EVSE Power Cord Sealing and Strain Relief Against Fluid Intrusion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electric vehicle supply equipment (EVSE) power supply cords, particularly those operating at 120 VAC, require extended charging times for electric vehicle batteries, and there is a need for enhanced resistance to fluid intrusion to prevent corrosion and damage.
Innovation Solution
The EVSE power supply cord incorporates a wire cable with separate conductors, plug and socket terminals, and a combination of injection moldable polymers and thermoplastic elastomers for the plugs and sockets, along with in-mold bonding adhesives to provide strain relief and improved resistance to fluid intrusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If a 120VAC power supply cord is used, then the charging time is extended, but the charging speed is reduced
Solution Approach 1:
The patent applies parameter changes by switching the voltage parameter from 120VAC to 240VAC in the power supply cord. This voltage parameter change directly resolves the contradiction by reducing charging time while increasing charging speed, as the 240VAC configuration provides higher power delivery to the vehicle battery.
2Reliability
If traditional power supply cord construction is used, then manufacturing is simpler, but resistance to fluid intrusion is reduced
Solution Approach 1:
The patent applies composite materials by combining multiple materials in the power supply cord construction: the inner plug uses an injection moldable polymer for fluid tightness, while the outer plug uses a thermoplastic elastomer for strain relief and durability. This composite approach resolves the contradiction by achieving superior fluid intrusion resistance through material properties, while the injection molding process maintains manufacturing feasibility.
Solution Approach 2:
The patent applies the nested doll principle by placing the inner plug inside the outer plug, creating a nested structure. The inner plug provides fluid intrusion resistance, while the outer plug provides strain relief. This nested configuration resolves the contradiction by layering protective functions without significantly complicating the manufacturing process, as both plugs are formed using injection molding.
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
This design reduces battery charging time by up to 50% for 240 VAC options and enhances the durability of the cord by preventing fluid intrusion, thus protecting internal components from corrosion.
Implementation Method 1
in-mold bonding adhesive disposed intermediate the connection between the plurality of plug terminals and the plurality of separate conductors and the molded inner plug
Implementation Method 2
the molded inner plug is formed of an injection moldable polymer
Implementation Method 3
the molded outer plug is formed of a thermoplastic elastomer... the molded outer plug is shaped to provide strain relief between the molded inner plug and the wire cable
Data Source
AI summary
An electrical power supply cord includes a wire cable comprising a plurality of separate conductors, a plurality of plug terminals connected to the plurality of separate conductors, a molded inner plug encasing a connection between the plurality of plug terminals and the plurality of separate conductors, and an in-mold bonding adhesive disposed intermediate the connection between the plurality of plug terminals and the plurality of separate conductors and the molded inner plug.