EV Charging Connector Drainage Channels for Creep Current
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Solution Overview
Problem
Existing electrical plug type connectors for electric or hybrid vehicle charging sockets fail to adequately comply with safety requirements for high voltages and moisture resistance, particularly in coastal climates, as they do not effectively isolate drainage paths from each other and other current-carrying contacts, leading to potential creep current issues.
Innovation Solution
The connectors feature separate, integrally formed drainage channels for each contact chamber, preventing fluid contact and ensuring reliable creep current resistance by isolating drainage paths, which are also designed to be cost-effective and easier to assemble.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If drainage openings are provided in contact chambers to discharge water, then water discharge capability is improved, but creep current resistance deteriorates due to potential electrical connection between drainage paths
Solution Approach 1:
The drainage system is segmented into separate drainage channels for each contact chamber. Each drainage channel is isolated from others and from current-carrying contacts, preventing electrical connection between drainage paths while maintaining water discharge capability. This segmentation resolves the contradiction by allowing water discharge without creating creep current paths.
Solution Approach 2:
The drainage function is extracted and separated from the contact chambers and current-carrying paths. Drainage channels are formed as distinct, isolated pathways that do not intersect with electrical contacts, thereby removing the potential for electrical connection while preserving water discharge functionality.
2Reliability
If separate drainage channels are formed integrally in housing, then creep current resistance is improved, but manufacturing complexity increases
Solution Approach 1:
The drainage channels are merged into the housing structure as integral features formed during housing manufacturing. By combining the drainage function with the housing itself rather than adding separate components, the design achieves complex drainage pathways without increasing assembly complexity or part count.
Solution Approach 2:
The housing structure serves multiple functions: it provides mechanical protection, structural support, and integrated drainage pathways. This multi-functionality reduces the need for separate drainage components, simplifying manufacturing while maintaining creep current resistance through properly designed drainage channels.
3Reliability
If drainage channels are isolated from current-carrying contacts, then safety is improved, but air exchange capability deteriorates
Solution Approach 1:
Different regions of the housing have different qualities: areas near contacts provide electrical isolation while areas away from contacts provide air exchange pathways. The drainage channels are designed with local quality variations that allow air passage in non-critical zones while maintaining electrical isolation in critical zones near current-carrying contacts.
Solution Approach 2:
The housing material itself acts as an intermediary that allows air exchange while providing electrical isolation. The non-conductive housing material enables air pathways to pass through it without creating electrical connection, serving as both a mechanical structure and an electrical insulator that mediates between the need for air exchange and contact safety.
Data Source
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AI summary
The present invention relates to an electrical plug type connector for electrically contacting a mating connector, as required in particular as a charging socket for an electric or hybrid vehicle. The plug type connector (100) has an electrically insulating housing (102) having at least two contact chambers (108a-e) and at least two power contact elements (112) which are each received in one of the contact chambers (180a-e). Each of the contact chambers (108a-e) is connected to a separate drainage channel (132a-e) for discharging fluids from the plug type connector (100), and each of the drainage channels (132a-e) is formed in the housing (102) integrally and in a state separated from the at least one other drainage channel, respectively.