EV Charging Connector Heat Pipe Cooling Without IP Rating Loss
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Solution Overview
Problem
Existing electric vehicle charging connectors face limitations in achieving high current ratings due to heat generation, with passive cooling designs leading to inadequate IP ratings and increased weight, and active cooling systems requiring additional components like pumps.
Innovation Solution
The design incorporates an external enclosure with an inner compartment and a heat pipe that conducts heat from the heat source to the environment, with at least part of the heat pipe outside the enclosure to enhance thermal performance and maintain IP protection, using a structure to protect the condenser from environmental exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If passive cooling is used with hollows in the enclosure, then thermal performance is improved, but IP rating deteriorates and weight increases
Solution Approach 1:
The heat-dissipating function is extracted from the enclosed housing and placed outside via the heat pipe condenser. The evaporator remains inside to extract heat from power contacts, while the condenser extends outside the enclosure to dissipate heat to the environment, separating the cooling function from the sealed enclosure structure.
Solution Approach 2:
The heat pipe acts as an intermediary thermal conduction path between the internal heat sources (power contacts) and the external environment. It transfers heat from the evaporator inside the enclosure to the condenser outside, enabling thermal management without compromising the IP rating of the enclosure.
2Temperature
If passive cooling is used with hollows in the enclosure, then thermal performance is improved, but weight increases
Solution Approach 1:
The passive heat pipe system replaces heavier active cooling mechanisms (pumps, liquid circulation systems) that would be required to achieve similar thermal performance. The heat pipe utilizes phase change and capillary action without mechanical components, significantly reducing weight while maintaining effective heat dissipation.
3Power
If high current flows through the cable and power contacts, then charging power is improved, but heat generation increases
Solution Approach 1:
The heat generated by high current flow through power contacts is converted into a manageable thermal flow path. The heat pipe captures this harmful heat at the evaporator and transports it to the condenser outside the enclosure, where it is dissipated to the environment, transforming the harmful thermal effect into a controlled heat transfer process.
4Temperature
If at least a part of the heat pipe is arranged outside the external enclosure, then thermal performance is improved, but device complexity increases
Solution Approach 1:
The heat pipe is segmented into two functional parts: the evaporator section inside the enclosure that contacts heat sources, and the condenser section outside the enclosure that dissipates heat to the environment. This segmentation allows each part to be optimized for its specific function while maintaining a relatively simple overall structure.
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 design achieves high thermal performance and maintains adequate IP ratings, ensuring safety and compliance with standards while reducing weight and enhancing mechanical stability.
Implementation Method 1
The electric vehicle charging connector further comprises a heat pipe comprising an evaporator and a condenser. The evaporator is attached to a heat source in the compartment inside the inner enclosure, configured to conduct heat from the heat source via the external enclosure to the environment
Implementation Method 2
configured to conduct heat from the heat source via the external enclosure to the environment
Data Source
AI summary
An electric vehicle charging connector (100) comprising an external enclosure (104), an inner enclosure, and a compartment (102) for power contacts. The external enclosure (104) encloses an inner enclosure (103), and is configured to receive and guide a cable (101) from a back end (111) of the electric vehicle charging connector (100) to the inner enclosure (103) at a front end (113) of the electric vehicle charging connector (100). The inner enclosure (103) comprises the compartment (102) and is configured to provide the cable (101) to the compartment (102). The electric vehicle charging connector (100) further comprises a heat pipe (106) comprising an evaporator (107), and a condenser (109). The evaporator (107) is attached to a heat source in the compartment (102) inside the inner enclosure (102), configured to conduct heat from the heat source via the external enclosure (104) to the environment, wherein at least a part of the heat pipe (106) is arranged outside the external enclosure (104).