Charging Socket Busbar Assembly for Safe High-Power Connection
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Solution Overview
Problem
The challenge in electric vehicle charging is to minimize charging times while ensuring safe and reliable assembly of high-power electrical connections, which require low transition resistances and secure connections to handle high voltages, and to maintain long-term stability and protection against environmental influences.
Innovation Solution
A connecting arrangement with a housing made from non-conductive materials, featuring busbars with a rectangular cross-section and side recesses for secure locking, and integrating conductive materials like aluminum with coatings for enhanced conductivity and thermal management, along with retaining means and seals for safety and insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high charging powers with high currents and voltages are used to minimize charging times, then charging speed is improved, but the risk of contact during assembly and maintenance increases
Solution Approach 1:
The charging connection system is divided into separate components: a charging socket with housing and a connecting arrangement with busbars. The housing encloses the high-voltage components during assembly, allowing safe handling while maintaining high charging power capability when connected.
Solution Approach 2:
The housing acts as an intermediary protective barrier between assembly personnel and the high-voltage busbars. It provides mechanical enclosure and electrical insulation, enabling safe assembly operations while the internal components maintain high power transmission capability.
2Use of energy by moving object
If high charging powers are transmitted through the charging path, then charging efficiency is improved, but transition resistances must be minimized requiring precise connections
Solution Approach 1:
The busbar is integrated directly into the housing structure, merging the electrical connection component with the protective enclosure. This integration ensures stable, low-resistance electrical contact while reducing the number of separate connection points that would require precise alignment.
3Reliability
If the housing is made from non-conductive materials for safety, then electrical insulation is improved, but thermal management becomes more challenging
Solution Approach 1:
The housing is designed with differentiated thermal properties in different regions. Areas near heat-generating components have enhanced thermal conduction paths, while other regions maintain electrical insulation. This local optimization allows the non-conductive housing to manage heat effectively without compromising safety.
4Reliability
If all electrical contacts are covered and sealed after assembly, then safety and service life are improved, but assembly complexity increases
Solution Approach 1:
The busbar is pre-integrated into the housing structure during manufacturing, with connection points prepared in advance. This preliminary preparation allows for simpler final assembly while ensuring that all electrical contacts are properly enclosed and sealed from the outset.
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 provides a safe, efficient, and reliable high-power electrical connection system that reduces charging times, ensures secure assembly, and protects against environmental factors, enhancing the service life of components and user safety.
Implementation Method 1
The housing of the connecting arrangement can be formed from a non-conductive material... a combination of a plurality of materials... a non-conductive material such as plastics material, ceramic, and/or glass
Implementation Method 2
the entire transmission path of the charging station socket from the charging station socket, via the vehicle-side charging socket, as far as the battery must offer very good electrical conduction
Implementation Method 3
at least partially thermally highly conductive materials... a housing formed at least partially from a metal material can provide a high thermal capacity and a high thermal conductivity to the surrounding environment
Data Source
AI summary
The invention relates to a connecting arrangement, a charging socket and to a system of a charging socket and a connecting arrangement, which are distinguished by in each case a high thermal conductivity and thermal capacity and allow a reliable assembly. In particular, this is made possible by the use of a busbar with a tapering connecting bolt with through hole.