Cooled Charging Plug Contact Assembly for High-Current Heat Dissipation
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Solution Overview
Problem
Existing cooling solutions for high-current contacts in charging systems for electric vehicles are inadequate due to insufficient cooling medium volume flows, undersized cooling elements, and inefficient heat transfer, leading to overheating and safety concerns.
Innovation Solution
A contact arrangement with a direct connection of the conductor and cooling hose to the contact element, facilitating improved heat transfer and creating a cooling-medium safety reservoir to ensure reliable cooling even in case of failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the contact element dimensions are increased to transmit higher charging currents, then the current-carrying capacity is improved, but the spatial requirements, weight, and costs increase
Solution Approach 1:
The patent combines the contact element with a cooling device into an integrated assembly. The cooling device includes a cooling medium conduit that is directly coupled to the contact element, allowing cooling fluid to flow through channels in direct thermal contact with the contact element. This merging enables efficient heat removal from high-current contacts without requiring larger contact dimensions, thus resolving the contradiction between current-carrying capacity and spatial requirements.
2Temperature
If passive or active cooling is applied to contacts to enable small-dimensioned contacts to transmit high currents, then the heating is reduced, but the device complexity increases
Solution Approach 1:
The cooling device is designed to be self-contained and integrated with the contact element. The cooling medium conduit is directly coupled to the contact element, creating a self-service cooling system where the contact element itself serves as part of the cooling pathway. This integration reduces overall system complexity compared to separate external cooling systems, while effectively reducing contact heating through direct cooling medium contact.
3Productivity
If cooling medium volume flow is increased to improve cooling efficiency, then the heat transfer is enhanced, but the risk of cooling failures and safety concerns increase
Solution Approach 1:
The patent incorporates a safety reservoir as part of the cooling device that can store cooling medium. This reservoir acts as a buffer or cushion against cooling failures by providing a reserve of cooling medium that can maintain cooling function even if the primary cooling flow is interrupted or fails. This beforehand cushioning enhances reliability while allowing the system to operate with high cooling medium volume flows for improved cooling efficiency during normal operation.
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 enables increased current transmission with reduced heating, improved cooling efficiency, and enhanced safety through a larger cooling-medium volume flow and a buffer against cooling failures.
Implementation Method 1
a cooling element which is in direct contact with the second connection region of the power contact... a cooling-fluid channel arranged within the cooling element... cooling fluid is not in direct contact with the power contact
Implementation Method 2
a cooling-fluid feed connection and a cooling-fluid discharge connection... fluidically connected thereto by means of a cooling-fluid channel arranged within the cooling element
Data Source
AI summary
The invention relates to a contact assembly for plug connections, i.e., charging plugs, for transmitting electric power, having at least one device for producing an electrically conductive connection and at least one device for cooling purposes, i.e., for dissipating heat produced by the transmission of electric power using the conductive connection, wherein the electrically conductive device has at least one connection region for coupling to at least one cooling area border and at least one contact region, and the coupling is carried out directly in an integrative manner so that the cooling effect is supported as a result of the at least partly direct physical contact between the electrically conductive device and the coolant. The invention additionally relates to plug connections, i.e., charging plugs, comprising at least one such contact assembly.