Plug Connector Housing as a Heat Transfer Path for EV Charging
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Solution Overview
Problem
Existing plug connector parts in electric vehicles face issues with overheating due to high current intensity, leading to increased resistance and hindered charging processes, while prior solutions increase weight, cost, and reduce installation space.
Innovation Solution
Designing the housing region up to the contact element as a heat transfer element using thermally conductive plastics with embedded fillers or a fluid-filled channel to enhance thermal conductivity without additional bulky components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If separate heat transfer elements are added to contact elements, then heat dissipation is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the housing structure with the heat transfer function by making the housing itself thermally conductive through embedded fillers. This eliminates the need for separate heat transfer elements attached to contact elements, thereby reducing structural complexity while maintaining effective heat dissipation from the contact elements through the housing material.
Solution Approach 2:
The housing is designed to serve multiple functions: structural enclosure and thermal management. By incorporating thermally conductive fillers into the housing material, the housing simultaneously provides mechanical protection and heat dissipation pathways, eliminating the need for dedicated heat transfer components and reducing overall device complexity.
2Temperature
If massive cuboidal heat capacity elements are used, then heat dissipation is improved, but weight and installation space increase
Solution Approach 1:
Instead of using massive heat capacity elements throughout the structure, the patent applies thermal management locally by embedding conductive fillers specifically in the housing regions that require heat dissipation. This localized approach provides effective heat transfer pathways from contact elements while minimizing additional weight compared to bulk heat sink structures.
Solution Approach 2:
The housing uses composite materials consisting of base plastic matrix reinforced with thermally conductive fillers (such as aluminum oxide, boron nitride, or aluminum particles). This composite structure provides enhanced thermal conductivity without the weight penalty of solid metal heat sinks, achieving effective heat dissipation with minimal weight increase.
3Temperature
If thermally conductive fillers are embedded in housing, then thermal conductivity is improved, but manufacturing complexity increases
Solution Approach 1:
The patent modifies the thermal conductivity parameter of the housing material by incorporating fillers during the molding process. This approach integrates thermal management into the base manufacturing process rather than requiring separate assembly steps, thereby maintaining manufacturing simplicity while achieving enhanced thermal conductivity through material parameter modification.
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
Achieves efficient heat dissipation, maintaining a compact structure, reducing manufacturing costs, and optimizing weight without the need for protruding attachments.
Implementation Method 1
at least one region of the housing which extends up to the contact element is designed as a heat transfer element... the region in question, which forms the heat transfer element, has increased thermal conductivity compared to the rest of the housing
Implementation Method 2
the region in question has at least one channel with a fluid located therein. The fluid is usually both thermally conductive and electrically insulating
Data Source
AI summary
A plug connector part is provided for mechanically and electrically connecting to a mating plug connector part, in particular a motor vehicle-side charging socket for coupling to a charging plug as components of an electric charging infrastructure for electric or hybrid motor vehicles, or vice versa. The basic structure of the plug connector part has a housing and at least one electric contact element which is arranged in the housing. Additionally, a heat transfer element is provided which thermally contacts the electric contact element. According to the invention, at least one housing region which extends up to the contact element is designed as a heat transfer element.