Metal-Reinforced EV Charging Socket Fastening Against Plug Impact
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Solution Overview
Problem
Charging sockets in electric vehicles are prone to damage due to high forces acting on the fastening regions during charging, particularly when impacted by a charging plug, leading to potential breakage and instability.
Innovation Solution
The housing of the charging socket is formed with a metal material in the fastening regions to enhance stability and absorb external forces, potentially combining with plastic material in a hybrid design, using metal inserts and screws or threads for secure fastening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the housing is entirely formed from plastic material, then the ease of manufacture is improved, but the strength and stability in the fastening region deteriorate under high forces
Solution Approach 1:
The housing is formed as a composite structure combining plastic material and metal material. The plastic housing provides ease of manufacture and basic structural function, while metal inserts are integrated into the fastening regions to provide the necessary strength and stability under high forces during charging operations.
Solution Approach 2:
Instead of making the entire housing from metal, the invention applies metal material locally only in the fastening regions where high strength is required. This localized reinforcement maintains ease of manufacture for the majority of the housing while providing targeted strength enhancement where needed.
2Strength
If the housing is entirely formed from metal material, then the strength is improved, but the ease of manufacture and cost deteriorate
Solution Approach 1:
The housing combines plastic and metal materials, leveraging the manufacturing advantages of plastic injection molding for the main housing body while using metal inserts only where structural strength is critical. This composite approach maintains ease of manufacture while providing necessary strength.
Solution Approach 2:
Metal material is applied locally only in the fastening regions rather than throughout the entire housing. This localized approach provides the necessary strength enhancement while minimizing the complexity and cost associated with manufacturing with metal materials.
3Ease of manufacture
If plastic housing is used, then the cost is reduced, but the reliability under high loads deteriorates
Solution Approach 1:
The hybrid plastic-metal construction provides cost-effective reliability enhancement. The plastic housing maintains low manufacturing costs, while strategically placed metal inserts in the fastening regions provide the structural reliability needed to withstand high forces during charging operations without compromising the overall cost structure.
Solution Approach 2:
Reliability is enhanced locally in the fastening regions through metal reinforcement rather than throughout the entire housing. This targeted approach provides the necessary reliability under high loads while minimizing the cost increase that would result from using metal throughout the entire housing structure.
Data Source
AI summary
A charging socket for mounting in a body of an at least partially electrically driven motor vehicle includes: a housing; at least one contact element accommodated in the housing; and at least one fastening region formed on the housing configured to fasten the charging socket to the body of the motor vehicle. The housing includes a metal material at least in regions. The housing includes the metal material at least in a region of the at least one fastening region.