EV Charging Plug Contact Tracks and Cooling
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Solution Overview
Problem
Existing charging plug/socket systems face challenges in transferring high charging currents without increasing plug dimensions, leading to heat issues and limited rapid charging capabilities, as standard designs require larger contact pins and increased installation space and costs.
Innovation Solution
The use of large-area contact tracks on the exterior of a conical or cylindrical plug body, allowing for increased contact area without enlarging the plug size, and the integration of a cooling system within the plug body to manage heat, including a cooling medium circulation system with valves for efficient cooling during rapid charging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If larger contact pins are used to transfer higher charging currents, then the charging current capacity is improved, but the plug dimensions and installation space increase
Solution Approach 1:
The patent transitions from traditional pin-shaped contact elements to contact tracks formed as annular rings on the plug surface. This dimensional change from linear pins to circular tracks increases the contact area without proportionally increasing the plug's overall dimensions, allowing higher current capacity while maintaining compact size.
Solution Approach 2:
Multiple contact tracks are arranged concentrically on the plug body, merging multiple contact functions into a compact circular layout. This allows multiple electrical connections to be made in a small space, increasing current capacity without proportionally increasing plug volume.
2Power
If larger contact pins are used to transfer higher charging currents, then the charging current capacity is improved, but the manufacturing costs increase
Solution Approach 1:
The patent replaces traditional mechanical pin contacts with contact tracks that can be formed through printing or coating processes. This substitution of manufacturing methodology reduces complexity and cost compared to precision machining or assembling multiple pin components, while achieving higher current capacity.
3Temperature
If standardized plug geometries are used to limit temperature increase, then the temperature control is improved, but the rapid charging capability is limited
Solution Approach 1:
The patent changes the geometric parameters of the contact elements from narrow pins to wide annular tracks. This parameter change increases the contact area and improves heat dissipation capacity, allowing the plug to handle higher currents for rapid charging while maintaining temperature within acceptable limits.
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 the transfer of higher charging currents with smaller plug dimensions, reduces heat buildup, and allows for the accommodation of additional components like cooling systems, enhancing the efficiency and safety of electric vehicle charging.
Implementation Method 1
an electrical connecting body that has a cooling fluid duct for cooling the connecting body with a cooling fluid
Data Source
AI summary
A female charging socket for transferring charging current to an electrical vehicle via a male charging plug, wherein the charging socket has a hollow socket body to receive a plug body of the charging plug, wherein electrical contact areas running concentrically are interior to the charging socket and distributed therein in an axial direction; wherein the charging plug is insertable into the hollow socket body, the charging plug being formed of a conical or cylindrical plug body and having exterior thereto multiple electrical contact tracks running concentrically around the plug body distributed axially for making electrical contact with the electrical contact areas of the charging socket, and wherein the charging socket further comprises at least one spanning contact adapted to bring into electrical contact and hold at least one of the electrical contact areas of the charging socket with a corresponding respective electrical contact track of the charging plug.