Multi-Component Charging Socket Housing with Elastomeric Sealing
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Solution Overview
Problem
Charging sockets in motor vehicles are exposed to environmental influences like moisture and dust when the charging flap is opened, posing a risk to the live contact pins, and existing solutions do not provide a reliable and simple sealing mechanism.
Innovation Solution
A contact housing for the charging socket made as a multi-component injection molded part, where the main body is a first component and the sealing areas are formed by a softer, more elastic second component, which encloses the contact pins in a form-fitting manner, ensuring a permanent and reliable seal through a channel system in the injection molding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the charging socket is exposed to allow plug insertion, then ease of operation is improved, but protection against dust and liquid ingress deteriorates
Solution Approach 1:
The patent employs an elastomeric sealing component that forms a flexible seal around the contact pins within the contact housing. This elastomeric material creates a protective barrier that prevents dust and liquid ingress while allowing the charging socket to remain accessible for plug insertion, thus resolving the contradiction between ease of operation and protection against harmful factors.
2Object-affected harmful factors
If separate sealing components are added to protect contact pins, then protection against dust and liquid ingress is improved, but device complexity increases
Solution Approach 1:
The patent integrates the sealing function directly into the contact housing structure by using an elastomeric component that is molded as part of the housing assembly. This merging of the sealing element with the main housing structure provides effective protection against dust and liquid ingress while avoiding the complexity of separate, additional sealing components and their associated assembly steps.
Solution Approach 2:
The contact housing is constructed as a multi-material component, combining a rigid housing material with an elastomeric sealing material. This composite structure allows the housing to maintain its structural integrity while the elastomeric portion provides flexible sealing, achieving protection against environmental factors without requiring complex separate sealing mechanisms.
3Ease of manufacture
If a multi-component injection molded contact housing is used, then ease of manufacture is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent incorporates the sealing areas directly into the injection molding process of the contact housing. By pre-forming the sealing structures during the initial molding operation rather than adding them as separate components later, the manufacturing process is simplified and the sealing geometry is established with the precision inherent to injection molding technology.
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
The solution provides a simple and reliable sealing of the charging socket, preventing dust and liquid ingress around the contact pins and lighting devices, ensuring the socket remains functional and protected in harsh environments.
Implementation Method 1
sealing areas forming at least the respective edges of the receiving openings are made from a second component, which is more elastic than the first component
Data Source
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AI summary
The invention relates to a contact housing (14) for a charging socket (10) of a motor vehicle, comprising a plug interface (12) with several receiving openings (16) for receiving respective contact pins (18, 20, 22, 24, 26, 28, 30) which can be connected to a charging plug for charging a battery of the motor vehicle, wherein the contact housing (14) is a multi-component injection-molded part, the main body (40) of which is made from a first component, and sealing areas (42) forming at least the respective perimeters of the receiving openings (16) are made from a second component (41) which is more elastic than the first component. The invention further relates to a charging socket (10) for a motor vehicle with such a contact housing (14) and to a method for manufacturing such a charging socket (10).