Charging Connector Heat Transfer Structure for Terminal Cooling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Connectors used in vehicles for charging electric vehicle batteries face challenges in maintaining the operating temperature within standard limits, especially during rapid charging, due to limited natural heat dissipation and space constraints.
Innovation Solution
A connector design that incorporates a terminal-equipped electric wire, a housing with a resin and metal holder, and a heat transfer member with elasticity, which is compressed and deformed to enhance heat dissipation between the terminal and the housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If natural heat dissipation is used during rapid charging, then the connector structure remains simple, but the terminal operating temperature exceeds standard limits
Solution Approach 1:
A heat transfer member (made of heat-conductive rubber or resin) is introduced as an intermediary between the terminal and the housing. This member has high heat conductivity to efficiently transfer heat from the terminal to the housing, while also providing cushioning and shock absorption. The heat transfer member acts as a mediator that resolves the contradiction by enabling effective heat dissipation without requiring complex active cooling systems or structural modifications.
Solution Approach 2:
The heat transfer member is made of composite material (heat-conductive rubber or resin) that combines thermal conductivity with elastic properties. This composite material allows the component to simultaneously perform heat transfer and mechanical cushioning functions, achieving effective heat dissipation while maintaining a simple connector structure without additional components.
2Temperature
If a metal holder is added for heat dissipation, then heat dissipation performance improves, but the connector size and installation space increase
Solution Approach 1:
The heat transfer member is integrated into the existing holder structure (resin holder or metal holder), merging the heat dissipation function with the existing structural component. This integration allows the holder to simultaneously provide mechanical support and thermal management functions, improving heat dissipation performance without increasing connector size or requiring additional separate components.
Solution Approach 2:
The heat transfer member is designed as a thin-walled or flexible component that can conform to the terminal and housing interfaces. This thin-film approach enables effective heat transfer across the interface without adding significant volume or thickness to the connector assembly, thus improving heat dissipation while maintaining compact dimensions.
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 suppresses excessive temperature rises in the terminal during rapid charging, achieving excellent heat dissipation performance while maintaining the connector's compact size and installation space.
Implementation Method 1
a heat transfer member having elasticity. The housing includes a first housing having a terminal accommodating portion configured to accommodate the terminal, and a second housing configured to hold the terminal-equipped electric wire... The heat transfer member is disposed in a compressed and deformed state between an outer circumferential surface of at least one of the electric wire connection portion of the terminal and the end portion of the electric wire and an inner circumferential surface of the second housing, the heat transfer member contacting in a pressed manner the outer circumferential surface of the at least one of the electric wire connection portion and the end portion of the electric wire and the inner circumferential surface of the second housing.
Data Source
AI summary
A connector includes a terminal-equipped electric wire having a terminal connected to an end portion of an electric wire, housing to accommodate the terminal and to hold the terminal-equipped electric wire and a heat transfer member having elasticity. The housing includes a first housing having a terminal accommodating portion, and a second housing to hold the terminal-equipped electric wire. The second housing includes a resin holder to be mounted on an electric wire connection portion of the terminal and the end portion of the electric wire, and a metal holder to be externally mounted on the resin holder. The heat transfer member is disposed in a compressed and deformed state between an outer circumferential surface of at least: one of the electric wire connection portion of the terminal and the end portion of the electric wire and an inner circumferential surface of the second housing.