Modular EV Charger Housing for Connector and Installation Flexibility
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Solution Overview
Problem
The adoption of electric vehicle (EV) chargers is hindered by the evolution of charging standards and their inflexible design, which makes them incompatible with various EV models and installation locations, requiring frequent rewiring for different charging port configurations.
Innovation Solution
A modular EV charger system comprising two separate housings with adaptable electrical circuitry and connectors, allowing easy reconfiguration of connectors and installation in different locations through a conduit system and threaded ports for secure alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional EV charger uses a fixed design with integrated housing, then the structure is simple and manufacturing is easier, but the charger cannot adapt to different EV models and installation locations, requiring frequent rewiring
Solution Approach 1:
The charger is divided into separate modular components: a power supply unit and a connector unit that can be independently configured. This segmentation allows different connector types to be paired with the same power supply, enabling adaptation to various EV models without redesigning the entire charger.
Solution Approach 2:
The modular design creates universal interfaces that can accommodate multiple connector types (e.g., different EV charging standards). The power supply unit serves multiple functions by working with various connector units, making the system versatile across different EV models and installation scenarios.
2Ease of operation
If an EV charger is designed as a single integrated unit, then the device is simpler to manufacture, but it requires rewiring when installing in different locations or changing connector types
Solution Approach 1:
By separating the charger into modular units with standardized connection interfaces, the system becomes easier to reconfigure for different installations. Each module can be independently manufactured and then assembled, simplifying both manufacturing processes and field installation.
Solution Approach 2:
The modular architecture enables dynamic reconfiguration of the charger system. Connector units can be swapped or repositioned based on installation requirements without requiring complex rewiring, making the system adaptable to changing operational needs.
3Adaptability or versatility
If EV chargers use standardized fixed designs, then manufacturing and deployment are easier, but they cannot accommodate the evolution of charging standards and new EV models
Solution Approach 1:
The modular design incorporates universal connection standards that can accommodate multiple charging protocols and EV models. When new charging standards emerge, only the connector unit needs to be updated rather than the entire charger system, reducing reconfiguration time and maintaining compatibility across evolving standards.
Data Source
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AI summary
An EV charger includes a modular housing system that includes a first housing and a second housing. The first housing is adapted to enclose electrical circuitry that connects power source inputs from a power source input cable to EV charging outputs of an EV charging output cable. The first housing includes a first port and a second port. The first housing receives the input cable through the first port and sends the output cable through the second port. The second housing includes multiple ports. The second housing receives the output cable through one of its ports. The second housing further includes an EV charging socket or a tethered EV charger connector for charging an EV. In one embodiment, the second housing can be separated from the first housing using a conduit. In another embodiment, the second housing can be directly connected to the first housing.