Cooled Plug Connector for Electric Vehicle Charging
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Solution Overview
Problem
Existing connector parts for electric vehicle charging face challenges in managing high charging currents without excessive heating, as contact elements must be larger to handle increased currents, leading to space, weight, and cost issues.
Innovation Solution
The integration of a sleeve element with a cooling channel around the contact element's shank section, allowing coolant to flow and dissipate heat, providing active cooling without complex cooling hose routing, and using a thermally conductive paste for enhanced heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the contact element is dimensioned larger to handle increased charging currents, then the current-carrying capacity is improved, but the space required, weight and costs increase
Solution Approach 1:
The cooling channel is integrated within the contact element itself, with the coolant flow path nested around the central axis of the contact element. This allows the cooling function to be embedded within the existing structure rather than adding external cooling components, thereby reducing overall weight while maintaining high current-carrying capacity
Solution Approach 2:
A coolant is introduced as an intermediary substance that absorbs heat from the contact element during current transmission. The coolant flows through the cooling channel, transferring thermal energy away from the contact element, enabling it to maintain high current-carrying capacity without proportionally increasing its dimensions and weight
2Power
If the contact element is dimensioned larger to handle increased charging currents, then the current-carrying capacity is improved, but the space required increases
Solution Approach 1:
The cooling channel is integrated within the contact element itself, with the coolant flow path nested around the central axis of the contact element. This allows the cooling function to be embedded within the existing structure rather than adding external cooling components, thereby reducing overall space requirements while maintaining high current-carrying capacity
Solution Approach 2:
Instead of increasing the cross-sectional area of the contact element to improve current-carrying capacity, the solution utilizes the longitudinal dimension by creating a cooling channel that extends along the length of the contact element. This dimensional approach allows heat dissipation without proportionally increasing the contact element's footprint
3Power
If active cooling is provided on the contact element, then the current-carrying capacity with small dimensions is improved, but the device complexity increases
Solution Approach 1:
The cooling channel is merged with the contact element structure itself, forming an integrated component rather than separate cooling apparatus. The cooling channel walls are formed as part of the contact element's body, eliminating the need for additional cooling housings or external mounting structures, thereby reducing device complexity while enabling active cooling
Solution Approach 2:
The contact element serves multiple functions simultaneously: it conducts electrical current and provides its own cooling infrastructure through the integrated cooling channel. This multi-functionality eliminates the need for separate cooling devices, reducing overall system complexity while maintaining high current-carrying capacity
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
This solution enables high current-carrying capacity with smaller contact element dimensions, effectively managing heat dissipation and preventing excessive heating, thus optimizing space, weight, and cost considerations.
Implementation Method 1
a cooling channel which is formed in or on the body and extends around the plug-in opening for conducting a coolant past the shank section so as to cool the contact element
Implementation Method 2
Heat generated on the shank section of the contact element can be dissipated via the coolant
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A plug connector part (1) comprises a plug section (100, 101) for plugging connection to an associated counter plug connector part (40), and at least one contact element (11A, 11B) which is arranged on the plug section (100, 101) and has at least one electrically conductive contact section (111) for plugging connection to an associated counter contact element (41) of the counter plug connector part (40), and a shaft section (110) connected to the contact section (111) for securing an electrical line (20) to the contact element (11A,11B). In addition, a casing element (15) is provided which can be attached to the shaft section (110) of the at least one contact element (11A, 11B), and which has a body (150), a plug opening (158) formed in the body (150) for receiving the shaft section (110) and a cooling channel (159) formed in or on the body (150) and extending around the plug opening (158) for conducting a coolant. In this way, a plug connector part is provided which can provide an active cooling for a contact element in order to achieve a high current load capacity in spite of a comparatively small-dimensioned contact element.