DE102014000519B4 - Charging socket and method for assembling a charging socket - Google Patents

Abstract

Socket (21a, 21b, 29) for mounting on an at least partially electrically powered vehicle, with
A connection (20, 24) for feeding electrical energy into the vehicle,
A cable (12) having an outer insulation (13) electrically connected to the terminal (20, 24), and
- A plastic element (22 a, 22 b, 28) made of a foamed plastic, with which a portion of the charging socket (21 a, 21 b, 29), in which the cable (12) to the terminal (20, 24) is electrically connected, is foamed .
wherein the cable (12) extends along the connection (20) along a first axis (18a) and at an exit point from the plastic element (22b) along a second axis (18b), the first and second axes being at an angle ( α) of more than 20 degrees.

Description

Technical area

The present invention relates to a charging socket for mounting on an at least partially electrically driven vehicle and to a method for assembling such a charging socket.

Since petrochemical raw materials are becoming increasingly scarce and in many places strict limits for the CO ₂ emissions of motor vehicles apply, the powertrain of motor vehicles is increasingly being electrified. So-called plug-in hybrid vehicles and pure electric vehicles each have a charging socket, via which the battery of the motor vehicle electrical energy can be supplied from outside. The supply can be done usually via normal household sockets or via fast charging stations.

A charging socket in the sense of the present patent application can be understood in particular as a connection point of an at least partially electrically driven motor vehicle, in particular an electric or hybrid motor vehicle, to which an external charging line can be connected to supply a battery of the motor vehicle with electrical energy from outside the vehicle To supply motor vehicle.

State of the art

From the US 2013/0224969 A1 is a charging socket for an at least partially electrically powered vehicle previously known. The charging socket has several connections for feeding electrical energy into the vehicle, which are sealed on the vehicle side by means of sealing rings. Despite the sealing rings, moisture penetration into the charging socket can not be completely ruled out under unfavorable circumstances, which can lead to corrosion and short-circuiting even leading to fire.

Furthermore, from the DE 197 54 236 A1 an electrical cable with molded part known. In this, a connection surface area of the cable peripheral surface is completely encapsulated, encapsulated or foamed with a plastic material to form the molded part. The connecting surface area is at least a partial length of at least one connected to the cable peripheral surface intermediate layer in the manner of a ring or a sleeve, wherein the intermediate view is made of a material to which adheres the plastic material of the molding.

From the DE 10 2006 041 596 A1 a connector for a servomotor is known. In the connector, a cable is held in a terminal area by a housing made by injection molding.

Finally, out of the US 2010/0311269 A1 a solar module is known in which a housing for a combination with a cable is also injection-molded.

Description of the invention

Against this background, it is an object of the present invention to propose a charging socket, which has an improved tightness, especially against moisture.

Another object is to provide a method for assembling a charging socket, which leads to a charging socket according to the invention.

According to the invention, these objects are achieved by the subject matters of the independent patent claims. The dependent claims indicate embodiments of the invention.

Accordingly, the present invention includes a charging socket for mounting to an at least partially electrically powered vehicle having a port for injecting electrical energy into the vehicle and a cable having an outer insulation electrically connected to the port. According to the invention, the charging socket moreover comprises a plastic element made of a foamed plastic with which a region of the charging socket in which the cable is electrically connected to the terminal is foamed. For the purposes of the invention, plastic can also be understood to mean a synthetic resin.

The plastic element seals an inner connection area of the charging socket against moisture, thus preventing corrosion and thus extending the service life of the charging socket. In addition, due to the plastic element, the charging socket can not be opened improperly without damaging the charging socket. In this way, manipulations can be effectively avoided. In addition, space-optimized charging sockets can be realized taking into account a minimum bending radius of the cable by the plastic element. The plastic element may be designed such that an additional sealing of the cable can be omitted at an exit point of the plastic element.

Preferably, the plastic element not only surrounds the immediate area of the charging socket in which the cable is electrically connected to the terminal, but also adjacent to the External insulation of the cable. This achieves a wide-area seal.

According to the invention, the cable extends at the terminal for feeding electrical energy into the vehicle along a first axis and at an exit point from the plastic element along a second axis, wherein the first and second axes at an angle of more than 20 degrees, in particular more than 45 degrees, preferably more than 70 degrees. These angles make it possible to adapt the charging socket to the space available in the vehicle.

In one embodiment of the charging socket, the outer insulation of the cable contains silicone or consists essentially of silicone. By silicone, for example, polysiloxanes can be understood. Silicone rubber is preferably used, for example modified silicone rubber SiR. Silicone is used in particular in so-called high-voltage cables as external insulation. High-voltage cables are preferred for voltages between 42 volts and 600 volts. At these voltages, the cables can heat up considerably. Therefore, silicone is used as external insulation, because silicone is durable up to 180 ° C (for example, up to 3000 hours) temperature resistant. For a short time (for example up to 240 hours over the life of the cable), silicone can withstand temperatures up to 205 ° C. In so-called low-voltage cables, which are designed for voltages between 1 and 41 volts, usually other external insulation materials are used, such as e.g. Polyvinyl chloride, polyurethane or polyethylene. As a rule, these materials can only be permanently loaded up to 105 ° C. If temperatures in excess of 150 ° C may occur, other materials, e.g. Silicone, needed.

The plastic may comprise polyurethane or consist of polyurethane. Polyurethane foam is particularly suitable for sealing. The polyurethane may for example have a density of 700 kg / m ³ to 900 kg / m ³ measured according to DIN EN ISO 845 and / or a Shore A hardness of 50 to 70 measured in accordance with DIN 53505. Particularly advantageous is a density of the polyurethane of 800 kg / m ³ to 820 kg / m ³ and a Shore A hardness of 58 to 62, in particular substantially 60. At the above densities and Shore A hardnesses are particularly good sealing properties of the polyurethane.

The plastic element may have substantially the shape of a truncated cone. The connection for feeding electrical energy into the vehicle can be arranged in a region of a base surface of the truncated cone and the cable preferably leaves the plastic element via a cover surface of the truncated cone. The selected truncated cone shape takes into account the fact that it is advantageous to distribute the connections for feeding electrical energy, where a charging plug is to be inserted into the socket, over a fairly large first area, so that the connections easily and reliably accessible from the outside are, while on a cable outlet side of the plastic element already a smaller second area is sufficient. The shape of a truncated cone provides these two surfaces and is very economical with material.

In one embodiment, the cable has a connecting element, which is positively and / or non-positively connected to the outer insulation of the cable. The connecting element is also foamed with the plastic, so that the connecting element is materially and / or positively connected to the plastic element.

Due to the high currents and voltages necessary for efficient and fast charging of an at least partially electrically powered vehicle, the use of silicone for the outer insulation of the cable is advantageous. Polyurethane foam adheres to silicone but only very bad. With the help of the connecting element, this problem can be counteracted. In this case, the connecting element is preferably designed such that a good adhesion to the plastic element is achieved. By the connecting element, a strain relief along an axis of the cable can be improved.

In one embodiment, the connecting element projects beyond the outer insulation in a radial direction of the cable. In this way, the connecting element for the plastic element along an axis of the cable forms a projection, which leads to a positive connection between the connecting element and the plastic element and thus causes a strain relief.

The connecting element can be designed, for example, as a metal crimp, in particular made of copper. Such a metal crimp is particularly easy to produce and assemble. Copper is particularly suitable as a material because polyurethane foam adheres well to copper.

Preferably, the metal crimp is formed from a sheet having, for example, a thickness between 0.5 and 2 millimeters. In particular, a thickness between 0.8 and 1.2 millimeters has proved to be advantageous. The thicknesses mentioned represent a good compromise between economical material consumption and good quality Adhesion between the outer insulation and the metal crimp and a sufficient positive connection between the metal crimp and the plastic element.

In one embodiment, the sheet has a substantially parallelepipedal main body and two end pieces complementary to each other in a mutually bent state of the sheet, which are integrally connected to the main body on opposite sides of the main body. The main body may comprise, for example, two main surfaces parallel to each other, two mutually parallel side surfaces perpendicular to the main surfaces, and two connecting surfaces perpendicular to the main surfaces and side surfaces. The distance between the side surfaces corresponds to the width of the connection surfaces. This width of the pads may be divided into an exposed width portion and a terminal width portion. At the connection width section, an end piece is then respectively connected, which has, on a side opposite the connection surface, an end width which substantially corresponds to the width of the exposed width section. This special shape of the metal sheet makes it possible for the end pieces of the metal crimp to lie one behind the other along the axis of the cable after the metal crimp has been crimped.

The terminal width portion and the width portion may be the same width. In this case, the end pieces would be essentially cuboid. However, in one embodiment, the terminal width portion is 1.5 to 3 times as wide as the exposed width portion. As a result, the end pieces become narrower at an increasing distance from the terminal surface. Due to the broader compared to the exposed width section connecting section, transitions between the pads and the end pieces can be conveniently configured radii, so that sharp corners are avoided, which could lead to distortions during crimping.

Preferably, the metal crimp is shaped and bent around the cable such that there is a gap between the end pieces. In addition, there may be a gap between the exposed width sections and the end pieces. When the exposed width portion and the terminal width portion have different widths, the gap extends in at least a portion obliquely to the axis of the cable. The plastic engages in the gap, so that a positive connection between the metal crimp and the plastic element is reinforced. As a result, the strain relief in the direction of the axis of the cable can be improved. Due to the partially oblique course of the gap to the axis of the cable additionally results in a relief with respect to a rotational movement of the cable about its axis.

In one embodiment, the metal cimp cuts into the outer insulation at at least one location. As a result, a positive connection is created or reinforced between the connecting element and the outer insulation of the cable.

In one embodiment, the charging socket has a plurality of connections and / or a plurality of cables. Each cable is electrically connected to at least one connection. An area of the charging socket in which the cable (s) is / are electrically connected to the terminals is foamed with the plastic. Each cable may be configured as indicated above. The plastic element can seal several, preferably all, connections between the cables and the terminals.

According to a further aspect, the invention comprises a method for assembling a charging socket, which has a connection for feeding external electrical energy into an at least partially electrically driven vehicle. According to the method, a cable is provided with an outer insulation that is electrically connected to the terminal. An area of the charging socket in which the cable is electrically connected to the terminal is foamed with a plastic.

All device features that have been discussed above with reference to the charging socket according to the invention are, unless otherwise stated, analogously applicable to the inventive method.

This means in particular that the method according to the invention in one embodiment comprises the step of positively and / or non-positively connecting a connecting element to the outer insulation of the cable, wherein the connecting element is also foamed in the step of foaming.

As already stated above, the connecting element can be designed as a metal crimp, in particular made of copper. In this case, the positive and / or non-positive connection can be effected by means of crimping.

In one embodiment, the positive and / or non-positive connection comprises the step of impressing ends of the metal crimp into the outer insulation so that the ends cut into the outer insulation. This creates a positive connection during crimping in addition to adhesion.

Short description of the figures

Further details of embodiments of the invention as well as related advantages will be explained below with reference to the figures. Show

1A a sheet metal for a metal crimp in a plan view;

1B the sheet out 1A in a perspective view;

2A a cable with an outer insulation, on which the sheet is made 1A to be crimped;

2 B a cable with an outer insulation and a metal crimp;

3A the cable off 2 B in electrical connection with terminals of an embodiment of a charging socket housing;

3B a first embodiment of a charging socket according to the invention in a sectional view;

3C a second embodiment of a charging socket according to the invention in a sectional view;

4A the cable off 2 B in electrical connection with terminals of a further embodiment of a charging socket housing;

4B a third embodiment of a charging socket according to the invention and

5 an embodiment of a method according to the invention.

In the following description, the same and equivalent elements, unless otherwise indicated, are given the same reference numerals.

The 1A and 1B show an embodiment of a sheet from which an embodiment of a metal crimp is to be formed. The sheet 1 has a substantially cuboid main body 2 on. This main body 2 comprises two main surfaces parallel to each other 3 , two to the main surfaces 3 vertical, mutually parallel side surfaces 4 and two to the main surfaces 3 and side surfaces 4 vertical connection surfaces 5 , which are shown in dashed lines. The distance between the side surfaces 4 corresponds to the width 6 the connection surfaces 5 , The width 6 the connection surfaces 5 Divides into an exposed width section 7 and a connection width section 8th on. At the connection width section 8th is in each case an end piece 9 connected to one of the pad 5 opposite side 10 a final width 11 having the width of the exposed width portion 7 essentially corresponds.

In the 2A is an embodiment of a cable 12 illustrates that an exterior insulation 13 having. With the cable shown 12 it is a high-voltage cable with two strands 14 additionally with one coat each 15 are isolated. Because the cable 12 is designed for high currents and voltages, it requires a particularly temperature-resistant outer insulation made of silicone. Since polyurethane sticks very badly on silicone, the sheet is 1 around the cable 12 bent around by crimping, so that a frictional connection between the metal crimp 16 that's from the sheet metal 1 exists, and the outer insulation 13 of the cable 12 arises. The cable 12 out 2A is in 2 B shown again after crimping the metal crimps. As you can see there, the metal crimp towers over 16 the outer insulation 13 in a radial direction of the cable 12 , The sheet consists of copper. The connection width section 8th is about twice as wide as the exposed width section 7 , Again 2 B can be taken, is the metal crimp 16 shaped like this and around the cable 12 bent that between the exposed width sections 7 and the tails 9 a gap 17 consists. The gap 17 runs in a partial area obliquely to an axis 18 of the cable 12 , At the interface 5 opposite side 10 are the tails 9 such in the outer insulation 13 indented that the metal crimp 16 there in the outer insulation 13 cuts, creating a positive connection between the metal crimp 16 and the outer insulation 13 is improved.

The 3A shows an embodiment of a charging socket housing 19 , the two connections 20 for feeding electrical energy into the vehicle. The strands 14 already in 2 B shown cable 12 are with the connections 20 of the charging socket housing 19 electrically connected.

The area in which the cable 12 with the connections 20 is electrically connected, and the metal crimp 16 are foamed with a plastic to the in 3B in a sectional view shown first embodiment of a charging socket according to the invention 21a manufacture. By foaming with the plastic arises in 3B plastic element shown 22a ,

Again 3B can be seen, presses the metal crimp 16 the outer insulation 13 together so that between the metal crimp 16 and the outer insulation 13 of the cable 12 a traction consists. Since the metal crimp 16 in addition to the connection surface 5 opposite sides 10 the tails 9 in the outer insulation 13 cuts in (cf. 1A . 1B and 2 B ), there is additionally a positive connection between the metal crimp 16 and the outer insulation 13 , The plastic element 22a adheres to the metal crimp 16 so that the plastic element 22a with the metal crimp 16 is connected cohesively. Additionally exists along the axis 18 of the cable 12 a positive connection between the plastic element 22a and the metal crimp 16 which leads to a strain relief.

In the 3C is a second embodiment of a charging socket according to the invention 21b shown, in which the cable 12 at the connection 20 along a first axis 18a and at an exit point of the plastic element 22b along a second axis 18b extends, wherein the first and second axis to each other at an angle α of 80 degrees. Depending on the available space, the first or the second embodiment may be more advantageous.

The 4A shows a further embodiment of a charging socket housing 23 with two connections 24 for feeding electrical energy into the vehicle. The cable 12 with the outer insulation 13 is with these connections 24 electrically connected. In addition, the charging socket has 23 a connection 25 on that with a neutral 26 is coupled. Because the neutral 26 It does not need to be coated with silicone to keep it from overheating. Instead, it has an outer insulation made of polyvinyl chloride, which adheres quite well to polyurethane foam. That's why the neutral is 26 not equipped with a connecting element. From the charging socket housing 23 go in addition to different signal and monitoring lines 27 from, which are designed as low-voltage cable. Again, its external insulation is not silicone, so no fastener is needed to make a good bond with the polyurethane foam. With the help of the signal and monitoring lines, for example, the temperature of the charging socket is monitored and a light emitting diode in the charging socket is controlled, which indicates the state of charge of the vehicle battery. The area of the charging socket in which the cable 12 with the connections 24 is electrically connected, is foamed with polyurethane, so that a corresponding plastic element 28 will be produced.

The 4B shows a third embodiment of a charging socket according to the invention 29 with the plastic element 28 , The cable 12 as well as the neutral conductor 26 and the low-voltage cables 27 leave the plastic element 28 on a deck surface 30 of the truncated cone. At the exits 31 are also wrap bands 32 arranged to achieve an additional seal.

In the illustrated embodiments, the cable comprises two strands each. Two strands are usually used with charging sockets designed for 3.3 kW. For example, with this power, it may take 8 hours for the vehicle battery to be charged. Charging sockets rated at 22 kW typically use five-strand cables, three of which are for three phase phases, one is neutral, and another is ground. A charge can be completed after 1 hour at this power.

In the 5 an embodiment of a method according to the invention for assembling a charging socket is shown. According to the method V, a charging socket housing with a connection for supplying external electrical energy to an at least partially electrically driven vehicle is initially provided in step S1. In step S2, a cable with an outer insulation is then provided. A connecting element is connected to this outer insulation of the cable in step S3 form-fitting and / or non-positively by means of crimping. In step S4, the cable is electrically contacted to the terminal. The area of the charging socket in which the cable is electrically connected to the terminal is then foamed with a plastic in step S5.

LIST OF REFERENCE NUMBERS

 1

sheet

 2

main body

 3

main area

 4

side surface

 5

terminal area

 6

Width of the connection surface

 7

exposed width section

 8th

Connection width section

 9

tail

10

the pad opposite side of the tail

11

End width of the tail

12

electric wire

13

external insulation

14

braid

15

Coat of the strand

16

Metallcrimp

17

gap

18

Axis of the cable

18a

 first axis of the cable

18b

 second axis of the cable

19

Embodiment of a charging socket housing

20

connection

21a

 first embodiment of a charging socket according to the invention

21b

 second embodiment of a charging socket according to the invention

22a

 Plastic element

22b

 Plastic element

23

another embodiment of a charging socket housing

24

Connection for feeding electrical energy

25

connection

26

neutral

27

Signal and monitoring cables

28

Plastic element

29

third embodiment of a charging socket according to the invention

30

Top surface of the truncated cone

31

output

32

wrap

S1

Providing a charging socket with a connection for feeding electrical energy into the vehicle

S2

Providing a cable with an external insulation

S3

positive and / or non-positive connection of a connecting element with the outer insulation of the cable

S4

electrically connecting the cable to the terminal

S5

Foaming a portion of the charging socket in which the cable is electrically connected to the terminal, with a plastic

V

Embodiment of a method according to the invention

Claims (15)

Charging socket ( 21a . 21b . 29 ) for mounting on an at least partially electrically driven vehicle, having - a connection ( 20 . 24 ) for feeding electrical energy into the vehicle, - a cable ( 12 ) with an external insulation ( 13 ) connected to the port ( 20 . 24 ) is electrically connected, and - a plastic element ( 22a . 22b . 28 ) made of a foamed plastic, with which an area of the charging socket ( 21a . 21b . 29 ), in which the cable ( 12 ) with the connection ( 20 . 24 ) is electrically foamed, wherein the cable ( 12 ) at the connection ( 20 ) along a first axis ( 18a ) and at an exit point of the plastic element ( 22b ) along a second axis ( 18b ), wherein the first and second axes are at an angle (α) of more than 20 degrees to each other. Charging socket ( 21a . 21b . 29 ) according to the preceding claim, wherein the plastic element ( 22a . 22b . 28 ) to the outer insulation ( 13 ) of the cable ( 12 ) adjoins. Charging socket ( 21a . 21b . 29 ) according to one of the preceding claims, wherein the outer insulation ( 13 ) of the cable ( 12 ) Contains silicone. Charging socket ( 21a . 21b . 29 ) according to one of the preceding claims, wherein the plastic element ( 22a . 22b . 28 ) Polyurethane. Charging socket ( 21a . 21b . 29 ) according to the preceding claim, wherein the polyurethane has a density of 700 kg / m ³ to 900 kg / m ³ and / or a Shore A hardness of 50 to 70. Charging socket ( 29 ) according to one of the preceding claims, wherein the plastic element ( 28 ) has substantially the shape of a truncated cone, wherein the connection ( 24 ) is arranged on a base of the truncated cone and the cable ( 12 ) the plastic element ( 28 ) on a top surface ( 30 ) of the truncated cone leaves. Charging socket ( 21a . 21b . 29 ) according to one of the preceding claims, wherein the cable ( 12 ) a connecting element ( 16 ), which with the outer insulation ( 13 ) of the cable ( 12 ) positively and / or non-positively and with the plastic element ( 22a . 22b . 28 ) is connected cohesively and / or positively. Charging socket ( 21a . 21b . 29 ) according to the preceding claim, wherein the connecting element ( 16 ) the outer insulation ( 13 ) in a radial direction of the cable ( 12 ) surmounted. Charging socket ( 21a . 21b . 29 ) according to claim 7 or 8, wherein the connecting element ( 16 ) is designed as a metal crimp. Charging socket ( 21a . 21b . 29 ) according to the preceding claim, wherein the metal crimp ( 16 ) from a sheet ( 1 ) having a thickness between 0.5 and 2 millimeters. Charging socket ( 21a . 21b . 29 ) according to the preceding claim, wherein the sheet ( 1 ) a substantially cuboid main body ( 2 ) and two mutually complementary in a bent state of the sheet metal end pieces ( 9 ) connected to the main body ( 2 ) are integrally connected on opposite sides. Charging socket ( 21a . 21b . 29 ) according to the preceding claim, wherein the metal crimp ( 16 ) shaped and around the cable ( 12 ) is bent that between the end pieces ( 9 ) a gap ( 17 ) to an axis ( 18 ) of the cable is inclined. Charging socket ( 21a . 21b . 29 ) according to any one of claims 9 to 12, wherein the metal crimp ( 16 ) at least one place in the outer insulation ( 13 ). Charging socket ( 21a . 21b . 29 ) according to one of the preceding claims, wherein the charging socket has several connections ( 20 . 24 ) and / or several cables ( 12 ), each cable having at least one connection ( 20 . 24 ) is electrically connected. Method (V) for assembling a charging socket, which comprises a connection for feeding external electrical energy into an at least partially electrically driven vehicle, the method comprising the steps of: - providing a cable (S2) with an outer insulation, - electrically connecting the cable with the connection (S4) and - foaming (S5) of a portion of the charging socket in which the cable is electrically connected to the terminal, with a plastic such that the cable ( 12 ) at the connection ( 20 ) along a first axis ( 18a ) and at an exit point of the plastic element ( 22b ) along a second axis ( 18b ), wherein the first and second axes are at an angle (α) of more than 20 degrees, in particular more than 45 degrees.

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