Hinged Seal Cap Structure for Contaminant-Protected EV Connectors
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Solution Overview
Problem
Electrical connectors in electric vehicles face degradation in charging performance due to contamination from dirt and moisture, which compromises the integrity of the charging terminals and contacts.
Innovation Solution
A hinged seal cap system that covers multiple cable openings, featuring a split body configuration with locking mechanisms, designed to be fitted over conductive cables after installation, providing a secure seal against contaminants and strain relief.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the electrical connector is left open for charging operations, then charging accessibility and ease of operation are improved, but the connector is exposed to dirt, moisture and contaminants that degrade charging performance
Solution Approach 1:
The seal cap is designed as a movable protective cover that can dynamically open to allow charging cable insertion and closing to seal the connector. The hinge mechanism enables the cap to transition between open and closed positions, providing dynamic protection rather than a fixed state.
Solution Approach 2:
The seal cap acts as an intermediary element between the electrical connector and the external environment. It provides a physical barrier that can be selectively applied, mediating between the need for charging access and the need for contaminant protection.
2Object-affected harmful factors
If a fixed seal cap is used to protect the connector, then protection against contaminants is improved, but accessibility for charging operations deteriorates
Solution Approach 1:
The seal cap transforms from a static protective cover to a dynamic one that can open and close. The hinge mechanism allows the cap to be moved between a closed position for protection and an open position for charging access, resolving the contradiction between protection and accessibility.
3Manufacturing precision
If multiple separate cap components are used to cover each cable opening, then sealing precision is improved, but device complexity increases
Solution Approach 1:
Multiple separate cap components that would individually cover each cable opening are merged into a single integrated seal cap structure. This unified cap covers multiple cable openings simultaneously, reducing the number of parts while maintaining sealing effectiveness through its continuous peripheral wall design.
Solution Approach 2:
The single seal cap performs multiple functions: it seals multiple cable openings, provides strain relief for multiple cables, and offers structural support. This multi-functional design eliminates the need for separate components for each cable opening.
Data Source
AI summary
A cap for an electrical connector comprises a first cap body defining a first portion of a first circular opening, and a second cap body defining a second portion of a first circular opening. The second cap body is hingedly connected to the first cap body and movable between an open position and a closed position. In the closed position, first and second portions of the first cap body and the second cap body define a circular opening sized to receive a conductive cable therethrough.