EV Charging Socket Contact Structure for Heat and Joule Loss Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Electric vehicle charging sockets face challenges in minimizing charging times and managing heat dissipation due to high electrical conductivity and Joule losses during the charging process, requiring improved electrical and thermal performance.
Innovation Solution
A charging socket and connecting part design featuring conductive materials like copper and silver-plated plug-in bolts, a busbar with high heat capacity, and a connecting key bolt system for efficient heat dissipation and low resistance transitions, utilizing materials like aluminum for lightweight and cost-effective conductivity.
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 Joule losses and heat generation increase
Solution Approach 1:
The patent changes the physical parameters of the transmission path components by using copper with high electrical conductivity (≥58 MS/m) and increasing the cross-sectional area of conductive elements. This reduces transition resistances and allows higher charging powers to be transmitted with reduced Joule losses, resolving the contradiction between charging speed and energy loss
Solution Approach 2:
The patent employs composite material structures including copper-plated steel plug-in bolts and aluminum busbars with copper contacts. These composite materials combine the advantages of different materials (strength of steel, conductivity of copper, lightweight of aluminum) to optimize both electrical performance and mechanical properties, reducing heat generation while maintaining high charging capability
2Loss of time
If high charging powers are transmitted through the charging socket, then charging time is reduced, but temperature increase and heat dissipation challenges worsen
Solution Approach 1:
The patent converts the harmful heat generated by Joule losses into a manageable thermal problem by designing an integrated cooling system. The cooling channels are positioned to directly cool the busbar and plug-in bolt interfaces, transforming the heat generation issue into a controlled thermal management solution that enables sustained high-power charging
Solution Approach 2:
The patent applies local quality enhancement by concentrating cooling capacity at the specific locations where heat generation is highest (busbar contacts and plug-in bolt interfaces). The cooling channels are strategically positioned to provide localized heat removal exactly where needed, rather than uniform cooling throughout the housing
3Loss of energy
If transition resistances are reduced to improve electrical conductivity, then charging efficiency is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent merges the electrical contact function with mechanical fastening function in the plug-in bolt design. The plug-in bolt simultaneously provides structural support, electrical contact, and mechanical connection, ensuring consistent contact pressure and low transition resistance without requiring separate adjustment mechanisms. This integrated design reduces sensitivity to manufacturing tolerances
4Loss of energy
If copper materials are used throughout the transmission path for optimal conductivity, then electrical performance is improved, but weight and cost increase
Solution Approach 1:
The patent applies local quality optimization by using copper only at critical locations where electrical contact occurs (plug-in bolts and contact surfaces), while using lighter aluminum for the busbar body and housing structures. This selective material distribution maintains optimal electrical conductivity at contact points while reducing overall weight and cost
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 enhances electrical current transmission and heat dissipation, reducing charging times and ensuring reliable, efficient energy transfer while minimizing heat accumulation, thus improving the overall performance of electric vehicle charging systems.
Implementation Method 1
heat caused by Joule losses during the charging process
Implementation Method 2
the entire transmission path from the charging station socket to the vehicle's charging socket to the accumulator must have very good electrical conductivity
Implementation Method 3
a busbar with high heat capacity
Implementation Method 4
temperature management and thus the absorption and dissipation of heat
Data Source
AI summary
The invention relates to a charging socket with a connecting part, in particular for use in electromobility, wherein a plug-in bolt arranged in the charging socket has at least one recess in which a connecting key bolt of the connecting part engages.