Heat-Transfer Connector Structure for Rapid-Charging Temperature Control
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Solution Overview
Problem
Connectors for electric vehicles face challenges in maintaining terminal operating temperatures within safety standards during rapid charging, as natural heat dissipation is insufficient, and adding heat dissipation members can compromise miniaturization and installation space.
Innovation Solution
A connector design featuring a housing with a resin holder and metal holder that incorporates a heat transfer member with elasticity, allowing efficient heat absorption and dissipation, preventing excessive temperature rise while maintaining compactness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a member for heat dissipation (such as a metal plate) is assembled to the outside of the connector, then the heat dissipation performance is improved, but the connector size increases and installation space is compromised
Solution Approach 1:
The housing is integrated with heat dissipation fins directly formed as part of its structure, merging the housing function with heat dissipation function into a single component. This eliminates the need for separate heat dissipation members while maintaining effective heat dissipation surface area, thus resolving the contradiction between heat dissipation performance and connector size.
Solution Approach 2:
The housing serves multiple functions simultaneously: it provides structural support, electrical insulation, and heat dissipation through integrated fins. This multi-functionality allows the connector to achieve effective heat dissipation without adding extra components that would increase overall size, thereby resolving the technical contradiction.
2Temperature
If natural heat dissipation is used, then the connector structure remains simple and compact, but the terminal temperature rises excessively during rapid charging
Solution Approach 1:
The heat dissipation fins are integrated directly into the housing structure, combining the housing and heat dissipation components into one piece. This approach improves heat dissipation capability during rapid charging while avoiding the complexity of separate heat dissipation systems, thus resolving the contradiction between temperature control and structural simplicity.
3Volume of moving object
If the connector is miniaturized to save installation space, then the installation space requirement is reduced, but the heat dissipation capability deteriorates
Solution Approach 1:
Heat dissipation fins extend in the radial direction from the housing body, utilizing the radial dimension to increase heat dissipation surface area without increasing the longitudinal length of the connector. This dimensional approach allows effective heat dissipation while maintaining a compact overall connector size, resolving the contradiction between miniaturization and heat dissipation capability.
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 connector effectively suppresses terminal temperature increases during rapid charging, ensuring safe operation and excellent heat dissipation performance without hindering miniaturization or installation space.
Implementation Method 1
a heat transfer member (20) having elasticity. The heat transfer member (20) is disposed in a compressed and deformed state so as to be in close contact between an outer peripheral surface of at least one of an electric wire connection portion (17) of the terminal (12) and an end portion (11c) of the electric wire (11) and an inner peripheral surface of the second housing (50)
Data Source
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AI summary
A connector includes a terminal-equipped electric wire having a terminal connected to an end portion of an electric wire, housing to accommodate the terminal and to hold the terminal-equipped electric wire and a heat transfer member having elasticity. The housing includes a first housing having a terminal accommodating portion, and a second housing to hold the terminal-equipped electric wire. The second housing includes a resin holder to be mounted on an electric wire connection portion of the terminal and the end portion of the electric wire, and a metal holder to be externally mounted on the resin holder. The heat transfer member is disposed in a compressed and deformed state between an outer circumferential surface of at least one of the electric wire connection portion of the terminal and the end portion of the electric wire and an inner circumferential surface of the second housing.