Charging Connector Holder Cooling for Fast EV Recharge Turnaround
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Solution Overview
Problem
Existing vehicle charging systems face challenges in effectively dissipating heat generated during high-current charging, leading to elevated temperatures that hinder immediate recharging due to insufficient cooling mechanisms, particularly in designs that are heavy or inefficient.
Innovation Solution
A vehicle charging station incorporating a holder with an active cooling device, such as a fan, and a passive cooling device using heat pipes with condenser fins, along with a control circuit to manage cooling based on temperature or time, to rapidly dissipate heat from the battery charging connector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If liquid cooled cable or openings in enclosure are used to remove heat from heat source, then heat dissipation is improved, but device weight increases and structural complexity increases
Solution Approach 1:
The cooling function is extracted from the charging cable itself and relocated to the charging station. The charging station incorporates an active cooling device with a cooling element that contacts the charging plug, separating the cooling system from the cable and reducing cable weight while maintaining effective heat removal capability.
Solution Approach 2:
A cooling element acts as an intermediary between the charging plug heat source and the active cooling device. This cooling element conducts heat from the charging plug to the cooling device, enabling efficient thermal coupling without requiring the cable itself to contain complex cooling channels or liquid cooling systems.
2Temperature
If liquid cooled cable or openings in enclosure are used to remove heat from heat source, then heat dissipation is improved, but device complexity increases
Solution Approach 1:
The cooling function is extracted from the charging cable itself and relocated to the charging station. The charging station incorporates an active cooling device with a cooling element that contacts the charging plug, separating the cooling system from the cable and reducing cable weight while maintaining effective heat removal capability.
Solution Approach 2:
The cooling system is designed to automatically activate based on temperature sensing. A temperature sensor detects when the charging plug exceeds a threshold temperature, and the control unit automatically activates the active cooling device, eliminating the need for manual intervention or complex control systems.
3Temperature
If cooling time between charging periods is extended, then heat dissipation is improved, but productivity decreases
Solution Approach 1:
The active cooling device enables continuous or near-continuous charging operations by rapidly removing heat between charging sessions. The system can actively cool the charging plug during idle periods, maintaining lower temperatures that allow for shorter cooling intervals and higher charging session frequency compared to passive cooling alone.
Solution Approach 2:
The active cooling device can be activated in advance or immediately after charging to rapidly reduce the charging plug temperature. This preliminary cooling action prepares the system for the next charging session much faster than natural passive cooling, reducing the idle time between charging operations.
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 system significantly reduces cooling times, allowing the connector to recover quickly for subsequent charging sessions, enhancing thermal performance and extending the system's rating under transient and steady-state conditions without increasing weight or complexity.
Implementation Method 1
a passive cooling device using heat pipes with condenser fins
Implementation Method 2
heat can be conducted away from the heat sources using liquids
Implementation Method 3
an active cooling device configured to remove heat from a heat source of the battery charging connector when the battery charging connector is on the holder, and dissipate the heat into the ambient air
Data Source
Figure 1~2b
Figure 3~4
Figure 5~6b
AI summary
The present invention relates to a vehicle charging station (500) comprising a holder configured to hold a battery charging connector (100), and a cooling device configured to remove heat from a heat source of the battery charging connector (100) when the battery charging connector is on the holder, and dissipate the heat into the ambient air.