Busbar-Cooled Connector Cover for Fast-Charging Heat Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
High power electrical connector assemblies, such as those used in fast charging systems for electrical vehicles, face issues with contact resistance leading to thermal energy buildup, which can damage the assembly if thermal limits are exceeded, and require effective thermal management to meet industry performance standards.
Innovation Solution
The electrical connector assembly incorporates various thermal management features, including coolant channels, thermoelectric devices, airflow ports, and cooling fins, along with dielectric thermal interface materials and seals, to efficiently manage heat and prevent damage, allowing for customization based on cooling infrastructure and thermal load.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high power electrical connector assemblies are used for fast charging systems, then charging speed and power transmission capability are improved, but contact resistance causes thermal energy buildup that can damage the assembly
Solution Approach 1:
The patent converts the harmful thermal energy generated by contact resistance into a manageable parameter by implementing cooling channels and heat dissipation structures. The cooling liquid flows through channels in the connector housing to actively remove heat, transforming the thermal problem into a controlled heat exchange process that enables high power transmission without damage.
Solution Approach 2:
The patent employs a hydraulic cooling system where cooling liquid is circulated through internal channels of the connector housing. This fluid-based heat removal mechanism efficiently transports thermal energy away from the electrical contacts, enabling sustained high power operation by preventing thermal accumulation that would otherwise damage the assembly.
2Temperature
If cooling structures are added to manage thermal energy, then temperature control is improved, but device complexity increases
Solution Approach 1:
The patent merges the cooling function with the structural housing by integrating cooling channels directly into the connector housing. This integration eliminates the need for separate cooling components, as the housing simultaneously serves as both the structural enclosure and the heat dissipation pathway, thereby reducing overall device complexity while maintaining effective temperature control.
Solution Approach 2:
The connector housing is designed with multi-functionality, serving both as the structural enclosure for electrical components and as the heat dissipation system through integrated cooling channels. This universal design allows a single component to fulfill multiple functions, avoiding the addition of separate cooling devices and thus preventing an increase in overall system complexity.
3Temperature
If multiple cooling features are integrated into the cover, then thermal management effectiveness is improved, but manufacturing complexity increases
Solution Approach 1:
The patent segments the cooling function into multiple independent features including cooling channels, heat dissipation fins, and thermoelectric device mounting structures. Each feature can be designed and manufactured separately using appropriate processes, then integrated into the final cover assembly. This segmentation allows for specialized manufacturing techniques for each cooling feature while maintaining overall thermal management effectiveness.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively manages thermal energy within the connector assembly, preventing damage and ensuring compliance with industry standards by actively or passively cooling the electrical busbars, thereby maintaining optimal operating temperatures during high-power transactions.
Implementation Method 1
a coolant channel (102) in fluidic communication with the inlet port (104) and the outlet port (106)
Implementation Method 2
passing a cooling liquid therethrough
Implementation Method 3
a thermoelectric device (202)
Implementation Method 4
a plurality of cooling fins (502) extending from the cover (500)
Implementation Method 5
a plurality of cooling fins (502) extending from the cover (500)
Implementation Method 6
dielectric thermal interface materials
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An electrical connector assembly (10) includes a connector housing (16) defining a cavity (18) in which an electrical busbar (14) is disposed. The connector housing (16) defines an opening to the cavity (18). The electrical connector assembly (10) also includes a cover (100, 200, 300, 400, 500, 600) attached to the connector housing (16) and configured to cool the busbar (14), arranged proximate the busbar (14) to extract heat from the busbar (14). The cover (100, 200, 300, 400, 500, 600) is selected from a plurality of cover designs configured to actively or passively cool the busbar (14).