Wall-Integrated EV Charger Layout to Eliminate Exposed Cables
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Solution Overview
Problem
Existing electric vehicle chargers are inconvenient due to their space-consuming design, potential for cable damage, and exposure to user accidents, particularly with free-standing and wall-mounted chargers that require external cabling.
Innovation Solution
A wall-integrated EV charging station with a recessed box unit and a front panel, featuring tempered glass or fiberglass, that houses charging units and sockets, minimizing external cabling and reducing accident risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If free-standing charger posts are used, then charging functionality is provided, but they take up much space and can be accidentally hit by the car or user may trip on the cables
Solution Approach 1:
The charging unit is merged with the wall structure by integrating it into a box unit that is installed within a wall opening. The charging socket protrudes only slightly from the wall surface, combining the charging function with the architectural element of the wall, thereby eliminating the need for separate free-standing charger posts and reducing space occupation.
Solution Approach 2:
The charging unit is relocated from a three-dimensional free-standing structure occupying floor space to a two-dimensional wall-integrated structure. By embedding the box unit within the wall and having the front panel emerge only slightly, the solution transforms the spatial footprint from volumetric to planar, significantly reducing the area occupied while maintaining charging functionality.
2Ease of operation
If wall-mounted chargers with external cabling are used, then charging functionality is provided, but cables encumber the user and can be accidentally hit
Solution Approach 1:
The external cabling is extracted from the system by integrating the charging unit directly into the wall structure. The charging socket is built into the wall with minimal protrusion, eliminating the need for external cables that connect from a socket to the charger. This removes the harmful element of exposed cables that could be damaged or cause electrical leaks.
Solution Approach 2:
The wall itself acts as an intermediary structure that houses the charging unit and provides a protected pathway for electrical connections. By embedding the charging unit within the wall cavity and using the wall structure as the mounting and protection medium, the solution eliminates exposed cables while maintaining electrical connectivity.
3Ease of operation
If chargers protrude significantly from the wall, then charging functionality is provided, but they can be accidentally hit by the user
Solution Approach 1:
The front panel is designed with localized functionality, emerging only slightly from the wall surface at the specific location where the charging socket is needed. The majority of the box unit is recessed into the wall, creating a local protrusion that provides charging accessibility while minimizing the overall profile to reduce the risk of accidental impact.
Data Source
Figure 1~2
AI summary
Electric vehicle charger comprising a box unit (1) configured to be integrated in a wall and to house at least one charging unit, and attached to a tempered-glass or fiberglass front panel (3),the area of the front panel (3) being wider than the box unit (1), so that, when the charger is installed in the wall, the back of the front panel (3) is in contact with the wall, emerging between 1 - 2 cm. from it. The front panel (3) has at least one socket (4) operatively coupled to the at least one charging unit.