Charging Plug Contact-Free Switch Design for Corrosion Prevention
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Solution Overview
Problem
Charging plugs for electric vehicles are prone to moisture and contamination, leading to corrosion and electromigration issues that can compromise their functionality over time, especially when used outdoors.
Innovation Solution
A charging plug design featuring a contactless interaction between the actuation member and switching member, where the switching member is protected within an enclosed conduction chamber and the actuation member is outside, utilizing a magnet sensor and permanent magnet for switching control, allowing for moisture-resistant operation without the need for sealing and enabling easy manual actuation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the actuation member and switching member are arranged inside the conduction chamber to enable direct mechanical interaction, then the switching operation is reliable and precise, but the components are exposed to moisture and contamination causing corrosion and electromigration
Solution Approach 1:
The charging plug is divided into two separate chambers: an enclosed conduction chamber containing the switching member and plug contacts, and an external actuation region. This segmentation isolates the sensitive electrical components from moisture and contamination while maintaining reliable switching operation through the enclosed chamber design.
Solution Approach 2:
A sealing wall acts as an intermediary barrier between the enclosed conduction chamber and the external environment. This sealing wall prevents moisture and contamination from reaching the switching member and plug contacts, while still allowing the switching operation to function through the sealed interface.
2Object-affected harmful factors
If the actuation member is sealed inside the conduction chamber with the switching member, then protection from moisture is achieved, but sealing components become brittle and permeable over time compromising the seal
Solution Approach 1:
The actuation member is extracted from the enclosed conduction chamber and positioned externally. This eliminates the need for sealing the actuation member, as it is now outside the sealed environment. The switching member remains protected inside the chamber, but the actuation mechanism operates from the external environment where sealing is not required.
Solution Approach 2:
The interaction between the actuation member and switching member transitions from a three-dimensional mechanical connection to a contactless interaction through the sealing wall. The actuation member influences the switching member through magnetic or capacitive coupling across the barrier, eliminating the need for physical penetration seals.
3Duration of action of stationary object
If the actuation member is arranged outside the conduction chamber to eliminate sealing requirements, then long-term durability is improved, but contactless interaction is required which increases device complexity
Solution Approach 1:
The direct mechanical interaction between the actuation member and switching member is replaced with a contactless interaction mechanism. Magnetic fields or capacitive coupling are used to transmit the switching signal across the sealing wall, eliminating the need for complex mechanical seals while maintaining reliable actuation.
Solution Approach 2:
The sealing wall serves multiple functions: it provides moisture protection for the conduction chamber, acts as a barrier against contamination, and simultaneously enables contactless interaction between the external actuation member and the internal switching member. This multi-functionality reduces overall device complexity despite the contactless requirement.
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 design effectively protects internal components from moisture and contamination, ensuring long-term functionality by preventing electromigration and corrosion, while allowing for reliable and safe charging operations.
Implementation Method 1
the switching member has a switching sensor which converts physical environmental properties to changes in switching state and the switching device has a switching source which brings about the physical properties
Data Source
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AI summary
The invention relates to a charging plug (1) for connection to a charging socket of a device which is intended to be charged, for example, a motor vehicle which is at least partially driven by electrical energy, or a device which provides charging energy. In order to prevent the charging plug from prematurely becoming defective as a result of corrosion or electromigration, there is provision according to the invention for a switching device (27) of the charging plug (1) to be arranged partially inside and partially outside an enclosed conduction chamber (18).