Electric Coupling Temperature Sensing With Directional Heat Conduction
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Solution Overview
Problem
Existing methods for temperature measurement in electrical charging processes, such as those for electric vehicles, require extensive installation work and long heat conduction paths, which are inefficient and prone to inaccuracies due to heat loss.
Innovation Solution
An apparatus featuring a thermally conductive component support with a printed circuit board and temperature sensor arrangement that minimizes heat loss and allows for automated assembly, using a thermally conductive region for directional heat transport from the contact element to the sensor, ensuring accurate temperature measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If temperature sensors are connected via cable to current-carrying and voltage-carrying elements, then temperature measurement is possible, but installation work increases and heat conduction path lengthens causing heat loss
Solution Approach 1:
The temperature sensor is integrated directly into the circuit board that is already part of the electrical coupling element, eliminating the need for separate cable connections. This merging of the temperature sensing function into the existing circuit board structure reduces installation complexity while maintaining measurement capability.
Solution Approach 2:
A thermally conductive component support is introduced as an intermediary between the contact element and the temperature sensor. This mediator efficiently transports heat from the contact element to the temperature sensor mounted on the circuit board, reducing heat loss along the conduction path while keeping the sensor electrically isolated from high-voltage components.
2Ease of manufacture
If temperature sensors are mounted on printed circuit board, then installation work is reduced, but heat conduction path remains long causing heat loss
Solution Approach 1:
A thermally conductive component support is introduced as an intermediary between the contact element and the temperature sensor. This mediator efficiently transports heat from the contact element to the temperature sensor mounted on the circuit board, reducing heat loss along the conduction path while keeping the sensor electrically isolated from high-voltage components.
Solution Approach 2:
The component support is designed with differentiated thermal conductivity: it provides high thermal conductivity in the region where heat transport is needed (between contact element and sensor) while maintaining electrical insulation properties in other regions. This localized optimization of material properties reduces heat loss without compromising safety.
3Measurement precision
If thermally conductive component support is used, then heat loss is reduced and measurement accuracy improves, but device complexity increases
Solution Approach 1:
The component support serves multiple functions simultaneously: it provides mechanical support for the temperature sensor, acts as a thermal conductor to transport heat from the contact element, and provides electrical insulation to protect the low-voltage sensor circuit. This multi-functionality reduces the need for additional separate components, thereby limiting the increase in device complexity.
Solution Approach 2:
The temperature sensor is integrated directly into the circuit board that is already part of the electrical coupling element, eliminating the need for separate cable connections. This merging of the temperature sensing function into the existing circuit board structure reduces installation complexity while maintaining measurement capability.
4Productivity
If automated assembly is enabled, then productivity increases, but manufacturing precision requirements increase
Solution Approach 1:
The component support is designed as a separate, pre-formed component with integrated thermal conduction pathways and mounting features. This segmentation allows the thermal management function to be implemented as a modular element that can be precisely manufactured independently and then assembled automatically, reducing the precision requirements for the final assembly process.
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 simplifies temperature measurement during electrical charging by reducing heat loss and enabling accurate detection, while allowing for automated assembly and reduced thermal conductivity to prevent overheating, thus ensuring safe and efficient charging processes.
Implementation Method 1
a component support disposed on the contact element, the component support comprising a thermally conductive region in direct contact with the contact element
Data Source
AI summary
This disclosure relates to a device for detecting the temperature of an electric coupling element. The device includes an electric contact element which is designed to conduct an electric current to an electric component. A component support is also included and arranged on the contact element and includes a thermally conductive region in direct contact with the contact element. The component support is equipped with a printed circuit board which includes at least one temperature sensor that detects the temperature of the electric coupling element.