WO2010117594A2

WO2010117594A2 - Charging connecting device for an electrically powered motor vehicle

Info

Publication number: WO2010117594A2
Application number: PCT/US2010/027903
Authority: WO
Inventors: Christian Beck; Jürgen Herzig
Original assignee: Illinois Tool Works Inc.
Priority date: 2009-04-08
Filing date: 2010-03-19
Publication date: 2010-10-14
Also published as: WO2010117594A3; DE102009016895A1

Abstract

A charging connecting device for a motor vehicle being powered at least partially electrically, the device comprising a connecting body, said connecting body being fixable at an opening of the motor vehicle and forming a connecting space, the device further comprising an electric connecting device for electrically connecting an accumulator of the motor vehicle with an electric supply source provided outside the motor vehicle for charging the accumulator, characterized in that the electric connecting device comprises a charging cable, said charging cable being connectable to the accumulator and having an electric plug device for connecting with the electric supply source, in that the electric connecting device comprises a cable roll-up device with a cable roll, being rotatably supported, wherein the cable roll is biased into a roll-up position, in which the charging cable is rolled up on the cable roll and the plug device is located inside the connecting space formed by the connecting body and is accessible from the outside, so that the plug device for connecting with the external electric supply can be pulled out of the connecting body together with the charging cable, wherein the charging cable is rolled off the cable roll against the bias of the same.

Description

CHARGING CONNECTING DEVICE FOR AN ELECTRICALLY POWERED MOTOR VEHICLE

The invention relates to a charging connecting device for an at least partially electrically powered motor vehicle, comprising a connecting body, said connecting body being fixable at an opening of the motor vehicle and forming a connecting space, the device further comprising an electric connecting device for electrically connecting an accumulator of the motor vehicle with an electric supply source provided outside the motor vehicle for charging the accumulator.

For reasons of environmental protection, completely or partially electrically powered vehicles will in future make up an ever larger proportion of the automobile market. Such vehicles have at least one accumulator which at least partially powers the vehicle. It is necessary here for the accumulator to be charged on a regular basis. For this purpose, such vehicles have an electric connecting device via which the accumulator can be connected to an external voltage supply. The connecting device may be provided, for example, in a vehicle cavity, similar to a tank cavity. By opening a flap, the access from the outside to the connecting device, for example a plug-type coupling, is enabled.

In known vehicles of this type, a charging cable is carried along, for example in the trunk of the vehicle, which charging cable has to be removed from the trunk for a charging process and connected to the connecting device of the vehicle at one end and to the external voltage supply at the other. However, this is relatively complex. Furthermore, there is the risk of forgetting to place the charging cable back into the vehicle after a charging process. If a charging process is subsequently necessary at another location, another cable has to be obtained. In the worst case, the accumulator cannot be charged and the vehicle can no longer be operated. Furthermore, the known cable must have a relatively large length so that it can reach even a voltage supply which is further away, as may be the case, for example, in public garages. As a result, the cable takes up considerable space in the vehicle.

Taking the explained prior art as a starting point, the invention is based on the object of making available a charging connecting device of the type mentioned at the beginning, which permits a charging process at any time in a simple and flexible way and at the same time takes up little space.

This object is achieved according to the invention by means of the subject matter of claim 1. Advantageous refinements can be found in the dependent claims, the description and the figures.

The invention solves the problem for a charging connecting device of the type mentioned at the beginning, in that the electric connecting device comprises a charging cable, said charging cable being connectable to the accumulator, and an electric plug device for connecting with the electric supply source, in that the electric connecting device comprises a cable roll-up device with a rotatably mounted cable roll, wherein the cable roll is biased into a roll-up position, in which the charging cable is rolled up on the cable roll and the plug device is located inside the connecting space formed by the connecting body and is accessible from the outside, so that the plug device for connecting with the external electric supply can be pulled out of the connecting body together with the charging cable, wherein the charging cable is unrolled from, the cable roll against the bias of the same.

The charging connecting device has a connecting body which, for example like tank cavities which are known per se, is inserted into a vehicle opening. The connecting body may have, in particular, a floor and side walls and therefore form a recess as a connecting space. The plug device is a plug connector and may be, in particular, a plug.

The charging connecting device comprises a cable roll-up device with a cable roll which is arranged, for example, on the side of the connecting body turned away from the outside of the device (and therefore the outside of the vehicle in the mounted state) . The cable roll can therefore be arranged behind the connecting body. A charging cable is held in the rolled-up state on the cable roll by bias which is made available, for example, by a spring. The charging cable is guided through the vehicle opening. In the mounted state of the charging connecting device, the charging cable is electrically connected by one of its ends to the accumulator of the vehicle. Its other end has the plug device. The charging cable may have here a length of more than one meter, in particular several meters, in order to make available, by means of the plug device, a connection between the accumulator and external electric supplies which are further away.

In the rolled-up state of the charging cable, the plug device is arranged in the connecting space, and the charging cable runs through the connecting body and the opening in the motor vehicle to the cable roll which is located on the side of the connecting body lying opposite the plug device. The charging cable can then be pulled manually out of the connecting space through the opening on the plug device and plugged, for the charging process with the plug device, onto a corresponding plug device of the external electric supply. In this way, the vehicle accumulator is electrically connected to the external supply. After the charging process has ended, the plug device is released from the external supply and the cable is automatically rolled onto the cable roll again owing to the bias, and in the process the cable is pulled back into the connecting space together with the plug device.

According to the invention, a charging connecting device of a motor vehicle having an integrated automatic roll-up device for the charging current cable, such as is known per se from other devices, is therefore provided. In this way, the vehicle battery or batteries can be charged in a more convenient way than in the prior art. In particular, there is no need to carry along a separate charging cable which, for the charging process, has to be connected, at one end, to a plug device in a cavity and, at the other end, to a plug device of the external voltage supply. Instead, in the normal operating mode of the vehicle the cable is rolled onto the cable roll which is arranged within the vehicle body. For the purpose of charging, the cable is simply pulled out of the connecting space and connected to the external electric supply. In the process, the cable can be adapted in a flexible way to external supplies which are at different distances away by pulling the cable out of the connecting space to an appropriate degree. After the charging process has ended, the cable is automatically rolled onto the cable roll again and thus stored in a safe and space-saving fashion for the operation of the vehicle. The cable is therefore carried along at any time and cannot be forgotten, for example after a charging process has taken place.

According to one refinement which is particularly compatible with practice, the connecting body may be a cavity body which forms a recess as a connecting space, wherein the charging connecting device also comprises a flap with which the access from the outside to the recess formed by the cavity body can be optionally enabled or closed. The charging connecting device can therefore be a charging cavity. By opening and closing the flap, the access to the recess and therefore to the plug device of the charging cable is enabled or closed. The flap can be connected in an articulated fashion using, for example, a hinge joint on a side wall of the connecting body. In the rolled-up state of the charging cable, the plug device is in the recess and the recess can be closed with the flap. When the flap is opened, the plug device can then be grasped from the outside by a hand in the recess. In order to permit easier removal of the plug device including the cable, a plug arresting means, which holds the plug device in the cavity for it to be grasped by a hand, can be provided in the cavity or, for example, on a hinge arm of the flap. The accumulator serves to at least partially power the vehicle. The term accumulator, is, of course, also to be understood here as comprising a combination of a plurality of individual accumulators to form an accumulator group. For example, the vehicle may be a partially electrically powered vehicle (hybrid vehicle) or an exclusively electrically powered vehicle (electric vehicle) . According to one refinement, the charging connecting device can accordingly also have an opening or a neck for connecting with a fuel tank conduit of the motor vehicle. This refinement therefore comprises a hybrid vehicle in which an electric charging process and refueling can take place by means of the same cavity. The charging connecting device can therefore (also) be a tank cavity.

The opening of the motor vehicle may be, for example, a body opening or an opening in a bumper, into which opening the connecting body is insertable. The charging connecting device is therefore located in an opening in the motor vehicle and can be enabled or closed using the flap, for example.

According to a further refinement, the cable roll-up device can comprise a cleaning device past which the charging cable is guided when being rolled up or unrolled from the cable roll and is cleaned in the process. Such a cleaning device may comprise, for example, one or more brushes, stripping lips, sponges or the like. In this way, coarse cleaning of the cable is carried out, in particular before it is rolled up onto the cable roll, so that operational faults due to contamination are avoided. According to a further refinement, the charging connecting device can comprise an integrated accumulator charge display. The charge display indicates the respective charge state of the accumulator. In this way, the latter can be read conveniently and it can particularly easily be determined when the charging process is terminated. The charge display can be integrated, for example, into the connecting body.

According to a further refinement, the cable roll-up device can comprise an arresting device, said arresting device arresting the cable roll releaseably against rolling up in the state in which the charging cable is at least partially unrolled from the cable roll. In this refinement, the cable roll is arrested in the partially or completely unrolled state of the cable, that is to say against moving back into the roll-up position. The bias can therefore act on the cable roll, and the unrolled cable is not pulled back into the connecting space. The cable is therefore not tensioned in an undesired way in the unrolled state in which it is connected to the external supply. Furthermore, when the plug device is released from the external supply, sudden pulling back of the cable and of the plug device into the connecting space and therefore possible damage to the body work surrounding a body opening, or the like, by the plug device is avoided. In the arrested state of the cable roll, the cable can, however, be unrolled further. The arresting process therefore acts in only one rotational direction of the cable roll. Releasing the arresting means causes the bias to act again on the cable roll and causes the cable to be rolled up again onto the cable roll owing to the bias, provided there is no sufficient opposing force acting. In order to release the arresting means, it is possible, for example, to provide a pushbutton key on the connecting body. However, it is also conceivable for the arresting means of the cable roll to be releaseable by pressing the completely opened flap in its opening direction. The flap is therefore pressed over into the opening direction and as a result the cable roll-up mechanism is released. Such a refinement does not require any additional switches.

According to a further refinement, a recess may be provided on the connecting body and/or the flap, through which recess the charging cable may be guided in the closed position of the flap. The recess can be, for example, a groove or depression. In the closed state of the flap it forms an opening or a lead-through for the cable. When the cable is unrolled and lead out of the cavity, the flap can therefore be closed. As a result, the connecting space can be closed during the charging process and therefore protected against contamination. For this purpose, the recess can also comprise a corresponding seal, for example a sealing lip. It is also possible for the connecting body and/or the flap to comprise a seal which, when the flap is closed, prevents penetration of contamination or humidity into the connecting space formed by the connecting body. The seal is provided here between the flap and the connecting body, in particular in the region of a bearing face of the flap against the connecting body. The seal can therefore be a sealing element which runs, for example, around the outer edge of the flap and/or the edge of the opening of the connecting body which is to be closed off by the flap. According to a further refinement, the charging connecting device can comprise at least one sensor which detects the rolled-up state of the charging cable and/or detects damage to the charging cable and/or which detects an electric overload of the charging cable. Such sensors may be, in particular, electronic sensors. The sensors increase the protection of the device. The sensor signals may be fed, for example, to a central control device of the motor vehicle, by means of which central control device suitable measures can be initiated on this basis. It is therefore possible for states which are detected by the sensors, for example damage to the cable, to be indicated to the driver of the vehicle and/or to a maintenance person. In this context, in each case at least one sensor may be provided for each of the states to be detected. Sensors which detect a rolled-up state of the charging cable on the cable roll or damage to the cable may be, for example, optical sensors. It is also possible to provide that upon detection of an at least partially unrolled state of the charging cable, starting of the motor vehicle is prevented. For this purpose, the sensor can be suitably connected to a control device of the vehicle which, in the event of a corresponding sensor signal, prohibits starting of the vehicle. Furthermore, it is possible to provide that a sensor for detection of an electric overload of the charging cable is a temperature sensor. In the state in which the cable is rolled up on the cable roll, the cable forms a coil which heats up in accordance with the charging current flowing through the cable. Excessive warming can damage the cable and/or other components of the charging connecting device. This is detected in good time by a temperature sensor. It is then possible, for example, for the charging current to be reduced or the charging process to be interrupted by a control device to which the sensor signals are connected.

According to a further refinement, the charging connecting device can comprise an illumination device, which, when the flap is opened, illuminates the connecting space formed by the connecting body, in particular the recess. This increases the convenience. The refinement is advantageous in particular in purely electric vehicles and when the charging connecting device is used only for electrical charging. If there is a cavity which is used simultaneously for refueling, such illumination is undesired owing to the risk of explosion.

The electric connecting device can also comprise a second plug device fixedly arranged in the connecting body for connection with an electric supply source provided outside the motor vehicle. The plug device may be, for example a plug socket. It can be provided for a higher charging power (charging current or charging voltage) than the plug device on the charging cable. A quick charging process of the accumulator is therefore possible using the fixed plug connector. In contrast, the plug device on the charging cable may be configured, for example, for conventional voltages. It is also possible to provide a serviceable solution with which a damaged vehicle cable can easily be replaced.

The invention also relates to an at least partially electrically powered motor vehicle, comprising an accumulator, a charging connecting device according to the invention and an opening, in particular a body opening or an opening in a bumper, into which the connecting body of the charging connecting device is inserted, wherein the charging cable is connected to the accumulator (in particular permanently) .

An exemplary embodiment of the invention will be explained below in more detail with reference to schematic figures, in which:

Figure 1 shows a charging connecting device according to the invention in a perspective view,

Figure 2 shows the charging connecting device from figure 1 in a further perspective view,

Figure 3a) shows the charging connecting device from figure 1 in a front view,

Figure 3b) shows the detail A from figure 3a) ,

Figure 4 shows the charging connecting device from figure 1 in a plan view, and

Figure 5 shows the charging connecting device from figure 1 in a side view.

Unless stated otherwise, identical reference symbols in the figures denote identical objects. Figures 1 to 5 show a charging connecting device 10 according to the invention in different views. In figure 1, the charging connecting device 10 is shown in a perspective view from its front side and obliquely from above. In figure 2, the charging connecting device 10 is shown from its rear side and obliquely from above. The charging connecting device 10 has a connecting body 12 which is manufactured, for example, using an injection molding method, in the illustrated example a cavity body 12, with a floor 14 and side walls 16. In this way, the cavity body 12 forms a recess 18 as a connecting space 18. The charging connecting device is inserted with the cavity body 12 into an opening, for example a body opening or an opening in a bumper, of a motor vehicle (not illustrated in more detail) . The charging connecting device 10 also has a flap 24 which can be pivoted by means of a pivoting arm 22 which is pivotably mounted on a hinge joint 20. In figures 1 and 3, the flap 24 is shown in the opened state in which it enables the access to the recess 18. The cavity opening can be closed by pivoting the flap 24 by means of the pivoting arm 22, so that the access to the recess 18 is also closed. In figures 2, 4 and 5, the flap 24 is shown in the closed state. This design of a motor vehicle cavity is known per se for conventional tank cavities .

The charging connecting device 10 according to the invention also comprises an electric connecting device for electrically connecting an accumulator (not illustrated) of the vehicle to an electric supply source (likewise not illustrated) which is provided outside the vehicle, for a charging process for charging the accumulator. The connecting device has a charging cable 26 which can be electrically connected by one of its ends to the accumulator in a way which is not illustrated in more detail. At its other end, the charging cable 26 has an electric plug device 28, in the illustrated example an electric plug 28. The plug 28 can be plugged onto the external supply source so that an electric connection is produced between the vehicle accumulator and the supply. The electric connecting device also has a cable roll-up device with a rotatably mounted cable roll 30. In the illustration in figure 4, the rotational axis of the cable roll 30 runs centrally through the circular upper side of the cable roll 30 and perpendicularly with respect to the plane of the drawing. The cable roll 30 is arranged on the rear side of the cavity body 12 and therefore in the mounted state it is arranged on the side of the cavity body 12 facing away from the outside of the vehicle. The cable roll 30 is biased by a spring (not illustrated) into a roll-up position in which the charging cable 26 is rolled completely onto the cable roll 30, and the plug device 28 is arranged within the recess 18. However, in this state, when the flap 24 is opened the plug 28 is accessible from the outside in the recess 18 and can be grasped by a hand. For this purpose, a plug arresting means 29 is provided which holds the plug 28 in the recess 18 for manual grasping. From this position, the plug 28 and therefore the charging cable 26 can be pulled out of the recess 18 for connection to the external supply. It is to be noted for the purpose of illustration in figures 1 and 3a) the plug 28 is respectively shown once in the state in which it is pulled back into the recess 18 and once in the state in which it is partially pulled out of the recess 18. Of course, just one plug 28 is provided, the figures showing both states of the plug 28 only for the purpose of illustration.

The cable roll-up device also comprises a cleaning device 32, in this case a cleaning brush 32, which can be seen in figure 3b) , which shows the detail A from figure 3a) in an enlarged form. When the cable 26 is pulled out of the recess 18 and pushed back into the recess 18 it passes through the cleaning brush 32 and is therefore cleaned, in particular before it is rolled up onto the cable roll 30.

The cable roll-up device also has an arresting device 34 which arrests the cable roll 30 releaseably so as to prevent the cable 26 from rolling up again, in a state in which said cable 26 is at least partially unrolled from the roll 30. The cable 26 is therefore firstly held in the rolled-out state after it has been pulled out of the charging connecting device 10. The arresting device 34 can be released by a pushbutton key 36 which is provided on the floor 14 of the cavity body 12. As a result, the arresting of the cable roll 30 is released and the bias which is provided by the spring causes the cable roll 30 to rotate when a corresponding opposing force fails to occur, thereby causing the cable 26 to be rolled up, said cable 26 being pulled back, together with the plug 28, into the recess 18 of the charging connecting device 10. As an alternative to the pushbutton key 36, it is also conceivable to release the roll-up mechanism by, for example, pressing over of the flap 24 in the opened position.

The cavity body 12 also has, in the region of its lower side wall 16, a guide element 38 through which the cable 26 is guided. In this way, the cable 26 is guided out of the cavity body 12 at a defined position. The flap 24 has a corresponding, groove-shaped recess 40 on its lower edge. In the closed state of the flap 24, the cable 26 which is guided through the guide element 38 runs straight through the recess 40, so that when the cable 26 is guided out of the recess 18 the flap 24 can be closed. This is shown in figure 4. At its lower end, the recess 40 has a sealing lip 42. Furthermore a circumferential seal 44 is also provided on the edge of the cavity body 12 which bounds the cavity opening. The sealing lip 42 of the recess 40 and the seal 44 of the cavity body 12 protects the recess 18 against the ingress of water or dirt in the closed position of the flap 24.

Furthermore, an accumulator charge display 46 is integrated into the floor 14 of the cavity body 12. In the illustrated example, it is composed of five light- emitting diodes 46 which display the charge state. They may be, for example, of different colors, with the completely charged state of the accumulator being displayed by illumination of all the diodes 46. Furthermore, a second plug device 48, here a plug socket 48 is fixedly arranged in the cavity body 12. It can be closed or opened by means of a pivotably mounted flap 50. While the plug 28 serves for connection to a conventional voltage source, the second plug socket 48 serves for connection to a high-voltage source and therefore for a quick charging process.

The charging connecting device 10 according to the invention can also have an illumination device (not illustrated in more detail) which is arranged on the cavity body^" and which illuminates the recess 18 in the opened position of the flap. Furthermore, one or more sensors may be provided which detect, for example, an at least partially unrolled state of the charging cable and/or damage to the charging cable and/or an electric overload of the charging cable. The sensor signals may be present at a central control device of the vehicle. In this context, malfunctions which are detected by the sensors may be displayed, for example, to a user, or other countermeasures may be taken, for example a charging process may be interrupted or a start of a motor vehicle may be prohibited. The charging connecting device can also comprise an opening or a neck (not illustrated in more detail) for connecting with a fuel tank conduit of the motor vehicle. This is conceivable in what are referred to as hybrid vehicles which are powered both electrically and with fuel.

With the charging connecting device 10 according to the invention it is possible to charge a vehicle accumulator or a vehicle accumulator group in a particularly simple and convenient way, wherein the connecting device 10 and, in particular, its electric connecting device are embodied at the same time in a space-saving fashion.

Claims

1. A charging connecting device for a motor vehicle powered at least partially electrically, the device comprising a connecting body (12), said connecting body being fixable at an opening of the motor vehicle and forming a connecting space (18) , the device further comprising an electric connecting device for electrically connecting an accumulator of the motor vehicle with an electric supply source provided outside the motor vehicle for charging the accumulator, characterized in that

• the electric connecting device comprises a charging cable (26) , said charging cable being connectable to the accumulator and an electric plug device (28) for connecting with the electric supply source,

• the electric connecting device comprises a cable roll-up device with a cable roll (30) , which is rotatably supported,

• wherein the cable roll (30) is biased into a roll-up position, in which the charging cable (26) is rolled up on the cable roll (30) and the plug device (28) is located inside the connecting space (18) formed by the connecting body (12) and is accessible from the outside, so that the plug device (28) for connecting with the external electric supply can be pulled out of the connecting body (12) together with the charging cable (26) , wherein the charging cable

(26) is unrolled from the cable roll (30) against the bias of the same.

2. The charging connecting device as claimed in claim 1, characterized in that the connecting body (18) is a cavity body (18) which forms a recess (18) as a connecting space (18) and in that the charging connecting device comprises a flap (24) with which flap the access from the outside to the recess (18) formed by the cavity body (12) can be optionally enabled or closed.

3. The charging connecting device as claimed in claim 2, characterized in that the charging connecting device (10) further comprises an opening or a neck for connecting with a fuel tank conduit of the motor vehicle .

4. The charging connecting device as claimed in one of the preceding claims, characterized in that the opening of the motor vehicle is a body opening or an opening in a bumper, into which opening the connecting body (12) is insertable.

5. The charging connecting device as claimed in one of the preceding claims, characterized in that the cable roll-up device comprises a cleaning device (32) , past which the charging cable (26) is guided when being rolled-up or unrolled from the cable roll (30) and is cleaned in the process.

6. The charging connecting device as claimed in one of the preceding claims, characterized in that the charging connecting device (10) comprises an integrated accumulator charge display (46) .

7. The charging connecting device as claimed in one of the preceding claims, characterized in that the cable roll-up device comprises an arresting device (34), said arresting device arresting the cable roll (30) releasably against rolling up in the state in which the charging cable (26) is at least partially unrolled from the cable roll (30) .

8. The charging connecting device as claimed in claims 2 and 7, characterized in that the arresting of the cable roll (30) is releasable by pressing the fully opened flap (24) into its opening direction.

9. The charging connecting device as claimed in claim 2 or as claimed in claim 2 and one of the preceding claims, characterized in that a recess (40) is provided on the connecting body (12) and/or on the flap (24), through which recess the charging cable (26) may be guided in the closed position of the flap (24) .

10. The charging connecting device as claimed in claim 9, characterized in that the recess (40) comprises a sealing means (42) .

11. The charging connecting device as claimed in claim 2 or as claimed in claim 2 and one of the preceding claims, characterized in that the connecting body (12) and/or the flap (24) comprises a sealing means (44), which sealing means when the flap (24) is closed, prevents penetration of contamination or humidity into the connecting space (18) formed by the connecting body (12) .

12. The charging connecting device as claimed in one of the preceding claims, characterized in that the charging connecting device (10) comprises at least one sensor, which detects the rolled-up state of the charging cable (26) and/or which detects damage to the charging cable (26) and/or which detects an electric overload of the charging cable (26) .

13. The charging connecting device as claimed in claim 12, characterized in that upon detection of an at least partially unrolled state of the charging cable (26) starting of the motor vehicle is prevented.

14. The charging connecting device as claimed in one of claims 12 or 13, characterized in that a sensor for detection of an electric overload of the charging cable (26) is a temperature sensor.

15. The charging connecting device as claimed in claim 2 or as claimed in claim 2 and one of the preceding claims, characterized in that the charging connecting device (10) comprises an illumination device, which, when the flap (24) is opened, illuminates the connecting space (18) formed by the connecting body (12) .

16. The charging connecting device as claimed in one of the preceding claims, characterized in that the electric connecting device comprises a second plug device (48), fixedly arranged on the connecting body

(12) for connection with an electric supply source provided outside the motor vehicle.

17. A motor vehicle at least partially powered electrically, comprising an accumulator, a charging connecting device (10) as claimed in one of the preceding claims and an opening, on which the connecting body (12) of the charging connecting device (10) is mounted, wherein the charging cable (26) is connected with the accumulator.

18. The motor vehicle as claimed in claim 17, characterized in that the opening is a body opening or an opening in a bumper, into which the connecting body (12) is inserted.