Charging Plug Connector Pneumatic Cooling
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Solution Overview
Problem
Current EV charging connectors face challenges with thermal management due to flat contact elements, leading to inefficient heat dissipation and potential mechanical and safety issues, especially when handling higher currents and voltages required for fast charging of heavy vehicles.
Innovation Solution
The implementation of a charging plug connector that utilizes a compressed air stream for cooling, guided through the connector to directly cool the power contact components, enhancing heat transfer and incorporating safety features to manage air flow and pressure for efficient cooling and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If flat contact elements are used for mating interface, then mechanical connection is simplified, but heat dissipation efficiency deteriorates
Solution Approach 1:
The patent replaces flat contact elements with cylindrical contact elements. This curvature change increases the surface area for heat dissipation and improves thermal management while maintaining the mating interface functionality. The cylindrical shape allows for better heat evacuation from the contact tips compared to flat surfaces.
Solution Approach 2:
The patent introduces a new dimension for heat management by implementing internal cooling channels within the cylindrical contact elements. This allows coolant flow through the center of the contacts, creating a three-dimensional thermal management system that addresses the heat dissipation issue without compromising the simplified mating interface design.
2Temperature
If forced liquid cooling is used for cable and contacts, then cooling effectiveness is improved, but system complexity and water ingress risk increase
Solution Approach 1:
The patent transitions from liquid cooling to pneumatic cooling by using compressed air instead of liquid coolant. This eliminates the risk of water ingress into the connector while maintaining effective cooling of the cable and contacts. The compressed air system provides sufficient heat removal without the complications associated with liquid handling.
Solution Approach 2:
The patent replaces the liquid-based thermal management system with an air-based system. This substitution eliminates the need for sealed liquid channels and reduces the complexity of the cooling system while improving reliability by removing the water ingress vulnerability inherent in liquid cooling systems.
3Power
If connector design handles higher currents (1000 A), then charging power is improved, but heating losses and thermal management difficulty increase
Solution Approach 1:
The cylindrical contact elements provide increased surface area compared to flat contacts, enabling more effective heat dissipation. This geometric change helps manage the heating losses that increase with higher current handling capability, allowing the connector to safely operate at 1000 A and above.
Solution Approach 2:
The patent implements pre-cooling of the compressed air before it enters the connector housing. This preliminary cooling action ensures that the air entering the connector is at its lowest temperature, maximizing the heat removal efficiency and addressing thermal management challenges before the air contacts the high-current 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
This solution significantly improves thermal management and safety of EV charging connectors, reducing heat exchange issues and mechanical failures, while being cost-effective and familiar in the automotive sector, with the added benefit of using widely available and standard compressed air.
Implementation Method 1
The charging plug connector is configured to guide a compressed air stream, which is provided to the compressed air connector, to the power contact component for cooling it
Implementation Method 2
a second connecting region electrically coupled to a charging cable for providing of electrical energy to the power contact component
Data Source
Figure 1~2
Figure 3~4
Figure 5a~5b
AI summary
A charging plug connector (100) for transfer of electrical energy to a corresponding connecting device (210) is described, with: at least one power contact component (122), including: a first connecting region (120) for galvanic connection to a corresponding connection region of the connecting device (210); a second connecting region (124) electrically coupled to a charging cable (130); wherein the power contact component (122) is configured to provide electrical energy from the charging cable (130) to the first connecting region (120); a charging plug housing (107) covering the power contact component (122); and a compressed air connector (110), which is mechanically coupled to the charging plug housing (107), wherein the charging plug connector (100) is configured to guide a compressed air stream, which is provided to the compressed air connector (110), to the power contact component (122) for cooling it.