Charging Connector Cooling Link for High-Current EV Interfaces
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Solution Overview
Problem
High currents flowing through charging devices for electric vehicles lead to heating issues and reduced current output, posing safety risks and violating temperature regulations, particularly at transition points like charging connectors and sockets.
Innovation Solution
An Advanced Cooling Device (ACD) is introduced, comprising a thermally and electrically conductive power link connected to a cooling unit, positioned between the charging connector and socket, which reduces temperatures and enhances current handling capacity by dissipating heat through various methods such as heat pipes, forced air convection, and Peltier cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high currents are conducted through charging cables and connectors, then charging power is improved, but temperature increases causing safety risks and reduced current output
Solution Approach 1:
The patent introduces a cooling arrangement as an intermediary component between the charging connector and charging socket. This cooling arrangement includes a cooling unit with thermal contact to the power link, acting as a mediator to transfer heat away from the high-current conducting path, thereby enabling high power transmission without excessive temperature increase
Solution Approach 2:
The patent replaces passive thermal management with active cooling systems. Instead of relying on natural heat dissipation, the invention incorporates active cooling units (such as Peltier elements, forced convection systems, or liquid cooling) that actively pump heat away from the connector, substituting passive thermal conduction with active thermal management
2Temperature
If cooling arrangements are added to reduce temperature, then temperature control is improved, but device complexity increases
Solution Approach 1:
The cooling arrangement is applied locally only at the charging connector and socket interface where heat generation is most critical, rather than cooling the entire charging system. This localized approach provides effective temperature control at the problem source while minimizing the overall complexity and cost of the cooling system
Solution Approach 2:
The cooling unit is integrated within or alongside the existing connector housing structure, with the cooling elements nested within the connector body. The power link serves dual purposes as both electrical conductor and thermal interface, nesting the cooling function within the existing electrical connection framework rather than adding separate external cooling systems
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 ACD effectively reduces temperatures at charging connectors and neighboring parts, allowing higher continuous current output while ensuring safety compliance with temperature regulations, enabling higher charging currents than previously feasible.
Implementation Method 1
dissipating heat through various methods such as heat pipes
Implementation Method 2
dissipating heat through various methods such as heat pipes, forced air convection
Implementation Method 3
dissipating heat through various methods such as heat pipes, forced air convection, and Peltier cells
Data Source
AI summary
A cooling arrangement for being arranged between a charging connector of an electric vehicle charging system and a charging socket of an electric vehicle includes a power link that is electrically and thermally conductive and configured for being arranged between a charging contact of the charging connector and a socket contact of the charging socket, wherein the power link is thermally connected to a cooling unit.