Electrical Connector Liquid Cooling Busbar Thermal Management
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Solution Overview
Problem
High power electrical connector assemblies, such as those used in fast charging systems for electrical vehicles, face issues with contact resistance leading to thermal energy conversion and potential damage due to temperature rise, necessitating effective thermal management to meet industry performance standards.
Innovation Solution
The electrical connector assembly incorporates various thermal management features, including coolant channels, thermoelectric devices, airflow ports, and cooling fins, along with dielectric thermal interface materials and seals, to efficiently manage heat and prevent damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high power electrical connector assemblies are used to carry 90 kilowatts or more, then power transmission capability is improved, but temperature rise due to contact resistance increases causing potential damage
Solution Approach 1:
The patent extracts the thermal management function from the electrical connector assembly by incorporating a separate cooling system with coolant channels. This allows the electrical components to focus on power transmission while the cooling system independently handles heat removal, resolving the contradiction between high power capability and temperature control
Solution Approach 2:
The patent introduces a dielectric thermal interface material as an intermediary between the electrical busbar and cooling plate. This material simultaneously provides thermal conduction to transfer heat away from the busbar while maintaining electrical insulation, enabling both high power transmission and effective cooling without direct metal-to-metal contact that would compromise insulation
2Temperature
If thermal management features are added to manage heat, then temperature control is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple functions into the cooling plate component: it serves as both the cooling element with coolant channels and the electrical insulator separating the busbar from the housing. This integration reduces the number of separate components needed, managing temperature effectively while limiting the increase in device complexity
Solution Approach 2:
The cooling plate performs multiple functions simultaneously: thermal conduction to remove heat, electrical insulation to maintain safety, and structural support within the connector assembly. This multi-functionality allows effective temperature control without proportionally increasing device complexity, as one component accomplishes what would otherwise require multiple separate elements
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
These features effectively manage thermal energy within the connector assembly, preventing damage and ensuring compliance with industry standards by maintaining optimal temperature levels during high-power operations.
Implementation Method 1
an inlet port (304) in fluidic communication with an outlet port (306) configured to carry a liquid coolant flow through a terminal position assurance member
Implementation Method 2
The cover may have a dielectric thermal interface material layer which in the intimate thermal contact with the electrical busbar
Implementation Method 3
b) a thermoelectric device (202)
Implementation Method 4
c) an inlet port (304) in fluidic communication with an outlet port (306) configured to carry a liquid coolant flow through a terminal position assurance member
Data Source
AI summary
An electrical connector assembly includes a connector housing defining a cavity in which an electrical busbar is disposed. The connector housing defines an opening to the cavity. The electrical connector assembly also includes a cover configured to enclose the cavity. The cover has an inlet port, an outlet port, and a coolant channel that is in fluidic communication with the inlet port and the outlet port. A portion of the cover is in intimate thermal contact with the electrical busbar.