EV Charging Plug Connector Latching for Axial Load Retention
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Solution Overview
Problem
Existing plug connector parts for electric vehicle charging systems face challenges in securely holding contact elements under axial loads during plugging and unplugging, which can lead to detachment and compromise the integrity and safety of the connector.
Innovation Solution
A plug connector part design featuring a housing with a first latching device and contact elements with a second latching device, where the latching element has a locking portion that engages with a locking opening on the printed circuit board, ensuring secure engagement and preventing disengagement under load, thereby maintaining contact element position and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If contact elements are designed as solid metal elements for transmitting large currents, then current transmission capability is improved, but the risk of detachment under axial load increases
Solution Approach 1:
The latching device is segmented into multiple functional components: a first latching device on the housing, a second latching device on the contact element, and a locking device that secures the latching engagement. This segmentation allows each component to perform its specific function while working together to securely retain the contact element under high current conditions.
Solution Approach 2:
The latching device is designed to engage the contact element in a preliminary manner before full insertion, with the latching element engaging the latching groove on the contact element's lateral surface. This preliminary engagement prevents detachment during the plugging process before the locking device fully secures the connection.
2Reliability
If latching devices are used to secure contact elements, then contact element retention is improved, but device complexity increases
Solution Approach 1:
The latching device combines multiple functions into an integrated mechanism: the first latching device on the housing, the second latching device on the contact element, and the locking device work together as a unified system. This merging reduces overall complexity compared to using separate, independent securing mechanisms for each function.
Solution Approach 2:
The latching device is designed to automatically engage and lock during the plugging process without requiring additional manual operations. The latching element engages the latching groove and the locking device secures the connection automatically as the plug connector part is inserted, eliminating the need for separate manual latching or securing steps.
3Reliability
If contact elements are held firmly in position to resist plugging forces, then connection reliability is improved, but the difficulty of unplugging increases
Solution Approach 1:
The latching device incorporates elastic elements that provide dynamic characteristics to the connection. The elastic latching element can deform to engage and disengage from the latching groove, allowing the connection to be secure during operation but easily released when needed. This dynamic behavior enables reliable connection during plugging while maintaining ease of unplugging.
Data Source
AI summary
A plug connector part for a charging system for charging an electric vehicle includes: a housing forming at least one plug-in portion for plug-in connection to a mating plug connector part along a plug-in direction; at least one electrical contact element arranged on the plug-in portion for transmitting an electric current; and a printed circuit board enclosed in an interior of the housing, the printed circuit board having at least one electrical or electronic functional module. The housing has a first latching device having at least one latching element, and the at least one electrical contact element has a second latching device. In a mounted position of the plug connector part, the at least one latching element of the first latching device is engaged with the second latching device of the at least one electrical contact element so as to hold the at least one electrical contact element in position.