Charging Socket Connector Cooling With Electrical Isolation

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Solution Overview

Problem

Existing plug-in connector parts face challenges in achieving effective heat dissipation and reliable electrical insulation, particularly when high voltages are applied, due to the integration of cooling elements that are either insufficiently insulated or increase weight and cost.

Innovation Solution

The cooling element is electrically insulated from the contact element, using thermally conductive materials with embedded fillers or an electrically insulating heat transfer element to ensure thermal conductivity without electrical coupling, and optionally combining these methods for enhanced insulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If cooling elements are electrically connected to contact elements for heat dissipation, then heat dissipation efficiency is improved, but electrical insulation reliability deteriorates due to high voltage transfer risks

Engineering Contradiction:

Improvecontact element temperatureVSAvoidelectrical insulation reliability

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

An electrically insulating heat transfer element is introduced as an intermediary between the contact element and cooling element. This mediator enables thermal energy transfer while preventing electrical conduction, thus resolving the contradiction between heat dissipation efficiency and electrical insulation reliability.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The heat transfer element is made from composite materials that possess both high thermal conductivity and high electrical insulation properties. This allows the single component to simultaneously achieve effective heat dissipation and reliable electrical insulation under high voltage conditions.

Inventive Principle:

Principle #40Composite materials

2Temperature

If solid cuboidal metal cooling elements are used for heat dissipation, then cooling performance is improved, but device weight and cost increase

Engineering Contradiction:

Improvecooling performanceVSAvoidconnector part weight

Core Design Contradiction:

TemperatureVSWeight of stationary object

Solution Approach 1:

The patent employs composite materials with high thermal conductivity but low density to create cooling elements that maintain effective cooling performance while significantly reducing weight compared to traditional solid metal cooling elements.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The cooling element utilizes porous material structures that provide adequate thermal management while reducing mass. The porous architecture allows for heat dissipation through increased surface area while maintaining lower weight than solid cuboidal metal designs.

Inventive Principle:

Principle #31Porous materials

3Reliability

If insulation between cooling elements is increased to prevent electrical short circuits, then electrical insulation reliability is improved, but heat dissipation efficiency deteriorates

Engineering Contradiction:

Improveelectrical insulation reliabilityVSAvoidheat dissipation efficiency

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The insulation material between cooling elements is formulated as a composite with high electrical resistivity and high thermal conductivity. This enables the insulation layer to prevent electrical short circuits while simultaneously allowing efficient heat transfer from the cooling elements.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent optimizes the insulation layer thickness and material properties to achieve a balance where electrical insulation is sufficient for high voltage applications while thermal resistance remains low enough to maintain effective heat dissipation from multiple cooling elements.

Inventive Principle:

Principle #35Parameter changes

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 design allows for efficient heat dissipation and reliable electrical insulation, preventing voltage transfer to the cooling element while maintaining lightweight and cost-effective construction.

Implementation Method 1

a cooling element (5) which is in thermal contact with the electrical contact element (3)

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

an electrically insulating heat transfer element (6) which thermally connects the contact element (3) and the cooling element (5)

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

the contact element (3) and the cooling element (5) are electrically insulated from one another

Methodology Applied

Scientific EffectElectrical insulation: Thermal Insulation

Data Source

PatentUS20260027923A1Plug-in connector part

Publication Date: 2026.01.29 KIEKERT AG

AI summary

The invention relates to a plug-in connector part for mechanical and electrical connection to a mating plug-in connector part, in particular relates to a charging socket (1) on a motor vehicle for coupling with a charging plug as constituent parts of an electric charging infrastructure for electric or hybrid motor vehicles, or vice versa, having a housing (2) composed of plastic and also having at least one electrical contact element (3), which is arranged in the housing (2). A cooling element (5), which is in thermal contact with the electrical contact element (3), is also realized. According to the invention, the contact element (3) and the cooling element (5) are electrically insulated from each other.