Integrated EV Charging Plug With Cooling Ducts and Clean Contacts
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Solution Overview
Problem
Existing charging station systems for electric vehicles face challenges in providing a reliable and compact solution for both electric and thermal energy transfer, often resulting in complex and bulky designs that complicate connections and cooling efficiency.
Innovation Solution
A charging station with a charger plug featuring a dual-connector design, where electric and fluid connectors are integrated on protrusions that align with corresponding recesses in the charging receiver, enabling simultaneous and efficient electrical and cooling connections, and a protective housing with cleaning mechanisms to maintain contact integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate electric and fluid connectors are used, then electrical connection and cooling connection are provided, but the device becomes bulky and complex
Solution Approach 1:
The patent combines the electric connector and fluid connector into a single integrated connector assembly. The electric contacts and fluid inlet/outlet ducts are arranged on the same protrusion structure, allowing both electrical and thermal connections to be established simultaneously through a single coupling action, thereby reducing device complexity while maintaining connection reliability
2Reliability
If multiple separate connectors are used, then all connections are provided, but the charging station size increases
Solution Approach 1:
The electric connector and fluid connector are merged into a single integrated structure where both connectors share common components such as the housing and protrusion structure. This integration significantly reduces the overall volume of the charger plug while ensuring that both electrical and cooling connections are reliably established
3Ease of operation
If electric contacts are exposed, then electrical connection is established, but contact integrity deteriorates due to contamination
Solution Approach 1:
The cleaning mechanisms are positioned to automatically clean the electric contacts before the coupling operation is completed. This preliminary cleaning action removes contaminants that would otherwise interfere with electrical connection, ensuring both ease of operation and long-term reliability of the contact interface
4Reliability
If protection housing is added, then contact protection is provided, but insertion complexity increases
Solution Approach 1:
The protection housing for the electric connector and the protection housing for the fluid connector are merged into a single integrated protection structure. This unified housing is opened by a single operation triggered by the insertion process, thereby providing comprehensive protection while maintaining simplicity of operation
Data Source
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AI summary
This invention relates to a charger plug (2) comprising a first electric connector (4) comprising first and second electric contacts (5, 5'), to be coupled with a second electric connector (7) of a charging receiver (8) to connect the first and second electric contacts (5, 5') with first and second electric contacts (6, 6'), comprising a first fluid connector (9) comprising a first fluid inlet duct (10) and a second fluid outlet duct (11), to be coupled with a second fluid connector (12) of the charging receiver (8) to connect the first fluid inlet duct (10) with a third fluid outlet duct (13) and the second fluid outlet duct (11) with a fourth fluid inlet duct (14), the first and second electric contact (5, 5') are located on first and second protrusions, the first fluid inlet duct (10) and the second fluid outlet duct (11) passing respectively through the first and second protrusion.