EV Charging Plug Shutter for DC Port Protection During AC Charging
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Solution Overview
Problem
Existing electric vehicle charging systems face ergonomic issues and protection challenges, particularly with the DC port being exposed during AC charging, leading to potential degradation and handling difficulties due to the need for separate caps, which can be forgotten or damaged.
Innovation Solution
A male plug with a shutter projecting from the body to cover the DC port during charging, integrated into the charging cable, ensuring protection and eliminating the need for separate caps, thereby improving ergonomics and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate cap is used to protect the DC port during AC charging, then the DC port is protected from degradation, but the device complexity increases and ergonomic problems occur when handling the charging cable
Solution Approach 1:
The patent combines the DC port protective cap function directly into the male plug body of the AC charging cable. The shutter is integrated as an inherent component of the plug, eliminating the need for separate caps. This merging approach maintains DC port protection while reducing overall system complexity and improving ergonomics by consolidating protective functions into the existing charging cable structure.
Solution Approach 2:
The male plug is designed with multi-functionality, serving both as the AC charging connector and as the protective cover for the DC port. The shutter component performs dual functions: protecting the DC port during AC charging and being automatically managed during DC charging operations. This universal design eliminates the need for separate protective devices.
2Reliability
If a separate cap is used to protect the DC port, then the DC port is protected, but ergonomic difficulties arise due to the heaviness and rigidity of the cable
Solution Approach 1:
By integrating the protective shutter into the male plug body, the invention eliminates separate handling of protective caps. The shutter moves with the plug during insertion and removal operations, requiring no additional manual intervention from the user. This integration directly addresses ergonomic difficulties by reducing the number of discrete components the user must manage.
Solution Approach 2:
The shutter is designed to automatically perform its protective function without requiring separate user action. During AC charging, the shutter remains in place protecting the DC port. During DC charging, the shutter is automatically displaced by the DC connector insertion. This self-service mechanism improves ease of operation by eliminating the need for users to manually attach or detach protective caps.
3Reliability
If a removable cap with anti-loss link is used to protect the DC port, then the DC port is protected, but the cap can be torn off by the closing of the hatch
Solution Approach 1:
By integrating the shutter into the male plug body, the invention eliminates the vulnerable anti-loss link attachment mechanism. The shutter becomes an inherent structural component of the plug rather than a separately attached element. This merging eliminates the risk of the protective component being torn off during hatch closure or cable movement.
Solution Approach 2:
The shutter is designed as a self-contained component of the plug assembly that requires no separate attachment mechanisms. It moves and positions itself automatically during charging operations without relying on external attachment links that could fail or be damaged by hatch closure forces.
Data Source
Figure 1~2
Figure 3
AI summary
The present invention relates to a male plug (4) for charging an electric traction energy accumulator for a motor vehicle (1), comprising a connector with electrical contacts extending longitudinally from a body of said male plug, said connector being connected to an electrical power supply cable configured to form an electrical charging bridge to a first charging port of the motor vehicle; remarkable in that said male plug further comprises a shutter (6; 106) projecting from the body near the connector with electrical contacts, said shutter being configured to close a second charging port of the motor vehicle arranged directly below the first charging port, during an electrical charging of said motor vehicle.