EV Plug Temperature Sensor Integration via Shrink Tubing
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Solution Overview
Problem
Existing charging systems for electric or hybrid vehicles are sluggish in temperature regulation due to the slow response time of temperature sensors, requiring modifications to integrate sensors into connectors and increasing production costs.
Innovation Solution
A plug design that thermally and mechanically connects a commercially available temperature sensor directly to the plug using shrink tubing, allowing for rapid temperature detection without altering the connector housing, and utilizing sensors like NTC or PTC thermistors for efficient charging control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If temperature sensors are integrated into the connector housing, then temperature detection capability is improved, but response time remains slow (up to 20 minutes)
Solution Approach 1:
The patent introduces thermal paste as an intermediary substance between the temperature sensor and the plug contact. This thermal paste improves thermal conductivity and ensures efficient heat transfer from the contact to the sensor, enabling rapid temperature detection without the sluggish response times of conventional sensor integrations.
Solution Approach 2:
The temperature sensor is pre-positioned and thermally coupled to the plug contact before the plug is inserted into the socket. This preliminary thermal connection ensures that temperature monitoring begins immediately upon insertion, eliminating delays associated with post-assembly sensor integration.
2Reliability
If temperature sensors are integrated into the connector, then charging control is improved, but production costs increase
Solution Approach 1:
The patent employs commercially available, cost-effective temperature sensor elements that can be easily integrated into the connector. These affordable sensors provide sufficient reliability for charging control applications without requiring expensive specialized components, thereby maintaining low production costs while improving charging safety and control.
Solution Approach 2:
The connector design allows for straightforward integration of temperature sensors using standard assembly techniques and readily available components. The sensor can be mounted and thermally coupled using simple procedures, reducing manufacturing complexity and cost while ensuring reliable charging temperature monitoring.
3Measurement precision
If sensor head is pressed against plug contact, then thermal contact is improved, but mechanical stability must be maintained
Solution Approach 1:
The shrink tube serves as a mechanical intermediary that secures the sensor head to the plug contact. When heated, the shrink tube contracts and firmly holds the sensor head in place, maintaining both excellent thermal contact and mechanical stability during plug insertion, usage, and removal cycles.
Solution Approach 2:
The patent utilizes the thermal expansion properties of the shrink tube material. The tube is applied in its expanded state to allow easy placement around the sensor head and plug contact, then heated to cause contraction. This thermal shrinking process creates a firm mechanical bond that maintains stable thermal contact without requiring additional fastening elements.
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 rapid temperature recording and efficient charging regulation, reducing response time significantly and maintaining low production costs while ensuring electrical insulation and using standard sensors.
Implementation Method 1
The sensor head is in direct contact with an area of one of the live plug contacts. This enables very rapid heat transfer.
Implementation Method 2
The sensor head is held by a shrink tube in the area of one of the live plug contacts and is pressed against the area of one of the live plug contacts by the shrinking process of the heat-shrink tubing.
Data Source
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AI summary
The invention relates to a plug comprising a charging cable, a plug housing and live power contacts for a charging current, wherein at least one temperature sensor is arranged in the plug housing for a charging control and/or a charging monitoring, wherein a quick charging control is achieved with reduced production costs. This is achieved in that the temperature sensor consists of a sensor head and sensor connection pins, wherein the sensor head is in direct contact with a region of a live plug contact and the connection pins are arranged parallel to the live plug contact, and in that via a shrinking tube, the sensor head is retained in the region of the corresponding live plug contact and is pressed against the region of the live plug contact, whereby a shrinking process occurs, wherein the shrinking tube completely surrounds the region of the plug contact and the sensor head, such that the temperature sensor is connected to the plug contact via the shrinking tube in a heat-conducting and mechanical manner on one side, and the temperature is arranged in a type of heat chamber formed by the shrinking tube on the other side.