EV Charging Cable Cap Toggle Mechanism for Sealed Connector Protection
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Solution Overview
Problem
Existing charging cables for electric vehicles suffer from issues such as loose protective caps that can scratch the vehicle's paint, collect contaminants, and allow water ingress, leading to malfunctions, and are prone to cap loss due to flexible attachments.
Innovation Solution
A charging plug and cable design featuring a protective cap secured by a toggle lever mechanism with wire brackets, ensuring the cap is pressed against the plug in a first position to cover the connector, and swivels upward to a second position during use, preventing water and dirt ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the protective cap is attached flexibly to the charging cable, then the protective cap can be easily removed and attached, but the protective cap may slide down and lie on the ground causing damage
Solution Approach 1:
The protective cap is designed with different functional zones: an upper region with attachment features for secure connection to the charging cable, and a lower region that maintains coverage function. The cap structure transitions from flexible attachment at the top to rigid coverage at the bottom, with each zone optimized for its specific function.
Solution Approach 2:
The protective cap incorporates a movable design that allows it to transition between different positions: attached to the charging cable during storage/transport, and detached during charging operation. This dynamic capability enables the cap to adapt to different operational states while maintaining both ease of operation and reliability.
2Ease of operation
If the protective cap hangs down loosely when plugged into the car, then the cap can be easily attached, but the cap may scratch the paint finish and collect contaminants
Solution Approach 1:
The protective cap is designed with preliminary protective features: a sealed structure that prevents contaminant entry, and positioning features that ensure the cap remains in a protected position during charging. The seal and structural design proactively prevent paint scratching and contamination before they can occur.
Solution Approach 2:
The protective cap utilizes a sealed membrane or film structure that creates a barrier against contaminants while maintaining flexibility for attachment and removal. This flexible sealed structure prevents rainwater and dirt from entering the connector area while allowing the cap to be easily attached and detached.
3Reliability
If the protective cap is placed on the charging plug after charging, then the connector is protected, but water can get into the charging plug causing malfunctions
Solution Approach 1:
The protective cap incorporates a sealed membrane structure that creates a water-tight barrier when covering the connector. This flexible sealed film prevents water from penetrating into the charging plug while maintaining the ability to be easily attached and removed.
Solution Approach 2:
The protective cap is designed to nest over the connector in a fitted manner, with the cap's internal structure conforming to the connector's external shape. This nested configuration ensures complete coverage and sealing, preventing water ingress while maintaining compact storage when attached to the charging cable.
4Ease of operation
If a plastic rope or plastic cable is used to attach the protective cap, then the cap can be easily fastened, but the rope can easily be torn off and the cap lost
Solution Approach 1:
The attachment mechanism combines multiple materials with complementary properties: a flexible component for ease of attachment and a rigid or high-strength component for durability. This composite attachment structure integrates the advantages of both flexible and strong materials to prevent both difficult fastening and easy detachment.
Solution Approach 2:
The attachment features are integrated directly into the protective cap and charging cable structure rather than using separate fastening elements. The cap includes built-in attachment interfaces that combine securing function with structural integrity, eliminating the need for separate plastic ropes or cables that could tear off.
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 design effectively seals the electrical contacts, prevents cap loss, and avoids paint scratches by keeping the cap secure, thus enhancing reliability and durability.
Implementation Method 1
with a seal
Implementation Method 2
a bracket closure, comprising a second wire bracket fastened on the protective cap, engaging with the first wire bracket and forming together with it a toggle lever mechanism
Data Source
AI summary
A charging plug and a charging cable for electric vehicles, as well as a method for using the charging cable, are provided.