Modular Charging Interface for Electric Vehicles
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Solution Overview
Problem
Existing charging interfaces for electric and partially electric vehicles are inflexible, costly, and difficult to assemble, maintain, and repair due to their rigid plastic housing and soldered connections.
Innovation Solution
A modular charging interface with interchangeable interface elements for AC and DC contacts, framed by a detachable closure cover, allowing for standardized connector formation and easy assembly, maintenance, and repair, utilizing a printed circuit board for robust connections and enhanced protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cast plastic housing with soldered contact elements is used, then structural integrity and electrical connection stability are improved, but manufacturing cost increases and ease of repair deteriorates
Solution Approach 1:
The charging interface is divided into separate modular components: interface elements (housing portions) and contact elements (terminal blocks). These modules can be independently replaced, allowing repair of worn contacts without replacing the entire housing structure, thus improving ease of repair while maintaining connection stability through robust terminal block design.
Solution Approach 2:
The contact elements are extracted as separate replaceable modules from the housing structure. The terminal blocks with contact elements can be independently removed and replaced, separating the permanent housing structure from the wear-prone electrical contacts, enabling cost-effective repairs without replacing the entire assembly.
2Strength
If a cast plastic housing with soldered contacts is used, then structural integrity is improved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The housing is segmented into interface elements that can be separately manufactured using cost-effective injection molding techniques. This modular approach allows standardized production of housing portions and contact assemblies, reducing overall manufacturing costs while maintaining structural integrity through precise inter-module connections.
Solution Approach 2:
The contact elements are designed as replaceable terminal blocks that can be independently replaced when worn. This allows the expensive housing structure to be reused while only replacing the lower-cost contact modules, reducing long-term manufacturing and maintenance costs.
3Reliability
If soldered contact elements are used, then electrical connection reliability is improved, but assembly time and labor cost increase
Solution Approach 1:
The electrical connection system is segmented into pre-assembled terminal block modules that maintain reliable soldered connections internally. These complete modules are then installed as single units, preserving electrical connection reliability while significantly reducing assembly time compared to installing and soldering individual contacts.
Solution Approach 2:
The terminal blocks with contact elements are pre-assembled and pre-soldered as complete modules before final installation. This preliminary assembly ensures reliable electrical connections are established in a controlled manufacturing environment, allowing rapid installation during vehicle assembly without requiring on-site soldering operations.
Data Source
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AI summary
The invention relates to a modular charging interface (1) for at least partially electrically powered vehicles, comprising a first interface element (10) for receiving AC contacts (20) and control contacts (21), and a second interface element (11) for receiving DC contacts (22). The first interface element (10) and the second interface element (11) each have at least one corresponding form element, such that the first interface element (10) and the second interface element (11) are connected in such a way that a standard-compliant plug-in face (4) is formed on an outer surface (A) facing away from the vehicle.