claims 1 to 7, characterized in that the pull rope (12) is led out of a housing (2) of the locking device (1) and has an external coupling element (13, 26).

9. Locking device (1) according to one of claims 1 to 8, characterized in that the pull cable (12) is made of a polyamide, preferably with a tensile strength of >40 mPa per mm 2 gebildet i st .

10. Locking device ( 1 ) according to one of claims 1 to 9 , characterized in that the pull rope ( 12 ) has a tensile strength of at least 150 Newtons (N) , preferably > 170 N .

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