Flip-Chip Temperature Sensor for EV Connector
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Solution Overview
Problem
Existing connectors for electric vehicle battery charging suffer from delayed temperature response due to remote placement of temperature sensors, leading to potential overheating and inaccurate heat dissipation measurements, which can damage the connector or charging station.
Innovation Solution
A connector design with a temperature sensor element directly integrated on the electrically conductive contact element, utilizing a flip-chip measuring element and conductor track sections as heat brakes for improved thermal coupling, minimizing heat dissipation and allowing for faster response times and more accurate temperature measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the temperature sensor element is placed away from the electrically conductive contact element, then the device complexity is reduced, but the measurement precision and response time deteriorate
Solution Approach 1:
The temperature sensor element is directly integrated onto the electrically conductive contact element, merging the sensing function with the contact structure. This eliminates the need for separate sensor mounting and thermal coupling components, reducing device complexity while ensuring direct temperature measurement at the heat generation point.
Solution Approach 2:
The temperature sensor element is embedded within or directly attached to the electrically conductive contact element structure. This nesting approach allows the sensor to be positioned exactly where temperature measurement is critical, achieving high measurement precision without adding external components that would increase device complexity.
2Ease of manufacture
If the temperature sensor element is placed away from the electrically conductive contact element, then the ease of manufacture is improved, but the response time deteriorates
Solution Approach 1:
The temperature sensor element and electrically conductive contact element are manufactured as an integrated unit or directly bonded together. This merging eliminates the need for separate assembly steps and ensures immediate thermal coupling, achieving fast response time while maintaining ease of manufacture through standardized integration processes.
Solution Approach 2:
The temperature sensor element is pre-positioned and thermally coupled to the electrically conductive contact element during the manufacturing process. This preliminary action ensures that the sensor is already in optimal thermal contact before the connector is assembled, enabling fast response time without complicating the final assembly process.
3Reliability
If thermally conductive copper leads are used to connect the temperature sensor element, then the electrical conductivity is improved, but the measurement precision deteriorates due to heat dissipation
Solution Approach 1:
The problematic copper leads that cause heat dissipation are removed from the temperature measurement path. Instead, the temperature sensor element is directly connected to the electrically conductive contact element through thermally conductive but electrically isolated means, extracting the heat dissipation issue while maintaining reliable electrical connections elsewhere in the connector.
Solution Approach 2:
An intermediary material or structure is introduced between the temperature sensor element and the electrically conductive contact element. This intermediary provides thermal coupling for accurate temperature measurement while electrically isolating the sensor, preventing heat dissipation through copper leads that would distort the temperature reading.
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 provides enhanced thermal coupling between the temperature sensor and the contact element, resulting in faster response times and higher measured temperatures, preventing overheating and ensuring safer operation.
Implementation Method 1
a temperature sensor element for detecting the temperature of the electrically conductive contact element and arranged at the second end region of the electrically conductive contact element
Implementation Method 2
a first conductor section designed as a heat-resistant element, wherein a first terminal of the flip-chip measuring element is electrically connected to the first connection element via the first conductor section designed as a heat-resistant element
Data Source
Figure 1~3
AI summary
The invention relates to a plug-in connector for disconnecting and connecting at least one electrical contact for charging a rechargeable battery unit of a motor vehicle, having: at least one electrically conductive contact element with a contact region at a first end region of the electrically conductive contact element for releasable electrical connection to a corresponding contact element, and with a connection region at a second end region of the electrically conductive contact element for connection to at least one electrical conductor, wherein the second end region is situated opposite the first end region; and at least one temperature sensor element for detecting a temperature of the electrically conductive contact element and arranged at the second end region of the electrically conductive contact element, wherein the temperature sensor element comprises a substrate with a first connection element and a second connection element which is arranged on said first connection element, a flip-chip measuring element and a first conductor track section which is designed as a heat retarder, wherein a first connection of the flip-chip measuring element is electrically connected to the first connection element by means of the first conductor track section which is designed as a heat retarder. The present invention further relates to a motor vehicle comprising a rechargeable battery unit and a plug-in connector, and also to a charging station for charging a rechargeable battery unit of a motor vehicle, comprising a plug-in connector.