EV Charging Connector Docking Station with Elongated Latching Recess
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Solution Overview
Problem
The existing electric vehicle charging station docking stations face difficulties in properly aligning and stowing the J1772 electrical connector due to the heavy gauge of the power cord, making it cumbersome for users to dock the connector correctly.
Innovation Solution
The docking station features an elongated arched latching recess that allows the connector's latching element to be engaged anywhere along its length, ensuring secure latching and easy stowage without requiring precise alignment, facilitated by a latching flange extending along the recess and a biasing spring for smooth engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the power cord is made with heavy gauge to handle high current charging, then the current carrying capacity is improved, but the ease of alignment and docking of the connector becomes worse
Solution Approach 1:
The latching recess is segmented into multiple zones along its elongated path, allowing the connector to be received at different positions. This segmentation enables the heavy gauge power cord to be docked successfully even when alignment is not perfect, as the latching element can engage at multiple locations along the recess.
Solution Approach 2:
The latching recess extends in a linear dimension rather than being a single-point receptacle. This dimensional extension transforms the docking interface from a precise point-to-point connection to a line-to-point connection, providing tolerance for misalignment while maintaining secure latching.
2Ease of operation
If the latching element is extended to provide alignment tolerance, then the ease of docking is improved, but the precision of latching engagement may be compromised
Solution Approach 1:
Different portions of the elongated latching recess have different functional qualities. The recess provides alignment tolerance in the longitudinal direction while maintaining precise lateral positioning through the latching flange and wall structures. This local differentiation of quality allows both ease of docking and secure latching to coexist.
Solution Approach 2:
The latching flange acts as an intermediary element that translates the extended engagement of the latching element into secure latching. The flange provides a bearing surface that ensures proper positioning and engagement force distribution, maintaining latching precision despite the extended interaction length.
Data Source
AI summary
A docking station for stowing an electrical connector adapted to connect a power source to a re-chargeable battery in a vehicle powered at least partially by the battery. The connector has a first end connected to a power cable for coupling the connector to the power source, and a second end that includes multiple first electrical terminals adapted to engage mating second electrical terminals in a receptacle. The second end also includes a protruding latching element adapted to engage a cooperating latching element in a receptacle for latching the connector to the receptacle. A stowing receptacle adapted to receive the second end of the connector when the connector is not in use includes an elongated recess adapted to receive the protruding latching element when the protruding latching element is located anywhere along the length of the elongated recess.