EV Charging Inlet DC Terminal Module With Bottom Cable Access
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Solution Overview
Problem
Conventional charging inlet assemblies for electric vehicles are difficult to service due to the need for disassembly and removal from the vehicle to access terminal assemblies and cable harnesses, making maintenance time-consuming.
Innovation Solution
A DC terminal module with a housing that extends between a front and rear, featuring a cable mount at the bottom for receiving a DC cable assembly, allowing for electrical connection without rear access, enabling service without removing the charging inlet assembly from the vehicle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the charging inlet assembly uses conventional terminal housing design with rear-mounted terminals, then the electrical connection is reliable, but the servicing becomes difficult and time-consuming
Solution Approach 1:
The patent repositions the cable connection interface from the rear dimension to the bottom dimension of the terminal housing. This dimensional shift allows service personnel to access and connect cable assemblies from below the vehicle, eliminating the need to remove the charging inlet assembly from the front for servicing, thus reducing service time while maintaining reliable electrical connection
2Ease of operation
If the charging inlet assembly is designed as an integrated unit, then the structural integrity is high, but the accessibility for maintenance is poor
Solution Approach 1:
The patent segments the terminal housing into functionally independent sections: the front portion houses the charging receptacle and terminals, while the bottom portion provides accessible cable connection points. This segmentation allows maintenance personnel to service the cable connections without disturbing the front-mounted charging components, improving maintenance accessibility while preserving the overall structural integrity of the integrated charging inlet assembly
Data Source
AI summary
A DC terminal module for a charging inlet assembly of an electric vehicle includes a housing having a housing base mounted to a charging inlet housing. The housing includes a cable mount at a bottom that receives a DC cable assembly from the bottom. The DC terminal module includes a DC terminal assembly received in a terminal chamber with a pin terminal extending into a receptacle of the charging inlet assembly for mating with the charging connector. The DC terminal assembly includes a terminal busbar extending from the pin terminal to the cable mount at the bottom of the DC housing for electrical connection to the DC cable assembly at the bottom of the DC housing.