EV Charging Connector Matrioska Design for Flashover Prevention
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current charging connectors for electric vehicles face issues with flashovers due to metallic components, poor mechanical protection, and inadequate protection against dust and water ingress, leading to potential damage and reduced dielectric properties.
Innovation Solution
A charging connector design featuring a 'matrioska' structure with internal and external mechanical connectors, using clips instead of screws to maintain the contact compartment housing, and sealing with potting resin and gaskets to achieve IP67 or IP68 ratings, along with a mating interface for enhanced mechanical and water protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallic screws are used to fix the contact compartment housing to the mechanical connector, then the mechanical strength and assembly reliability are improved, but the dielectric properties deteriorate due to flashover risk between conducting components and fixing materials
Solution Approach 1:
The patent removes metallic screws from the critical assembly between the contact compartment housing and the mechanical connector. Instead, it uses a snap-fit design where the contact compartment housing is elastically deformable and can be inserted into and retained by the mechanical connector without metallic fasteners, thereby eliminating the flashover risk while maintaining mechanical strength.
Solution Approach 2:
The patent introduces an intermediate elastic material (the elastically deformable contact compartment housing itself) that acts as both a structural component and a fastening mechanism. This elastic housing deforms during assembly to engage with the mechanical connector, providing both mechanical strength and dielectric protection without requiring metallic screws.
2Ease of manufacture
If the connector design uses traditional assembly methods with screws and gaps, then the manufacturing simplicity is improved, but the protection against dust and water ingress deteriorates
Solution Approach 1:
The patent employs a nested design where the contact compartment housing is inserted into the mechanical connector, and the entire connector assembly is then inserted into the charging station's receiving structure. This nested arrangement eliminates gaps between components, providing IP67 or IP68 protection against dust and water ingress while maintaining manufacturing simplicity through elastic snap-fit assembly.
Solution Approach 2:
The patent uses an elastically deformable contact compartment housing that acts as a flexible shell. This elastic housing deforms during assembly to create a tight seal within the mechanical connector, preventing dust and water ingress without requiring complex gaskets or sealing mechanisms, thus maintaining ease of manufacture.
3Stability of the object's composition
If metallic fixing components are used close to electrical contacts, then the assembly stability is improved, but the risk of flashover and mechanical damage to electrical components increases
Solution Approach 1:
The patent completely removes metallic fixing components from the assembly near electrical contacts. The contact compartment housing is retained solely through elastic deformation and geometric interlocking with the mechanical connector, eliminating the flashover risk while maintaining assembly stability through the elastic retention mechanism.
Solution Approach 2:
The patent employs a disposable-like design where the entire contact compartment housing is designed as a single-use elastic component that is inserted and retained without metallic fasteners. This approach prioritizes safety by eliminating metallic components near electrical contacts, accepting that the housing may need replacement rather than repair.
Data Source
Figure 1
Figure 2
AI summary
According to a first aspect, a charging connector (100) for charging a battery of a vehicle (206) is provided. The charging connector (100) comprises a contact compartment housing (106), which is configured to form at least one contact compartment for hosting electrical contacts (106) to provide a connection between a charging station (204) and a vehicle (206), an external mechanical connector (102), an internal mechanical connector (104). The internal mechanical connector (104) encloses the contact compartment housing (106), and the external mechanical connector (102) encloses the internal mechanical connector