Conical EV Charging Cable Coil for Compact Torsion-Free Storage
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Solution Overview
Problem
The existing charging cables for electric vehicles are bulky, difficult to store, and prone to damage due to torsion when rolled up, with vulnerable connection points that can be damaged if not stored properly.
Innovation Solution
A charging cable designed to be stored in a conical coil with varying diameters and turns, using a thermal shaping process to create a restoring force that allows it to compactly return to its rest position, ensuring compliance with recommended bending radii and minimizing damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the charging cable is made longer to overcome greater distances, then the charging range is improved, but the cable becomes bulkier and more difficult to store
Solution Approach 1:
The cable is configured to wind itself into a conical coil where the cable section is arranged in multiple subsections with decreasing diameters. Each subsection contains turns that nest within the previous larger subsection, creating a compact conical structure that efficiently stores long cable lengths in minimal space.
Solution Approach 2:
The cable is pre-shaped during manufacturing into a conical coil configuration with specific diameter ratios. This preliminary shaping creates a restoring force that automatically guides the cable into the correct wound position during storage, eliminating the need for manual rolling and ensuring proper storage geometry is achieved every time.
2Volume of moving object
If the charging cable is manually rolled up for storage, then the cable can be compacted, but torsion occurs causing damage to wires and connection points
Solution Approach 1:
The cable is pre-shaped during manufacturing into a conical coil configuration with specific diameter ratios. This preliminary shaping creates a restoring force that automatically guides the cable into the correct wound position during storage, eliminating the need for manual rolling and ensuring proper storage geometry is achieved every time.
Solution Approach 2:
The patent specifies precise parameter relationships: the difference between consecutive subsection diameters is 2-4 times the cable diameter, and each subsection contains 2-5 turns. These parameter changes ensure that the cable winds smoothly without torsion while achieving compact storage volume.
3Volume of moving object
If the charging cable is made more compact for storage, then the storage space is reduced, but the bending radius may become too small causing cable damage
Solution Approach 1:
The patent specifies precise parameter relationships: the difference between consecutive subsection diameters is 2-4 times the cable diameter, and each subsection contains 2-5 turns. These parameter changes ensure that the cable winds smoothly without torsion while achieving compact storage volume.
Solution Approach 2:
Different subsections of the cable have different local qualities in terms of winding diameter. The cable transitions from larger diameter turns at the base to smaller diameter turns at the apex, with each local section optimized to maintain adequate bending radius while contributing to overall compactness.
4Reliability
If the charging cable connection points are made more robust to prevent damage, then the reliability is improved, but the cable weight and bulk increase
Solution Approach 1:
The cable is pre-shaped during manufacturing into a conical coil configuration with specific diameter ratios. This preliminary shaping creates a restoring force that automatically guides the cable into the correct wound position during storage, eliminating the need for manual rolling and ensuring proper storage geometry is achieved every time.
Solution Approach 2:
The cable's own elastic restoring force serves the function of guiding it into proper storage position. The cable automatically winds itself into the conical coil configuration without external assistance, ensuring connection points are properly positioned and protected during storage.
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 allows for easy and space-saving storage of the charging cable, preventing damage by maintaining a stable deformation that automatically returns to its conical rest position, ensuring optimal use of length and reducing the overall length compared to other winding methods.
Implementation Method 1
A charging cable (1) designed to be stored in a conical coil with varying diameters and turns, using a thermal shaping process to create a restoring force
Implementation Method 2
The cable section (2) is shaped such that the cable section is held in a rest position by a restoring force
Data Source
Figure 1~2b
Figure 3
Figure 4
AI summary
The invention relates to a charging cable (1) for charging an electric vehicle, which has a conical winding. The charging cable (1) has a plurality of turns with progressively smaller diameters, wherein at least two turns have the same diameter. The charging cable (1) is shaped such that the conical winding shape (rest position) is maintained stably and that the charging cable (1) returns to its rest position after use. This facilitates proper storage of the charging cable (1) and prevents damage to the inside of the cable.