EV Charging Outlet Base With Prewired Modular Installation
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Solution Overview
Problem
The installation of electric vehicle charging stations is complex and time-consuming due to the need for multiple steps, including rough-in wiring and subsequent inspections, which increases labor costs and difficulty in connecting wires to receptacles, especially in various outdoor and indoor locations with different geometries.
Innovation Solution
An electric vehicle charging structure comprising a base portion with a base compartment and a main unit that mate via electrical connectors, allowing for easy installation and wiring access from multiple sides, with a terminal block for secure conductor coupling and protection against moisture and damage, facilitating quicker and safer installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional multi-step installation process is used for electric vehicle charging stations, then electrical connections can be established, but installation complexity and time consumption increase significantly
Solution Approach 1:
The patent combines the base portion and main unit into a single integrated charging structure with pre-established electrical connections. The base portion includes a base compartment with electrical connectors that directly mate with corresponding connectors in the main unit, eliminating the need for separate wiring steps and reducing installation complexity while maintaining reliable electrical connections.
Solution Approach 2:
The electrical connectors and wiring are pre-installed and configured within the base portion before the main unit is attached. The base compartment contains power terminals and internal electrical conductors that are already connected and ready for use, allowing the main unit to be simply mated to the base portion without requiring on-site wiring or complex electrical assembly.
2Reliability
If traditional wiring methods are used, then electrical connections can be made, but labor costs and installation time increase
Solution Approach 1:
The base portion and main unit are designed as integrated components with electrical connectors that mate directly together. The base compartment houses all necessary wiring and terminals in a consolidated arrangement, allowing the entire electrical connection system to be installed in a single attachment operation rather than through multiple separate wiring steps.
Solution Approach 2:
All electrical wiring, terminals, and connectors are pre-configured within the base portion during manufacturing. The internal electrical conductors are already connected to the power terminals and extend through the base compartment to the electrical connectors, so that when the main unit is attached, functional electrical connections are immediately established without requiring on-site wiring work.
3Reliability
If conventional outlet installation is used, then electrical functionality is achieved, but adaptability to different locations and geometries is limited
Solution Approach 1:
The base portion is designed as a universal mounting structure with a base compartment that can accommodate various electrical configurations. The electrical connectors and terminals are positioned to work with different main unit orientations and types, allowing the same base portion to be installed in diverse locations including outdoor and indoor settings with different geometries and mounting requirements.
Data Source
AI summary
An electric vehicle charging structure can include a base portion including a front surface and a rear surface, a base compartment that is rigidly coupled to the base portion, the base compartment defined by a base compartment upper surface and a base compartment lower surface that each protrude away from the front surface of the base portion, an electrical connector passing through the base compartment upper surface at a specified location, a conduit entry opening in the base compartment configured to allow insertion of electrical service conductors to inside the base compartment, a power terminal inside the base compartment, the power terminal configured to removably secure the electrical service conductors, and an internal electrical conductor inside the base compartment electrically coupling the power terminal to the electrical connector.