Modular Charging Inlet Spotlight Without Light Guides
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Solution Overview
Problem
Existing illumination systems for electric vehicle charging inlets are costly due to the need for light guide materials and are difficult to maintain or replace, as they are typically integrated with the charging unit and require specific design adaptations.
Innovation Solution
A modular spotlight assembly with a first frame and a second frame, encapsulating a circuit carrier and illumination source, which is removably attached to the charging inlet, allowing easy assembly, maintenance, and adaptation to existing housings by directing light externally without the need for light guides.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the illumination system is placed on the back part of the charging inlet with LED connected to PCB, then the illumination system can provide lighting function, but it requires light guide material which increases production costs and cannot be reached from outside for maintenance
Solution Approach 1:
The illumination system is divided into a modular assembly that includes the LED, PCB, and housing as a separate replaceable unit. This modular spotlight assembly can be independently removed and replaced without affecting the charging inlet structure, enabling easy maintenance while eliminating the need for light guide materials that increase production costs.
Solution Approach 2:
The illumination system is extracted from the integrated charging inlet structure and placed in a separate modular assembly that attaches to the front surface. This extraction eliminates the need for light guide materials connecting the rear LED to the front inlet, reducing production costs while maintaining accessibility for maintenance by allowing the assembly to be removed from the outside.
2Adaptability or versatility
If the illumination system is integrally formed with the charging inlet, then the structure is compact, but it requires specific design adaptations and cannot be adapted to existing housings
Solution Approach 1:
The modular spotlight assembly is designed with universal mounting features that can be attached to various charging inlet configurations without requiring specific design adaptations. The assembly includes standardized mounting elements that accommodate different housing types, enabling the same illumination module to be used across multiple charging inlet designs.
Solution Approach 2:
The illumination system transitions from a static integrated structure to a dynamic modular assembly that can be easily attached and detached. This dynamic configuration allows the assembly to adapt to different charging inlet types through simple mounting mechanisms rather than requiring complex integrated designs for each housing type.
3Illumination intensity
If the illumination system uses light guide material to direct light from rear LED to front inlet, then the illumination function is achieved, but production costs increase
Solution Approach 1:
The light guide material is completely removed from the system. Instead, the LED is positioned within the modular assembly to directly illuminate the charging inlet from the front, eliminating the need for light guide materials and associated production costs while maintaining effective illumination.
Solution Approach 2:
The illumination approach is inverted from the conventional rear-LED-with-light-guide configuration to a front-facing LED arrangement. The LED is positioned within the modular assembly to emit light directly toward the charging inlet, reversing the traditional light path and eliminating the need for light guide materials.
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
This solution reduces production costs and facilitates easy handling and replacement of components, enabling the illumination system to be adapted to various charging inlet designs while providing effective external illumination for plug insertion and charging status indication.
Implementation Method 1
an illumination source (141) electrically connected to the circuit carrier (140)... the light of the illumination source (141) coming out externally through the second frame (120)
Data Source
AI summary
A spotlight modular assembly for providing external illumination to a charging inlet includes a first frame having a plurality of locking devices securing the spotlight modular assembly to the charging inlet, a second frame, and a circuit carrier and an illumination source electrically connected to the circuit carrier. The circuit carrier and the illumination source are encapsulated within the first frame and the second frame. A light of the illumination source comes out through the second frame. The spotlight modular assembly is removably attached to the charging inlet with the light of the illumination source directed toward the charging inlet.