Modular EV Charging Connector Assembly for Serviceable Terminals
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Solution Overview
Problem
Electric vehicle charging connectors are cumbersome and difficult to assemble, with complex designs that are not serviceable, leading to high assembly complexity and maintenance challenges due to frequent mating and un-mating cycles.
Innovation Solution
A modular electric vehicle charging connector design featuring interchangeable AC and DC terminals, a dielectric housing with aligned cavities, and a cover with access portals, allowing for simplified assembly and serviceability, with threaded fasteners for secure attachment and environmental seals to ensure proper alignment and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional electric vehicle charging connector design is used, then the connector provides necessary electrical connection functionality, but the assembly complexity becomes very high due to many separate wire leads, terminals, seals, retainers, and fasteners
Solution Approach 1:
The patent combines multiple separate components (wire leads, terminals, seals, retainers, fasteners) into an integrated connector assembly where the housing incorporates built-in seals and retainers, reducing the number of separate parts that need to be assembled and lowering overall assembly complexity
Solution Approach 2:
The connector is divided into modular sections including a housing with integrated AC terminals, a separate DC terminal assembly with its own housing, and a common latching mechanism, allowing each module to be manufactured and assembled independently before final integration
2Ease of repair
If traditional electric vehicle charging connector design is used, then the connector provides necessary electrical connection functionality, but the connector becomes non-serviceable and difficult to maintain due to complex design
Solution Approach 1:
The AC and DC terminal assemblies are designed as separate, independently serviceable modules that can be removed and replaced without disassembling the entire connector, enabling targeted maintenance and repair of specific components
Solution Approach 2:
The connector incorporates user-accessible features such as a manual release button for the latching mechanism and clearly marked terminal sections, allowing end-users to perform basic service operations like disconnecting the connector without requiring specialized tools or expertise
3Productivity
If traditional electric vehicle charging connector design is used, then the connector provides necessary electrical connection functionality, but the number of processing steps increases due to handling many separate components
Solution Approach 1:
The housing integrates multiple functions including structural support, environmental sealing, and terminal retention features into a single molded component, eliminating the need for separate assembly steps for seals and retainers and reducing total assembly time
Solution Approach 2:
Seals and retention features are pre-integrated into the housing during manufacturing, and terminal assemblies are pre-configured with their own internal connections, so that during final assembly only minimal connection steps are required rather than processing each component separately
Data Source
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AI summary
An electrical connector (10) includes a plurality of cylindrical electrical terminals (12) connected to ends of a plurality of first electrical cables (14), a housing (18) defining a plurality of housing terminal cavities (16) in which the plurality of cylindrical electrical terminals (12) is disposed, and a cover (20) attached to the housing (18) having a plurality of cover cavities (22) that is axially aligned with the plurality of housing terminal cavities (16). The plurality of cover cavities (22) is configured to receive the plurality of cylindrical electrical terminals (12) as it is inserted within the plurality of housing terminal cavities (16).