Electric Connector for High Power Charging

An electric connector includes a connector body having a connector core and two protruding cuboidal elements that, together, form a U shape. At least one conducting element is arranged at an inner side of the protruding cuboidal element. The conducting element protrudes, at least partly, from the inner side. The conducting element is arranged slidably between two notches, which are arranged in the cuboidal element. The conducting element and at least one notch of the two are configured for conducting charging current.

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application claims priority to European Patent Application No. 21213402.7, filed on Dec. 9, 2021, which is incorporated herein in its entirety by reference.

FIELD OF THE DISCLOSURE

The present disclosure relates to electric connectors, particularly for high power charging of, e.g., electric vehicles, and to a method for the use of such electric connectors.

BACKGROUND OF THE INVENTION

Charging connectors may be used for charging electric vehicles, but are not limited to that application. Conventional charging connectors may, in many cases, be limited to a maximum current of about 500 A. However, there may be a need for charging connectors that are able to deal with higher currents. Those charging connectors may have higher requirements, for instance concerning their maintainability.

BRIEF SUMMARY OF THE INVENTION

In a general aspect, the present disclosure describes a charging connector, particularly with an improved maintainability.

One aspect of the disclosed embodiments relates to an electric connector for high power charging, the connector comprising a connector body, comprising a connector core and two protruding cuboidal elements, the connector core and the two protruding cuboidal elements forming a rectangular U, and at least one conducting element, arranged at an inner side of the protruding cuboidal element, wherein the conducting element protrudes, at least partly, from the inner side, and wherein the conducting element is arranged slidably between two notches, the notches arranged in the cuboidal element, and wherein the conducting element and at least one notch of the notches are configured for conducting charging current.

The electric connector for high power charging is designed for being able to conduct currents of more than 500 A. At least in some embodiments, the electric connector may be able of delivering a maximum current of about 3 kA and a voltage of about 1.5 kV; however, there may be embodiments that may be configured for lower powers, which may include a maximum current of less than 500 A. The electric connector may, for instance, be used for charging heavy vehicles (e.g. trucks, vessels or aircraft), but may also be used for devices that need high power, such as motors or electric buffers.

Inside the connector, a connector body is arranged. The connector body is configured for supporting a transport of current. The connector body may have any form, e.g. a cubic block, a cylinder, or may be of another form. The connector core and two protruding cuboidal elements form a rectangular U. The rectangular U may have rounded corners. The rectangular U may be configured for surrounding a conducting structure, at least by the two protruding cuboidal elements, which may be configured for touching the conducting structure at least laterally. The conducting structure may act as a mechanical and/or electrical counterpart for the protruding cuboidal elements. The conducting structure may be arranged in or on a vehicle. The two protruding cuboidal elements may have an electric contact or conducting element, i.e. at least one electric contact protruding, at least partly, from an inner side of at least one of the cuboidal elements. There may be embodiments that have conducting elements on both inner sides and/or that have a plurality of conducting elements. The connector body and/or the protruding cuboidal elements may be massive and/or may have cooling structure, for example cooling channels, e.g. as a passage for a cooling fluid.

The conducting element is configured for conducting the charging current. In at least some embodiments, the total charging current is distributed among a plurality of conducting elements. The conducting elements may comprise or consist of highly conducting material, such as copper, others or a conducting alloy, possibly with a highly conducting coating material, such as gold or silver. The conducting elements may be elastic, at least partly, to reduce an electric transition resistance to the conducting structure by exerting a pressure on the conducting structure.

The conducting element is arranged slidably between two notches, wherein the notches are arranged in the cuboidal element. The conducting element may be designed as an arc or as a U or similarly, so that each one of the ends of the arc (etc.) are able to engage into each one of the corresponding notches. For reducing an electric transition resistance between the conducting element and the corresponding notch, the conducting element may exert some pressure on the notches. Additionally or as an alternative, the conducting element and/or the corresponding notch may be coated with a material that reduces the electric transition resistance or contact resistance and/or improves the slidability. The end of the conducting element and the corresponding notch may have a corresponding form; for instance, both are rounded or rectangular, hexagonal, or of another form. Alternatively, end of the conducting element and the corresponding notch may have a form that enables “cutting” into the notch; for instance, the notch may have a rounded form, and the end of the conducting element may be rectangular. Both the conducting element and the notches are configured for conducting the charging current, thus enabling a transfer of high power to the corresponding conducting structure.

The design of the electric connector as described above and/or below may not only enable a transfer of high power between the connector and the corresponding conducting structure, e.g., by many means that reduce electric transition resistances. The design of the electric connector further improves the connector's maintainability and/or its serviceability, particularly because the slidably arranged conducting element(s) can easily be pulled out of the notches. Then, the conducting element(s) may be substituted or repaired. This may advantageously reduce the lifetime cost of the connector.

DETAILED DESCRIPTION OF THE INVENTION

FIG.1shows schematically an electric connector10according to an embodiment. The connector10has a handle11, which may help for plugging the connector10into a corresponding conducting structure (not shown), which may be arranged in or on an electric vehicle, on a mating face19. The handle11may be part of an external enclosure12of the connector10and/or integrated into the external enclosure12. The connector10shown further has a cable16and a fluid channel18, for cooling fluid, inside the external enclosure12. The cable16and the fluid channel18lead to an internal enclosure14, which holds a connector core22(see, e.g.,FIG.2) and protruding cuboidal elements24. The connector10may have further components, e.g., control or pilot pins17and/or further ones, which are neglected in this description.

FIG.2shows schematically a part of an electric connector10—e.g., the one shown inFIG.1—according to an embodiment. This part comprises a connector body20, comprising a connector core22, which is connected to cables16and fluid channels18. The connector body20further comprises two protruding cuboidal elements24, wherein the connector core22and the two protruding cuboidal elements24form a kind of U, particularly a rectangular U. The U may have rounded inner corners (not shown). Each of the cuboidal elements24has an outer side28and an inner side26and, further, an upper edge25. InFIG.2, there are—as an example—three conducting elements30visible, which are arranged at an inner side26of one of the protruding elements24. The other protruding cuboidal element24, whose inner side is not visible inFIG.2, may also have conducting elements30.

FIG.3shows schematically an element of an electric connector10according to an embodiment, namely a part of an inner side26of a protruding cuboidal element24, where a plurality of conducting elements30are arranged.FIG.3further shows a detachable top element40(shown with dashed lines), which is arranged on top of an upper edge25of the cuboidal element24. It can clearly be seen that the top element40“closes” the conducting elements30(more precisely: notches, where said conducting elements30can slide, see below). Thus, the top element40prevents the conducting element30from sliding out of the notches. Details of the notches are explained below.

FIG.4shows schematically an element of an electric connector10according to an embodiment, namely a longitudinal section A-A ofFIG.3.FIG.4shows that conducting elements30are arranged within notches32, which are arrange in the cuboidal element24. The notches32may be milled into the cuboidal element24, or otherwise inserted into it. The notches32are part of an opening, which is open towards the inner side26of a protruding cuboidal element24. The conducting elements30protrude partly from the inner side26. When a corresponding conducting structure—e.g. of an electric vehicle— (not shown) is surrounded by the cuboidal elements24, charging current may be transferred via the conducting elements30to the corresponding conducting structure. The conducting elements30may be elastic, so that some pressure is exerted on the conducting structure, thus reducing an electric transition resistance between the conducting elements30and the conducting structure. In this embodiment, the ends of the conducting elements30and the corresponding notches32have a corresponding form, i.e. both are formed rectangular, so that the conducting elements30can slide between the two notches32.FIG.5shows a variation of the conducting elements30. Their ends are formed as a shoe, so that they can slide between the two notches32. The conducting elements30protrude partly from the inner side26.

FIG.6shows schematically an element of an electric connector10according to an embodiment. Again, the conducting elements30are arranged slidably between two notches32, the notches32arranged in the cuboidal element, and the conducting elements30protrude partly from the inner side26. Furthermore, a detachable top element40is shown, which has been slid to the right (see arrow45), to get access to the conducting elements30. Before removing the detachable top element40, a screw42had been loosened. After having detached the top element40, the conducting elements30can be drawn out its holding notches32. Then, the slidably arranged conducting elements can easily be pulled out of the notches32. After that, the conducting elements30may be substituted or repaired.

FIG.7andFIG.8show schematically an element of an electric connector10according to an embodiment. InFIG.7, the detachable element40is arranged at an outer end of the notches32and, thus, prevents the conducting element30from sliding out of the notches32. InFIG.8, a variation of the conducting element30is shown.

LIST OF REFERENCE SYMBOLS

In various embodiments, the connector further comprises a detachable top element, wherein the detachable top element is arranged at an outer end of at least one of the notches, thus preventing the conducting element from sliding out of the notches. The design of the detachable top element may depend on the form of the notches. For instance, if the notches are designed with a dead end and open to an upper edge of the protruding cuboidal element, then the detachable top element may be arranged at the upper edge, thus covering the notches (or at least one of them) and preventing, by this arrangement, the conducting element from sliding out of the notches. In cases when the notches are designed with open ends on both sides, then one detachable top element may be arranged on each one of the open ends. Analogously, if the notches are designed with an open end towards the distal end of the connector body, then the detachable top element may be arranged on said distal end.

In various embodiments, the detachable top element is arranged by form-locking and/or force-locking structure, particularly by at least one of: a screw, a clip, a bayonet lock, a pin, a magnets, and/or by further structure.

In various embodiments, the connector core, the two protruding cuboidal elements and/or the detachable top element comprise or consist of copper, and conductive and/or protective outer coat. The materials may include several types of alloys. The notches may be of the same material as the protruding cuboidal elements, e.g. milled into the protruding cuboidal element.

In various embodiments, the connector core and/or the two protruding cuboidal elements contain channels for cooling fluid. The cooling fluid may be a non-conducting fluid. The cooling channels may advantageously further increase the power the connector is configured for.

In various embodiments, the connector core is formed as a cuboidal block or as a cylinder. This may advantageously improve the manner how the connector core is arranged inside the connector.

In various embodiments, the conducting element comprises or consists of at least one of: copper, steel, aluminum, and/or the conducting element is at least partly elastic. These properties may improve the electric conductivity and/or a transition resistance to the conducting structure and/or to the protruding cuboidal elements.

In various embodiments, the conducting element is coated with a material that reduces the electric transition resistance and/or improves the slidability, particularly with silver, silver-graphite composites, gold, rhodium, and/or similar materials.

In various embodiments, the notches are arranged in parallel and/or perpendicularly to an upper edge of the protruding cuboidal element. This may provide a high flexibility for individual designs of the connector, possibly within a prescribing norm.

In various embodiments, the connector comprises a plurality of conducting elements, and/or the conducting elements are arranged along the inner side of each one of the protruding cuboidal elements. Said plurality of conducting elements may contribute to enabling a transport of high power by the connector.

An aspect of the present disclosure also relates to a method of use of a connector as described above and/or below for high power charging, particularly of electric vehicles. The connector may be used for delivering a maximum current in a range of 3 kA and a maximum voltage of in the range of 1.5 kV. The connector may preferably be configured for delivering DC power.

For further clarification, the invention is described by means of embodiments shown in the figures. These embodiments are to be considered as examples only, but not as limiting.