This is a representative supporting project for Xingyuan Electric in the EV-charger industry (anonymized, not a named customer; figures below are representative industry ranges, not specific contract data). The client is a charger maker needing AC / DC outdoor charger housings, with core demands of structural waterproofing, heat dissipation and batch appearance consistency, plus export packaging.
1. Client pain points
- Outdoor shells leaked at door seams and cable entries; rain tripped the charging modules;
- DC fast-charge power modules ran hot; the original shell's cooling was insufficient, derating in summer;
- At thousand-unit volume, shell colour and assembly gaps varied, hurting brand look;
- Export models needed fumigated crates and moisture protection the original supplier could not hold steady.
2. Our solution
The shell used structural waterproofing by protection grade: continuous welds + double door-seam seals + bottom waterproof glands. Cooling was graded by power — natural convection with reserved fan / heat-exchanger mounts, with airflow isolation when needed. Finishing was galvanized base + weathering powder (≥720h salt spray); volume used fixtures for door/frame interchangeability. Export types got fumigated wooden crates with rust and VCI moisture protection.
3. Representative project parameters
| Item | Representative approach |
|---|---|
| Protection | IP54 / IP65 (continuous weld + double seal + waterproof glands) |
| Cooling | Natural convection + reserved fan / heat-exchanger mounts |
| Finishing | Galvanized base + weathering powder (≥720h salt spray) |
| Batch interchangeability | Fixture control, stable gaps |
4. Outcome
After the sample passed water-spray and temperature-rise tests we moved to volume, delivering thousand-set batches with far fewer leak complaints; export packaging passed destination-country inspection first time. This matches our EV charger enclosure design logic.
5. Reusable lesson
Charger-housing reliability is 70% structural waterproofing, 30% cooling and batch consistency. Fix the protection grade and salt spray at design stage, make fixtured interchangeability solid, and get export packaging right first time — that beats patching leaks later.