Rotating EV Charging Port Structure for Compact Sealing
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Solution Overview
Problem
Conventional electric vehicle charging port covers have complex structures, large opening sizes, poor rigidity, and stability issues, making them inconvenient, costly, and aesthetically unappealing.
Innovation Solution
The electric charging port design features a rotating triangular prism charging port box with integrated fast and slow charging sockets, a sealed hollow cylinder, and a sealing ring, eliminating the need for additional hinges and dust covers, allowing for compact, cost-effective, and aesthetically pleasing operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional charging port covers are used, then charging function is provided, but structure becomes complex and rigidity deteriorates
Solution Approach 1:
The charging port cover is divided into multiple independent sections corresponding to different charging sockets. Each section can be independently opened or closed, allowing the structure to be simplified while maintaining functionality. The segmentation enables each part to be optimized separately, reducing overall structural complexity while improving rigidity through focused reinforcement where needed.
Solution Approach 2:
The charging port cover adopts a nested structure where the cover panel is integrated into the charging port housing. The cover can be folded or retractable, nesting within the housing when not in use. This eliminates the need for separate complex mounting mechanisms and improves rigidity by creating a more integrated, structurally sound design.
2Ease of operation
If charging port cover is exposed, then charging convenience is improved, but safety deteriorates due to burn risk
Solution Approach 1:
The charging port cover is designed as a dynamic structure that can automatically open or close based on detection of charging cable insertion or user proximity. Sensors detect the presence of a charging cable or hand接近, and the cover responds by opening to allow charging or closing to prevent contact with exposed electrical components. This dynamic behavior maintains charging convenience while eliminating burn risks.
Solution Approach 2:
The charging port cover incorporates automatic detection and response mechanisms that eliminate the need for manual operation. The system self-activates when a charging cable is detected or when a user approaches, automatically opening the cover to enable charging. This self-service capability ensures safety by preventing accidental contact with exposed ports while maintaining convenient charging access.
3Ease of operation
If conventional opening methods are used, then charging port accessibility is improved, but device complexity increases
Solution Approach 1:
The complex internal opening mechanisms are extracted and replaced with a simple magnetic release system. Magnets embedded in the charging port housing interact with corresponding magnets in the cover, creating a simple hold-release mechanism. This extraction of complexity maintains easy accessibility while dramatically simplifying the overall structure.
Solution Approach 2:
Traditional mechanical hinges, springs, and linkages are replaced with a magnetic field-based system. The magnetic attraction between magnets in the housing and cover provides the holding force, while simple mechanical actuators or even manual pressure releases the magnetic hold to open the cover. This substitution eliminates complex mechanical systems while maintaining ease of operation.
4Ease of operation
If charging port cover is made larger, then charging socket accessibility is improved, but weight increases
Solution Approach 1:
The charging port cover is designed with non-uniform thickness and material distribution. Areas requiring high accessibility have greater thickness or reinforced structure, while other areas use thinner, lighter materials. This local optimization ensures that sockets remain easily accessible while minimizing overall weight by avoiding unnecessary material in areas where it is not needed.
Solution Approach 2:
The charging port cover uses composite materials combining lightweight polymers with reinforcing fibers or metal inserts only where structurally necessary. The main body uses lightweight plastic for minimal weight, while strategic reinforcement with carbon fiber or thin metal layers provides structural integrity and socket protection without significant weight increase, maintaining accessibility while controlling weight.
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
The solution provides a compact, lightweight, and cost-effective charging port with improved rigidity and stability, enabling easy switching between charging modes and sealing, while being compatible with various charging bases and reducing maintenance complexity.
Implementation Method 1
a sealing ring arranged at the charging opening
Implementation Method 2
the charging port box rotatably connected with the sealed box through the rotation shaft
Data Source
AI summary
The disclosure an electric charging port and electric vehicle, and relates to the technical field of charging devices. The electric charging port includes: a charging port box, a rotation shaft and a sealed box. The charging port box includes two bottom surfaces, multiple side surfaces and at least two charging sockets, and the two charging sockets are located on different side surfaces. The rotation shaft is respectively fixedly connected with the two bottom surfaces. The charging port box is located in the sealed box, and the charging port box is rotatably connected with the sealed box through the rotation shaft. A charging opening is arranged on a side of the sealed box, and a sealing ring is arranged at the charging opening. The charging port of the disclosure is small in size, light in weight, low in cost, simple in structure, good in rigidity and compatibility.