Detachable Charging Socket Contact Assembly for Modular EV Repair
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Solution Overview
Problem
Existing plug sockets for electric vehicles face challenges in modular installation and maintenance, as conventional designs require replacement of entire wiring harnesses and components upon defects, lacking efficient thermal monitoring and compact design.
Innovation Solution
A plug socket design featuring a detachable contact assembly with a plate-shaped carrier base, using insulating material to separate conductive elements, allowing for modular installation and thermal monitoring, with a compact design enabling automated production and reduced component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional wiring harnesses are firmly connected to the charging socket, then electrical energy transmission is stable, but the entire wiring harness must be replaced upon defect
Solution Approach 1:
The patent divides the wiring system into separate modules: a fixed wiring harness connected to the housing, and a detachable contact assembly that can be independently replaced. The contact assembly with contact elements is separated from the main wiring harness through a plug connection, allowing the contact assembly to be replaced without replacing the entire wiring harness while maintaining stable electrical connections during operation.
2Ease of manufacture
If individual conductors are used for signal and grounding lines, then electrical connections are established, but the wiring becomes complex and time-consuming
Solution Approach 1:
The patent combines multiple individual conductors (signal lines, grounding lines, and power lines) into a single integrated contact assembly. This assembly includes all necessary contact elements mounted on a common carrier, allowing all electrical connections to be established through one plug-in operation rather than individually connecting multiple separate wires, thereby reducing assembly complexity and time.
3Reliability
If the charging socket is firmly connected to the wiring harness, then electrical stability is maintained, but automated production becomes difficult
Solution Approach 1:
The patent segments the charging socket into a fixed housing portion and a detachable contact assembly. The contact assembly with its contact elements can be independently manufactured and tested, then automatically plugged into the housing during assembly. This modular design enables automated production through standardized plug connections while maintaining stable electrical connections when assembled.
4Adaptability or versatility
If conventional designs are used, then component functionality is achieved, but component count increases and space is consumed
Solution Approach 1:
The patent merges multiple functional components (contact elements for power transmission, signal contacts, and grounding contacts) onto a single carrier board within the contact assembly. This integration reduces the total component count and space requirement while maintaining all necessary functional capabilities through the consolidated design.
Data Source
AI summary
A plug socket includes: a first connector face for connecting a plug for transmitting electrical energy and/or electrical signals via at least one contact element; and a second connector face having at least one contact assembly which is fastenable or is detachably fastenable thereto, and which has the at least one contact element, and/or via which the electrical energy and/or the electrical signals is transmittable by at least one electrical line.