EV Charging Cable Reel with Horizontal Ground Channel

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Solution Overview

Problem

Existing delivery element support systems for electric vehicle charging stations are inefficient, as they often result in cables being dragged on the ground, leading to wear, dirtiness, and safety hazards due to improper coiling and elevated mounting solutions that do not effectively prevent ground contact.

Innovation Solution

A system comprising a structure assembly with a delivery element that can move between extended and retracted conditions, supported by a line element and bracket assemblies, which allows for smooth retraction and extension while maintaining the cable off the ground, using a reel and biasing mechanism to automatically coil the cable when not in use.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If the delivery element is mounted vertically several feet above the ground, then the cable is kept off the ground to reduce wear and dirtiness, but the device complexity increases and installation becomes more difficult

Engineering Contradiction:

Improvewear and dirtiness of cableVSAvoidmounting structure complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent transitions from vertical mounting (elevating the cable several feet above ground) to horizontal mounting at ground level, using a different spatial dimension approach. The cable is routed through a channel in the base and emerges at ground level, eliminating the need for elevated mounting while keeping the cable off the ground through the horizontal pathway.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The patent introduces a channel as an intermediary structure between the base and the ground level. This channel serves as a protective pathway that guides the cable horizontally, preventing direct ground contact while avoiding the complexity of elevated mounting structures.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If the delivery element is allowed to drag on the ground during use, then the device complexity is reduced and ease of operation is improved, but the cable suffers from increased wear and dirtiness

Engineering Contradiction:

Improveease of cable deploymentVSAvoidwear and dirtiness of cable

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The patent performs preliminary action by pre-routing the cable through the channel and securing it to the base before use. The cable is attached at an intermediate point to the channel, which is already in place, eliminating the need for complex elevated mounting while preventing ground contact during operation.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If users manually coil the delivery element on a hook, then the cable is kept off the ground when not in use, but users may not coil it properly leading to improper storage and potential ground contact

Engineering Contradiction:

Improveproper cable storageVSAvoiduser dependency for proper coiling

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent implements self-service by designing an automatic retraction mechanism that pulls the cable back into the base when not in use. The spring mechanism automatically winds the cable onto the spool, eliminating dependency on user action to properly coil and store the cable, ensuring consistent and proper storage every time.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces the manual mechanical coiling action (user hand-coiling on a hook) with an automated mechanical retraction system. The spring-driven spool mechanism automatically winds the cable, substituting human effort with a reliable mechanical system that ensures proper storage without user intervention.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Object-affected harmful factors

If the delivery element is secured at a high vertical distance, then the cable is kept off the ground, but the device complexity and installation difficulty increase

Engineering Contradiction:

Improveground contact of cableVSAvoidinstallation ease

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The patent changes the mounting approach from vertical elevation to horizontal routing at ground level. The channel provides a horizontal pathway that keeps the cable off the ground without requiring vertical elevation, simplifying installation while achieving the same protective effect.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS20230378738A1System and method for delivery element support

Publication Date: 2023.11.23 MELITRON CORP

AI summary

A system including a structure assembly and a delivery element extending between a free end thereof positionable distal from the structure assembly and a secured end thereof attached to the structure assembly. The delivery element is movable between an extended condition and a retracted condition. The system also includes a line element and a number of bracket assemblies connecting the line element and the delivery element. The line element extends between an inner end thereof secured to the structure assembly and an outer end thereof secured to the delivery element proximal to the free end. The line element is movable relative to the delivery element as the delivery element is moved between the extended and retracted conditions thereof, and is slidingly receivable in apertures in the bracket assemblies as the delivery element is moved between the extended and retracted conditions thereof.