Vehicle Charging Socket PCM Heat Buffer for High-Current Contacts
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The contact resistance in charging sockets of electric vehicles leads to significant power loss in the form of heat, limiting charging power, especially at high currents, and existing cooling methods are inadequate to manage the increased heat generation from higher charging voltages.
Innovation Solution
Incorporating latent heat storage units with phase change materials (PCMs) directly coupled to the contact elements in the charging socket, which absorb heat during a phase change at a predefined temperature, reducing temperature rise and allowing for efficient heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If higher charging voltages are used to reduce power loss, then power loss is reduced, but the complexity of the charging system increases
Solution Approach 1:
The patent converts the harmful heat generated by contact resistance into a useful function by using it to trigger phase change in the PCM, which then absorbs excess heat and stabilizes temperature, transforming a problematic thermal effect into a beneficial thermal management mechanism
Solution Approach 2:
The patent utilizes phase transition of phase change material (PCM) between solid and liquid states at a predefined temperature to absorb and release heat, thereby stabilizing the temperature of contact elements during high-power charging operations
2Temperature
If contact elements are thermally coupled to latent heat storage unit, then temperature control is improved, but device complexity increases
Solution Approach 1:
The patent merges the container function with the current path function by designing the container to be electrically conductive and integrate it directly into the current path between contact element and terminal, eliminating the need for separate thermal coupling components and reducing structural complexity
Solution Approach 2:
The container serves multiple functions simultaneously: it encloses the phase change material, conducts electrical current, and provides thermal coupling to the contact element, thereby reducing the number of separate components needed in the system
3Loss of energy
If phase change material is held in containers arranged in current path, then heat absorption efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The patent combines the thermal management function and electrical conduction function into a single integrated container structure, which simplifies the manufacturing process by reducing the number of assembly steps and components while maintaining high heat absorption efficiency through direct thermal coupling
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 PCM-based latent heat storage units effectively manage heat generation, enabling higher charging currents without exceeding temperature limits, reducing component count and cost, and enhancing safety by maintaining a uniform temperature profile.
Implementation Method 1
a phase change of a phase change material (PCM) takes place in the latent heat storage unit at a predefined temperature and the phase change uses a large amount of energy
Implementation Method 2
The latent heat storage unit has a high heat capacity since a phase change of a phase change material (PCM) takes place in the latent heat storage unit at a predefined temperature and the phase change uses a large amount of energy
Implementation Method 3
The container is thermally coupled to the respective contact element and is arranged in a current path from the forward line to the return line
Data Source
AI summary
A charging socket for a vehicle, includes at least two contact elements, each contact element having a latent heat storage unit. The latent heat storage unit includes a phase change material arranged in a container. The container is thermally coupled to the respective contact element and is arranged in a current path between the contact element and a terminal of the contact element for a line of a wiring harness of the vehicle.