Piercing-Contact Cable Junction for Flexible EV Charging Lines
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Solution Overview
Problem
Existing cable connection systems for charging stations, particularly for electric vehicles, face challenges with high current requirements, necessitating large line cross-sections and inflexible flat cables that are difficult to route and install, and lack effective protection against short circuits and environmental factors.
Innovation Solution
A cable connection system using separate round cables routed parallel to each other, with a junction housing and connection boxes that allow for stripping-free contact, providing enhanced flexibility, ease of installation, and protection against short circuits and environmental factors, while ensuring quick and safe electrical connections to charging stations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If flat cables are used for through-lines with large line cross-sections (25 mm² or more), then high current requirements are met, but the cables become inflexible and difficult to route around corners
Solution Approach 1:
The patent divides the through-line into multiple separate round cables (e.g., three 16 mm² cables instead of one 25 mm² cable) to achieve the required current carrying capacity while maintaining flexibility. Each round cable can be routed independently around corners and through tight spaces, solving the inflexibility problem of flat cables while meeting high power requirements.
2Power
If flat cables with large line cross-sections are used, then high current requirements are met, but the weight increases making fastening to walls more difficult
Solution Approach 1:
The patent segments the current carrying function across multiple thinner round cables rather than using a single thick flat cable. This segmentation reduces the overall weight and makes the cables easier to handle, support, and fasten to walls while maintaining the required current carrying capacity through the combined cross-section of multiple cables.
3Reliability
If traditional cable connection methods are used, then electrical connections are established, but the installation complexity increases and protection against short circuits and environmental factors is insufficient
Solution Approach 1:
The patent combines multiple functions into integrated connection elements that simultaneously provide electrical connection, mechanical support, and environmental protection. The connection elements are designed to seal around the round cables, providing protection against water and dust while establishing reliable electrical connections, thereby reducing installation complexity despite the enhanced protection requirements.
Data Source
AI summary
A cable connection system connects a through-line to a charging station. The system comprises a plurality of cores of a through-line designed as separate round cables guided parallel to one another, a junction housing having a plurality of inlets and outlets for one round cable each of the through-line. The junction housing includes multiple outlets for junction lines, which can be connected to the charging station, as well as multiple connection boxes inserted into the junction housing, which can be connected to the charging station. Each connection box contacts a round cable of the through-line without stripping the insulation via piercing contact elements that are suitable for piercing the insulation of the respective round cable and making contact with its conductor. The connection box further connects each junction line to the corresponding round cable of the through-line.