Plug for plug-in connection and method

Abstract

The invention relates to a plug (10) for a plug connection for charging an electrically operable motor vehicle, comprising a housing (12) within which components of an electronic system and a first heat-conducting element (24) are arranged, at least one second heat-conducting element (24) being arranged in addition to the first heat-conducting element (24), the invention relates to a plug (10) for an electronic system (11), comprising a housing (12) and a plurality of heat-conducting elements (24) which are arranged opposite each other within the housing (12) while providing a receiving space (12a) in which components of the electronic system (11) arranged on the respective heat-conducting element (24) and further components for controlling the temperature of the electronic system (11) and / or the plug (10) are arranged. The invention also relates to a method for controlling the temperature of such a plug (10).

Description

Technical Field

[0001] This invention relates to a plug for a plug-in connection structure for an electrically operated motor vehicle, as described in the preamble of claim 1. Furthermore, this invention also relates to a method. Background Technology

[0002] DE102016216565A1 describes a charging cable for charging an energy storage device in a vehicle. The charging cable includes a grid-side interface for contacting a grid interface at which charging power with grid voltage is provided. A first plug is used to transfer current from the grid to an AC / DC converter integrated in the first charging plug. This AC / DC converter converts alternating current to direct current. The direct current is then transferred via the charging cable to a DC / DC converter in the vehicle, which adjusts the voltage and DC level to a level suitable for the vehicle's battery. This enables the charging of electrically powered motor vehicles or electric vehicles.

[0003] The corresponding electronic components for charging the high-voltage vehicle battery are integrated into the two plugs of the charging cable. A high-performance cooling system is provided to effectively dissipate the resulting power losses. However, this cooling system occupies a significant portion of the available structural space. This results in unfavorable component distribution and suboptimal heat dissipation in the prior art. Summary of the Invention

[0004] The objective of this invention is to design a charging plug or plug connection structure that maximizes efficiency and power density while providing an extremely compact design.

[0005] This task is accomplished according to the invention by means of a plug having the features of claim 1 and by means of the method according to the invention. Advantageous embodiments of the invention are the subject of the dependent claims and the description.

[0006] The electronics used to charge high-voltage vehicle batteries (with an exemplary charging power of 11kW) should be integrated into the two plugs of the charging cable to meet the high requirements for efficiency and power density, thereby achieving the most compact solution possible. However, as such solutions are further developed, the charging power may be further increased in the future. Therefore, integrating the electronics for charging high-voltage vehicle batteries into the two plugs of the charging cable should also be flexible enough to accommodate future requirements for even higher charging power.

[0007] A plug for a plug-in connection structure for charging an electrically powered motor vehicle is provided. The plug includes a housing in which electronic system components and a first heat-conducting element are disposed. Therefore, a plug is proposed for a plug-in connection structure for charging an electrically powered motor vehicle, particularly a passenger car. The plug includes a housing in which various electronic system components and a first heat-conducting element are disposed.

[0008] The electronic system is configured to provide all required functions. When the plug is inserted into the appropriate socket, the electronic system identifies the power demand and transmits the necessary energy to the vehicle's electronic system via the charging cable. This makes charging electric vehicles possible.

[0009] Heat is generated during the charging process, resulting in energy loss. This energy loss is an integral part of the charging process and should be minimized as much as possible by the present invention to maximize the efficiency of energy transfer.

[0010] One objective of this invention is to design a charging plug or plug connection structure that maximizes efficiency and power density while simultaneously achieving an extremely compact structural form.

[0011] To address the objectives of this invention and thus design a charging plug or plug-in connection structure that maximizes efficiency and power density while achieving an extremely compact form, it is specified that at least one second heat-conducting element is provided in the housing in addition to the first heat-conducting element. The first and second heat-conducting elements are arranged opposite each other within the housing, providing a accommodating space. Within this space are disposed components of the electronic system mounted on the respective heat-conducting elements, as well as additional components for temperature regulation of the electronic system and / or the plug.

[0012] In other words, in addition to the first heat-conducting element, at least one second heat-conducting element is provided. These two heat-conducting elements are disposed, fixed, or installed inside the housing and form a receiving space. Various components of the electronic system and additional components for temperature regulation of the electronic system and / or plug are disposed, fixed, or installed in this receiving space.

[0013] Effective heat dissipation is achieved through the use of multiple heat-conducting elements and by housing the components within a compact space. This helps minimize heat buildup during charging and thus reduces energy loss. Simultaneously, the plug's compact design maximizes energy transfer efficiency.

[0014] In an advantageous embodiment of the invention, the electronic system components include at least one circuit board, and, for example, at least one transformer. The precise design of the electronics or electronic system within the plug depends on structural specifications and the requirements of each component. However, it should be noted that all these components are collectively affected by planned temperature control to ensure optimized performance and function of the electronic system and therefore the plug. Additionally, the components for the electronic system and / or the plug may include at least one insulating element, or insulating elements may be disposed on the components of the electronic system. This feature allows critical components to be housed within the receiving space, enabling particularly effective heat dissipation and temperature control design. In particular, it is specified that heat-sensitive components, such as circuit boards and transformers, are positioned inside the plug to achieve optimized heat dissipation and temperature control.

[0015] In another advantageous embodiment of the invention, the air passages of the corresponding heat-conducting elements are oriented along the height direction of the housing to provide natural convection. Therefore, the heat-conducting elements are configured in the plug such that the extension direction of the air passages existing between the heat-conducting elements promotes natural convection in the vertical direction within the housing. This means that the heat-conducting elements are configured such that rising hot air can achieve effective circulation within the housing. As air rises through the air passages between the heat-conducting elements, the air is heated by a heat source and continues to rise. This natural rise of the hot air generates a convective airflow that effectively removes heat from the housing.

[0016] In another advantageous embodiment of the invention, the longitudinal extension direction of the corresponding heat-conducting element is specified to be oriented along the longitudinal direction of the housing. Thus, the heat-conducting element is positioned in the plug such that its longitudinal extension direction extends substantially parallel to the longitudinal direction of the housing. This means that the heat-conducting element extends from one side of the housing to the other. This arrangement allows heat generated by the internal components to be effectively conducted towards the heat-conducting element. This longitudinal orientation allows heat to be evenly distributed along the entire length of the housing and improves or facilitates heat dissipation.

[0017] In another advantageous embodiment of the invention, a fan is provided at one end of the elongated extension of the elongated housing to provide targeted forced convection. The fan is thus positioned such that it draws in or blows air from one end of the housing and guides the air selectively through heat-conducting elements and electronic components. Here, the fan provides controlled airflow, effectively removing heat from the components and simultaneously performing the set temperature regulation or cooling.

[0018] In another advantageous embodiment of the invention, the fan and transformer are disposed at one end of an elongated extension of the housing. This means that the fan and transformer are spatially close to or similarly arranged with each other and are disposed or located at the same end of the housing. This arrangement achieves effective heat dissipation because the fan can selectively draw in or blow away the hot air generated by the transformer.

[0019] In another advantageous embodiment of the invention, the heat-conducting element is configured as a heat pipe. A heat pipe is a heat-conducting element, specifically configured to efficiently transfer or transport heat from one region to another. They typically consist of a closed tube filled with a working fluid or medium or a special heat-conducting liquid. When heat is generated at one end of the heat pipe, the heat-conducting liquid evaporates and flows to a cooler region, where it condenses and releases heat.

[0020] In another advantageous embodiment of the invention, the heat-conducting element is configured as a pulsating heat pipe. The pulsating heat pipe is a further improvement on conventional heat pipes and has a special structure that enables more efficient heat transfer. Unlike conventional heat pipes, the pulsating heat pipe generates a pulsating motion of the heat-conducting liquid. This is particularly achieved by utilizing capillary forces, which cause the liquid to actively move back and forth between the evaporator and condenser. The pulsating heat pipe is especially effective in applications requiring rapid and efficient heat transfer, such as in plug applications. Another significant advantage of the pulsating heat pipe over other heat pipes is its ability to be geometrically integrated into thin sheet metal. For example, with this compact design, the cooling system can be used and applied in various applications where available space is limited.

[0021] In summary, heat pipes are an effective means of passive heat dissipation, while pulsating heat pipes offer a further option, enabling even more efficient heat transfer in demanding or specialized applications. Optimized geometric integration, such as as part of the housing cladding, is particularly advantageous here, as it can significantly increase the power density of charging devices.

[0022] Another aspect of the invention relates to a method for temperature regulation of a plug for a plug-in connection structure described in the foregoing aspect, the plug-in connection structure being used to charge an electrically operable motor vehicle. The method utilizes a directional heat flow generated by directing air channels in the corresponding heat-conducting elements. This orientation of the air channels supports natural convection within the housing in the vertical or height z-direction. Additionally, targeted forced convection is provided by a fan at the ends of the elongated extensions of the elongated housing.

[0023] A particularly advantageous aspect of this method is the use of heat pipes as heat-conducting elements. These heat pipes enable extremely efficient heat dissipation from the components in the plug. The orientation of the air channels and the use of heat pipes ensure optimized temperature regulation and cooling.

[0024] The combination of natural and forced convection enables precise control of thermal management within the plug, which in turn improves the efficiency of the charging process and extends the lifespan of electronic components. This is achieved by reducing the thermal resistance from heat sources (such as chips) to the environment by effectively utilizing both natural and forced convection. This method helps maintain the temperature at optimized levels and minimizes energy loss during the charging process.

[0025] In summary, this invention describes a housing-integrated cooling solution for mobile vehicle charging equipment.

[0026] The specifications stipulate that maximum cooling and temperature regulation potential should be utilized, particularly by using pulsating heat pipes as heat-conducting elements. Due to their high thermal conductivity, these pulsating heat pipes can effectively absorb heat generated by components and transport it to the finned radiator. Simultaneously, heat is evenly distributed via natural convection through the outer surface of the casing to fully utilize the cooling potential.

[0027] Using pulsating heat pipes offers several advantages, including increased power density, extended component lifespan, and improved efficiency through lower operating temperatures. This helps improve the overall performance and reliability of the device and enables effective heat dissipation and temperature regulation, which is particularly important for minimizing energy loss and maximizing energy transfer efficiency.

[0028] In other words, a plug or charging cable with at least one such plug is proposed, featuring a cooling scheme for mobile vehicle charging equipment. The scheme specifically addresses the plug itself and includes a double-sided enclosed cooling method with heat pipes. It particularly sets up electronic systems for highly integrated power electronics used in mobile DC charging solutions. The advantages of this scheme are multifaceted. First, the spatial decoupling of the heat source and heat sink enables improved or optimized volume utilization, as heat can be efficiently dissipated without adversely affecting available space. Second, it provides larger active and passive cooling surfaces, which helps maintain temperature stability in the electronic system. Finally, the robust heat dissipation method improves thermal management, thereby resulting in particularly more efficient temperature regulation or cooling.

[0029] Other features of the invention are derived from the claims, drawings, and description of the drawings. The features and combinations of features mentioned above in the specification, as well as the features and combinations of features mentioned below in the description of the drawings and / or shown individually in the drawings, can be used not only in their respective specified combinations, but also in other combinations or individually. Attached Figure Description

[0030] The invention will now be described in more detail with reference to a preferred embodiment and the accompanying drawings. The drawings show:

[0031] Figure 1 A schematic perspective view showing a feasible design of a plug, with the different main components of the plug;

[0032] Figure 2 A schematic cross-sectional view showing another feasible design for a plug with a housing;

[0033] Figure 3 Another schematic cross-sectional view showing an alternative feasible design for the plug; and

[0034] Figure 4 A schematic perspective view showing another feasible design for the plug.

[0035] In the accompanying drawings, identical and functionally identical elements are given the same reference numerals. Detailed Implementation

[0036] therefore, Figure 1 A plug 10 for a plug-in connection structure is shown, configured to charge an electrically operable motor vehicle. It is also feasible to provide or implement a bidirectional design for the plug 10, meaning it can not only be used to charge the motor vehicle but also to feed energy from the vehicle back to the corresponding power grid. Various components of the electronic system, essential for the function of the plug 10, are housed within a housing 12. A first heat-conducting element 24 is also disposed within the housing 12 to dissipate heat from the electronic components and to achieve temperature regulation, particularly heat dissipation.

[0037] Specifically, in this specification, in addition to the first heat-conducting element 24, at least one second heat-conducting element 24 is provided and thus present. These two heat-conducting elements 24 are arranged within the housing 12 such that they form a receiving space 12a, within which various components of the electronic system 11 and additional components for temperature regulation of the electronic system 11 and / or the plug 10 are disposed. Components of the electronic system 11 include, for example, at least one circuit board 20, at least one capacitor 16, and a transformer 14. Alternatively, the components for the electronic system 11 and / or the plug 10 may include at least one insulating element 22.

[0038] The air channels of the corresponding heat-conducting elements 24 are oriented such that they enable, and particularly promote, natural convection 30 in the height direction z of the housing 12. This makes effective cooling possible through natural airflow. The longitudinal extension direction of the heat-conducting elements 24 is oriented along the longitudinal direction x of the housing 12. This arrangement improves or optimizes heat transfer and thermal management.

[0039] An invisible fan 26, positioned below the heat-conducting element region 26a in the height direction Z, is located at the end of the elongated extension of the housing 12 to achieve targeted forced convection 32. This fan 26 can be combined with the transformer 14 at the same end of the housing 12 for effective temperature regulation. Finally, the heat-conducting element 24 can be constructed either as a conventional heat pipe or as a pulsating heat pipe. These heat pipes or pulsating heat pipes are used to efficiently remove heat from the component and achieve optimized temperature regulation.

[0040] therefore, Figure 1 The arrangement of the elements is designed to allow natural convection 30 to occur upwards in the height direction z. The heat-conducting element 24 has air channels oriented to allow hot air to rise. Simultaneously, forced convection 32 is promoted, directing the heat now located above towards the fan 26. This is achieved by the fan 26 drawing in air.

[0041] The combination of these two convective flows achieves effective cooling and temperature regulation, as the hot air rising from the heat-conducting element 24 is dissipated through natural convection 30, while the fan 26 generates a heat flow 34 directed towards the fan 26 to further regulate the temperature. This thermal arrangement enables optimized heat dissipation and effective temperature regulation or cooling of the plug 10 during the charging process.

[0042] Additionally, a method for temperature regulation of the plug 10 is described, in which directional heat flow 34 is used. This heat flow is generated by directing the air passage of the thermally conductive element 24 to provide natural convection 30 in the height direction z of the housing 12. Targeted forced convection 32 is provided at the ends of the housing 12 by a fan 26. The temperature regulation can also be performed by means of at least one thermally conductive element 24 configured as a heat pipe or a pulsating heat pipe. This method enables effective heat dissipation and temperature regulation during the charging process.

[0043] Figure 2 A schematic cross-sectional view of plug 10 is shown, including housing 12, transformer 14, circuit board 20, heat-conducting element 24, and fan 26, all disposed on one side. This illustration shows the possible spatial arrangement of the components of plug 10 or the possible arrangement of electronic system components inside plug 10.

[0044] Figure 3 Another schematic cross-sectional view of an alternative design for plug 10 is shown, illustrating housing 12 and transformer 14. However, compared to... Figure 2Conversely, in this view, the circuit board 20 and the heat-conducting element 24 are positioned not only above but also below the transformer 14 in the height direction z. Additionally, the heat-conducting element 24 can be seen. This illustration shows the spatial arrangement of components within the plug 10, particularly the dual-sided placement of the corresponding circuit board 20 and the corresponding heat-conducting element 24, and the accommodating space for components of the electronic system 11.

[0045] exist Figure 4 Another possible implementation of the plug 10 is shown in the figure. The outer housing 12 of the plug 10 is shown in dashed lines. The circuit board 20 with power components, the insulating element 22, the fan 26 located below the heat-conducting element region 26a in the height direction Z, and the transformer 14 are arranged inside the housing 12 and are particularly prominent.

[0046] Furthermore, two different methods for cooling the heat dissipation plug 10 are shown. Natural convection 30 occurs through natural air circulation. In addition, forced convection 32 occurs, which is activated by a fan 26 or an alternative device to control air movement for improved cooling.

[0047] In summary, a plug 10 for charging an electric vehicle is proposed, having a housing 12. Electronic components and first and second heat-conducting elements 24 are disposed within the housing, forming a receiving space 12a in which the electronic components and temperature-regulating components are housed. The electronic system includes a circuit board 20, a capacitor 16, and a transformer 14, and may also include an insulating element 22. The air channels of the heat-conducting elements enable natural convection 30 in the height direction z and are oriented along the longitudinal direction x of the housing. A fan 26 can provide targeted forced convection 32 at the ends of the housing. The heat-conducting elements can be implemented as conventional heat pipes or pulsating heat pipes. Therefore, the plug 10 achieves effective heat dissipation and temperature regulation when charging an electric vehicle.

[0048] List of reference numerals

[0049] 10 plugs

[0050] 11 Electronic Systems

[0051] 12. Shell

[0052] 14 Transformers

[0053] 16 Capacitors

[0054] 18 controllers

[0055] 20 circuit boards

[0056] 22 Insulating elements

[0057] 24 Thermal conductive elements

[0058] 26 fans

[0059] 30 Natural convection

[0060] 32 Forced convection

[0061] 34 Heat Flow

[0062] X Vertical direction

[0063] Y (horizontal direction)

[0064] Z-axis

Claims

1. A plug (10) for a plug-in connection structure for charging an electrically operable motor vehicle, the plug including a housing (12) having electronic system components and a first heat-conducting element (24) disposed inside the housing, characterized in that, At least one second heat-conducting element (24) is provided in the housing, wherein the heat-conducting element (24) is disposed opposite to each other inside the housing (12) while providing a receiving space (12a), in which the electronic system (11) components disposed on the corresponding heat-conducting element (24) and additional components for temperature regulation of the electronic system (11) and / or the plug (10) are provided.

2. The plug (10) according to claim 1, characterized in that, At least one insulating element (22) is provided on the components of the electronic system.

3. The plug (10) according to claim 1 or 2, characterized in that, The air passage of the corresponding heat-conducting element (24) extends along the height direction (z) of the housing (12) to provide natural convection (30).

4. The plug (10) according to any one of the preceding claims, characterized in that, The longitudinal extension direction of the corresponding heat-conducting element (24) is oriented along the longitudinal direction (x) of the housing (12).

5. The plug (10) according to any one of the preceding claims, characterized in that, A fan (26) is provided at one end of the elongated extension of the housing (12) to provide targeted forced convection.

6. The plug (10) according to claim 5, characterized in that, The fan (26) and transformer (14) are located at one end of the longitudinal extension of the housing (12) of the longitudinally elongated structure.

7. The plug (10) according to any one of the preceding claims, characterized in that, The thermally conductive element (24) has at least one heat pipe.

8. The plug (10) according to any one of the preceding claims, characterized in that, The heat-conducting element (24) has at least one pulsating heat pipe.

9. A method for temperature regulation of a plug (10) for a plug-in connection structure according to any one of claims 1 to 8, the plug-in connection structure for charging an electrically operable motor vehicle, wherein the temperature regulation is performed by directional heat flow (34) provided by orienting the air passages (24) of the respective heat-conducting elements (24) to provide natural convection (30) in the height direction (z) of the housing (12) and by providing targeted forced convection (32) by means of a fan (26) at one end of the longitudinal extension structure of the housing (12) in an elongated configuration.

10. The method according to claim 9, characterized in that, The temperature regulation is also performed by means of at least one heat-conducting element (24), which has at least one heat pipe or at least one pulsating heat pipe.

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