Charging Cable Connector Adapter Layout to Reduce Socket Torque
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Solution Overview
Problem
The existing charging cable technologies for electric vehicles require multiple connectors for different socket types, leading to high costs, space requirements, and mechanical instability due to the weight and distribution of electronic components, which can cause the connector to loosen from the socket.
Innovation Solution
An electrical connection unit with a connector adapter that allows a single connector to fit different socket shapes by offsetting the second plug face perpendicular to the mounting direction, reducing torque and weight distribution, and incorporating a compact design with a recessed section to minimize the center of gravity's distance from the socket, thus enhancing stability and reducing the need for multiple connectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple connectors with different plug faces are provided for different socket types, then adaptability to various sockets is improved, but device complexity and cost increase
Solution Approach 1:
The patent applies universality by designing a single connector housing that can accommodate multiple plug face types through interchangeable plug faces. The connector housing is designed with a universal interface that accepts different plug faces (e.g., NEMA 5-15, NEMA 14-50, IEC 60320), allowing one connector to serve multiple socket types. This eliminates the need for multiple separate connectors while maintaining adaptability to various charging sockets.
2Adaptability or versatility
If electronic components are integrated in the household-side connector, then adaptability is improved, but weight and torque increase causing connector loosening
Solution Approach 1:
The patent applies segmentation by dividing the connector into modular components: a lightweight connector housing that interfaces with the socket, and separate electronic components (voltage converter, switching unit, relay) that are positioned away from the connector or integrated into the cable assembly. This segmentation allows the connector itself to remain lightweight and mechanically stable, while still providing adaptability through the universal housing design. The electronic components are distributed to minimize their impact on connector weight and torque.
3Ease of manufacture
If the center of gravity of the connector is far from the socket, then ease of manufacture is improved, but mechanical stability deteriorates due to increased torque
Solution Approach 1:
The patent applies asymmetry by strategically positioning the connector housing and electronic components to create an asymmetric weight distribution that optimizes mechanical stability. The connector housing is designed with an asymmetric structure where the bulk of the housing material is positioned closer to the socket interface, and the center of gravity is deliberately placed near the socket connection point. This asymmetric design minimizes the torque lever arm while still allowing for ease of manufacture through standardized housing geometries and component placement.
Data Source
AI summary
The invention relates to an electrical connection unit, the electrical connection unit comprising:a connector (1), the connector (1) comprising:a first end (2) with a first plug face (3), set up for connection to a first socket (4);a second end (6);a connector adapter (9), comprising:a coupling (10) for coupling to the first plug face (3);a second plug face (11) for connecting to a second socket (12);wherein the connector adapter (9) is coupled to the first plug face (3) by means of the coupling (10),wherein the first plug face (3) has a protective conductor contact (14) and at least two, in particular current-carrying, contacts (15, 16), wherein the second plug face (11) has a further protective conductor contact (17) or a neutral conductor and at least two further, in particular current-carrying, contacts (18, 19), andwherein the second plug face (11) is offset perpendicular to a mounting direction (M) of the connector adapter (9) relative to the coupling (10) of the connector (1), and/orwherein the at least two further contacts (18, 19) are arranged closer to the second end (6) of the connector (1) relative to the at least two contacts (15, 16) and the protective conductor contact (14) is arranged between the at least two contacts (15, 16) and the at least two further contacts (18, 19).