EV Charging Connector Active Cooling for High-Current Thermal Limits
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Solution Overview
Problem
Existing electric vehicle charging connectors face limitations in thermal management, as passive cooling designs can only support current ratings up to 200 A, while active cooling methods require complex liquid cooling systems and pumps, making them heavy and costly for high-current applications.
Innovation Solution
The integration of a lightweight, economically viable fan-based active cooling system within the electric vehicle charging connector, combined with a heat pipe for enhanced thermal performance, allowing for efficient heat dissipation without the need for pumps or complex interfaces, and maintaining high IP protection levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If passive cooling designs are used, then the structure is simple and weight is reduced, but current rating is limited to 200 A
Solution Approach 1:
The cooling system is segmented into two independent parts: a passive heat pipe for baseline cooling and an active fan for enhanced cooling when needed. This segmentation allows the system to achieve high current ratings by combining the simplicity of passive cooling with the performance of active cooling, resolving the contradiction between structural simplicity and current rating capability.
Solution Approach 2:
The fan acts as an intermediary element that supplements the passive heat pipe cooling when additional cooling capacity is required. By introducing this intermediate active cooling component, the system can transition from limited passive cooling to enhanced combined cooling, enabling current ratings beyond 200 A while maintaining overall system simplicity.
2Productivity
If liquid cooling systems with pumps are used, then current rating exceeds 500 A, but weight and device complexity increase
Solution Approach 1:
The heavy and complex pump mechanism from traditional liquid cooling systems is extracted and replaced with a lightweight fan-based air cooling system. This extraction eliminates the need for pumps, hoses, and liquid coolant, dramatically reducing weight and complexity while maintaining the ability to achieve current ratings over 500 A through the fan's forced air convection.
Solution Approach 2:
The mechanical pump-based liquid circulation system is replaced with an electric fan-driven air flow system. This substitution eliminates complex mechanical moving parts, reduces weight, and simplifies the cooling architecture while achieving the same high current rating performance through forced convection air cooling.
3Productivity
If liquid cooling systems with pumps are used, then current rating exceeds 500 A, but device complexity increases
Solution Approach 1:
The complex pump, reservoir, and liquid circulation infrastructure is extracted from the cooling system and replaced with a simple fan assembly. This extraction dramatically reduces device complexity by eliminating multiple components and interconnections, while the fan alone provides sufficient cooling capacity for currents exceeding 500 A.
Solution Approach 2:
The complex mechanical liquid cooling system is replaced with a simple electrical fan system. This substitution reduces device complexity by replacing multiple mechanical components (pump, valves, hoses, reservoir) with a single electric fan that can be controlled electronically, achieving high current ratings with minimal complexity.
4Temperature
If hollows in enclosure for passive cooling are used, then cooling is achieved, but weight increases and effectiveness is limited
Solution Approach 1:
The heat pipe utilizes self-service capillary action to circulate working fluid without external power or pumps. The hollow enclosure structures serve dual purposes as both structural elements and heat conduction paths, allowing heat dissipation through the enclosure walls themselves. This self-service approach achieves effective cooling while minimizing additional weight compared to active pumped liquid cooling systems.
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 enables improved thermal performance, supporting current ratings beyond 500 A with reduced weight and complexity, achieving better cooling efficiency than existing designs by leveraging the synergy between active airflow and passive heat pipe cooling.
Implementation Method 1
the electric vehicle charging connector further comprises a heat pipe
Implementation Method 2
the fan that is arranged in the external enclosure causes an air flow which may be directed or turbulent, that cools the compartment and therefore also the power contacts in the compartment
Data Source
AI summary
The present invention relates to an electric vehicle charging connector (100) comprising an external enclosure (104) configured to receive and guide a cable (101) from a back (111) end to a front end (113) of the electric vehicle charging connector (100) and to enclose a compartment (102) in the front end accommodating power contacts, wherein the electric vehicle charging connector (100) further comprises an active cooling element (130).