Charging Cable Plug Vibration for Corroded Port Contact Cleaning
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Solution Overview
Problem
The degradation of charging ports and cables due to corrosion, dirt, and warping leads to reduced charging efficiency and potential harm to rechargeable batteries, especially in high-power systems like EVs and HEVs, resulting in longer charging times and battery degradation.
Innovation Solution
Implementing contact sensors and an electromechanical vibrator in the charging cable plug to detect contact and generate vibrations that loosen dirt, dust, and corrosive materials, improving the contact condition between the plug and port.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the charging cable is repeatedly plugged and unplugged from the port, then the connection is established for charging, but the contact condition degrades due to corrosion, dirt accumulation, and warping
Solution Approach 1:
The patent applies mechanical vibration through an electromechanical vibrator that generates vibrations at specific frequencies (20-2000 Hz, preferably 200-400 Hz) to clean the contact surfaces of the charging port and cable plug. The vibration loosens and removes accumulated dirt, dust, and corrosive materials from the contact surfaces, thereby maintaining reliable electrical contact and preventing degradation from repeated plugging and unplugging operations.
2Reliability
If the contact condition degrades over time, then the connection remains established, but the amount of electricity flowing through the connection is reduced
Solution Approach 1:
The electromechanical vibrator cleans the contact surfaces by generating mechanical vibrations that dislodge contaminants, thereby maintaining low electrical resistance and optimal electricity flow through the connection. This prevents energy loss that would otherwise occur due to degraded contact conditions.
3Productivity
If the charging cable connects to the port, then charging begins, but dirt and corrosive materials prevent full charging completion
Solution Approach 1:
The vibrator generates mechanical vibrations at frequencies between 20-2000 Hz to mechanically remove dirt, dust, and corrosive materials from the contact surfaces during the charging process. This cleaning action eliminates the harmful factors that would otherwise prevent full charging completion, ensuring that the battery can be fully recharged without interruption.
4Strength
If extreme degradation occurs, then the connection structure remains intact, but charging is completely prevented
Solution Approach 1:
The electromechanical vibrator provides preventive maintenance by continuously cleaning the contact surfaces through mechanical vibration, preventing the accumulation of contaminants that would lead to extreme degradation. This maintains reliable charging capability throughout the structural life of the connection, avoiding complete charging prevention even after extensive use.
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
Enhances charging efficiency by maintaining clean and secure connections, reducing energy loss, and preventing battery damage by ensuring full and secure charging, particularly in high-power systems.
Implementation Method 1
The electromechanical vibrator may be configured to vibrate the plug of the charging cable when the contact sensor determines the plug of the charging cable contacts the charging port. The vibrating of the plug of the charging cable may generate relative movement between the contact surfaces of the plug of the charging cable and prongs of the charging port based on transferred vibration from the electromechanical vibrator to the charging port via contact with the plug.
Implementation Method 2
The contact sensors may be configured to detect when a plug of a charging cable contacts a charging port.
Data Source
AI summary
Systems and methods are provided for improving a contact condition between a charging cable and a charging port. A charging cable may be plugged into a charging power to charge an electrical device. A charging cable may include a plug which may mate with prongs of a charging port. The plug may include sensors and a vibrator. The sensors may detect when a user intends to plug the charging cable into the charging port. Upon detection of intent to plug the charging cable into the charging port. The vibrator may be activated and may vibrate the plug. The vibration may generate relative movement between the prongs of the charging port and the plug. The movement may release dirt, dust, and corrosive materials from the charging port and plug, resulting in increased cleanliness. The movement may also assist in forming a more secure connection between the charging cable and plug.