Charging Plug Temperature Sensor Spacing
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Solution Overview
Problem
Existing plug-in charging connections face challenges in reliable temperature monitoring, especially when cooled components are involved, as temperature sensors' readings can be affected by active and passive cooling devices.
Innovation Solution
A load-contact module with a temperature sensor positioned at a distance from the mounting portion, potentially embedded in thermally conductive plastics and coupled with a thermally conducting contact spring, ensures accurate temperature monitoring by minimizing the impact of cooling devices, with a distance of at least 10 mm between the sensor and the mounting portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the temperature sensor is positioned close to the mounting portion for compact design, then the device complexity is reduced, but the temperature measurement precision is compromised due to interference from cooling devices
Solution Approach 1:
The patent positions the temperature sensor in a spatial dimension that is distant from the mounting portion (at least 10mm away), effectively using spatial separation to avoid thermal interference from cooling devices while maintaining measurement accuracy of the load contact region
2Power
If cooling devices are implemented to transfer higher charging power, then the power transfer capability is improved, but the temperature monitoring reliability is degraded due to interference with temperature sensor readings
Solution Approach 1:
The patent introduces a thermal insulation structure as an intermediary between the cooling devices and the temperature sensor, allowing the cooling function to operate effectively for high power transfer while preventing the cooling devices from interfering with the temperature sensor's ability to reliably monitor the load contact region
3Measurement precision
If the temperature sensor is placed near the load contact for accurate measurement, then the measurement precision is improved, but the sensor becomes susceptible to interference from cooling devices
Solution Approach 1:
The patent extracts the temperature sensor from the immediate vicinity of the cooling devices by positioning it at least 10mm away from the mounting portion, thereby separating the sensing function from the thermal management components while still enabling accurate temperature monitoring of the load contact region through strategic positioning
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 configuration allows for reliable temperature monitoring of the charging process without interference from cooling devices, enabling effective prevention of overheating and ensuring safe operation of charging systems.
Implementation Method 1
the temperature sensor being at a distance from the mounting portion... the thermal conductivity of the plastics material ensuring thermal coupling to surrounding components
Implementation Method 2
the temperature sensor may be received in a thermally conductive plastics material and/or may be cast in a thermally conductive plastics material at least in part. Therefore, the temperature sensor can be securely received by the plastics material within the load-contact module in a protected manner, the thermal conductivity of the plastics material ensuring thermal coupling to surrounding components
Data Source
AI summary
A load contact module for a charging plug-in connection includes: a load contact, which is designed to electromechanically contact a load contact to be inserted and/or slid on; a mounting portion, which is designed to connect the load contact module to a support of a charging plug and/or of a charging socket; and a temperature sensor for the temperature monitoring of a charging process, wherein the temperature sensor has a distance from the mounting portion.