Electrical Connector Cover with Liquid Cooling for Overheating Control

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Solution Overview

Problem

High power electrical connector assemblies, such as those used in fast charging systems for electrical vehicles, face overheating issues due to contact resistance and inadequate thermal management, with existing solutions like passive cooling mechanisms and airflow systems being insufficient in regulating temperature effectively.

Innovation Solution

An electrical connector assembly with a cover featuring liquid ports for coolant flow, a serpentine coolant duct, and a dielectric thermal interface material layer, along with a thermally conductive polymer or metallic bottom cover with cooling fins, to actively manage heat and prevent overheating.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If insulating covers are used to protect electrical terminals from environmental factors, then protection of electrical terminals is improved, but heat dissipation capability deteriorates

Engineering Contradiction:

Improveprotection of electrical terminalsVSAvoidheat dissipation capability

Core Design Contradiction:

Object-affected harmful factorsVSTemperature

Solution Approach 1:

The cover is divided into two distinct parts: an insulating cover portion that protects electrical terminals from environmental factors, and a thermally conductive portion that provides heat dissipation pathways. This segmentation allows each portion to optimize its specific function without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the cover are assigned different material properties: the insulating cover portion uses electrically insulating material for terminal protection, while the thermally conductive portion uses heat-conducting material for thermal management. This local differentiation of material properties resolves the contradiction between protection and heat dissipation.

Inventive Principle:

Principle #3Local quality

2Temperature

If passive cooling mechanisms such as heat sinks or fins are added to the cover, then heat dissipation is improved, but device complexity increases

Engineering Contradiction:

Improveheat dissipationVSAvoidstructural complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The thermally conductive portion is integrated directly into the cover structure, merging the cooling function with the protective housing. This eliminates the need for separate passive cooling attachments and reduces overall structural complexity while maintaining effective heat dissipation.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The thermally conductive portion serves multiple functions: it acts as both a structural component of the cover and a heat dissipation mechanism. This multi-functionality reduces the need for additional dedicated cooling components, thereby simplifying the overall device structure.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Temperature

If airflow systems with fans or vents are incorporated for thermal management, then heat dissipation is improved, but reliability deteriorates due to mechanical failures

Engineering Contradiction:

Improvethermal managementVSAvoidmechanical reliability

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The patent replaces active mechanical cooling systems (fans, motors) with a passive thermal conduction system using thermally conductive material. This eliminates moving parts that can fail mechanically, significantly improving reliability while maintaining effective heat dissipation through conductive pathways.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The thermally conductive portion automatically conducts heat away from electrical terminals through its inherent thermal conductivity without requiring external power sources or mechanical actuation. This self-service cooling mechanism eliminates the need for complex control systems and improves system reliability.

Inventive Principle:

Principle #25Self-service

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 effectively regulates temperature within the connector assembly, preventing overheating and ensuring reliable operation by efficiently dissipating thermal energy through liquid coolant flow and enhanced thermal management mechanisms.

Implementation Method 1

a dielectric thermal interface material layer... efficiently dissipating thermal energy through liquid coolant flow

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

liquid ports configured to receive a liquid coolant flow... serpentine coolant duct

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 3

a thermally conductive polymer or metallic bottom cover with cooling fins... actively manage heat

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS20240429650A1Electrical connector assembly with thermal management

Publication Date: 2024.12.26 APTIV TECHNOLOGIES AG

AI summary

The disclosure shows an electrical connector assembly including a connector housing with a cavity housing an electrical terminal, and a cover designed to enclose the cavity for protection and thermal management. The cover features a thermal management mechanism with multiple pneumatic ports strategically positioned to guide airflow through the cavity. This innovative design ensures efficient heat dissipation within the cavity, enhancing the overall performance and longevity of the electrical connector assembly.