Heated EV Charge Coupler for Snow and Ice-Free Connection
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Solution Overview
Problem
Electric vehicle (EV) charging stations face interference from snow and ice accumulation on the charge coupler during cold weather, which can hinder proper connection and user comfort.
Innovation Solution
Integration of a heating element within the charge coupler, controlled by sensors to detect environmental conditions, selectively heats the coupler to melt snow and ice, ensuring reliable charging and user comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a charge coupler is exposed to cold winter weather, then it is accessible for outdoor charging operations, but snow or ice accumulates on the charge coupler interfering with proper connection
Solution Approach 1:
The heating element is activated before the charging connection is made to preemptively melt snow and ice on the charge coupler. The controller detects cold environmental conditions and activates heating in advance, ensuring the coupler surfaces are clear of ice/snow before the user attempts connection, thus preventing connection interference while maintaining outdoor accessibility
Solution Approach 2:
The heating element converts the harmful cold temperature that causes ice accumulation into a beneficial warming effect. By actively heating the charge coupler, the system transforms the adverse cold weather condition into a controlled thermal environment that prevents ice formation and ensures reliable connection surfaces
2Ease of operation
If a charge coupler is exposed to cold winter weather, then it is accessible for outdoor charging operations, but user comfort is reduced when grasping the cold coupler
Solution Approach 1:
The heating element is specifically positioned within the handle portion of the charge coupler where the user grasps it. This localized heating approach warms only the user-contact area without requiring heating of the entire coupler assembly, thereby improving user comfort while maintaining outdoor accessibility and minimizing energy consumption
3Reliability
If a heating element is added to the charge coupler, then snow and ice are melted ensuring reliable charging, but device complexity increases
Solution Approach 1:
The heating element is integrated within the existing charge coupler housing and handle structure rather than being added as a separate external component. The heating element, controller, and power supply are merged into the coupler's internal architecture, ensuring the added heating functionality does not significantly increase overall device complexity while maintaining reliable charging operations in cold weather
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
Prevents interference from snow and ice accumulation, ensuring reliable charging operations and enhancing user comfort by maintaining the charge coupler at a warm temperature during cold weather conditions.
Implementation Method 1
the heating element includes a resistive heating element, e.g., a wire or coil
Implementation Method 2
selectively heating the charge coupler to help melt accumulated snow and ice
Data Source
AI summary
An electric vehicle supply equipment (EVSE) charging station for charging a propulsion battery pack of an electric vehicle (EV) includes a charging cabinet, an electrical cable, and a charge coupler. The charging station is operable for providing a charging voltage or current to the battery pack during a charging operation. The electrical cable has a distal end connected to the charging cabinet. The charge coupler is connected to a proximal end of the electrical cable and connects to a charge receptacle of the EV. The charge coupler includes at least one heating element connected to the charge coupler. The heating element is configured to selectively heat the charge coupler in response to the environmental state being indicative of accumulated snow or ice on the charge coupler.