High-Current Contact Cooling Using Phase-Change Coolant and Absorber
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Solution Overview
Problem
High-current contact elements in electric vehicle charging sockets overheat due to transmitted power, limiting the duration of maximum power transmission and requiring power reduction to prevent overheating.
Innovation Solution
A high-current contact device with a cooling system comprising a coolant container, an absorber container, and a valve, where the coolant changes phase to cool the contact element, and the absorber material absorbs the coolant, allowing continuous high-power transmission without overheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If maximum electric power is transmitted via the contact element, then charging speed is improved, but the contact element overheats and must be reduced in power
Solution Approach 1:
The patent utilizes phase transition of coolant from liquid to gas state to absorb heat from the contact element during high-power transmission, preventing overheating while maintaining charging speed. The coolant container holds liquid coolant that vaporizes when heated by the contact element, absorbing large amounts of thermal energy during the phase change process.
Solution Approach 2:
The patent introduces a coolant as an intermediary substance between the contact element and the environment. The coolant absorbs heat from the contact element through thermal conduction, then transports this heat away via phase transition and condensation in the absorber container, effectively mediating the heat transfer process.
2Use of energy by stationary object
If maximum electric power is transmitted for extended periods, then charging efficiency is improved, but the contact element overheats requiring power reduction
Solution Approach 1:
The patent implements continuous cooling action through the coolant circulation system. The coolant continuously absorbs heat from the contact element, transports it to the absorber container, and can be regenerated to repeat the cycle, ensuring uninterrupted thermal management during extended high-power charging operations.
Solution Approach 2:
The patent employs preventive cooling measures by having the coolant system ready in advance to handle heat generation. The coolant container is pre-filled with coolant, and the absorption system is prepared to receive and dissipate heat before critical temperatures are reached, cushioning against thermal overload.
3Temperature
If a cooling system is added to prevent overheating, then temperature control is improved, but device complexity increases
Solution Approach 1:
The cooling system is designed to be largely self-regulating. The coolant automatically absorbs heat from the contact element through thermal conduction when hot, and the absorber container passively receives and stores the thermal energy through phase change or heat absorption, minimizing the need for external control mechanisms.
Solution Approach 2:
The patent combines multiple functions into integrated components. The coolant container serves both as a heat source reservoir and a thermal management component. The absorber container integrates heat storage and dissipation functions. This merging reduces the number of separate components and simplifies the overall system architecture.
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 prolonged high-power charging without overheating, reducing the need to reduce electric power, optimizing the contact element's temperature and extending its service life, while allowing rapid and efficient charging of the traction battery.
Implementation Method 1
The coolant changes to a gaseous phase in the coolant container to cool the contact element
Implementation Method 2
the absorber material absorbs the coolant in the gaseous phase
Data Source
AI summary
A high-current contact device includes a contact element and a cooling device. The cooling device has a coolant container thermally connected to the contact element, an absorber container arranged at a distance from the coolant container and the contact element, a fluid line extending between the coolant container and the absorber container, and a valve arranged in the fluid line. The coolant container has a coolant and the absorber container has an absorber material. The coolant container is fluidly connected to the absorber container in a valve open position and is fluidly separated from the absorber container in a valve closed position. The coolant changes to a gaseous phase in the coolant container to cool the contact element. The fluid line conveys the coolant in the gaseous phase from the coolant container to the absorber container, and the absorber material absorbs the coolant in the gaseous phase.