Charging Connector Terminal Assembly With Faster Thermal Sensing
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Solution Overview
Problem
Existing charging connectors for electric vehicles suffer from delayed temperature detection in terminals, which can lead to unsafe overheating conditions.
Innovation Solution
A terminal assembly for charging connectors that includes a housing element holding N terminals, where each terminal is thermally coupled with a corresponding thermal sensor through a thermal interface material, allowing for rapid heat transfer and temperature detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heat is conducted from the terminal to the thermal sensor through the metal contact surface, coupling portion and support element, then the temperature can be monitored, but the detection time is delayed
Solution Approach 1:
The patent introduces thermal interface material as an intermediary substance between the terminal contact surface and the thermal sensor. This material is specifically designed to enhance thermal coupling and accelerate heat transfer from the terminal to the sensor, thereby reducing the detection time delay while maintaining reliable temperature monitoring. The thermal interface material acts as a mediator that optimizes the thermal pathway without requiring direct mechanical contact between the terminal and sensor.
Solution Approach 2:
The patent changes the thermal parameters of the interface between the terminal and sensor by introducing material with superior thermal conductivity properties. By selecting thermal interface material with appropriate thermal conductivity parameters, the system achieves faster heat transfer rates, directly addressing the time delay issue while preserving the reliability of temperature measurements.
2Reliability
If a coupling portion is used to thermally couple the thermal sensor with the opening, then temperature monitoring is achieved, but the device complexity increases
Solution Approach 1:
The patent merges the thermal sensing function directly into the support element structure. The thermal sensor is mounted on the support element in such a way that the support element itself becomes part of the thermal conduction path, eliminating the need for a separate coupling portion. This integration reduces the number of components and simplifies the overall device structure while maintaining effective temperature monitoring capability.
Solution Approach 2:
The support element is designed to serve multiple functions: it provides mechanical support for the thermal sensor, acts as part of the thermal conduction pathway, and eliminates the need for a separate coupling portion. By making the support element multi-functional, the patent reduces device complexity while preserving all necessary monitoring capabilities.
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 quick detection of excessive temperature rises in terminals, allowing for immediate countermeasures such as reducing or switching off the charging current, thereby enhancing safety and preventing damage.
Implementation Method 1
The heat generated by each terminal flows rapidly from the terminal to a corresponding thermal sensor through the thermal interface material in which the sensor is immersed
Data Source
Figure 1A~1B
Figure 2~3A
Figure 3B~3C
AI summary
The terminal assembly (1) comprises at least one terminal (10) for transmitting a charging current, and a temperature monitoring device (12) comprising a support element (120) and at least one thermal sensor (121) for detecting a rise in temperature of the at least one terminal (10). The at least one thermal sensor (121), mounted on a first surface (122) of said support element (120), is immersed in a thermal interface material (13) that fills a space between the first surface (122) of the support element (120) and a contact surface (100) that is thermally coupled with the at least one terminal (10), so that the at least one terminal (10) and the at least one thermal sensor (121) are thermally coupled by said thermal interface material (13) and said contact surface (100).