EV Charging Connector Interlock for Faster PCB Assembly
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Solution Overview
Problem
The connection of conductors in electric vehicle charging stations to electronic cards via flexible cables requires complex assembly, high manufacturing costs, and poses risks due to the need for specific tools and precise torque control, limiting production efficiency and increasing the risk of miswiring or overheating.
Innovation Solution
A quick connection device with cylindrical connectors featuring a male and female interlocking mechanism, eliminating the need for cables and manual screwing, allowing for secure and efficient electrical connection between charging sockets and electronic cards without specialized tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flexible electrical cables with clamping screws and terminal blocks are used to connect conductors to the electronic board, then reliable electrical connection is achieved, but assembly time increases significantly and manufacturing costs rise
Solution Approach 1:
The patent divides the connection system into modular components: a printed circuit board with integrated socket, a connector body with conductors, and a locking mechanism. This segmentation allows pre-assembly and testing of components separately, then quick final assembly by simply inserting the connector into the socket and engaging the locking mechanism, eliminating time-consuming cable routing and screw fastening operations.
Solution Approach 2:
The patent combines multiple functions into integrated components: the printed circuit board integrates the terminal block and socket; the connector body combines conductor holders, insulation, and locking mechanisms. This merging eliminates the need for separate cable management components and reduces the number of assembly steps while maintaining reliable electrical connections.
2Reliability
If flexible electrical cables and terminal blocks are used for connecting conductors, then electrical connection is established, but manufacturing costs increase due to copper material and additional components
Solution Approach 1:
The patent combines the terminal block function directly into the printed circuit board design, eliminating the need for separate terminal block components and reducing copper usage. The connector body integrates conductor holders and insulation in a single molded piece, reducing component count and assembly complexity while maintaining reliable electrical connections.
Solution Approach 2:
The printed circuit board serves multiple functions: it provides the electrical circuitry, acts as the terminal block for conductor connections, and provides the socket for the connector. This multi-functionality reduces the total number of components needed and simplifies the overall manufacturing process while ensuring reliable electrical connections.
3Reliability
If manual assembly with clamping screws and terminal blocks is used, then secure electrical connection is achieved, but production complexity increases and mass production becomes difficult
Solution Approach 1:
The patent segments the connection system into self-contained modules that can be pre-assembled and tested independently. The connector body with conductors and the PCB with integrated socket can be manufactured separately with quality control, then quickly finalized through simple insertion and locking, greatly simplifying mass production while ensuring reliable connections.
Solution Approach 2:
The locking mechanism is designed to automatically engage and secure the connector to the PCB socket when inserted, eliminating the need for manual screw tightening or complex fastening operations. The self-locking feature ensures secure electrical connections through a simple insert-and-lock operation that is easy to automate in mass production.
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 solution simplifies assembly and maintenance, reduces production time and costs, and minimizes the risk of miswiring, enabling faster and safer installation and maintenance of electric vehicle charging stations.
Implementation Method 1
an external elastic metallic sheath surrounding said body so as to ensure an electrical connection and a tight fit of the mutual interlocking
Data Source
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AI summary
The present invention relates to a quick connection device for an electric vehicle charging station, said charging station comprising a main housing delimiting an internal space, at least one electronic card (1) fixed in the internal space, at least one charging socket (2) fixed on the main housing or connected to the end of a charging cable exiting the main housing and terminating with connection points, said charging socket comprising output pins and conductors each connected to one of these pins.It is characterized in that it comprises connection interfaces (3, 4), each having a first connector (3) suitable for and intended to be connected to and secured to one of the conductors or connection points of the charging cable, and a second connector (4) suitable for and intended to be connected to and secured to the electronic board (1), said first and second connectors (3, 4) being further suitable for and intended to be assembled to one another by mutual male/female interlocking of their respective ends (3b, 4b). It also relates to an electric vehicle charging station comprising at least one such device.