EVSE Cable Non-Symmetrical Gap Extrusion for Torsional Strength

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing electric vehicle supply equipment (EVSE) cables lack sufficient torsional strength, moisture resistance, and stability due to conventional cylindrical fiberglass fillers, which fail to effectively fill gaps between conductor wires and prevent water ingress.

Innovation Solution

The EVSE assembly incorporates a cable with a non-symmetrical gap extrusion made of thermoplastic elastomer (TPE) material, extending helically along the conductor wires to create concave grooves, providing a staggered extrusion process that enhances torsional strength and stability while reducing capillary action and water ingress.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional cylindrical fiberglass fillers are used in EVSE cables, then the cable structure is simple to manufacture, but the torsional strength and moisture resistance are insufficient

Engineering Contradiction:

Improvetorsional strengthVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent applies asymmetry by transitioning from conventional cylindrical (symmetrical) fiberglass fillers to non-symmetrical gap extrusions with irregular cross-sectional shapes. This non-symmetrical geometry interlocks with the conductor wire bundle, significantly enhancing torsional strength and resistance to cable deformation while maintaining manufacturability through extrusion processes.

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The patent employs composite materials by combining TPE (thermoplastic elastomer) or PVC (polyvinyl chloride) materials with fiberglass reinforcement within the gap extrusion structure. This composite approach provides both the structural integrity for torsional strength and the manufacturing feasibility through extrusion, resolving the contradiction between strength and ease of manufacture.

Inventive Principle:

Principle #40Composite materials

2Stability of the object's composition

If conventional cylindrical fiberglass fillers are used in EVSE cables, then the manufacturing process is simple, but the cable stability and water ingress prevention are inadequate

Engineering Contradiction:

Improvecable stabilityVSAvoidstructure complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The non-symmetrical cross-sectional shape of the gap extrusion creates an irregular configuration that interlocks with the conductor wire bundle, providing superior cable stability and positioning. This asymmetrical design prevents cable degradation and maintains structural integrity during flexing and torsion, while the extrusion process keeps manufacturing relatively simple.

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The patent applies local quality by designing the gap extrusion with specific non-symmetrical geometries tailored to fill particular gap configurations between conductor wires. This localized optimization of the filler shape provides enhanced stability and water ingress prevention at critical locations without requiring complex overall cable restructuring.

Inventive Principle:

Principle #3Local quality

3Reliability

If conventional fillers are used in EVSE cables, then the cable structure is simple, but the gap filling effectiveness and capillary action prevention are insufficient

Engineering Contradiction:

Improvewater ingress preventionVSAvoidfiller structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The non-symmetrical gap extrusion design creates an irregular surface profile that effectively fills gaps between conductor wires and disrupts capillary action pathways. This asymmetrical geometry prevents water ingress by eliminating continuous capillary channels, achieving superior reliability without requiring overly complex multi-component structures.

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The patent utilizes materials with controlled porosity characteristics, where the non-symmetrical gap extrusion creates a structure that manages fluid pathways. The irregular geometry and material selection work together to prevent capillary action and water ingress, enhancing reliability while maintaining reasonable structural complexity through a single integrated extrusion component.

Inventive Principle:

Principle #31Porous materials

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 non-symmetrical gap extrusion in EVSE cables significantly improves torsional strength, moisture resistance, and stability, outperforming conventional fillers by maintaining structural integrity and preventing water ingress, thus ensuring reliable charging operations.

Implementation Method 1

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Data Source

PatentUS11453300B2Electric vehicle supply equipment cables with gap extrusions

Publication Date: 2022.09.27 FORD GLOBAL TECH LLC

AI summary

This disclosure describes electric vehicle supply equipment (EVSE) assemblies for use when charging plug-in electrified vehicles. An exemplary EVSE assembly may include a charger coupler and a cable connected to the charger coupler. The cable may include a plurality of conductor wires and a gap extrusion positioned within a gap between the plurality of conductor wires. The gap extrusion may include a non-symmetrical cross-sectional shape and may be made of a thermoplastic elastomer (TPE) material. The cable may be manufactured in a staggered extrusion process in which the gap extrusion is fed into a gap of a wound conductor wire bunch of the cable.