EV Charging Socket Heating Element for Ice Prevention

Solution Overview

Problem

Charging sockets for electric vehicles are predominantly passive, leading to difficulties in extreme weather conditions, such as freezing temperatures, where moisture ingress, icing, and ice formation can hinder the charging process or prevent plug insertion.

Innovation Solution

Incorporating a heating element, preferably an electrical resistance heating element, into the charging socket to actively control temperature, ensuring the contact sections remain functional and ice-free, even in low temperatures, by using heat conduction and transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a passive charging socket is used, then the device complexity is low and manufacturing is simple, but the reliability deteriorates in extreme cold conditions due to icing and moisture ingress

Engineering Contradiction:

Improvecharging reliabilityVSAvoidsocket structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The heating element is activated before the charging plug is inserted to pre-heat the contact section and prevent ice formation. This preliminary action ensures the charging interface is ready for use in cold conditions without waiting for plug insertion to trigger heating.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The physical state of the contact section is changed from cold to warm by introducing thermal energy through the heating element. This parameter change (temperature) prevents phase change of moisture from liquid to solid (ice), thereby maintaining charging functionality.

Inventive Principle:

Principle #35Parameter changes

2Ease of operation

If no heating element is provided, then the device complexity and energy consumption are low, but the ease of operation deteriorates in freezing temperatures due to difficult plug insertion

Engineering Contradiction:

Improveplug insertionVSAvoidsocket structure

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The heating element is activated before the charging plug is inserted to pre-heat the contact section and prevent ice formation. This preliminary action ensures the charging interface is ready for use in cold conditions without waiting for plug insertion to trigger heating.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The mechanical problem of ice blocking plug insertion is solved by replacing it with a thermal system. Instead of mechanically removing ice, a heating element melts the ice through thermal energy, making plug insertion easy without mechanical intervention.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If a heating element is added to the charging socket, then the reliability in cold conditions improves, but the device complexity and manufacturing cost increase

Engineering Contradiction:

Improvecharging reliabilityVSAvoidsocket manufacturing

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The heating element is designed to be self-regulating, activating automatically when cold conditions are detected and deactivating when the target temperature is reached. This self-service capability reduces the need for complex control systems and manual intervention, simplifying the overall manufacturing process.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The mechanical problem of ice blocking plug insertion is solved by replacing it with a thermal system. Instead of mechanically removing ice, a heating element melts the ice through thermal energy, making plug insertion easy without mechanical intervention.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The heating element ensures reliable and efficient charging by preventing mechanical blockages due to ice or snow, allowing for easy plug insertion and maintaining a defined temperature for effective charging, even in extreme weather conditions.

Implementation Method 1

the main body has at least one heating element for heating the at least one contact section

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

an electrical resistance heating element, into the charging socket to actively control temperature

Methodology Applied

Scientific EffectElectrical resistance: Electrical Resistance

Implementation Method 3

by using heat conduction and transfer

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Implementation Method 4

by using heat conduction and transfer

Methodology Applied

Scientific EffectHeat transfer: Convection

Data Source

PatentUS11203264B2Charging socket for an electrically driven vehicle

Publication Date: 2021.12.21 DR ING H C F PORSCHE AG

AI summary

Charging socket for an electrically driven vehicle, having a main body with at least one contact section having electrical contacts for receiving in an interlocking manner a mating contact section of a charging plug having electrical mating contacts for forming an electrical charging connection between the electrical contacts and the electrical mating contacts, wherein the main body has at least one heating element for heating the at least one contact section.