Charging Plug Load Contact Module With Overheat Sensing
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Solution Overview
Problem
Standardized charging plugs for motor vehicles face overheating issues during high-power charging, leading to potential damage, and existing active cooling systems may not adequately prevent overheating.
Innovation Solution
Incorporating a detachable and replaceable load contact module with a temperature sensor that measures and monitors the temperature of the load contact, allowing for abortion or interruption of the charging process when overheating is detected, thus preventing damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high levels of charging power are transmitted via standardized connections, then charging power increases, but damage to charging plug or socket due to overheating occurs
Solution Approach 1:
The patent implements temperature monitoring before damage occurs by placing temperature sensors in the load contact module that continuously measure temperature during charging operations. This preliminary detection allows the system to identify overheating conditions early and interrupt charging before damage occurs to the plug or socket
Solution Approach 2:
The patent establishes a feedback loop where temperature sensors monitor the load contact module temperature, relay data to a controller, and trigger charging interruption when threshold values are exceeded. This closed-loop feedback system enables real-time adjustment of charging power based on actual thermal conditions, allowing high power transmission while preventing overheating damage
2Temperature
If active cooling systems are used to cool the charging plug, then temperature control improves, but the charging plug may still overheat and be damaged during high-power transmission
Solution Approach 1:
The patent implements a self-monitoring system where temperature sensors in the load contact module autonomously detect temperature conditions and trigger protective actions without external intervention. The system serves itself by continuously assessing its own thermal state and initiating charging interruption when necessary, providing reliable protection that complements active cooling systems
Solution Approach 2:
The temperature monitoring system detects overheating conditions before they cause damage, allowing preliminary protective action to be taken. By monitoring temperature continuously and interrupting charging at predefined threshold values, the system prevents damage occurrence rather than responding after damage has happened
3Reliability
If the temperature sensor is integrated into the load contact module, then temperature monitoring reliability improves, but the device complexity increases
Solution Approach 1:
The patent combines the temperature sensor with the load contact module by securing the sensor to the module housing or integrating it into the module structure. This merging approach ensures the sensor moves with the load contact module during replacement, maintaining reliable temperature monitoring while using existing modular components rather than adding separate complex systems
Solution Approach 2:
The load contact module serves multiple functions: it provides electrical contacts for power transmission and houses the temperature sensor for thermal monitoring. This multi-functionality reduces overall device complexity by combining monitoring capabilities into an existing replaceable module rather than adding separate dedicated sensor assemblies
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 temperature sensor effectively prevents overheating damage by allowing for timely intervention during high-power charging, ensuring the longevity of the charging plug and socket.
Implementation Method 1
The load contact module (6) has a temperature sensor (16)
Implementation Method 2
The temperature sensor may be connected to the load contact via a material having high heat conductivity
Data Source
AI summary
A charging plug for a motor vehicle, having a connection module and a load contact module, the connection module being connectable to supply lines for supplying power, the load contact module having a load contact for transmitting charging power, and the load contact module being detachably and replaceably secured to the connection module, the load contact module including a temperature sensor.