Connector Cooling Element for High Current EV Charging
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Solution Overview
Problem
Existing connector parts for electric vehicle charging systems face challenges in managing high charging currents, as contact elements heat up significantly, requiring larger dimensions and increased weight and cost, while scaling limitations restrict further size reduction.
Innovation Solution
Incorporating a channel within the contact element to allow direct coolant flow, which absorbs and dissipates heat generated during high-current transmission, enabling smaller contact element designs with high current-carrying capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If contact elements are dimensioned larger to transmit high charging currents, then current-carrying capacity is improved, but weight and cost increase
Solution Approach 1:
The contact element is divided into functional segments: a solid conductive core for current transmission and a separate cooling system with channels for heat dissipation. This segmentation allows the core to be smaller while maintaining current capacity through effective thermal management.
Solution Approach 2:
A coolant acts as an intermediary substance that absorbs heat from the contact element and transports it away. The coolant flows through channels in the contact element, absorbing thermal energy and carrying it to external cooling components, thereby enabling the contact element to maintain smaller dimensions.
2Power
If contact elements are dimensioned larger to transmit high charging currents, then current-carrying capacity is improved, but device complexity increases
Solution Approach 1:
The cooling channels are integrated directly into the contact element structure, merging the electrical conductor and thermal management system into a single unified component. This integration reduces overall system complexity by eliminating separate cooling devices and simplifying assembly.
Solution Approach 2:
The contact element serves multiple functions simultaneously: it conducts electrical current and provides thermal management through embedded cooling channels. This multi-functionality reduces the need for separate components, thereby reducing device complexity.
3Power
If contact elements are dimensioned larger to transmit high charging currents, then current-carrying capacity is improved, but volume increases
Solution Approach 1:
Cooling channels are strategically positioned in regions of highest heat generation within the contact element, such as near the contact surfaces and current entry/exit points. This localized cooling approach maximizes thermal management efficiency without requiring the entire contact element to be enlarged.
Solution Approach 2:
Cooling channels are arranged in three-dimensional configurations within the contact element, utilizing vertical and radial spaces. This spatial arrangement allows effective cooling without increasing the external dimensions or volume of the contact element.
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 effectively cools the contact elements and load lines, allowing for smaller, lighter, and more cost-effective designs that can handle high charging currents without excessive heating.
Implementation Method 1
a coolant can be passed directly through the contact element. In this way, cooling is provided directly where heat is generated during operation of the connector part when an electric current is conducted via the contact element
Implementation Method 2
a coolant line is also extended within a load line, via which heat can be absorbed directly at the load line
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
The invention relates to a plug connector part (3) for connecting to a mating plug connector part (40), which plug connectorpart comprises a contact element (31, 32) for bringing into electrical contact with an associated mating contact element (400) of the mating plug connector part (40). The contact element (31, 32) has a contact section (310) for bringing into contact with the mating contact element (400) of the mating plug connector part (40) and a shaft section (312) for connecting a load line (21, 22) for transmitting an electric current. A channel (317) extends in the contact element (31, 32), to which channel at least one coolant line (23-26) can be fluidically connected in order to conduct a coolant through the contact element (31, 32). In this way, a plug connector part is provided which has a contact element that can have a high current-carrying capacity, for example for use in a charging system for charging an electric vehicle.