EV Charging Center Pad Layout for Standardized Provisioning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The installation of electric vehicle (EV) charging stations faces challenges due to differences in vendor-specific provisioning, leading to inefficiencies, safety hazards, and delays, as well as rusting issues with ferrous metallic housings when supported on concrete surfaces.
Innovation Solution
A standardized provisioning system using a precast concrete center pad with integrated power and communications conduit stub-ups, central and outer junction boxes, and raceways, which allows for modular and repeatable installations, elevates chargers for safety, and includes non-metallic components to prevent rusting and trip hazards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If vendor-specific ad hoc provisioning is used for each EV charging dispenser, then the installation can be tailored to specific dispenser requirements, but it results in considerable time, work and expense for installation, and delays that jeopardize EV readiness by the fixed launch date
Solution Approach 1:
The patent implements a universal provisioning system where a single standardized electrical provisioning design can serve multiple different EV charging dispenser types from various vendors (AC level 2, DC fast charge level 3, distribution modules). This eliminates the need for vendor-specific custom installations while maintaining compatibility with different dispenser requirements through standardized electrical connections and configurations.
Solution Approach 2:
The patent employs preliminary action by pre-configuring standardized electrical provisioning designs before actual dispenser installation. The standardized provisioning includes pre-planned electrical components, conduit routing, and connection points that are ready in advance, allowing rapid deployment of multiple dispenser types without time-consuming custom installations at each site.
2Ease of manufacture
If ad hoc electrical components including exposed junction boxes and raceways are used, then the installation can be completed with standard electrical components, but it creates potential trip hazards for personnel during installation and ongoing trip hazards for vehicle drivers during operation
Solution Approach 1:
The patent extracts the hazardous exposed electrical components (junction boxes and raceways) from the ground-level installation environment and relocates them to elevated positions on walls or structures. This removes the trip hazard for both installation personnel and vehicle drivers while maintaining the functionality of the electrical system using standard components.
Solution Approach 2:
The patent transitions electrical component placement from the horizontal ground plane to the vertical dimension by mounting junction boxes and raceways on walls and vertical surfaces. This dimensional change eliminates ground-level trip hazards while preserving electrical connectivity and access for maintenance.
3Strength
If ferrous metallic housing is used for EV charging dispenser, then the housing provides structural strength and durability, but it rusts when supported directly upon concrete surface due to moisture contact, outgassing of water from concrete, or chemical reactions
Solution Approach 1:
The patent introduces a non-ferrous metallic base plate as an intermediary element between the ferrous metallic housing and the concrete surface. This base plate acts as a mediator that prevents direct contact between the rust-prone ferrous housing and the moisture-containing concrete, thereby eliminating the rusting problem while maintaining the structural strength of the ferrous housing.
Solution Approach 2:
The patent creates a composite support structure combining non-ferrous metal (rust-resistant base plate) with ferrous metal (structural housing). The non-ferrous base plate layer provides corrosion resistance at the concrete interface, while the ferrous housing maintains its structural strength, creating a composite system that leverages the advantages of both materials.
Data Source
AI summary
Provided in this disclosure is a standardized provisioning for an electrical vehicle charging station. A center pad is configured to be moved and placed on a horizontal surface at a desired location. A central junction box is formed in the center pad for receiving a power conduit stub-up and a communications conduit stub-up. The power and communications conduit stub-ups extend vertically above the horizontal surface. A plurality of outer junction boxes are formed in the center pad, each configured to provide a power connection and a communication connection to a respective plurality of electrical charging dispensers. A plurality of raceways extend through the center pad from the central junction box to each of the respective outer junction boxes to provide passageways for the power and communications connections between the stub-ups and the plurality of electrical charging dispensers.