EV Charging Connector with Integrated Coolant Flow Path
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Solution Overview
Problem
Electric vehicles face challenges with slow energy storage and long recharging times due to inefficient energy transfer and heat management during charging, which limits their adoption, especially in applications requiring rapid recharging like electric aircraft.
Innovation Solution
A connector system that includes multiple conductors for direct and alternating current, a control signal conductor, a ground conductor, and a coolant flow path to facilitate fast charging while preventing overheating, along with proximity signal conductors for attachment verification, enabling efficient energy transfer and heat management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If fast charging is implemented, then recharging time is reduced, but heat generation increases causing overheating
Solution Approach 1:
A coolant flow path is introduced as an intermediary substance between the charging system and the battery to manage heat. The coolant circulates through the connector housing and absorbs excess heat generated during fast charging, preventing overheating while enabling high-power charging.
Solution Approach 2:
The charging system is segmented into multiple functional components: AC conductors, DC conductors, control signal conductors, ground conductors, and coolant flow paths. This segmentation allows independent optimization of each function, particularly enabling the coolant system to specifically address heat management without interfering with the charging function.
2Productivity
If multiple conductors are integrated into the connector, then energy transfer efficiency is improved, but device complexity increases
Solution Approach 1:
Multiple conductor functions (AC power, DC power, control signals, ground) and the coolant flow path are merged into a single integrated connector housing. This consolidation improves energy transfer efficiency by ensuring all necessary connections are made simultaneously through one mating action, while the housing structure manages the complexity internally.
Solution Approach 2:
The connector housing serves multiple functions simultaneously: it provides structural support, contains and directs coolant flow, houses multiple conductors for power and control, and enables attachment verification through proximity signal conductors. This multi-functionality reduces the need for separate components.
3Reliability
If attachment verification is implemented, then connection reliability is improved, but device complexity increases
Solution Approach 1:
The connector performs self-verification of attachment through proximity signal conductors that automatically detect when the connector is properly mated to the vehicle port. This self-service mechanism improves reliability without requiring external verification systems or additional manual steps.
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 system allows for rapid recharging of electric vehicles by ensuring efficient energy transfer and effective heat management, thereby overcoming the limitations of existing charging methods and enhancing the adoption of electric vehicles in demanding applications.
Implementation Method 1
at least a coolant flow path configured to contain a flow of a coolant
Data Source
AI summary
Aspects relate to a connector and methods of use for charging an electric vehicle. An exemplary connector includes a housing configured to mate with an electric vehicle port of an electric vehicle, where the housing includes a fastener for removable attachment with the electric vehicle port, at least a direct current conductor configured to conduct a direct current, at least an alternating current conductor, configured to conduct an alternating current, at least a control signal conductor configured to conduct a control signal, at least a ground conductor configured to conduct to a ground, at least a coolant flow path configured to contain a flow of a coolant, and at least a proximity signal conductor configured to conduct a proximity signal indicative of attachment with the electric vehicle port when the housing is mated with the electric vehicle port.