Charging Socket Heating for Frozen EV Connector Removal

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Solution Overview

Problem

Charging connectors in electric vehicles can freeze and become stuck during winter charging, as existing solutions only heat the charging port covers, leaving the connectors inaccessible.

Innovation Solution

A method for heating the charging socket using a heat conduction component and a heating component, selectively activated based on the charging type, to efficiently thaw frozen connectors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If only charging port covers are heated, then the charging port covers can be opened, but the charging connectors cannot be pulled out

Engineering Contradiction:

Improveopening of charging port coversVSAvoidremoval of charging connectors

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The heating system is divided into separate heating components: one for the charging port covers and another for the charging sockets. This segmentation allows independent control of heating for different parts, enabling the charging connector removal function to be activated separately when needed, thus resolving the issue where covers could be opened but connectors stuck.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The charging socket heating function pre-heats the charging sockets before charging connectors need to be removed. By maintaining the charging sockets in a warmed state even when charging port covers are already open, the system ensures that connectors remain removable throughout the charging process, not just at the beginning.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If heating components are always activated, then charging connectors can be removed, but energy consumption increases

Engineering Contradiction:

Improveremoval of charging connectorsVSAvoidenergy consumption of heating device

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The heating system dynamically adjusts its operation based on real-time conditions. The charging socket heating function is activated only when charging connectors are detected to be stuck or when temperature sensors indicate cold conditions. This dynamic control allows the system to maintain connector removability only when necessary, significantly reducing unnecessary energy consumption compared to continuous heating.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

Temperature sensors and charging status detection provide feedback to the control system, which then adjusts heating activation accordingly. When connectors are successfully removed or temperatures are adequate, the feedback signal deactivates the heating function, creating a closed-loop control system that balances reliability with energy efficiency.

Inventive Principle:

Principle #23Feedback

3Reliability

If heating is activated during charging, then connectors can be removed, but charging stability may be affected

Engineering Contradiction:

Improveremoval of charging connectorsVSAvoidcharging stability

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The heating function operates periodically rather than continuously during charging. The system monitors charging status and activates heating only during brief intervals when connector removal is attempted and fails. This periodic activation minimizes thermal interference with the charging process while still achieving the goal of removing stuck connectors.

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The heating function for charging sockets is extracted as a separate, independently controllable feature from the main charging system. This allows the heating to be activated only when specifically needed for connector removal, rather than being continuously coupled with charging operations, thus minimizing impact on charging stability while maintaining the ability to remove connectors when necessary.

Inventive Principle:

Principle #2Taking out (Extraction)

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

Effectively thaws frozen charging connectors by optimizing energy allocation based on charging type, ensuring the connectors can be easily removed during winter charging.

Implementation Method 1

the heat conduction component being configured to conduct heat generated during charging of the vehicle to the charging socket to heat the charging socket

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Implementation Method 2

the heating component being configured to heat the charging socket

Methodology Applied

Scientific EffectHeating: Heating

Data Source

PatentUS20250303891A1Method for heating charging socket, and vehicle and storage medium

Publication Date: 2025.10.02 BYD CO LTD

AI summary

A method for heating a charging socket includes: determining a charging type of a vehicle, where the charging type includes a first charging type and a second charging type, and the first charging type is different from the second charging type; selecting, from a heating device and according to the charging type, a component corresponding to the charging type to serve as a target heating device, the heating device including a heat conduction component and a heating component, the heat conduction component configured to conduct heat generated during charging of the vehicle to the charging socket to heat the charging socket, and the heating component configured to heat the charging socket; and controlling the target heating apparatus to heat the charging socket.