Liquid-Cooled Charging Connector Manifold for High-Current Heat Dissipation
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Solution Overview
Problem
Current charging connectors for electric vehicles are limited in their ability to dissipate heat, restricting the current loads they can support during fast charging.
Innovation Solution
A liquid-cooled charging connector design featuring concentrically coupled sleeves and a manifold assembly that creates a fluid flow path for cooling fluid to remove heat generated by electrical sockets, using thermally conducting materials to enhance heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional charging connectors are used, then the structure is simple, but the heat dissipation ability is limited and current load capacity is restricted
Solution Approach 1:
The connector is divided into multiple functional segments: electrical sockets for power transfer, thermally conducting sleeves for heat removal from each socket, and a manifold assembly with integrated fluid flow paths. This segmentation allows each component to specialize in its function while collectively achieving superior heat dissipation.
Solution Approach 2:
A cooling fluid serves as an intermediary medium between the electrical sockets (heat source) and the external environment. The fluid absorbs heat through the thermally conducting sleeves and manifold, transporting thermal energy away from the connector to achieve effective cooling.
2Productivity
If high current loads are used for fast charging, then charging time is reduced, but heat generation increases beyond the connector's dissipation capability
Solution Approach 1:
The cooling fluid flows continuously through the manifold assembly and fluid paths, maintaining constant heat removal throughout the charging process. This continuous cooling action enables sustained high current loads without thermal buildup, allowing fast charging to proceed at full speed throughout the entire charging cycle.
Solution Approach 2:
A liquid cooling system utilizing fluid dynamics is implemented through the manifold assembly with inlet and outlet conduits. The hydraulic flow of cooling fluid provides efficient heat transfer capability, enabling the connector to handle the thermal loads associated with high-current fast charging operations.
3Loss of energy
If thermally conducting materials are used in sleeves, then heat transfer efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The connector employs composite construction combining thermally conducting materials in the sleeves with electrical insulating materials in the manifold assembly. This composite approach allows optimization of each component for its specific function while maintaining manufacturability through standardized fabrication processes for each material type.
Solution Approach 2:
Thermally conducting materials are applied locally only where heat transfer is critical - specifically in the sleeves surrounding the electrical sockets - rather than throughout the entire connector. This localized application maximizes heat transfer efficiency at the heat generation points while minimizing overall manufacturing complexity and cost.
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 design effectively cools the charging connector, allowing it to handle higher current loads and reduce charging times by efficiently transferring heat away from the electrical components.
Implementation Method 1
The cooling sleeves are made from a thermally conducting material such that heat generated by electrical sockets can be removed by the cooling fluid
Implementation Method 2
Cooling fluid flows through the fluid flow path and cools the charging connector
Data Source
AI summary
A charging connector includes a first electrical socket and a second electrical socket. A first sleeve and a second sleeve are provided, such that the first sleeve is concentrically coupled to the first electrical socket and the second sleeve is concentrically coupled to the second electrical socket. A manifold assembly is adapted to enclose the first and second electrical sockets and the first and second sleeves, such that the first and second sleeves and the manifold assembly create a hollow interior space there between. An inlet conduit and an outlet conduit within the manifold assembly such that inlet conduit, the interior space, and the outlet conduit together create a fluid flow path.