Quick-Connect EV Charging Cable for Portable Level 2 Access
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Solution Overview
Problem
Existing electric vehicles require expensive high-voltage charging systems installed by skilled electricians and face a scarcity of charging stations, leading to long charging times and inconvenience when traveling.
Innovation Solution
A quick connect charging system with an elongated cable and power adapters that allow direct engagement with high-voltage devices in buildings, such as dryer outlets, breaker boxes, and AC disconnect boxes, enabling level 2 fast charging without professional installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If level 2 charging systems are installed, then charging speed is improved, but installation cost and complexity increase
Solution Approach 1:
The charging system is divided into separate modular components: a portable charging cable with quick-connect terminals, detachable power adapters, and a vehicle charging connector. This segmentation allows users to assemble the charging system without professional installation, eliminating the need for hardwired electrical panels while maintaining level 2 charging capability.
Solution Approach 2:
The system enables end-users to independently install and configure their own charging setup by connecting the portable cable to existing high-voltage outlets (dryer outlets, breaker boxes, AC disconnect boxes) without requiring skilled electricians. The quick-connect terminals and adapter designs allow non-experts to safely assemble the charging system themselves.
2Reliability
If dedicated charging stations are installed, then charging reliability is improved, but accessibility and portability worsen
Solution Approach 1:
The power adapters are designed to universally connect to multiple types of existing high-voltage building infrastructure including dryer outlets, breaker boxes, and AC disconnect boxes. This multi-functionality allows the same portable charging cable to be used across different locations and building types, dramatically increasing accessibility while maintaining reliable level 2 charging.
Solution Approach 2:
The portable charging cable acts as an intermediary device that bridges the gap between existing building electrical infrastructure and electric vehicle charging ports. By using readily available high-voltage outlets as intermediaries, the system provides reliable charging without requiring dedicated charging station installation, enabling charging at any location with appropriate electrical infrastructure.
3Ease of operation
If standard level 1 charging is used, then ease of operation is improved, but charging time increases
Solution Approach 1:
The system changes the electrical parameters of charging by connecting to high-voltage outlets (220v-240v, 30-50 amps) instead of standard 110v outlets. This parameter change enables level 2 charging that reduces charging time from 35-50 hours to 5-10 hours, while the portable design maintains the ease of operation characteristic of plug-and-play charging.
Data Source
AI summary
A quick connect vehicle charging system includes a charging cable and a vehicle charging connector having a plug and a controller that are connected to the first end of the charging cable. A first adapter having a plug, a wire and a terminal connects to the second end the charging wire to supply high voltage power from the dryer outlet to the vehicle charging connector. A second adapter having a circuit breaker, a wire and a terminal connects to the second end of the charging wire to supply high voltage power from the breaker box to the vehicle charging connector to perform level 2 vehicle charging. A third power adapter having an AC pullout switch, a wire and a terminal connects to the second end of the charging wire to supply high voltage power from the disconnect box to the vehicle charging connector to perform level 2 vehicle charging.