Charging Inlet Proximity Resistor Assembly Without Large PCB Pocket
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Solution Overview
Problem
Conventional charging inlet assemblies for electric vehicles have a large pocket for the control circuit board, increasing size, complexity, and cost.
Innovation Solution
A charging inlet assembly with integrated proximity resistor assembly that includes a housing with separate AC and DC sections, featuring a proximity resistor assembly with conductors that are side-loaded into the housing, reducing the need for a large pocket and optimizing the assembly's size and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a large pocket is provided in the housing to receive the control circuit board, then the proximity resistor assembly can be accommodated, but the overall size, complexity and cost of the charging inlet assembly increases
Solution Approach 1:
The proximity resistor assembly is integrated directly into the control circuit board by mounting the proximity resistor on the PCB and routing its leads through the existing terminal channels. This merging eliminates the need for a separate large pocket in the housing, as the resistor assembly becomes part of the control circuit board structure itself, thereby reducing overall housing volume and assembly complexity
Solution Approach 2:
The control circuit board serves multiple functions: it provides control circuitry, mounting for the proximity resistor, and routing for signal terminals. By making the control circuit board a multi-functional component that houses both the proximity resistor assembly and control electronics, the design eliminates the need for separate dedicated pockets, reducing housing complexity while maintaining all required functions
2Adaptability or versatility
If a control circuit board with proximity circuit is retained within the housing, then signaling protocols can be implemented, but the housing size and complexity increase due to the large pocket requirement
Solution Approach 1:
The proximity resistor is mounted directly on the control circuit board, merging the signaling component with the control electronics platform. This integration allows the control circuit board to provide both control functionality and proximity signaling capability, eliminating the need for additional housing volume to accommodate separate resistor assemblies while maintaining full signaling protocol adaptability
3Volume of moving object
If the proximity resistor assembly is integrated into the control circuit board, then the housing pocket size can be reduced, but the manufacturing complexity of the control circuit board increases
Solution Approach 1:
The proximity resistor assembly is designed as a modular component that can be separately manufactured and then mounted onto the control circuit board. This segmentation allows the resistor assembly to be produced independently using standard electronic component manufacturing processes, then integrated into the PCB during assembly, thereby avoiding increased PCB manufacturing complexity while still achieving housing volume reduction
Solution Approach 2:
The proximity resistor is pre-mounted onto the control circuit board during PCB assembly processes, and its leads are pre-routed through designated terminal channels. This preliminary integration during manufacturing preparation allows for streamlined production workflows and reduces assembly complexity, as the resistor positioning and routing are established before final housing assembly
Data Source
AI summary
A charging inlet assembly includes a housing extending between a front and a rear. The housing has DC terminal channels and AC terminal channels. The charging inlet assembly includes AC terminals, include a proximity terminal and a ground terminal, received in the corresponding AC terminal channels. The charging inlet assembly includes DC terminals received in the corresponding DC terminal channels. The charging inlet assembly includes a proximity resistor assembly having a plug body holding a resistor, a first resistor conductor and a second resistor conductor. The first resistor conductor is coupled between the resistor and the terminating end of the proximity terminal. The second resistor conductor is coupled between the resistor and the terminating end of the ground terminal.