On-Board EV Charging Cable Housing With Water Drainage
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Solution Overview
Problem
Existing recharging solutions for electric vehicles are complex, costly, and do not efficiently utilize available on-board space, lacking adaptability to different connector types and prone to water ingress.
Innovation Solution
A modular recharging unit with a hollow supporting and containment body formed by two plastic half-shells, featuring a drainage system and intuitive design, compatible with vehicle dimensions, and equipped with a coiled cable and drainage openings to prevent water accumulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional recharging solutions are used, then recharging function is provided, but device complexity and cost increase
Solution Approach 1:
The recharging unit is divided into two separate half-shells that can be coupled together, allowing for simplified manufacturing and assembly while maintaining the complete recharging function. Each half-shell can be produced independently and then joined to form the final protective enclosure.
Solution Approach 2:
The hollow supporting and containment body serves multiple functions simultaneously: it provides structural support, contains the charging cable and connector, and offers protective enclosure. This multi-functionality reduces the need for additional separate components, thereby simplifying the overall device structure.
2Reliability
If traditional recharging solutions are used, then recharging function is provided, but manufacturing cost increases
Solution Approach 1:
By dividing the containment body into two half-shells, the manufacturing process is simplified and can be performed using standard injection molding techniques for plastic parts. This segmentation allows for easier production, assembly, and potential repair, thereby reducing manufacturing costs while maintaining the recharging function.
Solution Approach 2:
The use of plastic material for the half-shells provides a cost-effective solution compared to metal enclosures. Plastic injection molding is a mature, low-cost manufacturing process that allows for high-volume production of complex shapes, reducing both material and manufacturing costs while maintaining adequate protective function.
3Volume of moving object
If compact recharging unit is installed, then space constraints are met, but water drainage capability is reduced
Solution Approach 1:
The drainage function is extracted as a specific feature of the hollow supporting and containment body, with dedicated drainage openings provided in the lower portion. This allows water to be actively removed from the enclosure while maintaining the compact overall structure, preventing water accumulation without requiring additional large-volume components.
Solution Approach 2:
The drainage openings are strategically positioned in specific locations on the hollow supporting and containment body where water would naturally accumulate (lower portions). This localized approach to water management ensures effective drainage in the critical areas while maintaining the compact overall design of the recharging unit.
4Reliability
If connector is permanently enclosed, then protection is improved, but ease of operation deteriorates
Solution Approach 1:
The coupling between the two half-shells is designed to be detachable rather than permanent, allowing the enclosure to transition between closed (protected) and open (accessible) states. This dynamic design enables the connector to be both protected during storage and easily accessible during charging operations, resolving the contradiction between protection and ease of operation.
Data Source
AI summary
A recharging unit for recharging one or more batteries of an electrically powered motor vehicle is permanently provided on board the motor vehicle. An electrical connector is carried by a charging cable, provided for connection to an external electrical socket. Aa hollow supporting and containment body is configured for receiving the charging cable and the electrical connector. The hollow supporting and containment body is formed by two half-shells that can be coupled together with mutual-fixing means so as to define a cavity, a proximal portion, and a distal portion. The hollow supporting and containment body has at least one drainage opening provided for preventing collection of stagnant water inside the body.