EV Charging Connector with Nested Enclosures for Dielectric Insulation
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Solution Overview
Problem
Current electric vehicle charging connectors face issues with insufficient dielectric insulation, leading to potential corrosion and leakage currents due to environmental influences, and have a short life cycle due to mechanical and electrical damage.
Innovation Solution
The charging connector design includes sealed independent compartments, a robust external enclosure, and a locking mechanism, with exchangeable contacts and a modular structure to enhance protection against environmental factors and facilitate maintenance, utilizing gaskets and resin for insulation and mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If current connector designs are used, then manufacturing simplicity is maintained, but dielectric insulation is insufficient leading to corrosion and leakage currents
Solution Approach 1:
The patent implements a nested enclosure structure where an internal enclosure is placed inside an external enclosure, creating multiple layers of protection. The internal enclosure houses the contact elements and provides first-level insulation, while the external enclosure provides second-level protection. This nested arrangement significantly enhances dielectric insulation and protects against corrosion and leakage currents without overly complicating the overall connector design.
Solution Approach 2:
The connector is segmented into distinct functional modules: contact elements, internal enclosure, external enclosure, and sealing components. This segmentation allows each component to be optimized for its specific function while maintaining overall reliability. The modular structure enables independent replacement and maintenance of individual components, addressing the reliability improvement need while managing complexity through functional separation.
2Reliability
If robust protection against environmental factors is implemented, then reliability is improved, but connector life cycle remains short due to mechanical damage and material fatigue
Solution Approach 1:
The patent incorporates a locking mechanism that dynamically secures the internal enclosure to the external enclosure, providing robust mechanical protection while allowing for controlled assembly and disassembly. This dynamic locking system prevents accidental opening during use (extending life cycle) but can be deliberately engaged/disengaged for maintenance, balancing protection needs with longevity requirements.
Solution Approach 2:
The nested enclosure structure provides beforehand cushioning by creating buffer zones between the environment and sensitive internal components. The sealing elements and multiple enclosure layers preemptively protect against environmental factors before they can cause damage, reducing stress on materials and extending the overall life cycle of the connector.
3Ease of repair
If exchangeable parts are implemented, then ease of maintenance is improved, but device complexity increases
Solution Approach 1:
The connector is divided into exchangeable modules (contact elements, internal enclosure, external enclosure) that can be independently replaced. This segmentation enables easy maintenance by allowing technicians to swap out specific components without replacing the entire connector, improving ease of repair while managing complexity through standardized modular interfaces.
Solution Approach 2:
The locking mechanism provides dynamic connectivity, allowing the enclosures to be securely locked during operation for reliability, but easily unlocked for maintenance. This dynamic feature enables the exchangeable parts design to switch between two states: firmly connected for protection and easily separable for repair, balancing ease of maintenance with controlled complexity.
Data Source
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AI summary
The invention relates to a charging connector for an electric vehicle comprising an internal connector (101), a mating interface (120), and an external enclosure (18). The internal connector (101) comprises at least two contact elements (102, 104), each configured to receive a charging wire (106, 108) on a first end and a contact on a second end, and to hold the contact. The internal connector (101) comprises further a contact holder (110) surrounding the connection elements and a front part of the connectors and which is configured to hold a potting cap (116) and the front part of the contacts. The internal connector (101) comprises further the potting cap (116) configured to receive a back part of the contact holder (110). The potting cap (116) is further configured to cover the back part of the internal connector (101) and a cable part containing the charging wires. The internal connector (101) comprises further a mating interface (120) covering the front part of the internal connector (101) and which is configured to receive a front part of the contact holder (110), and an external enclosure (118) consisting of two half shells and configured to cover a back part of the contact holder (110) and the potting cap (116). The mating interface (120) and the external enclosure (118) cover the potting cap (116) and are exchangeable.