Cable Heat Exchanger for EV Power Connector Cooling
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Solution Overview
Problem
Power connectors in charging inlet assemblies for electric vehicles experience increased temperature and potential damage due to higher current flows, necessitating an effective cooling system to manage heat generation.
Innovation Solution
A cooling system is integrated into the power connector, featuring a cable heat exchanger with a coolant channel and a thermally conductive separator to actively cool the power cables and terminals, utilizing a cooling adapter with supply and return ports for coolant flow, effectively dissipating heat from the power cables and terminals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If higher current is transmitted through the terminals for charging the battery, then the charging speed is improved, but the temperature of the terminals and power cables increases which may damage the components
Solution Approach 1:
A cable heat exchanger is introduced as an intermediary component between the power cable and the cooling system. The heat exchanger includes a coolant channel that allows coolant to flow through and absorb heat from the cable conductor, preventing direct thermal damage to the cable while enabling high current transmission for fast charging
Solution Approach 2:
A hydraulic cooling system is implemented using coolant flowing through channels in the cable heat exchanger and housing. The coolant absorbs heat from the power cable and terminals through thermal conduction, then transports the heat away from the connector assembly, enabling sustained high current operation without temperature damage
2Temperature
If a cooling system is added to the power connector, then the temperature control is improved, but the device complexity increases
Solution Approach 1:
The cable heat exchanger is integrated with the power connector housing, merging the cooling function into the existing structural component. The housing itself forms part of the cooling circuit, eliminating the need for separate cooling components and reducing overall system complexity while maintaining effective temperature control
Solution Approach 2:
The housing serves multiple functions: it provides structural support for the connector, encloses the internal components, and simultaneously acts as a coolant channel for heat dissipation. This multi-functionality reduces the number of separate components needed, simplifying the overall device while achieving effective cooling
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 cooling system effectively reduces the operating temperature of the power connectors, enabling higher current transmission while preventing damage, thereby enhancing the performance and reliability of the charging inlet assembly.
Implementation Method 1
a coolant channel for coolant flow through the cable heat exchanger for actively cooling the conductor of the power cable
Implementation Method 2
The cable heat exchanger is positioned in the chamber that is thermally coupled to the conductor of the power cable
Data Source
AI summary
A power connector includes a housing having a terminal channel holding a terminal. The terminal includes a mating pin at a front of the terminal and a cable connector at a rear of the terminal. The mating pin is positioned in the terminal channel for mating with a charging connector. The power connector includes a power cable including a conductor terminated to the cable connector at the rear of the terminal. The power connector includes a cable heat exchanger thermally coupled to the conductor of the power cable. The cable heat exchanger includes a coolant channel for coolant flow through the cable heat exchanger for actively cooling the conductor of the power cable. A thermally conductive separator electrically isolates the cable heat exchanger from the conductor of the power cable.