WO2024120715A1

WO2024120715A1 - Interchangeable insert for a charging socket and charging socket

Info

Publication number: WO2024120715A1
Application number: PCT/EP2023/080893
Authority: WO
Inventors: Veronika Gielhammer
Original assignee: Lisa Dräxlmaier GmbH
Priority date: 2022-12-05
Filing date: 2023-11-06
Publication date: 2024-06-13
Also published as: DE102022132133B3

Abstract

The present invention relates to an interchangeable insert (100) for a charging socket (500), wherein the interchangeable insert (100) has a carrier (104) made of a plastic material and at least two contact elements (102) which are overmoulded with the plastic material at least in some regions, wherein the carrier (104) has a mechanical interface (116) to a receptacle (502) of the charging socket (500) arranged on an inner side (514) of a socket face (516) of the charging socket (500), wherein the contact elements (102) have, on a front side (106) of the carrier (104), contact pins (110) corresponding to recesses (520) of the socket face (516) and, on a rear side (108) of the carrier (104), electrical interfaces (112) to a cable set.

Description

INTERCHANGEABLE INSERT FOR A CHARGING SOCKET AND CHARGING SOCKET

Technical area

The present invention relates to a replacement insert for a charging socket and a charging socket for an electric vehicle or a charger.

State of the art

The present invention is described below mainly in connection with charging connectors for electric vehicles.

An electrically powered vehicle can have a charging socket for charging the vehicle's traction battery. A charging plug from a charging cable can be plugged into the charging socket. The traction battery can be charged via the charging socket by a charger, i.e. a charging station, a wall box or a so-called charging brick. The charger can also have such a charging socket into which the other charging plug of the charging cable is plugged. Electrical contact elements are arranged in the charging socket in a way that prevents contact. The contact elements can be designed as contact pins and, with corresponding counterparts in the charging plug, create an electrically conductive connection with the charging cable. The contact elements are subject to mechanical wear and tear as a result of plugging and unplugging processes. If the charging socket is worn out, the entire charging socket can be replaced.

Description of the invention

One object of the invention is therefore to provide an improved charging socket using the simplest possible construction means. An improvement can, for example, relate to improved maintainability and an increased service life of the charging socket.

The object is solved by the subject matter of the independent claim. Advantageous developments of the invention are specified in the dependent claims, the description and the accompanying figures.

In the approach presented here, contact elements of a charging socket are arranged in an exchangeable replacement part. The contact elements are arranged in a carrier in such a way that they are in the intended relative positions to one another, i.e. in the places specified by a plug face of the charging plug or a socket face of the charging socket. If at least one of the contact elements is worn, the old replacement part with the old contact elements is exchanged, i.e. removed and replaced with a new replacement part or a replacement part with unworn contact elements. The replacement part can also be referred to as a replacement insert.

The replacement part is accessible from the back or the back of the charging socket. To do this, a service cover of the charging socket is opened and the interior of the charging socket is accessed through an opening. Inside, the old replacement part is electrically disconnected, mechanically dismantled, pulled out of the socket face and removed from the interior through the opening. The new replacement part is through the opening from behind into the interior of the charging socket and the contact elements are inserted through holes in the socket face towards the front of the charging socket. The new replacement part is then mechanically attached to the charging socket, electrically connected and the service cover is closed.

Thanks to the approach presented here, the service life of a charging socket is no longer limited by the wear and tear of its contact elements. When the contact elements are worn out, a small replacement part can be replaced and the charging socket is as good as new again. The replacement part can be replaced quickly and easily. The replacement part can be the same for many different vehicles and chargers. This means that the replacement part can be produced cost-effectively in large quantities thanks to economies of scale, and the storage of spare parts is also simplified.

According to a first aspect of the invention, a removable insert for a charging socket of a vehicle or a charging device is proposed, wherein the removable insert has a carrier made of a plastic material and at least two contact elements partially overmolded by the plastic material, wherein the carrier has a mechanical interface to a receptacle of the charging socket arranged on an inner side of a socket face of the charging socket, wherein the contact elements have contact pins arranged on a front side of the carrier corresponding to openings in the socket face and electrical interfaces to a cable set of the vehicle or the charging device on a rear side of the carrier.

According to a second aspect of the invention, a charging socket for a vehicle or a charging device is proposed, wherein the charging socket has a receptacle for an exchangeable insert according to the first aspect on an inner side of a socket face of the charging socket, wherein the receptacle on the inner side can be closed by a service cover. According to a third aspect of the invention, a charging socket according to the second aspect with a removable insert according to the first aspect is proposed, wherein the removable insert is arranged in the receptacle and contact pins of contact elements of the removable insert are arranged in the socket face and the receptacle is closed on the inside by the service cover.

A charging socket can have at least two contact elements for transmitting electrical energy between a charger and a charging cable or between the charging cable and a vehicle. With two contact elements, the charging socket can be designed in particular for charging with direct current. With five or more contact elements, the charging socket can be designed for charging with alternating current. The charging socket can also be designed for charging with direct current and alternating current and have at least seven contact elements for this purpose. The charging socket can also have contact elements for data transmission. The charging socket can correspond to a standardized standard for charging sockets.

The contact elements can be designed to form a plug connection with corresponding counterparts. The contact elements can have contact pins which can form the plug connection with corresponding sleeves as the counterparts. The counterparts or sleeves can be arranged in a charging plug.

The contact elements can be arranged in a plug geometry of the charging socket defined by the standard. The plug geometry can ensure centering and anti-twisting protection, as well as contact protection of the contact elements, with a corresponding counterpart of the charging plug. The plug geometry can define a plug face of the charging plug or a socket face of the charging socket. The plug face or socket face represents the positions of the contact elements. For example, the contact elements for transmitting direct current can be arranged in a flattened, rounded plug geometry next to each other. The contact elements for transmitting alternating current can be arranged in a round plug geometry with a flattened area. The contact elements for transmitting alternating current can be arranged at equal distances around a central contact element.

In the approach presented here, the contact elements are arranged in an exchangeable interchangeable insert. The interchangeable insert defines positions of the contact elements according to the plug geometry, without having the plug geometry itself. The plug geometry is part of the charging socket; in a charging socket for direct current and alternating current, the contact elements for direct current can be arranged in a direct current interchangeable insert. The contact elements for alternating current can be arranged in an alternating current interchangeable insert. The charging socket for direct current and alternating current can therefore have two interchangeable inserts.

The contact elements combined in a removable insert are molded around a common carrier or a base body. The carrier consists, for example, of an electrically insulating, thermoplastic material. The carrier mechanically connects the contact elements to one another and is designed to be mechanically attached to the charging socket. The carrier specifies the positions of the contact elements according to the plug geometry or the socket face. When installed, a front side of the removable insert is aligned towards the outside of the charging socket. This means that the plug geometry of the charging socket is arranged between the removable insert and the outside.

A mechanical interface of the carrier and a receptacle of the charging socket can be at least partially identical. In particular, elements for fastening and/or aligning the interchangeable insert on the charging socket can be identical. The mechanical interface can essentially be on the front of the carrier. The mechanical interface can also be arranged on the side surfaces of the carrier.

On the front of the carrier, the contact elements are designed in accordance with the standardized standard of the charging socket. On the opposite back side, the contact elements can be designed differently. The contact elements have an electrical interface on the back that fits a wiring harness of the vehicle or the charger. For example, the electrical interface of at least one of the contact elements can be designed as a flat contact. Likewise, the electrical interface of at least one of the contact elements can be designed as a round contact. The electrical interface of at least one of the contact elements can also be designed as a contact surface with a threaded hole or a threaded bolt.

At least one of the contact elements can have an electrically conductive stamped grid between the contact pin and the electrical interface. The stamped grid can be overmolded with the plastic material. A stamped grid can be made of a metal material. The stamped grid can be punched out of roll material or sheet material. The stamped grid can in particular be aligned transversely to the contact pins. The stamped grid can run within the carrier. The stamped grid can be used to arrange the electrical interface of the contact element laterally offset from the contact pin. In particular, an end of the stamped grid opposite the contact pin can be bent out of a main extension plane of the stamped grid and form a flat contact protruding from the carrier as the electrical interface.

Using several electrically insulated stamped grids, the electrical interfaces of the contact elements combined in the interchangeable insert can be arranged in a plug-in geometry of the cable set. The plug-in geometry of the charging socket and the cable set can different. The plastic material of the carrier can electrically insulate the lead frames from each other.

The interchangeable insert can have a ground contact. At least one of the contact elements can be electrically connected to the ground contact. When the interchangeable insert is inserted into the charging socket, a ground contact can be connected to a corresponding ground contact on the charging socket in order to achieve electrical potential equalization. The ground contact can be arranged laterally offset from the plug geometry of the charging socket or the contact pins of the interchangeable insert.

The ground contact can be a fastening point of the mechanical interface of the carrier. In particular, the ground contact can be screwed to the ground contact of the charging socket. A screw or threaded bolt can penetrate a through hole of the ground contact and be screwed with a thread in a threaded hole or a nut.

The ground contact can be electrically connected to the contact pin and the electrical interface via the lead frame. The lead frame can have a branch to the ground contact. The ground contact can thus be arranged laterally offset to the contact pin and/or the electrical interface.

The interchangeable insert can have at least one temperature sensor thermally coupled to at least one of the contact elements. A temperature sensor can be injected into the carrier between the contact elements, for example. The temperature sensor can monitor the temperature of the contact elements when electrical energy is transmitted. Temperature values from the temperature sensor can be transmitted to the electronics of the charging socket via a data interface of the interchangeable insert. The temperature sensor can be part of a sensor integrated into or plugged into the interchangeable insert. Electronic unit. The electronic unit can be designed as an overmolded circuit board, for example. The electronic unit can be arranged on the back of the interchangeable insert.

The mechanical interface of the carrier can have a screw receptacle at at least one fastening point for screwing the interchangeable insert to the charging socket receptacle. A screw receptacle can be a through hole for a screw or a threaded bolt. The screw or threaded bolt can be arranged in the screw receptacle for screwing. The screw can be screwed into the charging socket receptacle. A nut can be screwed onto the threaded bolt. A screw connection can enable a very secure connection between the interchangeable insert and the charging socket. The screw connection can be screwed and loosened several times.

The mechanical interface of the carrier can have a locking device at at least one fastening point for positively locking the interchangeable insert in the receptacle of the charging socket. A locking device can have a spring element and an undercut on a hook. The locking device can also be designed as a counterpart to the spring element and the hook. The spring element can be elastically deformed when the interchangeable insert is arranged in the receptacle. The hook can slide off the interchangeable insert and rust behind an edge when the interchangeable insert reaches the intended position. A mechanical positive locking can be achieved by rusting.

Short character description

Advantageous embodiments of the invention are described below under

Reference to the accompanying figures. They show: Figs. 1 to 3 show spatial representations of interchangeable inserts according to embodiments;

Fig. 4 shows spatial representations of contact elements for interchangeable inserts according to embodiments; and

Fig. 5 shows a spatial representation of a charging socket with an exchangeable insert according to an embodiment.

The figures are schematic representations and serve only to explain the invention. Identical or equivalent elements are provided with the same reference numerals throughout.

Detailed description

Fig. 1 shows a spatial representation of an interchangeable insert 100 according to an embodiment. The interchangeable insert 100 combines contact elements 102 of a charging socket in a compact, exchangeable unit. For this purpose, the interchangeable insert 100 has a carrier 104 made of a plastic material, in which the contact elements 102 are embedded such that they protrude on a front side 106 and a back side 108 of the carrier 104. On the front side 106, the contact elements 102 are designed as contact pins 110 of the charging socket. The interchangeable insert 100 here has seven contact elements 102 in accordance with the EN 62196 Type 2 standard. Five of the contact elements 102 are designed on the back side 108 as electrical interfaces 112 for connecting a cable set.

The electrical interfaces 112 are designed here as round contacts 114.

As a result, the contact elements 102 are essentially spindle-shaped and each extend along a continuous central axis. The carrier 104 defines the positions of the contact elements 102 according to the EN 62196 Type 2 standard. The carrier 104 has a mechanical interface 116 on its front side 106 for fastening and aligning the interchangeable insert 100 in a corresponding receptacle of the charging socket. The mechanical interface 116 has at least two screw receptacles 118 for screwing the interchangeable insert 100 behind a socket face of the charging socket.

Fig. 2 shows a spatial representation of an interchangeable insert 100 according to an embodiment. The interchangeable insert 100 essentially corresponds to the interchangeable insert in Fig. 1. Here, the electrical interfaces 112 are designed as flat contacts 200. The flat contacts 200 are arranged laterally offset from the contact pins 110 and are connected to the contact pins 110 by overmolded lead frames 202. The lead frames 202 run within the carrier 104. Ends of the lead frames 202 are bent essentially perpendicular to the rear side 108 of the carrier 104 and form the flat contacts 200.

In one embodiment, the interchangeable insert 100 has a ground contact 204. The ground contact 204 is arranged on a side of the rear side 108 opposite the flat contacts 200. The ground contact 204 is designed as a screw receptacle 118 of the mechanical interface 116. When the interchangeable insert 100 is screwed to the receptacle of the charging socket via the screw receptacles 118, the ground contact 204 is electrically connected to a ground contact of the receptacle when screwed.

Fig. 3 shows a spatial representation of an interchangeable insert 100 according to an embodiment. The interchangeable insert 100 essentially corresponds to the interchangeable insert in Fig. 2. Here, a cast electrical circuit 300 is arranged on the rear side 108. The circuit 300 has at least one temperature sensor and a data connection 302. The temperature sensor is thermally coupled to at least one of the contact elements 102 and represents a temperature of the contact element in a temperature value. The temperature value is provided for charging control via the data connection 302. The data connection 302 is arranged at the end of an arm protruding from the circuit 300.

Fig. 4 shows spatial representations of contact elements 102 according to embodiments. The contact elements 102 essentially correspond to the contact elements in Figs. 1 and 2. Here, the contact elements 102 are shown without the carrier or before overmolding.

The contact elements 102 according to the EN 62196 Type 2 standard are either designed as round contacts 114 with the electrical interfaces 112 as in Fig. 1, or are designed as flat contacts 200 with stamped grids 202 as in Fig. 2 with the electrical interfaces 112. In the variants with stamped grids 202, the ground contact 204 is also contacted via one of the stamped grids 202.

DC transmission contact elements 102 of charging sockets are shown as further embodiments of contact elements 102. The DC transmission contact elements 102 are arranged in pairs in a common carrier. The DC transmission contact elements 102 also have contact pins 110 on the front and electrical interfaces 112 on the back for connecting a cable set or flat conductors. The contact pins 110 have a significantly larger conductor cross-section compared to the contact pins according to the EN 62196 Type 2 standard.

In one embodiment, the electrical interfaces 112 are designed as round contacts 114. The contact elements 102 are essentially spindle-shaped. In one embodiment, the electrical interfaces 112 are designed as contact sleeves 400 for round contacts. The contact sleeves 400 are arranged laterally offset from the contact pins 110 and are connected to the contact pins 110 via lead frames 202 with a correspondingly large line cross-section.

The variants shown here thus result in four combinations of contact elements 102 according to the EN 62196 Type 2 standard and direct current transmission contact elements 102. The combinations are contact elements 102 according to the EN 62196 Type 2 standard with round contacts 114 and direct current transmission contact elements 102 with round contacts 114, contact elements 102 according to the EN 62196 Type 2 standard with flat contacts 200 and direct current transmission contact elements 102 with round contacts 114, contact elements 102 according to the EN 62196 Type 2 standard with round contacts 114 and direct current transmission contact elements 102 with contact sleeves 400 and contact elements 102 according to the EN 62196 Type 2 standard with flat contacts 200 and direct current transmission contact elements 102 with contact sleeves.

Fig. 5 shows a spatial representation of a charging socket 500 with a removable insert 100 according to an embodiment. The removable insert 100 corresponds to one of the previously described embodiments.

The charging socket 500 has a receptacle 502 for fastening the interchangeable insert 100. The receptacle 500 is arranged in an interior 504 of a housing 506 of the charging socket 500. The interior 504 is accessible through an opening 508 of the housing 506. The opening 508 is tightly closed by a service cover 510 during operation of the charging socket 500. The service cover 510 has a plug geometry 512 for inserting a plug of a cable set for connecting the charging socket 500. When the service cover 510 is arranged in the opening 508, the electrical interfaces 112 of the interchangeable insert 100 are arranged in the plug geometry 512. The receptacle 502 is arranged on an inner side 514 of a socket face 516 of the charging socket 500. The receptacle 502 has fastening points 518 for mechanically fastening the interchangeable insert 100. When the interchangeable insert 100 is fastened to the receptacle 502, the contact pins 110 are arranged in recesses 520 of the plug face 514 and are accessible from an outer side 522 of the charging socket 500 via a plug geometry 512 of the charging socket 500.

The interchangeable insert 100 can easily be replaced with a new interchangeable insert 100 through the opening 508 if the contact pins 110 show signs of wear.

In one embodiment, the charging socket 500 has a further receptacle 502 for a further interchangeable insert 100. The further receptacle 502 is arranged below the receptacle 502. The further receptacle 502 is covered by a further service cover 510 with a further plug geometry 512 and the electrical interfaces 112 of the further interchangeable insert 100 are arranged in the further plug geometry 512 of the further service cover 510. The further interchangeable insert 100 here has two direct current transmission contact elements. The charging socket thus corresponds to a Combo 2 charging socket 500 with two interchangeable inserts 100.

In the following, possible embodiments of the invention are summarized again or presented using slightly different wording.

Serviceable contacts are presented.

Due to the surface wear on the charging socket contacts during the charging process, contact resistance can increase over time and, as a result, lead to higher losses during the charging process. Worn contacts cannot currently be replaced. Therefore, either the charging socket or even the entire HV cable set is currently replaced. In the approach presented here, the contacts of the charging socket are designed to be replaceable. The solution principle can be applied in the AC and DC contact area. The contacts are designed as a removable insert that is molded over. The old "replacement insert" is removed through the opening in the service cover and a new replacement insert can be inserted.

The interchangeable insert can be used as an identical part or as a transfer part in different charging sockets.

Instead of replacing the entire charging socket, only the replacement insert with the contacts is replaced. This saves materials/raw materials and reduces costs. Replacing the replacement insert saves time compared to replacing the entire charging socket or the charging socket and the cable set. The service life of the charging socket can be increased by using replacement inserts.

The charging socket has a service opening in which a sealed service cover is attached. In the event of servicing, the service cover is removed in order to replace the replacement insert with a new one and then closed again.

In one variant, the contacts are overmolded. In another variant, the contacts are overmolded with a stamped grid. A populated circuit board/FPC (for temperature sensors, etc.) can be attached to the overmolded contacts. This results in a wide range of variants that can be implemented in AC and DC depending on the requirements of the charging socket.

Since the devices and methods described in detail above are exemplary embodiments, they can be modified to a wide extent by those skilled in the art without departing from the scope of the In particular, the mechanical arrangements and the relative sizes of the individual elements are merely exemplary.

LIST OF REFERENCE SYMBOLS

100 interchangeable inserts

102 Contact element

104 carriers

106 Front

108 Back

110 Contact pin

112 electrical interface

114 Round contact

116 mechanical interface

118 Screw holder

200 flat contact

202 Punched Grid

204 Ground contact

300 electrical circuit

302 Data connection

400 contact sleeve

500 charging socket

502 Recording

504 Interior

506 Housing

508 Opening

510 Service cover

512 Plug-in geometry

514 Inside

516 Can Face Attachment point

Recess

Outside

Claims

CLAIMS Interchangeable insert (100) for a charging socket (500), wherein the interchangeable insert (100) has a carrier (104) made of a plastic material and at least two contact elements (102) partially overmolded by the plastic material, wherein the carrier (104) has a mechanical interface (116) to a receptacle (502) of the charging socket (500) arranged on an inner side (514) of a socket face (516) of the charging socket (500), wherein the contact elements (102) have contact pins (110) arranged on a front side (106) of the carrier (104) corresponding to recesses (520) of the socket face (516) and have electrical interfaces (112) to a cable set on a rear side (108) of the carrier (104). Interchangeable insert (100) according to claim 1, in which at least one of the contact elements (102) has an electrically conductive stamped grid (202) between the contact pin (110) and the electrical interface (112), the stamped grid (202) being encapsulated by the plastic material. Interchangeable insert (100) according to one of the preceding claims, with a ground contact (204), wherein at least one of the contact elements (102) is electrically conductively connected to the ground contact (204). Interchangeable insert (100) according to claim 3, in which the ground contact (204) is a fastening point (518) of the mechanical interface (116) of the carrier (104). Interchangeable insert (100) according to claim 2 and one of claims 3 to 4, in which the ground contact (204) is electrically conductively connected to the contact pin (110) and the electrical interface (112) via the stamped grid (202). Interchangeable insert (100) according to one of the preceding claims, with at least one temperature sensor thermally coupled to at least one of the contact elements (102). Interchangeable insert (100) according to one of the preceding claims, in which the mechanical interface (116) of the carrier (104) is connected to at least one Fastening point (518) has a screw receptacle (118) for screwing the interchangeable insert (100) to the receptacle (502) of the charging socket (500). Interchangeable insert (100) according to one of the preceding claims, in which the mechanical interface (116) of the carrier (104) has a locking device at at least one fastening point (518) for positively locking the interchangeable insert (100) in the receptacle (502) of the charging socket (500). Charging socket (500) for a vehicle, wherein the charging socket (500) has a receptacle (502) for an interchangeable insert (100) according to one of claims 1 to 8 on an inner side (514) of a socket face (516) of the charging socket (500), wherein the receptacle (502) on the inner side (514) can be closed by a service cover (510). Charging socket (500) according to claim 9 with an interchangeable insert (100) according to one of claims 1 to 8, wherein the interchangeable insert (100) is arranged in the receptacle (502) and contact pins (110) of contact elements (102) of the interchangeable insert (100) are arranged in the socket face (516).