Replaceable Charging Connector Terminal for In-Situ EV Service
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Solution Overview
Problem
Charging connector terminals in electric vehicles suffer from durability issues due to harsh environments, leading to increased contact resistance, power loss, and corrosion, requiring costly and time-consuming replacement of the entire cable harness.
Innovation Solution
A charging connector assembly with replaceable electrical terminals featuring a threaded attachment and torque feature, allowing direct connection and detachment to the electrical conductor without disassembling the assembly, using a tool accessible from the user face.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If terminals are mounted in a direction from the inside toward the outside, then the terminal can be connected to the electrical conductor, but the terminal cannot be serviced or replaced without removing the charging connector assembly from the vehicle
Solution Approach 1:
The terminal is segmented from the charging connector assembly through a removable coupling mechanism. The terminal can be independently removed from the assembly by accessing the coupling from the user-accessible face, allowing service without disassembling the entire assembly from the vehicle.
Solution Approach 2:
A coupling mechanism acts as an intermediary between the terminal and the charging connector assembly. This coupling includes a fastening feature that can be accessed from the user face, serving as a mediator that enables terminal replacement without vehicle disassembly.
2Reliability
If the entire cable harness is replaced to service corroded or damaged terminals, then the terminal reliability is restored, but the repair cost and time increase significantly
Solution Approach 1:
The terminal is made a separable component from the cable harness through the removable coupling mechanism. This allows only the terminal to be replaced rather than the entire cable harness, reducing repair time and cost while restoring terminal reliability.
Solution Approach 2:
The terminal can be discarded and replaced independently while the charging connector assembly and cable harness are recovered and reused. This selective replacement approach reduces waste and repair resources while maintaining system reliability.
3Ease of operation
If the terminal is exposed to the external environment, then the charging connector can be mated with the charging inlet assembly, but the terminal suffers from durability issues due to debris, moisture and contaminants
Solution Approach 1:
The coupling mechanism provides dynamic control over terminal exposure. The terminal can be in an exposed state for mating operations or a protected state when enclosed by the charging connector assembly, allowing the system to adapt between operational modes.
Solution Approach 2:
The charging connector assembly housing provides beforehand protection against environmental contaminants. The terminal is enclosed within the housing during storage and non-operational periods, cushioning it from debris, moisture and contaminants before exposure is needed for mating.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables cost-effective and efficient replacement of worn or damaged terminals, maintaining long-term reliability and reducing downtime by allowing in-situ servicing.
Implementation Method 1
an electrical terminal having a base defining a corresponding threaded attachment feature configured to engage and disengage the threaded attachment feature of the electrical conductor
Implementation Method 2
The terminal defines a torque feature configured to cooperate with a tool to facilitate rotation of the terminal
Data Source
AI summary
The present invention discloses a charging connector assembly designed for an electrical energy transfer system. The assembly includes an electrical conductor with a threaded attachment feature and an electrical terminal with a base having a corresponding threaded attachment feature to engage and disengage the conductor's threaded feature directly. The terminal also features a torque feature that can be operated by a tool to rotate the terminal, enhancing installation and removal. The torque feature is conveniently accessible from a user-facing surface of the charging connector assembly when installed, providing ease of removal and replacement of the terminal when needed.