Reimagining EV Charge Inlets

Speciality chemicals company LANXESS has deployed modularity in the design of EV charging inlets. Team ACI looks at all that can change with its approach.

Thermoplastic compounds have raised the bar of design. Durethan polyamides and Pocan polyesters are claimed to have given designers a free hand at bringing concepts to life. Speciality Chemicals company Lanxess demonstrated a new design concept for charging inlets in the case of Electric Vehicles (EVs) using such customised material solutions. Installed in BEVs, the new modular design approach accommodates the use of the charging coupler of an external charging station. “Our approach is aimed at using a modular configuration to get the right material in the right place to meet the complex requirements applicable to the various components with the utmost precision,” explains Gregor Jaschkewitz, Application Developer at the High Performance Materials (HPM) Business Unit, credited for bringing the design to life. “At the same time, a high level of functional integration is intended to make it as easy as possible to assemble the entire unit, which means screwless assembly and minimal components to keep costs low,” he adds.

Sub-parts and thermal management

The key elements of this charging inlet design are the front and rear housings. There is a socket provided for the connector coming from the charging station and an actuator. The latter locks the connector in place to prevent it from being accidentally or deliberately pulled out during the charging process. The pin holder is another essential element of the inlet design. It holds the metallic connector pins in place, as well as a Printed Circuit Board (PCB) with cables for charging with direct or alternating current, among others.