7-Pole Vehicle Charging Socket with Protective Cap
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Solution Overview
Problem
Current vehicle charging systems are complex and require separate architectures to support various charging variants, including DC low and DC high charging, which limits compatibility with Type 1 and Type 1 Combo plugs, and poses safety risks due to exposed high-voltage contacts during DC low charging.
Innovation Solution
A charging apparatus with a 7-pole socket and a protective cap that detects its position, allowing for flexible charging connections using Type 1 or Combo 1 plugs, enabling DC low and DC high charging by selectively connecting direct-current contacts and ensuring safety through the cap's closed position during DC low charging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a vehicle is equipped with a charging socket for the type 1 plug, then AC charging and DC low charging (up to 80 A) are supported, but DC high charging (above 80 A) is not possible
Solution Approach 1:
The charging socket is designed with seven contacts that can serve multiple functions: contacts 1-5 provide AC charging and basic DC low charging, while contacts 6-7 enable DC high charging. The same physical socket infrastructure supports both Type 1 and Type 1 Combo plugs, allowing a single socket design to handle multiple charging standards and power levels without requiring separate dedicated sockets for each charging type.
Solution Approach 2:
The patent employs dynamic switching mechanisms including a protective cap that can move between open and closed positions, and power switching devices that dynamically connect or disconnect electrical paths. The protective cap's position determines whether DC high charging contacts are accessible, while power switching devices dynamically route power between different contact configurations based on the charging mode being used, enabling flexible adaptation between AC, DC low, and DC high charging.
2Reliability
If separate charging architectures are used for DC low and DC high charging, then charging compatibility is maintained, but system complexity increases
Solution Approach 1:
The patent merges DC low charging and DC high charging capabilities into a single unified charging socket with seven contacts. Instead of using separate dedicated sockets for different charging types, the invention combines all charging functions (AC, DC low, DC high) into one integrated socket that can accommodate both Type 1 and Type 1 Combo plugs, thereby reducing the number of separate charging architectures while maintaining support for multiple charging standards.
Solution Approach 2:
The seven-contact socket is segmented into functional groups: contacts 1-5 handle AC charging and basic DC low charging functions, while contacts 6-7 are dedicated to DC high charging. This segmentation allows independent control and switching of different charging modes within the unified socket, enabling reliable operation across multiple charging types without requiring completely separate architectures for each.
3Ease of operation
If DC low charging is enabled with exposed contacts, then charging functionality is provided, but safety risks increase due to high-voltage exposure
Solution Approach 1:
The protective cap serves as a physical intermediary between the user and the high-voltage contacts. When the cap is in the closed position, it mechanically blocks access to contacts 6 and 7, preventing accidental contact with high-voltage DC high charging terminals. The cap's position is detected by a cap sensor that communicates with the charging control device, which then controls the power switching devices to ensure high-voltage power is only supplied when the cap is open and properly positioned, thereby mediating between charging accessibility and safety.
Solution Approach 2:
The charging control device receives feedback from the cap sensor about the protective cap's position and uses this information to control the power switching devices. If the cap sensor detects that the cap is closed, the control device prevents high-voltage power from being supplied to contacts 6 and 7. This feedback mechanism ensures that high-voltage DC high charging can only occur when the protective cap is in the safe open position, automatically enforcing safety protocols while maintaining charging functionality.
Data Source
AI summary
A vehicle charging apparatus includes a charging source, a charging plug, a charging socket, a charging control device, an alternating-current charging device and a power switching device. The charging socket has seven electrically assignable contacts, the first contact being connected as a pilot contact by way of a pilot line with the charging control device, the second contact being connected as proximity contact by way of a proxy line with the charging control device, the third contact being connected as a protective grounding conductor contact by way of a ground line with the vehicle ground, the fourth contact being connected as a neutral conductor contact by way of a neutral line with the alternating-current charging device, the fifth contact being connected as a phase 1 contact by way of a phase 1 line with the alternating-current charging device, the sixth contact being connectable as a positive direct-current contact by way of a DC+ line and by way of the power separating device with an energy accumulator, and the seventh contact being connectable as a negative direct-current contact by way of a DC− line and by way of the power separating device with the energy accumulator. The DC+ line is connected by way of a first electric branch line with the neutral line or the phase 1 line, and the DC− line is connected by way of a second electric branch line with the neutral line or the phase 1 line.