EV Charging Inlet Busbar Layout for Passive Heat Dissipation
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Solution Overview
Problem
Existing electric vehicle charging inlets face challenges in efficiently dissipating heat without increasing complexity or cost, and existing active and passive cooling systems have limitations such as coolant management issues, high manufacturing costs, and cumbersome assembly processes.
Innovation Solution
The use of rectangular busbars with a high surface area per volume, which are ultrasonically welded to DC terminals and wire cables, providing efficient heat dissipation and simplifying assembly by reducing the need for flexible cables along the entire connection length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If active-cooled systems with coolant lines are used, then terminal contact interface temperature is effectively limited, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent extracts the cooling function from a separate active coolant system and integrates it directly into the busbar structure itself. The busbar serves dual purposes: electrical conduction and heat dissipation through its extended surface area, eliminating the need for separate coolant lines and heat exchangers.
Solution Approach 2:
The busbar is designed to perform multiple functions simultaneously: it conducts electrical current from the charging inlet and dissipates heat through its extended surface area. This multi-functional design eliminates the need for separate dedicated cooling components.
2Temperature
If passive-cooling systems with potting material are used, then heat dissipation is achieved, but manufacturing complexity and cost increase without significant temperature reduction
Solution Approach 1:
The patent changes the physical parameters of the busbar, specifically its cross-sectional geometry, from a conventional design to one with an extended surface area. This geometric parameter change enables passive heat dissipation through increased surface exposure without requiring additional cooling materials or complex assembly processes.
3Temperature
If conventional round cable connections are used, then flexibility is maintained, but heat dissipation surface area is insufficient
Solution Approach 1:
The patent introduces asymmetry in the busbar cross-section, using a rectangular or irregular shape rather than a symmetric round cable. This asymmetric geometry maximizes the surface area perpendicular to the heat flow direction, thereby enhancing heat dissipation while maintaining the necessary electrical and mechanical connection properties.
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 rectangular busbars effectively distribute heat across a larger surface area, allowing for longer charging times before reaching temperature thresholds and enabling easier assembly with reduced manufacturing complexity and cost.
Implementation Method 1
The first and second busbars are made of a thermally conductive material and each have a rectangular cross section
Implementation Method 2
The first and second busbars are ultrasonically welded to the first and second DC terminals, respectively, and to the first and second wire cables, respectively
Data Source
AI summary
An electrical connector assembly includes a connector housing defining a cavity and an opening providing access to the cavity, first and second direct current (DC) terminals disposed within the cavity, and first and second busbars electrically and mechanically attached directly to the first and second DC terminals respectively. The first and second busbars each have a rectangular cross section and wherein the first and second busbars extend through the opening such that portions of the first and second busbars are outside of the connector housing. A method of manufacturing an electrical connector assembly is also provided.