EV Charging Inlet Cooling Structure for High-Current Contacts
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Solution Overview
Problem
Charging inlets for electric vehicles face challenges in efficiently dissipating heat generated during high-current charging, as existing cooling systems are inadequate for mechanical contacts conducting high currents, leading to reduced charging power and longer charging times.
Innovation Solution
A charging inlet design featuring thermally interconnected conductors and a cooling member with a heat sink, along with a housing made from thermally conductive materials, and relays connected via sheet metal and connectors, to efficiently dissipate heat and maintain safety and efficiency during charging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high charging currents are used to reduce charging time, then charging power increases and charging time decreases, but heat generation at mechanical contacts increases leading to overheating
Solution Approach 1:
The patent extracts the heat dissipation function from the mechanical contact structure by introducing separate cooling channels that flow through the housing and contacts. This allows the charging inlet to handle high currents while the cooling system independently manages the heat generated, resolving the contradiction between high charging power and contact temperature control
Solution Approach 2:
The patent introduces cooling fluid as an intermediary substance that absorbs heat from the mechanical contacts and inlet poles. The cooling channels act as intermediary pathways that transfer heat away from the high-current contact points, enabling sustained high charging currents without overheating
2Temperature
If cooling systems are added to handle high currents, then heat dissipation improves, but device complexity increases
Solution Approach 1:
The patent merges the cooling system with the housing structure by integrating cooling channels directly into the housing body. This combination eliminates the need for separate cooling components and simplifies the overall device while maintaining effective heat dissipation from the mechanical contacts
Solution Approach 2:
The housing serves multiple functions: it provides structural support, contains the mechanical contacts, and simultaneously acts as a heat dissipation structure through integrated cooling channels. This multi-functionality reduces device complexity by eliminating the need for separate cooling components
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 enables consistent high charging currents by effectively dissipating heat, reducing resistance, and enhancing safety through efficient cooling and electrical decoupling, making it suitable for electric trucks with large battery capacities.
Implementation Method 1
at least one first conductor (5) interconnected electrically and thermally to the first inlet pole (3) and at least one second conductor (6) interconnected electrically and thermally to the second inlet pole (4)
Implementation Method 2
a cooling member (7) thermally interconnected to the first and the second conductor (5, 6) to provide a heat sink for the socket (2) and the plug during charging
Implementation Method 3
a housing made from thermally conductive materials
Data Source
AI summary
A charging inlet (1) for interconnecting an external power supply to a battery system of an electric vehicle to charge the battery system. The charging inlet (1) typically comprises a socket (2) suitable to receive during charging a compatible plug, wherein said socket (2) comprising at least one first inlet pole (3) and at least one second inlet pole (4) for connecting to the external power supply via the compatible plug. Usually a first conductor (5) is interconnected electrically and thermally to the first inlet pole (3) and a second conductor (6) is interconnected electrically and thermally to the second inlet pole (4). A cooling member (7) can be thermally interconnected to the first and the second conductor (5, 6) to provide a heat sink for the socket (2) and the plug during charging.