Elastic Heat-Conducting Plug Contact for EV Charging Cooling
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Solution Overview
Problem
Existing plug contacts for electric vehicle charging connectors face inadequate cooling of spring-loaded areas, leading to thermal issues due to high charging currents, which can result in damage from excessive heat generation.
Innovation Solution
A plug contact design featuring a contact element with a cooling element and a heat-conducting element that is elastic and thermally and mechanically connected, allowing for improved heat dissipation through a cooling fluid and/or Peltier elements, and a heat-conducting material that transports heat from the contact area to the cooling element without increasing the normal insertion force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling fluid circuits are used to cool plug contacts, then heat dissipation is improved, but the spring-loaded contact areas are insufficiently cooled
Solution Approach 1:
A heat-conducting element is introduced as an intermediary between the contact element and cooling element. This mediator efficiently transfers heat from the spring-loaded contact areas to the cooling fluid circuit, solving the insufficient cooling problem while maintaining the existing cooling system structure
Solution Approach 2:
The heat-conducting element is extracted as a separate functional component from the contact element. This allows the cooling function to be independently optimized and ensures that heat is actively removed from the spring-loaded areas without interfering with the contact mechanism
2Temperature
If rigid cooling structures are used, then heat dissipation is improved, but insertion force increases significantly
Solution Approach 1:
The heat-conducting element is designed with elastic properties, allowing it to dynamically adapt during insertion. The element can deform to accommodate the spring-loaded contact means during plugging, then maintain thermal contact during operation, providing both low insertion force and effective heat dissipation
3Power
If high charging currents are used to meet increasing power demands, then charging performance is improved, but thermal load on plug contacts increases
Solution Approach 1:
The elastic heat-conducting element maintains continuous thermal contact between the contact element and cooling element during operation. This ensures uninterrupted heat dissipation throughout the charging process, allowing sustained high current operation without thermal buildup
Solution Approach 2:
The elastic deformation of the heat-conducting element during insertion, which initially seems like a compromise, actually benefits the system by ensuring reliable thermal contact while accommodating manufacturing tolerances and assembly variations, converting a potential weakness into a robust thermal connection
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 design enhances the cooling efficiency of spring-loaded contact means, reducing heat generation and improving the current-carrying capacity of the plug contact, thus addressing thermal load challenges.
Implementation Method 1
a heat-conducting element arranged between the cooling element and the contact element, wherein the heat-conducting element is elastic and thermally and mechanically contacts the cooling element and the contact element
Implementation Method 2
a cooling element arranged at least partially around the contact region... A cooling fluid can also flow through the cooling element, at least in some areas
Implementation Method 3
The heat-conducting element is elastic... the at least one spring-loaded contact means can be formed from a highly electrically conductive material... the contact springs can first be moved away from the corresponding plug contact and then rest on the area of the corresponding plug contact with spring force
Data Source
Figure 1A~1B
Figure 2~3B
Figure 4A~5
AI summary
The invention relates to a plug contact for an electrical charging connector, said plug contact comprising: a contact element having a contact area with at least one spring-loaded contact means, and having a connection area for connecting an electrical conductor; a cooling element, at least regions of which are arranged around the contact area; and a heat-conducting element arranged between the cooling element and the contact element, wherein the heat-conducting element is elastic and thermally and mechanically contacts the cooling element and the contact element. The invention also relates to an electrical charging connector.