Fan-Cooled High-Current Connector for Terminal Overheating
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Solution Overview
Problem
Connectors used for high-voltage and large-current applications, such as in electric vehicles, face issues with heat buildup leading to decreased power efficiency and fire risk, necessitating effective temperature management.
Innovation Solution
A connector with an integrated cooling system comprising a temperature sensor, fan unit, controller, and exhaust cover, which automatically activates the fan to cool the terminal when temperature exceeds a threshold, and communicates warnings or safety signals to external devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If large current is supplied through the connector, then power transmission capability is improved, but heat generation increases leading to temperature rise
Solution Approach 1:
A cooling fan is introduced as an intermediary component to facilitate heat dissipation from the connector terminal. The fan actively moves air across the terminal surface, enhancing convective cooling and preventing excessive temperature rise during high-power operation
Solution Approach 2:
The patent replaces passive thermal management with an active mechanical cooling system. Instead of relying solely on natural convection or thermal conduction, a mechanically-driven fan is used to force air flow, thereby improving heat dissipation efficiency under high current conditions
2Temperature
If a cooling fan is added to the connector, then temperature control is improved, but device complexity increases
Solution Approach 1:
The cooling fan is configured to operate automatically based on temperature conditions without requiring external control systems. The connector structure itself provides the mounting and operational framework for the fan, allowing it to self-regulate cooling based on thermal conditions during operation
Solution Approach 2:
The cooling fan is integrated into the connector housing structure, merging the cooling function with the existing connector components. This integration approach minimizes additional structural complexity by utilizing available space and structural elements within the connector assembly
3Temperature
If the fan operates continuously to cool the terminal, then temperature management is improved, but energy consumption increases
Solution Approach 1:
The cooling fan operates periodically or intermittently based on thermal conditions rather than continuously. The system activates cooling only when temperature thresholds are exceeded, thereby managing temperature effectively while minimizing unnecessary energy consumption during normal operating conditions
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
The system effectively cools the connector terminals, maintains power efficiency, and ensures safety by preventing overheating and potential fires through automated temperature control and communication with external systems.
Implementation Method 1
a fan unit provided in the connector housing, and configured to operate when a temperature of the terminal member is higher than a preset threshold temperature
Implementation Method 2
at least one temperature sensor attached to the terminal member
Data Source
AI summary
A connector for large current according to the present disclosure includes: a terminal member capable of large current transmission; a connector housing in which the terminal member is accommodated; a temperature sensor attached to the terminal member; a fan unit provided in the connector housing, and configured to operate when a temperature of the terminal member is higher than a preset threshold temperature; and an exhaust cover provided on a side of the connector housing and opened/closed by wind pressure when the fan unit operates.