Charging Plug Sensor Feedthrough Sealing Near Contact Elements
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Solution Overview
Problem
Existing charging plug solutions for high-power applications, such as battery-electric vehicles, face challenges in efficiently routing sensors close to contact elements while maintaining reliable sealing against moisture ingress, particularly when high electrical currents are involved.
Innovation Solution
A sensor arrangement is positioned directly adjacent to the contact elements, with sealing elements guiding and sealing multiple sensor cables, featuring individual bores for each cable and a design with a sealing area and position-locking area to ensure hermetic sealing and precise cable routing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are positioned directly adjacent to the contact elements for improved measurement accuracy, then measurement precision is improved, but the cable routing becomes more complex and sealing requirements increase
Solution Approach 1:
The charging plug is divided into functionally independent modules: a sensor unit with sensors positioned adjacent to contact elements, a separate cable guidance element with multiple through-holes for individual cable routing, and a sealing element. This segmentation allows sensors to be optimally positioned for measurement accuracy while cable routing is simplified through dedicated guidance structures.
Solution Approach 2:
A cable guidance element acts as an intermediary component between the sensor cables and the charging plug housing. This guidance element provides structured pathways for cable routing and interfaces with the sealing element, simplifying the overall cable routing complexity while enabling precise sensor positioning.
2Adaptability or versatility
If multiple sensor cables are routed through the charging plug insert, then sensor functionality is improved, but the risk of water ingress increases
Solution Approach 1:
The sealing function is segmented and assigned to a dedicated sealing element that works in conjunction with the cable guidance element. This sealing element features multiple through-holes that individually guide and seal each sensor cable, maintaining hermetic sealing while accommodating multiple sensor cables for enhanced functionality.
Solution Approach 2:
The sealing element provides localized sealing quality at each cable penetration point through individually designed through-holes and sealing lips. This localized approach ensures that each sensor cable routing location is hermetically sealed according to its specific requirements, preventing water ingress while maintaining overall sensor functionality.
3Reliability
If a sealed cable feedthrough structure is used to prevent moisture ingress, then reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The sealed cable feedthrough function is segmented into separate, modular components: a cable guidance element and a sealing element. These can be manufactured independently using standard processes and then assembled together, reducing overall manufacturing complexity while maintaining high sealing reliability through dedicated sealing features.
Solution Approach 2:
The sealing element is designed to work in conjunction with the cable guidance element in a self-contained manner. The sealing lips and through-holes are integrated into the sealing element itself, which automatically provides the sealing function when assembled with the guidance element, eliminating the need for additional complex sealing processes or operations.
Data Source
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AI summary
The invention relates to a charging plug with contact elements for a detachable, electrically conductive connection of a battery-electric vehicle to a charging station, comprising a charging plug housing with at least one cable feedthrough, wherein at least one sensor is arranged adjacent to the contact elements and in the plugging direction in the front area of the charging plug, wherein the sensor cables are passed through the cable feedthrough and sealed against the charging plug housing with at least one sealing element.