Hot-Melt EVSE Coupler Sealing for Water and UV Resistance
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Solution Overview
Problem
Electrical connectors used for electric vehicle charging are vulnerable to water ingress, dust, UV light, impact, and chemical exposure, requiring enhanced protection while maintaining low manufacturing costs and safety compliance.
Innovation Solution
The use of hot melt adhesive to form a housing body that encapsulates the internal components, providing a water-resistant, UV-protected, and impact-resistant coupler with reduced component count, and ensuring compliance with safety standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If traditional sealing methods are used for electrical connectors, then protection against environmental hazards is provided, but manufacturing cost increases and harmful fumes are generated
Solution Approach 1:
The patent changes the physical and chemical parameters of the sealing material by using hot melt adhesive instead of traditional sealants. This substitution eliminates harmful fumes during application while maintaining protective properties against environmental hazards such as water, dust, UV light, impact, and chemical exposure.
Solution Approach 2:
The patent employs hot melt adhesive which is a cost-effective sealing solution that provides sufficient protection for the electrical connector without requiring expensive traditional sealing materials. The hot melt adhesive is applied and sets quickly, providing immediate protection without the need for expensive curing processes or materials.
2Object-affected harmful factors
If multiple components are used to protect internal connections, then environmental protection is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges multiple protective functions into a single hot melt adhesive application. The adhesive simultaneously provides sealing, bonding, cushioning, and environmental protection, eliminating the need for separate gaskets, seals, and protective components that would increase device complexity and manufacturing cost.
Solution Approach 2:
The hot melt adhesive serves multiple functions: it seals the connector housing against environmental hazards, bonds internal components in place, provides cushioning against impact, and protects against chemical exposure. This multi-functionality reduces the overall component count and simplifies the device structure.
3Object-affected harmful factors
If robust sealing materials are used to protect against environmental hazards, then protection is improved, but manufacturing cost increases
Solution Approach 1:
The patent uses hot melt adhesive as a cost-effective alternative to expensive robust sealing materials. The adhesive provides adequate protection against environmental hazards at a lower cost, and its quick-setting nature reduces manufacturing time and labor costs associated with applying and curing traditional sealants.
Solution Approach 2:
The patent changes the material selection parameters by choosing hot melt adhesive with appropriate viscosity, melting point, and adhesive strength to achieve the required protection level. This parameter optimization allows for effective sealing at lower material and manufacturing costs compared to using more expensive robust sealing 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 hot melt solution enhances the coupler's resistance to water, UV light, and chemicals, while reducing manufacturing costs and eliminating harmful fumes, ensuring safety and performance across a wide temperature range.
Implementation Method 1
the housing body encapsulates the portion of the bend relief, the one or more socket terminals, and the one or more wires connected to the one or more socket terminals
Implementation Method 2
at least a portion of the housing body may be made of hot melt
Data Source
AI summary
Systems and methods for a coupler including: a cable comprising a bend relief disposed at an end of the cable and one or more wires; a socket comprising one or more pins and one or more socket terminals, where the one or more pins are electrically connected to the one or more socket terminals; and a housing body disposed between the cable and the socket, where the housing body comprises a portion of the bend relief and the one or more wires connected to the one or more socket terminals, and where at least a portion of the housing body is made of hot melt such that the housing body encapsulates the portion of the bend relief, the one or more socket terminals, and the one or more wires connected to the one or more socket terminals.