Vehicle Charging Contact Base With Snap-Fit Bus Bar Isolation
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Solution Overview
Problem
Existing vehicle charging systems face inefficiencies due to high electrical resistance and potential for electrical shorts, particularly in designs using threaded fastening or welding for copper contacts, which result in voltage drops and safety hazards.
Innovation Solution
An electrical contact base with a ramp-shaped design featuring a snap-fit assembly of insulating materials and conductive bus bars with integrated end tabs and power feed tabs, reducing electrical resistance and preventing accidental contact through a polymer insulator shell assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If threaded fastening or welding is used to assemble copper contacts, then mechanical strength and electrical connection are improved, but electrical resistance increases and voltage drops occur
Solution Approach 1:
The patent merges the mechanical connection and electrical conduction functions into a single integrated copper contact component. The copper contacts are designed with interlocking geometries that provide both structural support and low-resistance electrical pathways, eliminating the need for separate fastening mechanisms that would introduce additional contact resistance.
Solution Approach 2:
The patent employs composite construction by integrating copper contacts with insulating materials in a hybrid assembly. The copper contacts maintain pure metal-to-metal contact surfaces for minimal electrical resistance, while the insulating materials provide mechanical support and electrical isolation, creating a composite structure that optimizes both electrical and mechanical performance.
2Strength
If threaded fastening or welding is used to assemble copper contacts, then mechanical strength is improved, but safety hazards increase due to potential electrical shorts
Solution Approach 1:
The patent introduces insulating materials as intermediary elements between conductive copper contacts and surrounding structures. These insulators act as mediators that prevent unwanted electrical contact and short circuits while allowing the copper contacts to maintain their mechanical strength and electrical conductivity where needed.
Solution Approach 2:
The patent segments the charging base into distinct conductive and insulating zones. The copper contacts are spatially separated and strategically positioned to make contact only with intended conductive surfaces, while insulating materials create physical and electrical barriers between different conductive elements, preventing short circuits.
3Stability of the object's composition
If traditional charging base designs are used, then structural stability is maintained, but charging efficiency decreases due to high electrical resistance
Solution Approach 1:
The patent combines structural support and electrical conduction functions into integrated copper contact components. The copper contacts are designed with geometric features that provide both mechanical stability through interlocking shapes and low-resistance electrical pathways, eliminating the need for separate fastening hardware that would introduce additional contact resistance and reduce charging efficiency.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enhances charging efficiency by minimizing electrical resistance and preventing shorts, ensuring safe and efficient energy transfer during vehicle charging without the need for fasteners, thus improving the overall performance and safety of charging systems.
Implementation Method 1
a snap-fit assembly of insulating materials and conductive bus bars with integrated end tabs and power feed tabs
Data Source
AI summary
An electrical contact base for charging a vehicle can include an insulating base, an insulating cover connected to the insulating base, and a bus bar captured between the insulating base and the insulating cover, where the vehicle is configured to contact the electrical contact base for charging the vehicle. The bus bar can have a contact plate and an integrally connected end tab. In some embodiments, the end tab defines an incline for guiding a brush of a vehicle onto the electrical contact base and into contact with the contact plate. In some embodiments, the insulating base and the insulating cover are formed of polymer insulator material. In some embodiments, the insulating base and the insulating cover are connected by a snap-fit connection. In some embodiments, the electrical contact base defines a lattice support structure.