EV Charging Socket Latching Assembly for Low-Force Removal
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Solution Overview
Problem
Existing charging socket mounting systems for hybrid and electric vehicles require high force for removal and are cumbersome, especially in confined spaces, and are sensitive to warping and bending, necessitating tight tolerances.
Innovation Solution
A charging port assembly with resilient and non-resilient latching means, including snap hooks and levers, that facilitate easy attachment and detachment of the charging socket to the holder or base plate, reducing the required force and improving tolerance requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a large number of rigid snap hooks are used to provide required strength, then the holding strength is improved, but the ease of operation deteriorates
Solution Approach 1:
The latching mechanism is divided into two distinct functional segments: resilient snap hooks for initial engagement and holding, and non-resilient latching means (locking pins/studs) for secure fixation. This segmentation allows each component to perform its specific function optimally - the resilient hooks provide easy initial attachment while the non-resilient latching means provide strong, permanent fixation that is still removable with tools.
Solution Approach 2:
A mounting tool acts as an intermediary device to engage with the non-resilient latching means and translate a small input force into the large force required to release the rigid snap hooks. The mounting tool mediates between the operator and the strong latching mechanism, enabling easy removal without requiring excessive force.
2Reliability
If tight tolerances are used to prevent warping and bending, then the reliability is improved, but the manufacturing precision requirements worsen
Solution Approach 1:
The design changes the mechanical parameters of the latching system by using resilient (flexible) snap hooks instead of purely rigid connections. This flexibility allows the system to accommodate variations in manufacturing tolerances and resist warping forces without requiring extremely tight tolerance specifications, while still maintaining reliable connection.
3Strength
If multiple rigid latching points are used, then the strength is improved, but the device complexity increases
Solution Approach 1:
The design merges the holding function and the locking function into a single integrated latching system. The resilient snap hooks and non-resilient latching means work together as a unified mechanism, eliminating the need for separate complex assembly steps while providing both easy initial attachment and strong secure fixation.
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 assembly allows for easier assembly and disassembly with lower force requirements, improved resilience against forces, and reduced manufacturing costs, while accommodating different vehicle models with identical charging sockets.
Implementation Method 1
resilient latching means, which may comprise snap hooks that engage with corresponding rims, ridges or grooves of the charging socket
Implementation Method 2
non-resilient latching means, which non-resilient latching means securely fix the charging socket to the base plate or holder. The non-resilient latching means may comprise lugs having openings that are arranged to receive locking studs or locking pins
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A charging port assembly (100) of a hybrid or electric vehicle comprises a holder or base plate (200) and a charging socket (300). The charging socket (300) is adapted to receive and guide two or more levers (308), which are connected in pairs by a respective bracket (310). The brackets (310) are adapted to cooperate with oblique guide planes (332) of the levers (308), for translating a displacement of the levers (308) relative to the bracket (310) in a first direction along the levers (308) into a displacement of the levers (308) in a second direction perpendicular to the first direction, thereby moving locking studs (334) of the levers (308) into non-resilient latching means (206) of the base plate, and fixing the charging socket (300) to the holder or base plate (200).