EV Charge Port Lockout Housing With Clip-Secured Plug Blocking
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Solution Overview
Problem
Existing electric vehicle (EV) lockout devices do not effectively prevent access to charge ports or charge plugs, lacking mechanisms to secure them during maintenance, repairs, or to prevent unauthorized use.
Innovation Solution
The development of EV lockout devices comprising housings and clips that engage with the charge port or plug, featuring flanges, channels, and guide rails to secure a lock, ensuring the charge port or plug is locked and inaccessible during maintenance or unauthorized use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If prior art lockout devices are used to lock the socket housing, then the charge port is locked, but access to the charge port is not prevented and charge plugs are not protected
Solution Approach 1:
The lockout device is designed with a universal housing that can accommodate different types of charge plugs (CCS Type 1, CCS Type 2, J1772, NACS/Tesla) through a standardized interface. The housing includes a base with front and back sides, flanges for engagement, and a clip support unit that can secure various plug types, making the device applicable to multiple charging components across different EV standards.
Solution Approach 2:
The lockout device is divided into distinct functional segments: a base portion for structural support, flanges for mechanical engagement with the charge port housing, a clip support unit for securing the charge plug, and openings for lock shackle passage. This segmentation allows each component to perform its specific function effectively while working together to provide comprehensive protection.
2Reliability
If a lockout device is installed to prevent unauthorized charging, then security is improved, but the device complexity increases
Solution Approach 1:
The lockout device combines multiple protective functions into a single integrated housing structure. The base, flanges, clip support unit, and lock openings are merged into one cohesive component that provides both physical locking capability and structural support, reducing the need for multiple separate protective devices while maintaining security effectiveness.
Solution Approach 2:
The lockout device is designed to be self-installing through the clip support unit that secures the charge plug in place, and self-securing through the integrated flange and ridge structures that engage with the charge port housing. The device works with standard padlocks and shackles, allowing users to complete the security function without requiring complex installation procedures or specialized tools.
3Reliability
If the housing structure includes multiple flanges and guide rails for secure engagement, then the locking reliability is improved, but the manufacturing complexity increases
Solution Approach 1:
The flanges, ridges, and guide rails are pre-formed as integral parts of the housing structure during manufacturing. The base includes pre-configured engagement features that automatically align with corresponding features on the charge port housing or charge plug, ensuring reliable engagement without requiring additional assembly steps or complex post-manufacturing adjustments.
Data Source
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Figure 2B
AI summary
An electric vehicle (EV) lockout device including a clip and a housing. The housing having a base with a front side and a back side. A first flange extends from the front side of the base and is configured to engage with an EV charge port or EV charge plug. A clip support unit extending from the back side of the base. The clip support unit including a first side plate having a first top end, a first bottom end, and a first opening disposed between the first top end and the first bottom end, and a second side plate having a second top end, a second bottom end, and a first opening disposed between the second top end and the second bottom end. The second side plate being disposed substantially parallel to the first side plate, and the second opening being substantially aligned with the first opening.