Waterproof Charging Interface with Enhanced Sealing and Locking Mechanism Prevents EV Electrical Failures

The Rising Threat: Water Ingress in EV Charging Ports

As global markets continue to aggressively promote new energy vehicles, market penetration has risen steadily year by year. However, with increased adoption comes increased visibility of vehicle faults. Among the most common failure cases are those caused by water ingress due to inadequate protection. The charging interface, as a critical component of any EV, has gradually drawn attention for its protective performance.

Water resistance directly impacts charging functionality. Design specifications must meet electrical protection rating system requirements, where higher ratings indicate better protection. In earlier years, protection rating requirements were relatively low. But as faults continue to emerge across the market, vehicle standards have become increasingly stringent. To ensure that charging interf   ace protection designs can meet the protection requirements of modern new energy vehicles, an optimized solution is urgently needed.

To address this challenge, the Tenglong Automotive engineering team has developed an optimized charging interface structure featuring an integrated waterproof design that significantly enhances both moisture and dust protection.

Engineering Excellence: Multi-Layer Sealing and Drainage Architecture

Thisproject introduces a comprehensive waterproof interface design with several protective features:

1. Housing and Cover Assembly: The device consists of a box body and a cover plate. A cylindrical socket body is mounted vertically in the center of the box interior. Vertical mounting plates are installed on the top and bottom inner walls near the box opening.

2. Integrated Drainage System: A water outlet channel is formed on the bottom side wall near the box opening. The outer end of the water outlet channel is open, while the inner end connects to the bottom of a secondary groove. Perforations are strategically placed on the inner wall of the water outlet channel to facilitate water evacuation.

3. Concealed Cover Latch: A recessed groove is formed on the outer side of the cover plate, with a latch plate installed at the top opening of the groove for secure yet accessible locking.

4. Waterproof Seal and Cable Sealing: A waterproof sealing ring is incorporated into the design. The socket tail section uses a sealing gasket to create a sealed interface with the cable wire, preventing moisture intrusion along the cable path.

Key Innovations for Reliable Charging

1. Effective Enclosure Locking: The structure effectively encloses, locks, and protects the charging socket body, making operation convenient while ensuring security.

2. Superior Waterproofing: Both the box body and cover plate deliver excellent waterproof performance, effectively preventing external water from flowing into the socket interior and ensuring reliable operation.

3. Compact Safety Architecture: The design achieves robust water and dust protection in a compact form factor, effectively preventing electrical leakage caused by operational issues and enhancing overall new energy vehicle safety.

Proven Results and Intellectual Property

The project represents an improvement on the company's existing invention patent: "A Locking Device for a New Energy Vehicle Charging Interface with Waterproof Structure" (Patent No. ZL201810502766.8). The patented design includes a box body and cover plate, with the cover mounted on the side opening of the box. A cylindrical socket body is installed in the center of the box interior. Horizontal cross-rods with limit baffles and limit protrusions extend from the inner side of the cover plate, while vertical mounting plates with multiple mounting holes receive these cross-rods.

The final evaluation committee—led by General Manager Ye Lizhang—confirmed that the project has successfully applied its patented成果 to new energy vehicle products, delivering excellent performance and achieving commercial sales with positive economic returns.

Commitment to Comprehensive EV Protection

This project reinforces Xiangyang Tenglong Automotive's commitment to holistic vehicle safety—addressing not just battery and powertrain systems but also the everyday components that customers interact with regularly. By integrating this waterproof charging interface design into our vehicle lineup, we ensure that every charging session remains safe, reliable, and free from water-related failures, even in challenging weather conditions.

RD15 Project Proposal for Optimized Design of a New Energy Vehicle Charging Interface with Waterproof Structure