EV Charging Connector with Segmented Housing and External Latch
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Solution Overview
Problem
Existing electric vehicle charging connectors lack durability and ease of repair, particularly in scenarios where they are accidentally driven over, as they are prone to damage and require complex disassembly to access internal components.
Innovation Solution
A connector assembly with a robust elongate housing and latching mechanism designed to withstand vehicle loading, featuring a contoured handle, transverse support ribs, and an externally accessible shell and latching mechanism for simplified repair, which includes a lever, linkage, cam, and trigger system for secure attachment and detachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the connector assembly uses a robust housing with transverse support ribs to withstand vehicle loading, then durability and strength are improved, but device complexity increases
Solution Approach 1:
The housing is divided into a first housing portion and a second housing portion that can be separately assembled. This segmentation allows the robust structure with transverse support ribs to be manufactured and assembled in modular sections, reducing overall device complexity while maintaining the strength and durability needed to withstand vehicle loading.
Solution Approach 2:
Transverse support ribs are added to the housing structure to provide additional structural reinforcement in the transverse direction. This dimensional enhancement strengthens the housing to resist vehicle loading without requiring a complete redesign of the entire connector assembly, thereby improving durability with minimal increase in complexity.
2Ease of repair
If the latching mechanism is externally accessible for simplified repair, then ease of repair is improved, but reliability may worsen due to potential exposure to external damage
Solution Approach 1:
The connector assembly is segmented into an internally enclosed latching mechanism and an externally accessible shell. The shell can be removed or opened to allow repair of the latching mechanism without disassembling the entire connector, improving ease of repair while the enclosed design protects the mechanism from external damage during normal operation.
Solution Approach 2:
The shell acts as an intermediary between the latching mechanism and the external environment. It provides protective enclosure during normal operation to maintain reliability, while allowing controlled access for repair purposes, thus balancing protection with serviceability.
3Reliability
If the connector assembly protects electrical components through enclosed housing, then reliability is improved, but ease of repair worsens due to complex disassembly requirements
Solution Approach 1:
The housing is divided into removable first and second housing portions that enclose the electrical components. This segmentation allows the components to be protected during operation while enabling relatively simple access for repair by removing the housing sections, rather than requiring complex disassembly of the entire connector assembly.
Solution Approach 2:
The latching mechanism is extracted from the internal enclosure and made externally accessible. This allows the mechanism to be serviced independently without requiring disassembly of the enclosed housing that protects the electrical components, thus maintaining reliability while improving ease of repair.
4Ease of operation
If the connector assembly uses a contoured handle and trigger mechanism for secure attachment, then ease of operation is improved, but device complexity increases
Solution Approach 1:
A contoured handle with curved surfaces is provided on the connector assembly. The curved geometry provides ergonomic grip and leverage for operating the latching mechanism, improving ease of operation. The contoured design is integrated into the existing housing structure rather than adding separate complex mechanical components.
Solution Approach 2:
The trigger mechanism is designed to be actuated from the external side of the connector assembly, allowing the user to engage and disengage the latching mechanism by pulling or pressing external elements rather than manipulating internal components. This inverted approach simplifies operation while maintaining the necessary latching functionality.
Data Source
AI summary
A connector assembly is provided with a housing having an inlet for receiving an electrical harness, and an outlet for engaging a vehicle receptacle for facilitating electrical charging of a vehicle. The housing includes a plurality of transverse support ribs, a fulcrum and a series of guides. The housing is configured for supporting a distributed load. A latching mechanism, including a lever, linkage and trigger, is externally connected to the housing for selectively attaching the housing to the vehicle receptacle. The lever is pivotally connected to the fulcrum. The linkage is coupled to the lever for pivoting the lever. The trigger is mounted for translation and includes a series of apertures each sized for receiving one of the guides. The trigger actuates the linkage. A shell is disposed over the housing for retaining the latching mechanism to allow repair and/or replacement without exposing electronic components enclosed in the housing.