METHOD OF MANUFACTURING A CHARGING DEVICE WITH A CONTACT HOUSING OF AN ELECTRICALLY POWERED VEHICLE

Abstract

A method of manufacturing a charging device with a contact housing of an electrically powered vehicle including the steps of providing at least one electrical contact element having a contact area, the electrical contact element being electrically contactable with a corresponding contact element in said contact area; inserting the electrical contact element into an injection mold; and closing the injection mold and forming a cavity around the electrical contact element within the injection mold. Finally, an injection molding material is injected into the cavity of the injection molding tool, so as to produce a contact housing with integrated electrical contact element.

Claims

1. A method for manufacturing a charging device with a contact housing of an electrically operated vehicle, the method comprising: providing at least one electrical contact element comprising a contact area, wherein the electrical contact element is arranged in an electrical connection with a contact element in the contact area; inserting the electrical contact element into an injection mold; closing the injection mold and forming a cavity around the electrical contact element inside the injection mold; and injecting an injection molding material into the cavity of the injection molding tool thereby producing the contact housing with an integrated electrical contact element.

2. The method according to claim 1, wherein the step of injecting the injection molding material further comprises the step of cooling the electrical contact element.

3. The method according to claim 1, wherein the step of providing further comprises the step of introducing at least one undercut on the electrical contact element in the region of the cavity of the injection mold.

4. The method according to claim 1, wherein the step of providing further comprises the step of providing a support element attached to the electrical contact element.

5. The method of claim 4, wherein the step of attaching the support member to the electrical contact member further comprises the step of molding the support member to the electrical contact member.

6. The method according to claim 4, wherein the injection of the carrier element onto the electrical contact element and the injection of the injection molding material into the cavity of the injection molding tool are performed simultaneously.

7. The method according to claim 5, wherein the injection of the carrier element onto the electrical contact element and the injection of the injection molding material into the cavity of the injection molding tool are performed simultaneously.

8. The method according to claim 4, wherein at least one temperature sensor is attached to the support element.

9. The method according to claim 5, wherein at least one temperature sensor is attached to the support element.

10. The method according to claim 6, wherein at least one temperature sensor is attached to the support element.

11. The method according to claim 7, wherein at least one temperature sensor is attached to the support element.

12. The method of claim 8, wherein the step of molding the support member to the electrical contact member further comprises the step of overmolding the support member with the temperature sensor mounted thereon.

13. The method of claim 9, wherein the step of molding the support member to the electrical contact member further comprises the step of overmolding the support member with the temperature sensor mounted thereon.

14. The method of claim 10, wherein the step of molding the support member to the electrical contact member further comprises the step of overmolding the support member with the temperature sensor mounted thereon.

15. The method of claim 11, wherein the step of molding the support member to the electrical contact member further comprises the step of overmolding the support member with the temperature sensor mounted thereon.

16. The method according to claim 12, wherein the overmolding of the support element with the temperature sensor attached thereto and the injection of the injection molding material into the cavity of the injection molding tool are performed simultaneously.

17. The method according to claim 13, wherein the overmolding of the support element with the temperature sensor attached thereto and the injection of the injection molding material into the cavity of the injection molding tool are performed simultaneously.

18. The method according to claim 14, wherein the overmolding of the support element with the temperature sensor attached thereto and the injection of the injection molding material into the cavity of the injection molding tool are performed simultaneously.

19. The method according to claim 15, wherein the overmolding of the support element with the temperature sensor attached thereto and the injection of the injection molding material into the cavity of the injection molding tool are performed simultaneously.

20. A charging device with a contact housing for an electrically operated vehicle with at least one electrical contact element, which comprises a contact area, wherein the electrical contact element is configured to be electrically contacted in the contact area with a corresponding contact element and wherein the contact housing is designed in one piece and the electrical contact element is directly integrated.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0026] Further advantages, features, and details of the various embodiments of this disclosure will become apparent from the ensuing description of a preferred exemplary embodiment and with the aid of the drawings. The features and combinations of features recited below in the description, as well as the features and feature combination shown after that in the drawing description or in the drawings alone, may be used not only in the particular combinations recited, but also in other combinations on their own, without departing from the original scope or intent of the disclosure.

[0027] An advantageous embodiment of the invention is explained below with reference to the accompanying FIGURE. It shows:

[0028] FIG. 1 depicts a schematic representation of the method for manufacturing a loading device.

[0029] The FIGURE is merely a schematic representation and serves only to explain the invention. Identical or similarly acting elements are marked throughout with the same reference signs.

[0030] The FIGURE shows a schematic representation of the process for manufacturing a loading device.

DETAILED DESCRIPTION OF THE INVENTION

[0031] As used throughout the present disclosure, unless specifically stated otherwise, the term “or” encompasses all possible combinations, except where infeasible. For example, the expression “A or B” shall mean A alone, B alone, or A and B together. If it is stated that a component includes “A, B, or C”, then, unless specifically stated otherwise or infeasible, the component may include A, or B, or C, or A and B, or A and C, or B and C, or A and B and C. Expressions such as “at least one of” do not necessarily modify an entirety of the following list and do not necessarily modify each member of the list, such that “at least one of” “A, B, and C” should be understood as including only one of A, only one of B, only one of C, or any combination of A, B, and C.

[0032] In a first step, an electrical contact element is provided. In a first embodiment, the electrical contact element is a contact pin. In a second embodiment, the electrical contact element is a contact socket. The electrical contact element comprises a contact area, whereby electrical contacting of the charging device with a corresponding electrical contact element can be established. In the first embodiment example, the charging device is a charging socket. In the second embodiment, the charging device is a charging plug.

[0033] In a second step, a punching grid is provided as a support element (S2). A temperature sensor is soldered onto the stamping grid. The temperature sensor detects a temperature of the electrical contact element during electrical contacting with the corresponding electrical contact element.

[0034] The punching grid comprises latching hooks which latch into corresponding notches arranged around the electrical contact element. This secures the punching grid to the electrical contact element in a third step (S3).

[0035] The electrical contact element with the stamped grid attached to it is then inserted into a first mold half of an injection mold (S4).

[0036] By closing the first mold half with a second mold half (S5) of the injection mold, a cavity is formed in an area of the electrical contact element inside the injection mold around the electrical contact element. The cavity corresponds to the outer dimensions of a contact housing of the charging device.

[0037] Subsequently, an injection molding material is injected into the cavity (S6). Injection of the injection molding material produces the contact housing. The contact housing serves to fix the electrical contact element in the charging device and to protect electrical components which can be connected to the electrical contact element within the charging device. At the same time as the contact housing is manufactured, the contact housing is materially connected to the electrical contact element in the area of the cavity. This protects the electrical components arranged inside the charging device and part of the electrical contact element against splash water and dirt. By injecting and simultaneously producing the contact housing, no additional fastening elements are required for fastening the electrical contact element to the contact housing or additional sealing elements.

[0038] While the injection molding material is being injected, the contact area of the electrical contact element is cooled simultaneously. This takes place within the first mold half. By means of cooling channels arranged inside the first mold half, a steel core is flushed with water around the contact area.

[0039] After the injection molding material has cooled (S7), the contact housing made from the injection molding material with the integrated electrical contact element can finally be removed.

[0040] Having described some aspects of the present disclosure in detail, it will be apparent that further modifications and variations are possible without departing from the scope of the disclosure. All matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.