Conductive Vehicle Charging Contact With Vacuum Sealing
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Solution Overview
Problem
Conductive charging systems for vehicles face challenges in maintaining a dry contact area between the vehicle's charging contact and the external charging plate, leading to potential water ingress and reduced efficiency due to the need for continuous fan operation.
Innovation Solution
The conductive charging unit incorporates a protective cover with a circumferential hollow chamber and openings, which allows for a vacuum unit to suction air out of the chamber, creating a seal that prevents liquid and contaminants from entering the contact area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a fan motor is used to displace water or moisture from the contact point, then the contact area is kept free of liquids, but energy is continuously consumed and acoustic noise is generated
Solution Approach 1:
The patent replaces the mechanical fan motor system with a vacuum-based sealing system. Instead of using aerodynamic forces from a rotating fan to displace water, the invention uses a vacuum unit to create negative pressure in a hollow chamber, forming a seal that passively prevents water ingress without continuous mechanical motion
Solution Approach 2:
The patent creates a controlled environment by establishing a vacuum seal around the contact area. The hollow chamber with vacuum pressure creates an inert-like protective environment that prevents harmful factors (water, contaminants) from reaching the contact point, eliminating the need for active fan operation
2Object-affected harmful factors
If a fan motor is used to displace water or moisture from the contact point, then the contact area is kept free of liquids, but acoustic noise is generated
Solution Approach 1:
The patent eliminates the acoustic noise by replacing the mechanical fan system with a vacuum-based sealing mechanism. The vacuum unit operates without the continuous rotational motion of fan blades, thereby eliminating the primary source of acoustic noise while maintaining protection against water ingress
3Device complexity
If a sealing lip is used to prevent water entry, then the structure is simple, but it does not optimally solve the water ingress problem
Solution Approach 1:
The patent applies pneumatic principles by using a vacuum unit to create negative pressure in a hollow chamber. This pneumatic seal is more effective than a simple mechanical sealing lip, as the pressure differential actively prevents water ingress rather than relying solely on physical contact and friction
Solution Approach 2:
The protective cover with hollow chamber acts as a flexible barrier that can adapt to slight movements and vibrations while maintaining the vacuum seal. This flexible shell structure provides superior water protection compared to rigid sealing lips while accommodating operational dynamics
4Object-affected harmful factors
If the protective cover is extended together with the charging contact, then the contact area is protected during charging, but the device complexity increases
Solution Approach 1:
The patent merges the protective cover extension mechanism with the charging contact extension mechanism. Both components are actuated together as a unified system, eliminating the need for separate control mechanisms and reducing overall device complexity while maintaining continuous protection during the charging process
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 solution effectively seals the contact area from liquids and contaminants, reducing the need for continuous fan operation, saving energy, and enhancing charging efficiency while minimizing noise.
Implementation Method 1
a vacuum unit (34) which is designed to suction air out of the hollow chamber (30)
Data Source
AI summary
A conductive charging unit for a motor vehicle for electrically charging an energy storage device of the motor vehicle, including a charging contact unit with a charging contact which, for electrically conductive coupling to a charging connection of a charging plate external to the motor vehicle, is moved from a retracted position into an extended position in an extension direction and has a protective cover surrounding the charging contact unit perpendicular to the extension direction, which protective cover is extended together with the charging contact. The protective cover has a first end and a second end opposite in the extension direction with an edge region. The edge region has a circumferential hollow chamber, which includes at least one opening which provides a fluidic connection between the environment of the charging unit.