Contact element for an ev connector with capillary fluid cooling
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Solution Overview
Problem
Existing EV connector cooling systems face inefficiencies due to unavoidable contact resistance, leading to heat buildup, which current forced liquid cooling methods struggle to effectively dissipate.
Innovation Solution
A contact element with a capillary structure within its walls, forming a hollow chamber that uses an evaporating fluid to transport heat from the contact interface to cooler areas, combined with a dual-base cooling mechanism where the second base is fluid-cooled, enhancing heat transfer and dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If forced liquid cooling is used to cool the cable and contacts, then cooling capability is provided, but heat dissipation efficiency is insufficient due to contact resistance heat buildup
Solution Approach 1:
The patent employs phase transition of the cooling fluid (evaporation and condensation) within the capillary channels to enhance heat transfer efficiency. The fluid evaporates at the hot contact interface, absorbing latent heat, and condenses at cooler regions, releasing heat, creating a more efficient thermal management system compared to forced liquid cooling alone.
Solution Approach 2:
The patent replaces the mechanical forced liquid cooling system with a passive capillary-driven cooling mechanism. The capillary structure enables the cooling fluid to move through the contact element without requiring external pumps or forced circulation, eliminating mechanical complexity while improving heat dissipation at the contact interface.
2Loss of energy
If a hollow chamber with evaporating fluid is used to transport heat, then heat transfer efficiency is improved, but device complexity increases due to capillary structure integration
Solution Approach 1:
The patent merges the cooling fluid channel with the contact element structure itself. The capillary channels are integrated within the contact element's hollow chamber, combining the structural and cooling functions into a single unified component, thereby reducing overall device complexity while maintaining effective heat transfer.
Solution Approach 2:
The patent utilizes capillary structures (porous materials) within the contact element walls to enable passive fluid circulation. The porous capillary network provides the necessary surface area and flow paths for the cooling fluid to evaporate and condense efficiently, achieving high heat transfer without complex external cooling systems.
3Temperature
If capillary structure is integrated into the walls, then manufacturing complexity increases, but cooling efficiency is enhanced
Solution Approach 1:
The patent changes the physical parameters of the wall material by incorporating capillary structures with specific pore sizes and distributions. This parameter modification enables the walls to perform dual functions: maintaining structural integrity while facilitating passive capillary-driven cooling, thereby achieving enhanced temperature control without proportionally increasing manufacturing complexity.
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 interlocks two cooling mechanisms, utilizing the evaporating and condensing mechanism to efficiently dissipate heat generated at the contact interface, improving overall cooling efficiency and reducing heat buildup in EV connectors.
Implementation Method 1
The capillary structure receives the fluid that condenses at a cooler area of the connector and conducts the fluid to the hotter part of the connector where it evaporates.
Implementation Method 2
an evaporating fluid transports the heat to colder areas of the contact
Implementation Method 3
The capillary structure receives the fluid that condenses at a cooler area of the connector and conducts the fluid to the hotter part of the connector where it evaporates.
Implementation Method 4
The capillary structure receives the fluid that condenses at a cooler area of the connector
Data Source
Figure 1~2
Figure 3~4
Figure 5a~5b
AI summary
The invention relates to a contact element (105) for an EV connector (100) configured to connect a charging wire to a connector (100) interface on vehicle side. The contact element (105) has a front part (204) and at least one base (501, 502). The front part (204) comprises walls having an inner and an outer side that enclose a hollow chamber (303), which is partly filled with a fluid, and the inner side of the walls are designed having a capillary structure (302) .