Charging Socket Shutter Assembly for Secure Conductor Blocking
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Solution Overview
Problem
Conventional charging sockets lack effective and compact protection for conductive elements, which can lead to accidental activation by foreign objects, compromising safety and security.
Innovation Solution
The design incorporates shutter assemblies with movably mounted shutters that block mating ends in two positions, ensuring secure protection by requiring simultaneous activation by a plug to unblock the entrance, and automatically returning to the blocking state when the plug is removed, integrated within a housing that complies with industry standards like IEC 62196-2.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional charging sockets are used without effective protection, then the structure is simple and easy to manufacture, but the conductive elements are vulnerable to accidental activation by foreign objects, compromising safety
Solution Approach 1:
The shutter assemblies are pre-positioned in the charging socket to block access to conductive elements before any foreign object can cause accidental activation. The shutters are held in a closed position by springs until a plug is inserted, at which point the shutters automatically open to allow proper mating. This preliminary protective action ensures safety is established before use without requiring complex active control systems.
Solution Approach 2:
The protection mechanism is divided into multiple independent shutter assemblies, each protecting individual conductive elements or groups of conductors. Each shutter assembly operates independently with its own spring mechanism, allowing the system to provide comprehensive protection while maintaining structural simplicity. The segmentation allows the protection function to be distributed across multiple simple components rather than requiring a single complex protective system.
2Reliability
If shutter assemblies are added to protect conductive elements, then safety is improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The shutter assemblies are integrated directly into the housing structure of the charging socket, combining the protective function with the existing structural components. The shutters are mounted within the housing and utilize the housing walls and internal features for support and guidance, eliminating the need for separate mounting structures and reducing the number of discrete parts that would need to be manufactured and assembled.
Solution Approach 2:
The shutter assemblies are designed to be self-actuating through spring mechanisms that automatically open the shutters when a plug is inserted and automatically close them when the plug is removed. This self-service operation eliminates the need for external actuators, control systems, or manual intervention, simplifying the manufacturing process while maintaining reliable contact protection throughout the product lifecycle.
3Reliability
If the shutters block a larger portion of the mating end, then protection against foreign objects is improved, but the area available for legitimate plug insertion is reduced
Solution Approach 1:
The shutter assemblies are designed to be dynamic rather than static, automatically adjusting their position based on the presence or absence of a plug. The spring mechanisms allow the shutters to flex and open when a plug is inserted, providing full access to conductive elements, and automatically return to the closed position when the plug is removed. This dynamic behavior ensures maximum protection during idle periods while maintaining ease of operation during legitimate use.
Data Source
Figure 1A
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Figure 2
AI summary
A socket with compact protection for conductors against foreign objects. The socket comprises a housing having channels extending in a mating direction, power conductors disposed in the channels, and assemblies disposed on the channels to block entrances into the channels. The assemblies are within a chamber of the housing surrounded by a wall. Each assembly comprises a cover and shutters pivotably coupled to the cover. Each shutter has a blocking portion and an actuating portion configured to be actuated by the housing of a desired plug. When the actuating portion is actuated, the blocking portion moves away from blocking the entrance to the channel; and when a mating plug is removed and the actuating portion returns to its rest state, the blocking portion automatically moves back to block the entrance to the channel. Such a configuration reduces the risk of anything other than terminals of the desired plug contacting the conductors.