High-Voltage Charging Socket Pin Layout for Low-Resistance Contact
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Solution Overview
Problem
The electrification of automobility faces challenges in minimizing charging times for electric vehicles, requiring high conductivity across the charging transmission path and adapting to non-standardized plug geometries for efficient power transfer.
Innovation Solution
A plug connector with conductive metal pins and a housing made of non-conductive materials, featuring an eccentric arrangement of regions for enhanced heat dissipation and mechanical stability, along with a charging socket designed for force-fit and form-fit connections, to ensure low contact resistance and adaptability to various plug geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high currents and voltages are used to charge the accumulator quickly, then charging speed is improved, but contact resistance and heat generation increase
Solution Approach 1:
The plug connector is divided into multiple contact pins (first contact pin, second contact pin, third contact pin) that are spatially separated and arranged in a specific geometric configuration. This segmentation allows each contact pin to independently carry high current while distributing the thermal load, reducing overall contact resistance and heat generation at any single interface point.
Solution Approach 2:
The plug connector housing combines non-conductive materials (for electrical isolation) with conductive metal contact pins (for current transfer). This composite structure enables simultaneous achievement of low contact resistance at contact points and high electrical insulation where needed, allowing efficient high-power charging while managing energy losses.
2Productivity
If the plug geometry is adapted to specific charging stations, then power transmission efficiency is improved, but adaptability to different standards deteriorates
Solution Approach 1:
The plug connector is designed with a standardized receptacle geometry and multiple contact pins that can accommodate different charging plug types and configurations. The housing includes features like a collar and bearing surfaces that provide universal mechanical compatibility, while the internal contact pin arrangement allows adaptation to various electrical standards, enabling one connector design to serve multiple charging standards.
Solution Approach 2:
The plug connector incorporates force-fit and form-fit connection mechanisms that allow dynamic adaptation to different plug geometries. The retaining means and bearing surfaces enable the connector to mechanically adjust and secure various plug types, maintaining stable electrical contact while accommodating geometric variations across different charging standards.
3Volume of moving object
If the contact pins are arranged closely for compact design, then device size is reduced, but heat dissipation and mechanical stability worsen
Solution Approach 1:
The contact pins are arranged in an asymmetric, eccentric configuration rather than a symmetric compact layout. The first contact pin and second contact pin are positioned at different distances from the center, with the second contact pin having a larger diameter and positioned to optimize heat dissipation. This asymmetric arrangement provides adequate thermal spacing while maintaining compact overall dimensions.
Solution Approach 2:
Different regions of the connector are designed with different properties: the contact pin regions have high electrical conductivity and are positioned for optimal current transfer, while the housing regions provide thermal management and mechanical support. The collar and bearing surfaces are specifically designed at critical locations to enhance heat dissipation and mechanical stability without increasing overall connector volume.
4Stability of the object's composition
If force-fit connection is used for secure mounting, then mechanical stability is improved, but contact resistance and manufacturing difficulty increase
Solution Approach 1:
The connector incorporates pre-designed retaining means and bearing surfaces that are formed during manufacturing. These features include pre-positioned contact pins with predetermined geometries and pre-formed housing features like collars and recesses. This preliminary action during manufacturing simplifies assembly while ensuring secure force-fit connection and stable mechanical mounting.
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 enables efficient high-power charging by minimizing contact resistance and accommodating different plug geometries, ensuring rapid energy transfer while maintaining mechanical stability and heat dissipation.
Implementation Method 1
The plug connector comprises at least one plug-in pin made of an electrically conductive material, in particular a metal material
Implementation Method 2
A plug connector with conductive metal pins and a housing made of non-conductive materials
Implementation Method 3
featuring an eccentric arrangement of regions for enhanced heat dissipation and mechanical stability
Data Source
AI summary
The invention relates to a charging socket, a plug connector and a system of charging socket and plug connector for high-voltage applications, wherein in particular the plug connector comprises at least two plug-in pins which have in each case two regions. A first region has a greater cross-section than a second region. The first region has a recess at the front face of the first region.