EV Charging Connector Hybrid Cooling System
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Solution Overview
Problem
Current EV charging connectors face issues with water ingress, mechanical damage due to overheating, and insufficient cooling, where passive cooling is inadequate and active cooling is complex to implement.
Innovation Solution
A hybrid cooling system combining passive heat pipes with fins and active air cooling using an air tube, where an air stream generator within the charging station supplies air directly to the heat pipes' fins, enhancing thermal performance and preventing water ingress through a sealed inner compartment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If passive cooling devices are used, then the device complexity is reduced, but the cooling performance is insufficient to prevent overheating damages
Solution Approach 1:
The patent merges passive cooling (heat pipe) and active cooling (air stream generator) into a hybrid cooling system. The heat pipe provides passive heat transfer from the contact element, while the air stream generator actively cools the condenser fins, combining both approaches to achieve effective cooling without excessive complexity
Solution Approach 2:
The air tube serves as an intermediary component that delivers the air stream from the air stream generator directly to the condenser fins of the heat pipe, enabling the active cooling to effectively enhance the passive cooling system's performance
2Temperature
If active cooling devices are implemented, then the cooling performance is improved, but the device complexity increases significantly
Solution Approach 1:
The cooling system is segmented into distinct functional components: the heat pipe for passive heat transfer, the air tube for air delivery, and the air stream generator for active cooling. This segmentation allows each component to be optimized independently and simplifies the overall system architecture
Solution Approach 2:
The air stream generator serves multiple functions: it cools the condenser fins directly, enhances the heat pipe's cooling efficiency, and can be controlled based on temperature sensors to provide adaptive cooling only when needed, reducing overall system complexity
3Reliability
If the connector is sealed to prevent water ingress, then the reliability is improved, but the heat dissipation capability is reduced
Solution Approach 1:
The heat pipe is nested within the sealed inner housing, allowing the sealed compartment to protect against water ingress while the heat pipe's evaporator and condenser sections work together to transfer heat from the contact element to the air stream, maintaining both sealing and cooling effectiveness
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 effectively reduces temperatures within the EV charging connector, outperforming benchmark suppliers in thermal performance, while being lightweight, cost-effective, and easy to maintain, with reduced noise and no need for complex active cooling devices.
Implementation Method 1
The contact element (102) is connected to a passive cooling device, in particular to a heat pipe (106)
Implementation Method 2
The heat pipe (106) is mechanically and thermally connected to the contact element
Implementation Method 3
The condenser portion (109) comprises fins (108) and is arranged in a first compartment of the external housing (104)
Implementation Method 4
The condenser portion (109) comprises fins (108) and is arranged in a first compartment of the external housing (104)
Implementation Method 5
an air stream is lead to at least a part of the hot portions of the connector... air of the air stream flows around the hot portion
Data Source
AI summary
An electric vehicle (EV) charging connector comprises a charging cable. The charging cable comprises charging lines configured to carry charging current and at least one air tube. The contact element is connected to the charging cable and is the galvanic contact interface to a car inlet; and each air tube is configured to lead an air stream directly to the hot portion of the EV charging connector such that air of the air stream flows around the hot portion.