Vehicle Charging Socket PCM Cooling for High-Current Contacts
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Solution Overview
Problem
High contact resistance in electric vehicle charging sockets leads to power loss and heat generation, limiting charging power, especially at high currents, due to the inefficiency in dissipating heat generated by the contact elements.
Innovation Solution
The integration of a latent heat storage system with phase change materials (PCMs) directly coupled to the highly loaded contact elements in the charging socket, where the PCM absorbs energy during a phase change, preventing temperature rise until all material has changed phase, thus effectively dissipating heat generated by the contact elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If contact elements are used to establish conductive connection, then electrical energy transfer is enabled, but contact resistance causes power loss and heat generation that limits charging rate
Solution Approach 1:
The patent utilizes the phase transition properties of phase change materials (PCMs) to absorb heat generated at contact elements during charging. The PCM undergoes phase change (e.g., solid to liquid) at a predefined temperature, absorbing significant thermal energy and preventing temperature rise beyond this point until all PCM has changed phase. This allows higher charging currents to be sustained without exceeding thermal limits.
2Power
If contact elements are used to establish conductive connection, then electrical energy transfer is enabled, but heat generation causes temperature rise that limits charging power
Solution Approach 1:
The phase change material absorbs thermal energy at an approximately constant temperature until all of the phase-change material has undergone a phase change. If sufficient phase-change material is present, a temperature increase beyond this point can be prevented, enabling higher charging power without exceeding thermal limits.
Solution Approach 2:
The latent heat storage unit acts as an intermediary thermal management component between the contact elements and the environment. It provides a controlled thermal buffer that absorbs excess heat from contact elements during high-power charging, preventing direct temperature rise at the contact points.
3Temperature
If latent heat storage units are added to cool contact elements, then thermal management is improved, but device complexity increases
Solution Approach 1:
The container of the latent heat storage unit is designed to also serve as a current-conducting component (busbar or conductor) in the wiring harness. This merging of thermal management function and electrical conduction function into a single component reduces the number of separate parts needed, simplifying the overall construction while maintaining effective cooling of the contact elements.
Solution Approach 2:
The latent heat storage container performs multiple functions simultaneously: it encloses the phase change material for thermal management and conducts electricity as part of the current path. This multi-functionality reduces device complexity by eliminating the need for separate cooling components and electrical conductors.
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 solution significantly reduces temperature rise at the contact points, allowing for higher charging currents without exceeding thermal limits, improving charging efficiency and safety by effectively managing heat dissipation and reducing the risk of overheating.
Implementation Method 1
at a predefined temperature, a phase change material (PCM) undergoes a phase change within the PCM, and this phase change requires a significant amount of energy
Implementation Method 2
The latent heat storage system has a high heat capacity because, at a predefined temperature, a phase change material (PCM) undergoes a phase change within the PCM, and this phase change requires a significant amount of energy
Implementation Method 3
The containers therefore have a dual function: they both enclose the phase-change material and conduct electricity
Data Source
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AI summary
The present invention relates to a charging socket (100) for a vehicle, wherein the charging socket (100) has at least two contact elements (102) each with a latent heat storage device (108), wherein the latent heat storage device (108) has a phase change material (116) arranged in a container (114), wherein the container (114) is thermally coupled to the respective contact element (102) and is arranged in a current path (110) between the contact element (102) and a terminal (112) of the contact element (102) for a conductor of a wiring harness of the vehicle.