EV Charger Extension Plug Layout for Full-Contact Safety
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Solution Overview
Problem
Current charger extension cables for electric vehicles have inefficiencies in charging due to incomplete electrical contact and safety concerns caused by symmetrical pin arrangements, leading to reduced charging efficiency and increased danger.
Innovation Solution
The design features a male plug and female receptacle with circular cross-sections for the ground, live, and neutral pins/sockets, arranged asymmetrically to ensure complete contact and foolproof protection, enhancing charging efficiency and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If flat or polygonal cross sections of male plug and female receptacle are used, then manufacturing is simpler, but electrical contact is incomplete reducing charging efficiency
Solution Approach 1:
The patent applies circular cross-sections to the pins and sockets instead of flat or polygonal shapes. This curvature principle ensures that the pins can rotate freely and make complete contact with the corresponding sockets, achieving 360-degree electrical contact. This resolves the contradiction by maintaining manufacturing simplicity while dramatically improving charging efficiency through complete electrical contact.
2Ease of manufacture
If symmetrical arrangement of pins and sockets is used, then manufacturing and assembly is easier, but foolproof protection is eliminated increasing safety hazards
Solution Approach 1:
The patent implements an asymmetrical arrangement where the positions of the live wire pin and neutral pin relative to the ground pin are different. Specifically, the live wire pin is positioned at a first angle and the neutral pin at a second angle, creating an asymmetric configuration. This asymmetry provides foolproof protection by preventing incorrect insertion, as the pins can only make proper contact in the correct orientation, thereby eliminating safety hazards while maintaining ease of manufacture.
Data Source
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AI summary
A male plug and a female receptacle of a charger extension cable for electric vehicles is configured to be connected between a home electric circuit and a charging gun of a respective one electric vehicle, and the male plug and the female receptacle of the charger extension cable contains: a body of the charger extension cable. The body of the charger extension cable includes a first extension cord connected with a first male plug, and the first male plug is electrically connected with the home electric circuit having an incoming terminal electrically connected with a current output end of a main power switch of the home electric circuit in a power outgoing direction. The incoming terminal has a first female receptacle connected, and the first female receptacle is electrically connected with the first male plug of the first extension cord.