Cannot push portable charger into the car charge port! HELP!

Without a location no one can tell what sort of plug you use but for both J1772 and Type 2 one of the white plastic caps could have come off the car's socket and lodged into the plug.

 

Just here, they're white on the Kona

 

KiwiME or someone, can you please explain how those work. How is the required contact made when you use a DC fast charger? TIA

 

Well, all connections on a CCS Type 1 or Type 2 are of the "pin and sleeve" type, much as you'd see on a 16 or 32A caravan or welding 230VAC plug. The DC is of course conducted over the two large pins which have added plastic nubs over the tips. The sleeve (on the EVSE side) is made up of spring-loaded flexible segments while the pin is solid. Of the two halves one or both are floating, meaning held slightly loose in the plug so that they align axially naturally when connected and the full cylindrical electrical surface contact is obtained.

The plastic nubs on the tips of two DC contacts are almost certainly required by the relevant EN and/or SAE standard so that the socket (on the car) is "intrinsically safe" at the rated voltage against finger access, meaning without relying on external safety circuits, 'external' meaning in the car. It's possible that they also assist with insertion to open the sleeve segments against a material that won't wear silver plating off. Once the sleeve opens and travels past the plastic nub it will contact the pin.

Hope that answers the question without getting too complicated.



Sleeves, noting the springy contacts are inside.

 

Thanks KiwiME, I get it now.