Vehicle Charging Connector Thermal Pad for Reliable Temperature Sensing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical connectors in battery-powered electric vehicles suffer from damage during assembly due to the brittleness of silicone-based sealing pads used for thermal conductivity, leading to potential sealing failures and limited thermal contact with temperature sensors.
Innovation Solution
Incorporating a separate, thermally conductive pad with higher conductivity than the sealing pad, which is compressed between the sealing pad and a printed circuit board, ensuring stable thermal contact with the terminals and sensors, while allowing the sealing pad to be made of standard silicone rubber for robustness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If silicone rubber is used as sealing pad material to provide good sealing function, then sealing reliability is improved, but thermal conductivity deteriorates
Solution Approach 1:
The patent divides the thermal management function into two separate components: the sealing pad made of silicone rubber for sealing, and a separate thermal shunt for heat conduction. This segmentation allows each component to be optimized for its specific function without compromise.
Solution Approach 2:
The thermal shunt acts as an intermediary component between the contact terminals and the temperature sensor. It mediates the thermal path, conducting heat from the terminals to the sensor while being mechanically coupled to the sealing pad structure.
2Temperature
If additional ingredients are added to silicone to improve thermal conductivity, then thermal conductivity is improved, but material brittleness increases
Solution Approach 1:
The patent separates the thermal conduction function from the sealing material by introducing a dedicated thermal shunt component. This eliminates the need to modify the silicone rubber composition, thereby avoiding increased brittleness while still achieving improved thermal conductivity through the separate shunt element.
3Temperature
If sealing pad is made more brittle to improve thermal conductivity, then thermal conductivity is improved, but resistance to damage during assembly deteriorates
Solution Approach 1:
The patent creates a separate thermal shunt component that handles the thermal conduction function, allowing the sealing pad to remain made of flexible, damage-resistant silicone rubber. The thermal shunt can be optimized for thermal conductivity without compromising the mechanical properties of the sealing pad.
Solution Approach 2:
The thermal shunt serves as an intermediary that provides the thermal conduction path without requiring the sealing pad itself to be brittle. This intermediary component can be made from materials with high thermal conductivity while the sealing pad maintains its flexibility and damage resistance.
4Device complexity
If sealing pad serves dual function of sealing and thermal conduction, then device complexity is reduced, but manufacturing reliability deteriorates
Solution Approach 1:
The patent divides the functions into separate components: sealing pad for sealing and thermal shunt for thermal conduction. Although this increases component count slightly, it significantly improves manufacturing reliability by eliminating the need for brittle modified silicone and preventing sealing lamella breakage during assembly.
Solution Approach 2:
The thermal shunt is designed to be mechanically coupled to the sealing pad structure, allowing it to serve multiple purposes: providing the thermal conduction path and maintaining the structural integrity of the sealing assembly. This multi-functionality approach balances component separation with structural integration.
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
This design enhances thermal conductivity and reduces the risk of damage to temperature sensors by improving thermal contact and mechanical stability, ensuring reliable temperature monitoring and preventing sealing failures during assembly.
Implementation Method 1
a thermal conductive pad, having a higher thermal conductivity than the sealing pad and coupled to said sealing pad adjacent to the at least one hole, wherein said thermal conductive pad includes at least one first thermal contact surface in direct engagement with the at least one contact terminal, and a second thermal contact surface in direct engagement with the at least one thermal sensor, to transfer heat from the at least one contact terminal to the at least one thermal sensor
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The electrical connector (100) comprises at least one contact terminal (20); a sealing pad (30) with at least one hole (31) for receiving the at least one contact terminal (20); at least one thermal sensor (41) to monitor the temperature of the at least one contact terminal (20); characterized in that the electrical connector (100) further comprises a thermal conductive pad (50), having a higher thermal conductivity than the sealing pad (30) and coupled to said sealing pad (30) adjacent to the at least one hole (31), wherein said thermal conductive pad (50) includes at least one first thermal contact surface (51) in direct engagement with the at least one contact terminal (20), and a second thermal contact surface (52) in direct engagement with the at least one thermal sensor (41), to transfer heat from the at least one contact terminal (20) to the at least one thermal sensor (41).