EV Charging Connector Boss Segmentation for Ice Shear
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Solution Overview
Problem
Conventional connectors for electric vehicle charging cables face issues with water collection and freezing in small gaps between mounting plates, leading to unreliable opening and closing of the cover due to ice formation, which either allows water ingress or reduces stiffness when gaps are enlarged to prevent water collection.
Innovation Solution
The introduction of projections and depressions on the peripheral surface of the boss on the cover and housing side mounting plates reduces the surface area of the fine gap, making it easier to shear ice and prevent cover malfunction by increasing shear stress when rotating the cover.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the gap between housing side mounting plate and cover side mounting plate is reduced to avoid rattle, then the cover stability is improved, but water collects in the small gap by surface tension and freezes to cause cover malfunction
Solution Approach 1:
The boss is segmented with multiple projections and depressions on its peripheral surface, dividing the continuous surface into discrete geometric features. This segmentation prevents water from forming continuous pools in the gap, as the projections and depressions disrupt capillary action and surface tension effects, thereby reducing water collection while maintaining mechanical stability.
Solution Approach 2:
The boss structure incorporates local geometric variations through projections and depressions specifically at critical locations where water would otherwise accumulate. These localized features modify the surface properties in specific areas to prevent water adhesion and freezing, while the overall boss structure maintains the necessary mechanical connection and stability between mounting plates.
2Reliability
If the gap between mounting plates is enlarged to prevent water collection, then water freezing is avoided, but the cover loses stiffness and proper function
Solution Approach 1:
The boss is segmented with multiple projections and depressions on its peripheral surface, dividing the continuous surface into discrete geometric features. This segmentation prevents water from forming continuous pools in the gap, as the projections and depressions disrupt capillary action and surface tension effects, thereby reducing water collection while maintaining mechanical stability.
Solution Approach 2:
The boss structure incorporates asymmetric projections and depressions that create an uneven surface profile. This asymmetry prevents water from uniformly distributing across the gap, as the irregular geometry creates air pockets and disrupts continuous water films, thereby reducing water accumulation while maintaining structural integrity.
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
This design effectively prevents the cover from being stuck due to ice formation by minimizing water collection and facilitating easy ice shear, ensuring reliable operation in low temperatures.
Implementation Method 1
water likely collects such as dew condensation water or rain by its surface tension
Implementation Method 2
making it easier to shear ice and prevent cover malfunction by increasing shear stress when rotating the cover
Data Source
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AI summary
Configuration of a hinge for avoiding likely collection of water provides a connector to prevent difficulty of opening or closing a cover by freezing of the hinge. A connector (1) mounted in an electric vehicle and connected with a connector of a charging cable is provided with a housing (2), a cover (3) rotatively pivoted about the housing (2) so as to open or close the cover (3), and a shaft (7). The cover (3) is provided with a pair of cover side mounting plates (37) including a shaft hole (31) passing the shaft (7) therethrough, and the housing (2) is provided with a pair of housing side mounting plates (37) including a shaft hole (24a) passing a shaft (7) therethrough, and positioning the pair of cover side mounting plates (37) therebetween. The pair of cover side mounting plates (37) is provided with a boss cylindrically upstanding from each of faces opposite to the pair of housing side mounting plates (24), and passing the shaft (7) therethrough.