Translucent Polycarbonate Housing for EV Charging Connectors
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Solution Overview
Problem
Existing charging connection devices for electric vehicles are complex, costly, and often bulky, requiring significant manufacturing effort and assembly, which limits their market acceptance and potential due to high production costs and weight, while also posing safety concerns with live electrical components.
Innovation Solution
A charging connection device with a housing partially or entirely made of injection-molded plastic parts, featuring a translucent polycarbonate front wall for enhanced safety and aesthetics, which reduces manufacturing complexity and costs while maintaining high mechanical robustness and electrical insulation, minimizing the risk of electrical shock and mechanical damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If charging connection devices use traditional metal housings to ensure mechanical strength and safety, then protection against electrical shock and mechanical damage is improved, but manufacturing complexity and costs increase significantly
Solution Approach 1:
The patent replaces expensive metal housings with injection-molded plastic housings, using a cost-effective material that can be manufactured easily through molding processes. The housing is designed as a single-piece or minimally assembled plastic structure that provides sufficient protection for the charging device while dramatically reducing manufacturing complexity and cost.
Solution Approach 2:
The patent changes the material parameter from metal to plastic, specifically using polypropylene or similar polymers that can be injection-molded. This parameter change maintains the protective function while enabling simpler, more cost-effective manufacturing processes and reducing assembly requirements.
2Strength
If charging connection devices use solid metal housings to ensure mechanical strength, then breaking strength is improved, but weight increases
Solution Approach 1:
The patent changes the material density parameter by replacing metal with plastic, significantly reducing the weight of the housing while maintaining adequate mechanical strength through optimized plastic formulation and structural design in the injection-molded housing.
3Productivity
If charging connection devices use injection-molded plastic housings to reduce manufacturing costs, then production efficiency is improved, but perceived safety and robustness may worsen
Solution Approach 1:
The patent uses composite plastic materials, specifically polypropylene reinforced with glass fibers or other additives, that combine the manufacturing advantages of plastic injection molding with enhanced mechanical properties. This composite approach maintains perceived robustness and safety while enabling cost-effective mass production through injection molding.
Solution Approach 2:
The patent modifies the plastic material parameters by using reinforced polymers or specific formulations that enhance strength and durability, allowing injection-molded housings to achieve perceived robustness comparable to traditional metal constructions while maintaining manufacturing efficiency.
Data Source
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AI summary
The invention relates to a charging connection device (1) for electric vehicles, comprising at least one first interface (10) to feed electrical power from a fixed power supply network into the charging connection device (1), comprising at least one second interface (12) for controlled output of electrical power to an electric vehicle, comprising a plurality of electro-technical components for switching, measuring or monitoring the received and/or the output electrical power and comprising a multi-part housing (3) enclosing the electro-technical components. At least one control output element (40) is provided at least for signalling states of the charging connection device (1) to an operator. At least one first housing part (16), which defines at least subsections of the front face (18) of the housing, is formed as an injection moulded plastic part (24), the plastic forming at least the first housing part (16) having limited light-permeability, such that a light beam from an optical display or signalling means (41) positioned in the housing (3) can be visually perceived through the plastic of the first housing part (16).