EV Charging Cable-Housing Interface for Moisture-Resistant Connection

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Solution Overview

Problem

Existing charging systems for electrified vehicles fail to effectively prevent moisture and humidity ingress, which can compromise the integrity and efficiency of the charging process.

Innovation Solution

A charging system design featuring a housing with a projection surrounding the socket and a plug with a recessed configuration that diverts water away from the socket, utilizing angled segments to create a seamless, rib-free interface that integrates with the housing, ensuring a secure and moisture-resistant connection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a traditional flat interface is used between the plug and housing, then the manufacturing is simpler, but moisture and humidity can ingress into the socket compromising charging integrity

Engineering Contradiction:
Improvecharging process integrityVSAvoidinterface structure
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies dimensionality change by transitioning from a flat interface to a three-dimensional profiled interface. The projection extends beyond the housing exterior surface by 3-8 mm with a width of 1.5-3 mm, creating a raised barrier that physically blocks moisture ingress. This dimensional elevation transforms a two-dimensional sealing problem into a three-dimensional protective structure, effectively preventing moisture and humidity from reaching the socket while maintaining charging reliability.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The patent implements preliminary anti-action by designing the projection to preemptively block moisture and humidity before they can ingress into the socket. The projection acts as a preventive barrier that stops harmful environmental factors at the interface level, eliminating the need for complex internal sealing mechanisms and ensuring charging integrity from the outset.

Inventive Principle:
Principle #9Preliminary anti-action

2Reliability

If barbs and ribs are added to the projection for enhanced moisture resistance, then moisture ingress is better prevented, but the manufacturing complexity and potential for damage increase

Engineering Contradiction:
Improvemoisture resistanceVSAvoidprojection fabrication
Core Design Contradiction:
ReliabilityVSEase of manufacture

Solution Approach 1:

The patent extracts the harmful elements (barbs and ribs) from the projection design while retaining the essential moisture-blocking function. By removing these aggressive features, the design achieves moisture resistance through the projection's dimensional presence alone, simplifying manufacturing and reducing damage potential while maintaining reliability.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The patent applies local quality by concentrating the moisture protection function in the projection's elevated dimension rather than distributing it through complex surface features like barbs and ribs. The projection's height and width create a localized barrier that effectively prevents moisture ingress without requiring additional structural complexities, making the design both manufacturable and reliable.

Inventive Principle:
Principle #3Local quality

3Reliability

If the projection extends significantly beyond the housing surface, then moisture ingress is better blocked, but the overall device size increases

Engineering Contradiction:
Improvemoisture barrier effectivenessVSAvoidhousing dimensions
Core Design Contradiction:
ReliabilityVSLength of stationary object

Solution Approach 1:

The patent applies partial action by providing just enough projection extension (3-8 mm height, 1.5-3 mm width) to effectively block moisture ingress without excessive material. This optimized dimension provides sufficient protection against moisture and humidity while minimizing the increase in overall device size, achieving an optimal balance between reliability and compactness.

Inventive Principle:
Principle #16Partial or excessive action

Data Source

PatentUS12415430B2Battery charging system for electrified vehicle including interface for cable and housing
Publication Date: 2025.09.16 FORD GLOBAL TECH LLC
  • US12415430B2 patent drawing
  • US12415430B2 patent drawing
  • US12415430B2 patent drawing

AI summary

This disclosure relates to a battery charging system for an electrified vehicle, and in particular relates to an interface for a cable and a housing. The charging system includes a housing, a first cable including a plug configured to couple to a charging port of the electrified vehicle, and a second cable including a first plug configured to couple to an electrical outlet and a second plug configured to couple to a socket of the housing. Further, the housing includes a projection surrounding the socket and projecting beyond an adjacent exterior surface of the housing.