Charging Connector PCB Sensor Layout for Power Contact Overheating
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Solution Overview
Problem
The increased electric current intensity for faster charging of electric and hybrid vehicles poses a risk of overheating, potentially leading to fires, necessitating effective temperature monitoring at power contacts.
Innovation Solution
A connection device with a housing containing power contacts and a printed circuit board equipped with temperature sensors, where metal pads ensure optimal thermal conductivity and contact, allowing for rapid detection of abnormal temperature rises.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the electric current intensity is increased to reduce charging time, then the charging power is improved, but the risk of overheating increases
Solution Approach 1:
Temperature sensors are pre-installed at the power contacts to detect temperature changes before dangerous overheating occurs. This preliminary monitoring allows the system to take preventive action (interrupting power supply) before the harmful effect of overheating can manifest, thus enabling high current charging while preventing the associated overheating risk.
Solution Approach 2:
The temperature sensors provide continuous feedback on the thermal state of the power contacts. This feedback mechanism allows the charging system to monitor temperature in real-time and adjust or interrupt operation based on temperature conditions, enabling safe high-power charging by continuously responding to thermal conditions.
2Reliability
If temperature sensors are installed at power contacts to monitor overheating, then the safety is improved, but the device complexity increases
Solution Approach 1:
The temperature sensors are integrated directly into the housing structure at the power contact locations, merging the monitoring function with the existing structural components. This integration approach adds safety functionality without requiring separate complex sensor mounting systems, thus improving safety while minimizing the increase in device complexity.
Solution Approach 2:
The housing structure itself serves as the mounting platform for the temperature sensors, with grooves and retaining walls that are part of the normal housing design. This self-service approach means the existing structure provides the necessary support and positioning for sensors, avoiding the need for additional complex mounting mechanisms.
3Measurement precision
If multiple temperature sensors are installed to monitor all power contacts, then the measurement precision is improved, but the device complexity increases
Solution Approach 1:
Temperature sensors are selectively installed at specific power contact locations where temperature monitoring is most critical. This local quality approach ensures precise temperature measurement at key points without the need to instrument every possible location, achieving adequate monitoring precision with a limited number of sensors.
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 monitors and manages temperature at power contacts, mitigating the risk of overheating and ensuring safe charging operations by enabling early detection and intervention.
Implementation Method 1
a first metal pad which is compressed between the printed circuit board and an axial surface of the rear section of the first power contact
Data Source
AI summary
A connection device includes a housing, a power contact disposed within the housing, and a printed circuit board mounted in the housing having a first face provided with a first metal pad which is located between the printed circuit board and a surface of the power contact, and a second face provided with a first temperature sensor which is arranged opposite the first metal pad. A method of electrical connection to a vehicle to a charging cord provided with a charging socket is also provided.