WO2023131598A1

WO2023131598A1 - Plug connector having a sensor element for detecting a leakage current, arrangement comprising two plug connectors, and method for identifying a leakage current in a plug connector

Info

Publication number: WO2023131598A1
Application number: PCT/EP2023/050044
Authority: WO
Inventors: Christian Reinhold; Elmar Schaper; Thomas Führer
Original assignee: Phoenix Contact Gmbh & Co. Kg
Priority date: 2022-01-10
Filing date: 2023-01-03
Publication date: 2023-07-13
Also published as: LU501225B1

Abstract

The invention relates to a plug connector (100, 200) for forming a plug connection in a plug-in direction (X) in order to transmit electrical energy and/or electrical signals, wherein the plug connector (100, 200) has an insulating material housing (101, 201) with a plug-in section (102, 202), in which at least one first contact element (111, 211) and at least one second contact element (112, 212) are accommodated for the purpose of forming a plug-in face (103, 203), wherein the at least one first contact element (111, 211) and the at least one second contact element (112, 212) are arranged spaced apart from one another, wherein, between the at least one first contact element (111, 211) and the at least one second contact element (112, 212), at least one sensor element (121, 221) is arranged and configured in the insulating material housing (101, 201) such as to detect a leakage current (KS) between the at least one first contact element (111, 211) and the at least one second contact element (112, 212). The invention also relates to an arrangement (300) having a first plug connector (100) as a charging plug and having a second plug connector (200) as a charging socket and also to a method for identifying a leakage current (KS) in a plug connector.

Description

Connector with a sensor element for detecting a leakage current, an arrangement with two connectors and a method for detecting a leakage current in a connector

The present invention is in the field of electromobility and relates to a plug connector which is designed as a charging socket for an electrically driven vehicle and which is designed as a charging plug for a charging station for transmitting electrical energy and/or electrical signals. The connector has at least one sensor element for detecting a leakage current between at least one first contact element and at least one second contact element in order to ensure monitoring of the insulation resistance of the connector and, above all, to be able to detect insulation errors. The invention also relates to an arrangement with two plug connectors and a method.

In the field of electromobility, a standardized plug connector in the form of a charging plug is used to form a plug connection with a standardized plug connector in the form of a charging socket as part of the charging process for accumulators in an electrically driven vehicle (electric vehicle). The respective plug connectors can be specified, for example, according to the IEC 62196-3-1 standard, which also relates to direct current charging processes for electric vehicles with a pilot contact element and a control contact element. In order to ensure appropriate compatibility for forming a plug-in connection, the requirements for the geometric dimensions of the plug-in connector, especially in relation to the plug-in face, are standardized. In addition, environmental requirements, clearances, creepage distances and overvoltage categories are defined in standards and specifications.

Insulation strengths of electrical components and parts made of insulating materials are tested in grounded networks, for example with the help of monitoring devices. However, there are no practical solutions to date for detecting insulation faults between the potentials at the negative pole and at the positive pole in connection with DC charging systems for electric vehicles, whereas line protection is required and must be specified by the manufacturer of the charging system.

Devices for detecting insulation faults and associated leakage currents are known from the prior art. International patent application no. WO 2020/114593 A1 discloses a device for measuring the so-called leakage current using two electrodes, the electrodes being arranged in a leakage current path. An energy store in the form of a capacitor is electrically connected to the electrodes so that it can be charged by the leakage current. As soon as a predetermined voltage value is reached or exceeded, a radio module, which in turn is connected to the energy store, sends a corresponding radio signal.

In the German patent application no. DE 10 2014 219 913 A1, an overvoltage protection device with a monitoring function is described in order to monitor the degree of damage to overvoltage elements. The protective device has two current branches connected in parallel. The first current branch includes two series-connected overvoltage protection devices in the form of partial varistors of a multi-contact varistor. The second stream two also includes two series-connected overvoltage protection devices. The overvoltage protection devices each have a corresponding potential. A first measurement tap and a second measurement tap are provided for detecting a voltage between the respective overvoltage protection devices in order to derive a signal therefrom and to provide a status statement in relation to the overvoltage protection devices.

It is an object of the present invention to provide an improved connector for the transmission of electrical energy and/or electrical signals, preferably for a charging process of an electrically drivable vehicle (electric vehicle), in which monitoring of the insulation strength and, above all, detection of insulation faults, preferably between contact elements for the transmission of electrical energy in the form of direct current. It is a further object of the present invention to provide a two-connector assembly and a method for detecting a leakage current in a connector.

The object is solved by the features of claims 1, 13 and 14. Further exemplary embodiments and applications of the present invention result from the dependent claims and are explained in more detail in the following description with partial reference to the figures. According to a first general aspect, the invention relates to a plug connector for forming a plug connection essentially in one plugging direction in order to transmit electrical energy and/or electrical signals, the plug connector having an insulating material housing with a plugging section, in which at least one first contact element and at least one second contact element, is accommodated, with the at least one first contact element and the at least one second contact element being arranged spaced apart from one another, with at least one sensor element being arranged and configured in the insulating material housing between the at least one first contact element and the at least one second contact element is to detect a leakage current between the at least one first contact element and the at least one second contact element.

The at least one first contact element and the at least one second contact element are preferably each designed as a load contact element for transmitting electrical energy.

The plug connector according to the present invention can be designed as a charging plug and/or as a charging socket, which are configured to form a plug connection with one another.

With the present invention, a connector is provided, for example, in which damage and, above all, dangers caused by leakage currents can be avoided. Furthermore, in the connector according to the present invention, the entry and/or presence of a medium, preferably an electrically conductive liquid medium, can be detected and corresponding measures can be taken, for example initiating a shutdown of the charging process of an electrically driven vehicle (electric vehicle).

Thus, for example, the ingress of water through a break or crack in the insulating housing of the connector can be detected. In this way, for example, molluscs and other foreign bodies can also be detected.

The at least one sensor element can be arranged and designed in such a way that the leakage current is channeled and/or centralized on a surface of the insulating housing. The at least one sensor element can preferably be in the insulating material housing, preferably in the plug-in section, at or on the geometrically shortest Distance between the at least one first contact element and the at least one second contact element can be arranged.

As a result, the occurrence of a leakage current on the surface of the insulating material between the at least one first contact element and the at least one second contact element can be optimally detected by the at least one sensor element.

According to a further aspect of the invention, it can be provided that the at least one sensor element is at least partially in a wall section of the insulating material housing, preferably for delimiting the plug-in section in the plug-in direction and/or preferably at a narrow point, between the at least one first contact element and the at least one second Contact element is integrated, preferably substantially cohesively and / or substantially non-positively integrated, wherein the wall portion extends at least partially in the plug-in direction and / or perpendicular to the plug-in direction.

The wall section can be a side wall section inside the plug-in section and can also be designed to hold or carry the at least one first contact element and the at least one second contact element. It is also possible that the wall section extends at least in sections essentially in the insertion direction and is arranged between the at least one first contact element and the at least one second contact element.

It is possible for the at least one sensor element to be configured and integrated in the wall section in such a way that the wall section and the at least one sensor element form at least one essentially planar end face, which is preferably oriented essentially perpendicularly to the plug-in direction and/or which is preferably limits the plug-in section in the plug-in direction. Alternatively, it is possible for the at least one sensor element to protrude from an end face of the wall section, preferably at least in sections essentially in the direction of insertion.

According to a further aspect of the invention, it can be provided that the at least one sensor element is essentially plate-shaped and/or essentially flat, and is preferably connected essentially flush to a wall section of the insulating material housing to form an essentially planar end face. According to a further aspect of the invention it can be provided that the plug connector comprises at least one further sensor element which is configured to detect a further leakage current between the at least one first contact element and the at least one second contact element, the at least one further sensor element being on a integrated at least in sections in a wall section of the insulating housing between the at least one first contact element and the at least one second contact element, preferably essentially in the plug-in direction, the side facing away from the plug-in face, preferably integrated opposite the at least one sensor element in the plug-in direction.

Alternatively, it is possible for the at least one sensor element to extend at least through the wall section, preferably essentially in the plug-in direction, and/or preferably to extend at least in sections into the plug-in section, and/or for the at least one sensor element to essentially extend at least in sections is cylindrical or essentially pin-shaped or essentially lance-shaped.

The at least one sensor element and preferably at least one further sensor element can each comprise an electrode or each be designed as an electrode. The electrode can be made of an electrically highly conductive material, preferably a metallic material. Preferably, the electrode has a very low impedance and/or resistance, for example less than 1 ohm.

According to a further aspect of the invention, it can be provided that the at least one sensor element, and preferably at least one additional sensor element, is connected to a monitoring unit, wherein the monitoring unit is configured, one on the at least one sensor element, and preferably one on the at least one additional To compare sensor element, detected voltage, which is caused or influenced by the leakage current, with a reference voltage. The monitoring unit can at least partially include electrical and/or electronic components and elements. The monitoring unit can be part of the connector or, alternatively, part of a charging station.

The monitoring unit can have at least a first resistance element, which is connected to the at least one first contact element, and at least a second Having a resistance element which is connected to the at least one second contact element. The at least one first resistance element and the at least one second resistance element can be arranged and configured to form the reference voltage from the voltage present at the at least one first contact element and/or from the voltage present at the at least one second contact element, preferably by voltage division. The at least one first resistance element can differ from the at least one second resistance element with regard to the resistance value. For example, the at least one first resistance element can have a resistance value of 400 kOhm and the at least one second resistance element can have a resistance value of 600 kOhm in order to divide the voltage applied to the contact elements.

According to a further aspect of the invention, it can be provided that the monitoring unit has at least one comparator element or at least one operational amplifier and is configured to compare the generated reference voltage with the detected voltage, and/or a switching element depending on the generated reference voltage and the detected voltage steer. The switching element can be controlled by the monitoring unit, for example, in such a way that the charging process is switched off when a leakage current is detected.

It is possible for the insulating material housing to have at least one diverting element, preferably one diverting element each, for draining the at least one first contact element and the at least one second contact element, and for the at least one diverting element, preferably the respective diverting element, to be arranged and configured in the insulating material housing in this way , A medium located in the plug-in section, preferably a flowable or castable medium, is removed from the plug-in section. This is advantageous, for example, when the connector is designed as a charging socket and is installed in an electric vehicle in the appropriate position and alignment.

According to a second general aspect, the invention relates to an arrangement for forming a plug connection in order to transmit electrical energy and/or electrical signals, comprising a first plug connector as disclosed herein, the first plug connector being designed as a charging plug, and a second plug connector as disclosed herein , wherein the second connector is designed as a charging socket, and preferably in the formation of the plug connection, the at least one sensor element (121) of the first Connector contacted at least one sensor element of the second connector, preferably via a spring element.

According to a third general aspect, the invention relates to a method for detecting a leakage current in a connector, the connector preferably being configured as disclosed herein, wherein a voltage which is caused or influenced by the leakage current is detected by at least one sensor element; a reference voltage is formed from a voltage present at the at least one first contact element and/or from a voltage present at the at least one second contact element by means of voltage division by at least two resistance elements; the reference voltage formed is compared with the detected voltage, and falling below or exceeding a voltage difference between the reference voltage formed and the detected voltage is detected. The method according to the present invention can preferably be carried out, inter alia, with the monitoring unit which is configured for this purpose and has corresponding components and elements as disclosed herein.

In order to avoid repetition, features that are directed purely to the device of the plug connector according to the invention and/or that are disclosed in connection therewith should also apply as disclosed in accordance with the method and be claimable and vice versa.

The exemplary embodiments and features of the present invention described above can be combined with one another as desired. Further or other details and advantageous effects of the present invention are explained in more detail below with reference to the attached figures.

Show it:

1A shows a connector face with a connector section of an embodiment of the connector according to the present invention as a charging connector in a perspective view;

FIG. 1B shows the connector from FIG. 1A in a schematic representation; FIG.

2A shows a mating face with a mating section of an embodiment of the connector according to the present invention as a charging socket in a front view; FIG. 2B shows the connector from FIG. 2A in a schematic representation; FIG.

3 shows the plug connector from FIGS. 1A and 1B and the plug connector from FIGS. 2A and 2B with at least partial formation of a plug connection in a schematic representation;

4 shows an equivalent circuit diagram of the connector from FIGS. 1A and 1B with a modified monitoring unit.

Identical or functionally equivalent components or elements are identified in the figures with the same reference symbols. For their explanation, reference is also made in part to the description of other exemplary embodiments and/or figures in order to avoid repetition.

The following detailed description of the exemplary embodiments illustrated in the figures serves for the purpose of further illustration or clarification and is not intended to limit the scope of the present invention in any way.

FIG. 1A shows a perspective view of a connector face 103 with a connector section 102 of an exemplary embodiment of a connector 100 according to the present invention as a charging connector. The connector 100 is configured as a charging connector for forming a plug-in connection with a connector 200 according to the present invention as a charging socket (see Figures 2A to 3) essentially in the plug-in direction X in order to transmit electrical energy and/or electrical signals. The plug connector 100, 200 is thus configured as a charging plug 100 in one exemplary embodiment and as a charging socket 200 for an electric vehicle or as a charging socket 200 for an electric vehicle in a further exemplary embodiment.

For reasons of clarity, a grip element of the connector 100 for handling and a connection section of the connector 100 for a charging cable for connection to a charging column of a charging station are not shown in FIG. 1A. The plug connector 100 is preferably permanently connected to a charging station of a charging station via a charging cable, the charging station providing electrical energy for charging accumulators of electrically driven vehicles (electric vehicles). The connector 100 in Figure 1A is preferably specified according to the IEC 62196-3 standard or is preferably based at least in part on the requirements of the IEC 62196-3 standard. In other words, the connector 100 can be designed and/or specified according to the Combined Charging System (CCS) connector system standard as what is known as a combo-2 charging connector. It is alternatively possible for the connector 100 to be designed and/or specified according to a different standard or according to a different standard or according to a different specification, for example according to the "CHAdeMO standard" or according to the "ChaoJi stacked specification".

The connector 100 includes an insulating material housing 101, that is, a housing made of an insulating material with inherent electrical insulating properties. The plug-in section 102 is part of the insulating material housing 101. An end face of the plug-in section 102, preferably in the plug-in direction X, is used to form the plug-in face 103 of the connector 100. The insulating material housing 101 can be made in several parts. The insulating material housing 101 can be produced, for example, by at least one casting process and/or by at least one injection molding process with an insulating material.

The connector 100 is preferably used for charging accumulators of electric vehicles by means of direct current and for this purpose comprises a first contact element 111 and a second contact element 112. A charging voltage applied to the contact elements 111 and 112 during a charging process can be in a range from 400 V to 800 V, for example and is therefore relatively high.

The first contact element 111 and the second contact element 112 are each configured as a load contact element and are essentially sleeve-shaped, at least in sections, in order to mechanically connect a complementary, i.e. a correspondingly configured and formed, contact element 211, 212 of a connector 200 (see Figures 2A to 3). take up at least form-fitting and/or at least partially non-positively when forming a plug-in connection between the connector 100 as a charging connector and the connector 200 as a charging socket essentially in the insertion direction X. Both the first contact element 111 and the second contact element 112 are each surrounded or encased by an insulating material sleeve 107 and 108 and thus a sleeve made of insulating material. The first contact element 111 and the second contact element 112 are accommodated in the plug-in section 102 and arranged at a distance from one another. The distance between the first Contact element 111 and the second contact element 112 is identified by the reference symbol D in FIG. 1A.

Walls and/or wall sections of the plug-in section 102, preferably comprising the insulating sleeves 107 and 108, are preferably formed integrally in one piece. However, it is alternatively possible, for example, for the insulating material sleeves 107 and 108 to protect the contact elements 111 and 112 as individual parts, i.e. as individually manufactured components or elements, for example screwed into corresponding wall sections of the plug-in section 102 and thus of the insulating material housing 101.

The connector 100 includes the other contact elements 113 to 115, which are accommodated or arranged in a further area of the plug-in section 102 in corresponding insulating material sleeves (not specifically identified in FIG. 1A) and are only briefly described below. The contact element 113 serves as a protective contact element (so-called PE contact element). The contact elements 114 and 115 are used to transmit electrical signals between a charging station and an electric vehicle via the connector during a charging process. The contact element 114 represents the so-called pilot contact (Control Pilot/CP) and the contact element 115 represents the so-called proximity switch (Proximity Pilot/PP) and, in other words, are used for communication between the charging station and the electric vehicle during the charging process.

The charging connector 100 includes additional components and elements, which will be discussed in more detail below against the background of the present invention.

FIG. 1B shows the connector 100 from FIG. 1A in a schematic representation. The illustration in FIG. 1B preferably focuses on the contact elements 111 and 112 of the connector 100, which, as already described, transmit electrical energy as load contact elements. The illustration in FIG. 1B clearly shows that the contact elements 111 and 112 are accommodated or arranged in the insulating material sleeves 107 and 108 at least in sections.

Due to the relatively high electrical voltages that occur and the corresponding arrangement of the contact elements 111 and 112 in the insulating material housing 101, more precisely in the plug-in section 102 of the insulating material housing 101, so-called leakage currents KS can occur during operation of the plug connector 100 along a section of surfaces of the insulating material. Such a distance is also referred to as a so-called creepage distance and preferably represents the shortest distance along surfaces of the insulating material between conductive elements, here between the contact elements 111 and 112.

Such leakage currents can be dangerous both for the connector 100 as a charging connector, the connector 200 as a charging socket and thus for an electric vehicle during a charging process, and for a user of the connector 100 as a charging connector during handling. In order to protect users from the effects of electrical operating voltages applied to the contact elements 111 and 112, creepage distances and also so-called air gaps must be dimensioned sufficiently. An air gap is preferably the shortest distance in air between two conductive elements, here between the contact elements 111 and 112.

Leakage currents KS mainly result from a change in the insulating properties of the insulating material. Such changes are often caused by corresponding environmental conditions in which the connector 100 is operated. For example, moisture, dust and/or dirt within the plug-in section 102 promotes the formation of leakage currents on surfaces of the insulating material. So-called insulation faults then occur in the insulating material, and the insulation strength is thus reduced. In the case of the connector 100, this occurs primarily between the charging lines, i.e. the contact elements 111 and 112.

Figure 1B shows an example and a schematic of the course, i.e. the creepage distance, along which a leakage current KS with a corresponding electrical voltage drop along the creepage distance from the first contact element 111 in the direction of the second contact element 112 (or vice versa, depending on the electrical polarity or polarity of the Contact elements 111 and 112) forms.

In order to prevent the development of such a sometimes dangerous state, the connector 100 according to the present invention comprises a first sensor element 121, which is arranged and configured in the insulating housing 101 in such a way that the leakage current KS between the first contact element 111 and the second contact element 112 at least capture. The first sensor element 121 is preferably arranged (spatially) between the first contact element 111 and the second contact element 112 . The first sensor element 121 is preferably designed as an electrode or comprises at least one electrode. In other words is the first Sensor element 121 is configured to detect or detect an occurring voltage resulting from a leakage current between the contact elements 111 and 112, which is the case with an insulation fault and thus with reduced electrical insulating properties of the insulating material. In other words, the first sensor element 121 is arranged between the contact elements 111 and 112 acting as high-voltage potentials.

The first sensor element 121 is arranged and designed in such a way that the leakage current KS is channeled on corresponding surfaces of the insulating material housing 101, that is to say preferably on surfaces of the plug-in section 102. As can be seen from FIG. 1B, the leakage current KS migrates or runs in sections, starting from the contact elements 111 and 112, along the outer surfaces of the insulating material sleeves 107 and 108 in the direction of a transition region which is formed by the wall section 104 of the insulating material housing 101. The wall section 104 extends at least partially essentially in the plug-in direction X and thus from the plug-in section 102 into the interior of the insulating housing 101.

The first sensor element 121 is integrated at least in sections in the wall section 104 of the insulating material housing 101 . First sensor element 121 is preferably connected to the insulating material of wall section 104 in a materially bonded and/or at least non-positive manner or integrated therein at least in sections. In other words, the first sensor element 121 can be integrated in the wall section 104 by at least one casting process and/or by at least one spraying process of the insulating material. It is additionally or alternatively possible for the first sensor element 121 to be pressed into the wall section 104, preferably essentially in the plug-in direction X. The wall section 104 with the first sensor element 121 delimits, among other things, the plug-in section 102 in the plug-in direction X and creates a constriction in Referring to the creepage distance of the leakage current KS. As can be seen from Figure 1B, the first sensor element 121 is designed and integrated in the wall section 104 in such a way that the wall section 104 and the first sensor element 121 form at least one essentially planar end face 105. The essentially flat end face 105 is aligned and/or arranged essentially perpendicular to the plug-in direction X. The essentially flat end face 105 preferably delimits the plug-in section 102 in the insertion direction X. The first sensor element 121 is essentially plate-shaped and/or essentially flat and is flush with the wall section 104 to form the essentially flat end face 105. The connector 100 includes a second sensor element 122, which is preferably designed to be essentially identical to the first sensor element 121. The second sensor element 122 is configured to detect a further leakage current KS between the first contact element 111 and the second contact element 112 . The second sensor element 122 is integrated at least in sections in the wall section 104 of the insulating material housing 101 between the first contact element 111 and the second contact element 112 on a side facing away from the plug face 103, preferably in the plug-in direction X, preferably opposite the first sensor element 121 in the plug-in direction X integrated. With the second sensor element 122 it is possible to detect a further leakage current KS inside the connector 100, that is inside the insulating housing 101.

It is alternatively possible for the first sensor element 121 to extend at least through the wall section 104, preferably substantially in the plug-in direction X, and optionally to preferably extend at least in sections into the plug-in section 102. In this exemplary embodiment of the plug connector 100, the first sensor element 121 can be configured, at least in sections, to be essentially cylindrical or essentially pin-shaped or essentially lance-shaped.

The first sensor element 121 and the second sensor element 122 of the connector 100 are connected to a monitoring unit 130 . The monitoring unit 130 is preferably part of the plug connector 100 or alternatively arranged in a charging station which is connected to the plug connector 100 via a charging cable. Monitoring unit 130 is configured to at least compare a detected voltage of leakage current KS present on first sensor element 121 and preferably also on second sensor element 122, i.e. an electrical voltage resulting from leakage current KS, with a reference voltage. The monitoring unit 130 includes corresponding electrical and/or electronic components and elements and can preferably be equipped with its own, ie separate, housing in order to avoid environmental influences such as moisture, dirt and/or dust and their harmful effects.

To form a reference voltage, monitoring unit 130 includes a first resistance element 131 and a second resistance element 132. First resistance element 131 is connected to first contact element 111 or at least to an electrical conductor that is assigned to first contact element 111. The second resistance element 132 is connected to the second contact element 112 or at least with one electrical conductor connected, which is associated with the second contact element 112. In other words, the first resistance element 131 and the second resistance element 132 are connected to the positive pole and the negative pole, respectively. The resistance elements 131 and 132 are preferably in the form of voltage-proof resistors whose resistance values are preferably several 100 kOhms. The resistance elements 131 and 132 are accordingly arranged and configured to form a reference voltage from the voltage present at the first contact element 111 and from the voltage present at the second contact element 112 by voltage division. In other words, the resistance elements 131 and 132 form a voltage detection circuit in the form of a voltage divider.

In the initial phase of the reduction in the insulating properties of the insulating material and thus the impairment of the insulating effect, the resistance of the insulating material is, as expected, (still) correspondingly high and the potential of the first sensor element 121 and/or of the second sensor element 122 is increased by the finite resistance as the input resistance of the voltage detector circuit is kept at the level of the reference voltage by the resistance elements 131 and 132. As the insulating properties decrease, i.e. as the insulation weakens, the inherent resistance of the insulating material decreases and a leakage current KS begins to form.

Monitoring unit 130 also has an operational amplifier 133, operational amplifier 133 being configured to compare the reference voltage formed with the voltage detected at first sensor element 121 and/or at second sensor element 122 and, depending on the result of the comparison, preferably a switching element accordingly 134 of the monitoring unit 130 and/or to transmit the result to a communication unit 140 for further transmission to a charging station and/or to an electric vehicle. Alternatively, instead of the operational amplifier 133, a comparator element can also be used, which is configured to compare the reference voltage formed with the detected voltage. In other words, a shift between the detected voltage at the sensor elements 121 and 122 and a reference voltage, which is formed by the voltage divider between the charging lines, can thereby be detected.

Monitoring unit 130 thus recognizes that a voltage difference between the reference voltage formed and the voltage detected at first sensor element 121 and/or at second sensor element 122 is not reached or is exceeded and switching element 134 initiates, for example, switching off the charging process when the leakage current KS is detected.

Figure 2A shows a front view of a mating face 203 with a mating portion 202 of an embodiment of the connector 200 according to the present invention as a charging socket.

In addition to being configured and/or designed as a charging plug, the connector according to the present invention can also be configured and/or designed as a charging socket 200 . With the plug connector 100 as a charging plug and the plug connector 200 as a charging socket, a plug connection can be formed essentially in the plugging direction X in order to transmit electrical energy and/or electrical signals. This is clearly shown schematically in FIG.

The plug connector 200, as a charging socket, has essentially identical components and elements and/or components and elements with at least identical function with respect to the components and elements of the plug connector 100 described above with reference to FIGS. 1A and 1B. In other words, connector 200 forms a mating connector to connector 100.

Accordingly, the mating face 203 with the mating section 202 is part of the insulating housing 201 of the connector 200. The insulating housing 201 of the connector 200 can be produced, for example, by the same method as the insulating housing 101 of the connector 100. The connector 200 is a charging socket to the connector 100 as Charging connector designed more or less complementary in terms of geometric dimensions and includes in the plug-in section 202, a first contact element 211 and a second contact element 212 for the transmission of electrical energy. The first contact element 211 and the second contact element 212 are arranged spaced apart from one another as load contact elements and are configured to form a plug connection with the contact elements 111 and 112 of the plug connector 100 . In this case, the contact elements 211 and 212 are designed to be essentially pin-shaped, complementary to the contact elements 111 and 112 .

Furthermore, the connector 200 includes the contact element 213 as a protective contact element (so-called PE contact element), the contact element 214 as a pilot contact (Control Pilot/CP) and the contact element 215 as a proximity switch (Proximity Pilot/PP). The contact elements 213 to 215 When a plug-in connection is formed between connector 100 as a charging connector and connector 200 as a charging socket, they are assigned to one another essentially in the insertion direction X and make contact with one another in order to provide the corresponding communication functions between a charging station and an electric vehicle during the course of a charging process.

A leakage current KS can occur between the first contact element 211 and the second contact element 212 under appropriate environmental conditions, as described above with reference to the plug connector 100 by way of example, which is described in more detail below with reference to FIG. 2B.

FIG. 2B shows the connector 200 from FIG. 2A in a schematic representation.

A first sensor element 221 is integrated at least in sections between the first contact element 211 and the second contact element 212 in a wall section 204 of the insulating housing 201, which is preferably a middle or central wall section of the plug-in section 202, in such a way that the wall section 204 and the first Sensor element 221 form a substantially flat end face 205. The essentially planar end face 205 is aligned and/or arranged essentially perpendicularly to the insertion direction X. The essentially flat end face 205 preferably delimits the plug-in section 202 in the insertion direction X. The first sensor element 221 is essentially plate-shaped and/or essentially flat and is flush with the wall section 204 to form the essentially flat end face 205.

The connector 200 includes a second sensor element 222, which is preferably designed to be essentially identical to the first sensor element 221. The second sensor element 222 is configured to detect a further leakage current KS between the first contact element 211 and the second contact element 212 . The second sensor element 222 is integrated at least in sections in the wall section 204 of the insulating material housing 201 between the first contact element 211 and the second contact element 212 on a side facing away from the plug face 203, preferably in the plug-in direction X, preferably opposite the first sensor element 221 in the plug-in direction X integrated. With the second sensor element 222, it is possible to detect a further leakage current KS inside the connector 200, that is, inside the insulating housing 201 of the charging socket. The detection and evaluation takes place analogously to the connector 100 with the aid of a monitoring unit 230. The monitoring unit 230 is preferable to the monitoring unit 130 in FIG. 1B identically configured and/or formed, and includes corresponding resistive elements

231 and 232, an operational amplifier 233, a switching element 234 and a communication unit 240.

Figure 2B also shows that if an electrically conductive medium M, such as water, is present in the plug-in section 202 (shown here in the area of the first contact element 211), a corresponding leakage current KS can occur and be detected at least with the first sensor element 221 , which can be evaluated analogously to the above description and passed on to a charging station and/or an electric vehicle, for example, via the communication unit 240 in the form of corresponding signals.

It is also possible for medium M, which is often an electrically conductive medium M, located inside insulating housing 101 of connector 100 as a charging plug and inside insulating housing 201 of connector 200 as a charging socket to be detected with the respective second sensor elements 122 and 222 can be.

In order to remove medium M, which can often be an electrically conductive medium M, located in plug-in section 202 of plug connector 200 designed as a charging socket, from plug-in section 202, plug connector 200 can also have a first diverting element 251 and preferably a second diverting element 252.

The first diverting element 251 and the second diverting element 252 can, for example, each be designed as a channel or each as a hose. The first diverting element 251 is assigned to the first contact element 211 and the second diverting element 252 is assigned to the second contact element 212 and is used to empty the plug-in section 202 of the corresponding medium M.

FIG. 3 shows an arrangement 300 for forming a plug connection in order to transmit electrical energy and/or electrical signals. For this purpose, the arrangement 300 comprises the connector 100 from FIGS. 1A and 1B, which is designed as a charging connector, and the connector 200 from FIGS. 2A and 2B, which is designed as a charging socket. The plug-in connector 100 and the plug-in connector 200 form a plug-in connection as the first and second plug-in connector 100, 200 essentially in the plug-in direction X. When the plug-in connection is formed, the first sensor element 121 of the plug connector 100 makes contact with the first sensor element 221 of the plug connector 200, preferably via a spring element 301. The spring element 301 can be connected to the first sensor element 121 of the connector 100 or to the first sensor element 221 of the connector 200, for example. As a result, for example, leakage currents KS (not shown in FIG. 3 for reasons of clarity) can be detected either through connector 100 or through connector 200 and thus through a single connector 100, 200. Thus, for example, only a single monitoring unit 130, 230 is required, which monitors both the connector 100 and the connector 200.

Figure 4 shows an equivalent circuit diagram of a connector 100 from Figures 1A and 1B with a modified monitoring unit 130, wherein the connector 100 is preferably configured, among other things, to detect the entry of an electrically conductive medium M in the plug-in section 102 by detecting a leakage current (KS). .

The modified monitoring unit 130 comprises in each case two first resistance elements 131 and in each case two second resistance elements 132 which are configured to carry out a voltage division of the voltage present at the contact elements 111 and 112 . The first resistance elements 131 can have a resistance value of, for example, 400 kOhm and the second resistance elements 132 can have a resistance value of, for example, 600 kOhm and thus divide the applied voltage in a ratio of 40% to 60%.

FIG. 4 shows the voltage ratios with the partial voltages U1, U2 and U3 between the two contact elements 111 and 112 along the creepage path of the leakage current KS, which are represented by the partial distances D1 and D3. D2 characterizes a partial distance by a resulting geometric dimension of the first sensor element 121, ie the first electrode 121 for detecting the leakage current KS. The sum of the partial voltages Ul, U2 and U3 results in the total voltage UG between the first and the second contact element 111, 112.

The resistance of the insulating material between the first contact element 111 and the first sensor element 121 and between the second contact element 112 and the first sensor element 121 is symbolized in each case by a resistance RJ. Depending on the conditions to which the connector 100 is exposed, this resistance changes and becomes lower, for example, which leads to an increase in the voltage at the first sensor element 121 . Are the insulation resistances RJ of a similar order of magnitude or less than that Resistance elements 131 and 132 of the reference voltage divider change the voltage at the first sensor element 121.

By continuously monitoring the voltage at the first sensor element 121, especially when no charging process is taking place, i.e. when no charging current is flowing in the initialization phase but a charging voltage is present, a change, i.e. increase in this voltage can slowly Indication of an insulation fault or an insulation weakness of the insulating material that is slowly becoming apparent can be detected, preferably by monitoring unit 130.

The first and second resistance elements 131 and 132 are used to assign a constant voltage value for the operational amplifier 133 or, alternatively, for a comparator element, in order to form a reference voltage by appropriate voltage division and to compare it with the voltage detected at the first sensor element 121 and to determine a voltage difference.

The monitoring unit 130 and preferably the operational amplifier 133 is configured to detect falling below or exceeding a voltage difference between the reference voltage formed and the detected voltage, preferably as a function of at least one defined or predetermined criterion, preferably a voltage value.

The present invention is not limited to the embodiments described above. Rather, a large number of variants and modifications are possible, which also make use of the idea of the invention and therefore fall within the scope of protection. Preferably, the present invention also claims protection for the subject-matter and features of the subclaims independently of the claims referred to.

Reference List

100 connectors

101 insulating housing

102 mating section

103 mating face

104 wall section

105 face

106 face

107 insulating sleeve

108 insulating sleeve

111 contact element (load contact element)

112 contact element (load contact element)

113 contact element

114 contact element

115 contact element

121 sensor element

122 sensor element

130 surveillance unit

131 resistance element

132 resistance element

133 comparator element, operational amplifier element

134 switching element

140 communication unit

200 connectors

201 insulating housing

202 mating section

203 mating face

204 wall section

205 face

206 face

211 contact element

212 contact element

213 contact element 214 contact element

215 contact element

230 surveillance unit

231 resistance element

232 resistance element

233 comparator element, operational amplifier element

234 switching element

240 communication unit

251 discharge element

252 discharge element

300 arrangement

301 spring element

D distance

Dl partial distance

D2 (resulting) part distance

D3 part distance

KS leakage current

M Media

Ul partial voltage

U2 partial voltage

U3 partial voltage

UG total voltage

R_l resistance

X plug-in direction

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Claims

22

CLAIMS Plug connector (100, 200) for forming a plug connection in a plug-in direction (X) in order to transmit electrical energy and/or electrical signals, the plug connector (100, 200) having an insulating material housing (101, 201) with a plug-in section (102, 202), in which at least one first contact element (111, 211) and at least one second contact element (112, 212) are accommodated to form a mating face (103, 203), the at least one first contact element (111, 211) and the at least one second contact element (112, 212) are arranged at a distance from one another, with at least one sensor element (121, 221) in the insulating housing (101 , 201) is arranged and configured to detect a leakage current (KS) between the at least one first contact element (111, 211) and the at least one second contact element (112, 212). Connector (100, 200) according to Claim 1, wherein the at least one sensor element (121, 221) is arranged and designed in such a way that the leakage current (KS) is channeled on a surface of the insulating housing (101, 201). Connector (100, 200) according to claim 1 or 2, wherein the at least one sensor element (121, 221) is at least partially in a wall section (104, 204) of the insulating housing (101, 201), preferably for delimiting the plug-in section (102, 202) in the insertion direction (X) and/or preferably at a narrow point between the at least one first contact element (112, 211) and the at least one second contact element (112, 212) is integrated, preferably integrally and/or non-positively integrated, with the wall section (104, 204) extends at least in sections in the plug-in direction (X) and/or perpendicular to the plug-in direction (X). Connector (100, 200) according to claim 3, wherein the at least one sensor element (121, 221) is formed and is integrated in the wall section (104, 204) in such a way that the wall section (104, 204) and the at least one sensor element (121, 221) form at least one flat end face (105, 205), which is preferably aligned perpendicular to the plug-in direction (X) and/or which preferably delimits the plug-in section (102, 202) in the plug-in direction (X).

5. Connector (100, 200) according to any one of the preceding claims, wherein the at least one sensor element (121, 221) is plate-shaped and / or is flat, and preferably to form a flat end face (105, 205) on a wall section ( 104, 204) of the insulating housing (101, 201) flush.

6. Connector (100, 200) according to any one of the preceding claims, wherein the connector (100, 200) comprises at least one further sensor element (122, 222) which is configured to detect a further leakage current (KS) between the at least one first contact element ( 111, 211) and the at least one second contact element (112, 212), the at least one further sensor element (122, 222) on a side facing away from the plug face (103, 203), preferably in the plug-in direction (X), at least integrated in sections in a wall section (104, 204) of the insulating housing (101, 201) between the at least one first contact element (111, 211) and the at least one second contact element (112, 212), preferably in the plug-in direction (X) of the at least one Sensor element (121, 221) is integrated opposite.

7. Connector (100, 200) according to one of the preceding claims 1 to 5, wherein the at least one sensor element (121, 221) extends, preferably in the plug-in direction (X), at least through the wall section (104, 204), and /or preferably extends at least in sections into the plug-in section (102, 202), and/or wherein the at least one sensor element (121, 221) is at least in sections cylindrical or pin-shaped or lance-shaped.

8. Connector (100, 200) according to one of the preceding claims, wherein the at least one sensor element (121, 221) and preferably at least one further sensor element (122, 222) each comprises an electrode or is each designed as an electrode.

9. Connector (100, 200) according to any one of the preceding claims, wherein the at least one sensor element (121, 221), and preferably at least one further sensor element (122, 222), is connected to a monitoring unit (130, 230), wherein the monitoring unit (130, 230) is configured to have one on the at least one Sensor element (121, 221), and preferably a voltage detected at the at least one further sensor element (122, 222), which is caused or influenced by the leakage current (KS), with a reference voltage. Connector (100, 200) according to claim 9, wherein the monitoring unit (130, 230) has at least one first resistance element (131, 231), which is connected to the at least one first contact element (111, 211), and at least one second resistance element (132 , 232) which is connected to the at least one second contact element (112, 212), wherein the at least one first resistance element (131, 231) and the at least one second resistance element (132, 232) are arranged and configured, the reference voltage from the voltage present at the at least one first contact element (111, 211) and/or from the voltage present at the at least one second contact element (112, 212), preferably by voltage division. Connector (100, 200) according to claim 10, wherein the monitoring unit (130, 230) has at least one comparator element (133, 233) or at least one operational amplifier (133, 233) and is configured to compare the reference voltage formed with the detected voltage, and/or to control a switching element (134, 234) depending on the reference voltage formed and the detected voltage. Plug connector (100, 200) according to one of the preceding claims, wherein the insulating material housing (101, 201) has at least one discharge element (251, 252 ), preferably each having a diverting element (251, 252), and the at least one diverting element (251, 252), preferably the respective diverting element (251, 252), is arranged and configured in the insulating housing (101, 201) in this way in the plug-in section (102, 202) located medium (M), preferably flowable or castable medium (M), from the plug-in section (102, 202). 25 arrangement (300) for forming a plug connection to transmit electrical energy and / or electrical signals, comprising a first connector (100) according to any one of the preceding claims, wherein the first connector (100) is designed as a charging connector (100), and a second connector (200) according to any one of the preceding claims, wherein the second connector (200) is designed as a charging socket (200), and preferably when the connector is formed, the at least one sensor element (121) of the first connector (100) the at least one sensor element (221) of the second connector (200) contacted, preferably via a spring element (301). Method for detecting a leakage current (KS) in a connector (100, 200), wherein the connector (100, 200) is preferably configured according to one of the preceding claims 1 to 12, wherein:

• a voltage that is caused or influenced by the leakage current (KS) is detected by at least one sensor element (121, 221);

• a reference voltage from a voltage connected to the at least one first contact element (111,

211) and/or from a voltage present at the at least one second contact element (112, 212) by means of voltage division by at least two resistance elements (131, 132; 231, 232);

• the reference voltage formed is compared with the detected voltage, and

• falling below or exceeding a voltage difference between the reference voltage formed and the detected voltage is detected.

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