Electric Assembly Thermal Coupling for Fast Temperature Monitoring
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Solution Overview
Problem
Existing temperature monitoring systems in charging connectors for electric vehicles suffer from delayed temperature detection due to the time lag in transmitting heat through insulating bodies, which is unsuitable for rapid shutdown during overheating.
Innovation Solution
A temperature monitoring device with heat-conducting elements embedded in the support element, thermally connected via vias, allows direct and fast heat transfer from the electrical functional element to the sensor, minimizing time delay in detecting temperature changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If temperature sensors are embedded in an insulating body, then electrical isolation of temperature sensors from contact elements is achieved, but temperature change transmission is delayed due to the insulating body
Solution Approach 1:
A thermal coupling element (heat-conducting device) is introduced as an intermediary between the contact element and the temperature sensor. This mediator efficiently transmits thermal energy from the contact element to the sensor while the insulating body maintains electrical isolation, thus resolving the contradiction between electrical isolation and fast temperature detection
Solution Approach 2:
The system is segmented into distinct functional components: the insulating body for electrical isolation, the thermal coupling element for heat transmission, and the temperature sensor for detection. This segmentation allows each component to optimize its specific function without compromising the others
2Loss of time
If temperature sensors are placed close to contact elements, then temperature detection speed is improved, but electrical isolation becomes more difficult to maintain
Solution Approach 1:
The insulating body acts as an intermediary that maintains electrical isolation even when the temperature sensor is positioned close to the contact element. The thermal coupling element further mediates heat transfer through or near the insulating structure, enabling close proximity without compromising electrical safety
3Device complexity
If multiple temperature sensors are connected via a single cable, then device complexity is reduced, but temperature monitoring precision for individual contacts decreases
Solution Approach 1:
Each contact element is assigned its own temperature sensor and thermal coupling element, creating segmented monitoring units. This segmentation enables precise individual contact temperature monitoring while the overall system complexity is managed through modular design and standardized connection interfaces
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 rapid and efficient temperature monitoring of electrical components with minimal time lag, facilitating quick response to overheating and enabling timely countermeasures such as shutting down the charging process.
Implementation Method 1
at least one heat conduction device embedded in the body of the support element, wherein the at least one heat conduction device extends at least sectionally below the temperature sensor in the body and is thermally connected to the system element
Data Source
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AI summary
The invention relates to an electric assembly comprising a support element (44) which has a body (441) and a surface (442) formed on the body (441), an electric functional element (42) which is arranged on the support element (44), and a temperature monitoring device (5) which is arranged on the support element (44) for monitoring the temperature of the electric functional element (42). The temperature monitoring device (5) has a temperature sensor (50) arranged on the surface (442) of the support element (44), a contact element (51) which is arranged on the surface (442) of the support element (44), and at least one heat conducting device (53) which is incorporated into the body (441) of the support element (44). The at least one heat conducting device (53) extends at least partly below the temperature sensor (50) in the body (441) and is thermally connected to the contact element (51) via at least one through-connection (52). The contact element (51) is thermally coupled to a coupling surface (455) which is operatively connected to the electric functional element (42).