EV Plug Cap Assembly with Adjustable Suspension
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Solution Overview
Problem
Existing electrical plug caps for electric vehicle charging cables are prone to damaging the vehicle bodywork due to wind gusts and are exposed to environmental contaminants when not in use, and the connection mechanisms are prone to failure and loss.
Innovation Solution
A plug cap assembly with a flexible connection member that allows adjustable suspension, featuring a hinged or elastic band with a point of suspension and a locking mechanism, ensuring the cap does not bump into the vehicle body and remains protected from moisture and debris.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the protective cap is suspended close to the vehicle by a rigid or fixed-length connection, then the cap is easily retained and does not dangle freely, but the cap bumps into the vehicle bodywork due to wind gusts and causes damage
Solution Approach 1:
The patent applies a flexible connection member with adjustable suspension length that allows dynamic positioning of the protective cap. The connection member can be extended or retracted to adjust the distance between the cap and the vehicle, enabling the cap to be positioned away from the vehicle body to avoid damage while maintaining secure retention through the flexible connection.
2Device complexity
If the protective cap is suspended by a fixed-length band, then the structure is simple, but the cap interior is exposed to environmental contaminants when not in use
Solution Approach 1:
The flexible connection member with adjustable length allows the cap to be positioned in different locations relative to the vehicle. By extending the connection member, the cap can be suspended away from the vehicle body and environmental contaminants, protecting the cap interior while maintaining a relatively simple overall structure.
3Reliability
If the connection mechanism is fixed and non-adjustable, then the structure is simple and reliable, but the connection element cannot be easily replaced if it fails
Solution Approach 1:
The patent segments the connection system into a permanent connection element attached to the vehicle and a replaceable flexible connection member. This segmentation allows the flexible connection member to be easily removed and replaced if it fails, while the permanent connection element remains stable and secure on the vehicle.
4Object-affected harmful factors
If the protective cap is allowed to move freely with a long suspension, then the cap does not contact the vehicle body, but the cap becomes vulnerable to loss if the band snaps
Solution Approach 1:
The adjustable flexible connection member provides optimal suspension length that positions the cap away from the vehicle body to prevent contact damage, while the flexible nature and adjustability ensure the cap remains securely connected and less vulnerable to loss compared to rigid or overly long fixed connections.
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 adjustable suspension prevents cap collision with the vehicle body, keeps the cap interior protected, and allows for easy replacement of the connection element, addressing the issues of damage and contamination.
Implementation Method 1
a flexible connection member having a first end and a second end; a flexible connection between a cap top portion and said second end
Data Source
AI summary
A plug cap assembly for use on a plug (10) comprises a plug cap (20) configured for releasable arrangement on at least a part of a plug head portion, and comprises a flexible connection member (21) having a first end and a second end, a flexible connection (23) between a cap top portion (26) and said second end, and a connection element (24; 24′) releasably connected to the plug or to a cable (9). The flexible connection member may be moved with respect to the connection element and a suspended length (1) may be adjusted such that it is less than a distance (d) between the suspension structure (25) and an adjacent vehicle body (3).