EV Charger Housing with Charcoal Filter and Optical Port

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Solution Overview

Problem

Electric vehicle charging systems face challenges such as environmental damage, wear and tear, and the need for easy access and programming due to exposure to the elements and high operational stress, leading to potential malfunctions and short circuits.

Innovation Solution

The electric vehicle supply equipment incorporates a robust design with waterproof connectors, a universal/serial optical connection port, and a charcoal filter to absorb impurities, along with a modular construction for easy access and maintenance, ensuring protection against environmental factors and facilitating updates.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the charger is exposed to the environment for outdoor installation, then the electric vehicle can charge conveniently, but the charger suffers environmental damage such as corrosion and water exposure

Engineering Contradiction:

Improvecharging convenienceVSAvoidenvironmental damage

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The patent applies beforehand cushioning by providing a protective housing structure with sealed enclosures that prevent water and environmental contaminants from reaching internal electrical components. The housing includes gaskets, seals, and protective coatings that are pre-installed to cushion against environmental damage before it occurs, allowing the charger to be safely installed outdoors while maintaining charging convenience.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Productivity

If the charger operates at high voltage potential to charge quickly, then the charging speed increases, but the charger generates high temperature and may short circuit

Engineering Contradiction:

Improvecharging speedVSAvoidoperational temperature

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

The patent applies intermediary by introducing thermal management components such as heat sinks, thermal pads, and cooling channels that act as intermediaries between the high-voltage electrical components and the environment. These intermediaries transfer heat away from critical components during high-voltage operation, enabling fast charging while preventing overheating and short circuits.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Volume of moving object

If various components are located in close proximity to save space, then the charger size is reduced, but the components may lead to short circuiting

Engineering Contradiction:

Improvecharger sizeVSAvoidshort circuit risk

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The patent applies segmentation by dividing the charger into multiple isolated compartments and sections within the housing. Each compartment contains specific electrical components separated by insulating barriers and protective partitions. This segmentation allows components to be located in close proximity for compact size while preventing short circuits through physical and electrical isolation between different component groups.

Inventive Principle:

Principle #1Segmentation

4Adaptability or versatility

If the charger needs to be accessed for updates and programming, then the functionality can be updated, but the access requires disassembly and reassembly

Engineering Contradiction:

Improveupdate capabilityVSAvoidaccess difficulty

Core Design Contradiction:

Adaptability or versatilityVSEase of repair

Solution Approach 1:

The patent applies taking out by providing removable access panels or doors on the housing that can be easily detached to expose internal components for updates and programming. Critical components such as control boards and memory modules are designed to be accessible through these removable panels without requiring complete disassembly of the charger, enabling easy maintenance while maintaining protective enclosure when panels are closed.

Inventive Principle:

Principle #2Taking out (Extraction)

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 enhances the durability and maintainability of the charging system, preventing damage from environmental exposure and allowing for seamless updates, thereby extending its lifespan and ensuring reliable operation.

Implementation Method 1

a charcoal filter that couples to the chimney stack to absorb impurities generated by the first circuitry and the second circuitry

Methodology Applied

Scientific EffectAdsorption: Adsorption

Data Source

PatentUS8929069B2Electric vehicle charging system with robustness features and universal port

Publication Date: 2015.01.06 BOSCH AUTOMOTIVE SERVICE SOLUTIONS INC

AI summary

An electric vehicle supply equipment may include a first cover element including a well portion to accommodate a first circuitry, wherein the first circuitry includes a chimney stack that couples to a venting hole. Also, the electric vehicle supply equipment may include a second cover element including a recess portion to accommodate a second circuitry, wherein the second circuitry includes a charcoal filter that couples to the chimney stack to absorb impurities generated by the first circuitry and the second circuitry. Further, the electric vehicle supply equipment includes a universal/serial connection port configured to couple to peripheral devices, wherein the universal/serial connection port is an optical coupled connection.