EV Charging Socket Connector Assembly With Replaceable Sealing Ring
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Solution Overview
Problem
Existing connectors for new energy vehicles lack both good waterproof sealing performance and lightweight design, and their assembly is cumbersome, leading to high weight and difficulty in maintenance.
Innovation Solution
A connector assembly with a plug-in portion, support portion, and electrical connection framework, featuring a sealing portion that ensures waterproofing and a hollow support structure to reduce weight, along with a flexible electrical connection framework for easy installation and integration with the vehicle body, using conductive materials to prevent electromagnetic interference and facilitate production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If elastic material injection molding is used to achieve waterproof sealing, then waterproof sealing performance is improved, but the product weight increases and becomes difficult to repair and maintain
Solution Approach 1:
The connector assembly is divided into separate components: a connector body, a sealing ring, and a protective shell. The sealing ring is a separate element that can be independently replaced, whereas traditional elastic material injection molding creates an integrated structure where the sealing function is embedded in the molded material throughout the entire product.
Solution Approach 2:
The sealing ring is designed as a replaceable component that can be discarded and recovered independently when worn or damaged. This allows maintenance personnel to replace only the sealing ring rather than the entire connector assembly, facilitating easier repair and reducing waste of other functional components.
2Reliability
If elastic material injection molding is used to achieve waterproof sealing, then waterproof sealing performance is improved, but the product becomes difficult to repair and maintain requiring complete scrapping
Solution Approach 1:
The connector assembly is divided into separate components: a connector body, a sealing ring, and a protective shell. The sealing ring is a separate element that can be independently replaced, whereas traditional elastic material injection molding creates an integrated structure where the sealing function is embedded in the molded material throughout the entire product.
Solution Approach 2:
The sealing ring is designed as a replaceable component that can be discarded and recovered independently when worn or damaged. This allows maintenance personnel to replace only the sealing ring rather than the entire connector assembly, facilitating easier repair and reducing waste of other functional components.
3Adaptability or versatility
If flexible cables are used for electrical wiring harnesses, then adaptability to vehicle body shapes is improved, but automatic production and assembly cannot be realized
Solution Approach 1:
The electrical connection framework incorporates flexible portions and bending portions that allow the rigid framework to adapt to different vehicle body shapes and installation environments. This dynamic capability enables the framework to bend and conform to various geometries while maintaining its rigid structure for automatic fabrication and assembly processes.
Solution Approach 2:
The framework's flexibility is achieved through controlled changes in structural parameters - specific sections are designed with reduced rigidity or increased degrees of freedom to allow bending, while other sections maintain full rigidity for automated manufacturing. This parameter differentiation enables both adaptability and automatability.
4Adaptability or versatility
If flexible cables are used for electrical wiring harnesses, then adaptability to vehicle body shapes is improved, but contact friction with vehicle shell damages insulation layer causing short circuit
Solution Approach 1:
The electrical connection framework incorporates flexible portions and bending portions that allow the rigid framework to adapt to different vehicle body shapes and installation environments. This dynamic capability enables the framework to bend and conform to various geometries while maintaining its rigid structure for automatic fabrication and assembly processes.
Solution Approach 2:
The framework includes flexible portions that can bend and conform to vehicle body shapes without requiring contact with the vehicle shell. These flexible sections act as protective shells that accommodate geometric variations while preventing direct contact between the framework and external surfaces that could cause friction damage.
Data Source
AI summary
The present disclosure discloses a connector assembly, a charging socket and a vehicle, including a plug-in portion, a support portion, a connection terminal and an electrical connection framework, in which the plug-in portion is connected to the support portion, and the electrical connection framework is electrically connected to the connection terminal; the plug-in portion is provided therein with a plug-in cavity, and the connection terminal is at least partially located in the plug-in cavity; the support portion is provided therein with a supporting cavity, and connection portions of the electrical connection framework and the connection terminal are located in the supporting cavity; at least a sealing portion is further arranged in the supporting cavity, and the sealing portion seals the supporting cavity.