EV Charging Socket Temperature Sensor Routing Without Rear Cover Lead-Through
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Solution Overview
Problem
The existing charging sockets for new energy electric vehicles require a complex installation structure for temperature sensors, which increases manufacturing costs and reduces installation efficiency due to the need for lead perforations and seals.
Innovation Solution
A charging socket design that incorporates a flexible lead for the temperature sensor, which is electrically connected to the connection terminal of the electric adapter without passing through the rear cover, simplifying the installation and reducing the complexity of the product structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a lead-in temperature sensor is used with the lead passing through the rear cover, then the temperature monitoring function is achieved, but the product structure becomes complex and installation efficiency is reduced
Solution Approach 1:
The patent extracts the temperature sensor lead from the rear cover path and relocates it to connect directly to the electric adapter's connection terminal. This removes the need for lead perforation through the rear cover and eliminates the associated seal requirements, thereby simplifying the overall product structure while maintaining the temperature monitoring function.
Solution Approach 2:
The electric adapter's connection terminal serves as an intermediary component that receives the temperature sensor lead directly. This intermediary structure provides a convenient connection point within the housing, eliminating the need for the lead to pass through the rear cover and reducing structural complexity.
2Reliability
If a lead-in temperature sensor is used with the lead passing through the rear cover, then the temperature monitoring function is achieved, but the installation efficiency is reduced
Solution Approach 1:
The patent extracts the temperature sensor lead routing from the complex rear cover path and simplifies it by connecting directly to the electric adapter's connection terminal within the housing. This extraction of the lead path eliminates the need for lead perforation and seal installation steps, thereby improving installation efficiency.
3Reliability
If a lead-in temperature sensor is used with the lead passing through the rear cover, then the temperature monitoring function is achieved, but the manufacturing cost is increased
Solution Approach 1:
The patent extracts and eliminates the unnecessary components (lead perforation structure and seal) from the rear cover assembly. This reduction in component count and manufacturing steps directly lowers production costs while maintaining the essential temperature monitoring function through the simplified direct connection to the electric adapter.
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
This design simplifies the installation of the temperature sensor, improves assembly efficiency, and reduces production costs by eliminating the need for lead perforations and seals.
Implementation Method 1
The temperature sensor has a flexible lead, which is electrically connected to the input end of the connection terminal, so as to transmit the sensing signal of the temperature sensor to the output end of the connection terminal
Implementation Method 2
the charging socket further comprises a heat conduction pad for thermally contacting with the charging terminal, the temperature sensor is installed in the heat conduction pad to be thermally connected with the charging terminal via the heat conduction pad
Data Source
AI summary
A charging socket has a housing; a charging terminal installed in the housing; an electric adapter installed in the housing; and a temperature sensor for detecting the temperature of the charging terminal. The electric adapter has a body and a connection terminal provided in the body, and the connection terminal has an input end and an output end. The temperature sensor has a flexible lead, which is electrically connected to the input end of the connection terminal, so as to transmit the sensing signal of the temperature sensor to the output end of the connection terminal. The flexible lead of the temperature sensor is electrically connected to the connection terminal of the electric adapter in the charging socket without passing through the rear cover of the charging socket.