Connector Output Unit for Direct Contact Point Temperature Detection

Solution Overview

Problem

Indirect temperature measurement in high-power connectors is unreliable and slow, leading to potential damage due to overheating, especially in applications like electric vehicle charging, where currents exceed 100 A and rapid temperature detection is critical.

Innovation Solution

A direct temperature monitoring system using a connector tap and/or mating connector contact probe to determine the potential difference between the connector and mating connector contact elements, allowing for direct calculation of the contact point temperature based on the relationship between electric voltage and temperature.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If indirect temperature measurement is used with a temperature sensor located close to the contact point, then the device complexity is reduced, but the measurement precision and response speed deteriorate

Engineering Contradiction:

Improvedevice complexityVSAvoidtemperature measurement precision

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The patent replaces the mechanical/thermal temperature sensor system with an electrical measurement system. Instead of using a temperature sensor that physically contacts or approaches the contact point, the invention uses voltage measurement across the contact point to determine temperature through the relationship between voltage and temperature in high-current connectors. This substitution enables direct temperature determination at the contact point without spatial distance, achieving both high measurement precision and fast response while maintaining simple device structure.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Device complexity

If indirect temperature measurement is used with a temperature sensor located close to the contact point, then the device complexity is reduced, but the response speed deteriorates

Engineering Contradiction:

Improvedevice complexityVSAvoidresponse speed

Core Design Contradiction:

Device complexityVSSpeed

Solution Approach 1:

The patent replaces the mechanical/thermal temperature sensor system with an electrical measurement system. Instead of using a temperature sensor that physically contacts or approaches the contact point, the invention uses voltage measurement across the contact point to determine temperature through the relationship between voltage and temperature in high-current connectors. This substitution enables direct temperature determination at the contact point without spatial distance, achieving both high measurement precision and fast response while maintaining simple device structure.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Device complexity

If the contact point temperature is not monitored accurately, then the device complexity is reduced, but the reliability deteriorates due to potential overheating damage

Engineering Contradiction:

Improvedevice complexityVSAvoidreliability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent replaces the mechanical/thermal temperature sensor system with an electrical measurement system. Instead of using a temperature sensor that physically contacts or approaches the contact point, the invention uses voltage measurement across the contact point to determine temperature through the relationship between voltage and temperature in high-current connectors. This substitution enables direct temperature determination at the contact point without spatial distance, achieving both high measurement precision and fast response while maintaining simple device structure.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Enables quick and accurate detection of overtemperature at the contact point, preventing damage by interrupting power transmission when excessive temperatures are reached, thus ensuring the longevity of both connectors and charging infrastructure.

Implementation Method 1

allowing for direct calculation of the contact point temperature based on the relationship between electric voltage and temperature

Methodology Applied

Scientific EffectRelationship between electric voltage and temperature: Seebeck Effect

Data Source

PatentUS20240178622A1Connector having an output unit for connection to an evaluation unit for determining a temperature of a contact point and method for determining a temperature of a contact point of a connector

Publication Date: 2024.05.30 TE CONNECTIVITY SOLUTIONS GMBH

AI summary

A connector for determining a temperature of a contact point includes a connector contact element for electrically contacting the connector with a mating connector contact element of a mating connector at the contact point. The connector includes a connector tap for tapping a connector potential at the connector contact element and a mating connector contact probe for determining a mating connector potential of the mating connector contact element. The connector determines the temperature of the contact point from a potential difference between the connector potential and the mating connector potential.