Charging Inlet Proximity Resistor Assembly Without Control PCB
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Solution Overview
Problem
Conventional charging inlet assemblies for electric vehicles have a large size, complexity, and high cost due to the inclusion of a control circuit board and a housing pocket, which increases the overall dimensions and manufacturing costs.
Innovation Solution
A charging inlet assembly design that integrates a proximity resistor assembly within a rear cavity of the housing, eliminating the need for a separate control circuit board, and uses a retainer assembly to hold the resistor in place, reducing the overall size and complexity while maintaining electrical functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a control circuit board and housing pocket are included in the charging inlet assembly, then signaling protocol detection capability is improved, but the assembly size, complexity and cost increase
Solution Approach 1:
The patent extracts the proximity resistor function from the control circuit board and implements it as a standalone proximity resistor assembly. This separate resistor assembly includes only the essential components (resistor, contacts, retainer) needed for proximity detection, eliminating the need for a full control circuit board while maintaining signaling protocol detection capability.
Solution Approach 2:
The housing pocket is redesigned to serve multiple functions: it provides structural support for the proximity resistor assembly, acts as a mounting location for the retainer assembly, and maintains the signaling protocol detection capability. This multi-functional design reduces overall assembly complexity while preserving essential functions.
2Reliability
If a control circuit board and housing pocket are included in the charging inlet assembly, then signaling protocol detection capability is improved, but manufacturing cost increases
Solution Approach 1:
The patent extracts the proximity resistor function from the expensive control circuit board and implements it as a standalone proximity resistor assembly. This separate resistor assembly includes only the essential components (resistor, contacts, retainer) needed for proximity detection, eliminating the need for a full control circuit board while maintaining signaling protocol detection capability.
Solution Approach 2:
The proximity resistor assembly uses simple, inexpensive components (resistor, contacts, retainer clips) that can be easily manufactured and replaced if needed. This approach replaces the expensive control circuit board with a cost-effective solution that maintains essential functionality.
3Reliability
If a control circuit board and housing pocket are included in the charging inlet assembly, then signaling protocol detection capability is improved, but the overall dimensions increase
Solution Approach 1:
The patent extracts the proximity resistor function from the control circuit board and implements it as a standalone proximity resistor assembly. This separate resistor assembly includes only the essential components (resistor, contacts, retainer) needed for proximity detection, eliminating the need for a full control circuit board while maintaining signaling protocol detection capability.
Solution Approach 2:
The proximity resistor assembly is nested within the housing pocket, with the retainer assembly fitting inside the pocket and the resistor assembly mounted within the retainer structure. This nested arrangement utilizes existing housing space efficiently, avoiding additional dimensional increases while maintaining all necessary functions.
Data Source
AI summary
A charging inlet assembly includes a housing having a DC section having DC terminals received in DC terminal channels for mating with the DC charging connector and AC terminals received in AC terminal channels for mating with the AC charging connector. The DC terminals include a proximity terminal and a ground terminal. The proximity and ground terminals include terminating ends received in a rear cavity of the housing. The charging inlet assembly includes a proximity resistor assembly received in the rear cavity having a resistor, a first resistor conductor coupled between the resistor and the terminating end of the proximity terminal, and a second resistor conductor coupled between the resistor and the terminating end of the ground terminal.