Liquid-Cooled Charging Terminals With Closed-Loop Cavity Circulation
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Solution Overview
Problem
Current terminal cooling methods for direct-current charging devices are inefficient, leading to high temperatures that pose safety hazards, limit charging power, and shorten the service life of terminals.
Innovation Solution
A terminal cooling structure and system that includes a connecting tube, conductive terminals with sealed cavities, and cooling tubes, forming a complete loop for efficient heat dissipation through circulation of a cooling medium.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If liquid cooling with cylindrical cavities is used in terminals, then cooling function is provided, but effective circulation cannot be formed and heat dissipation efficiency is low
Solution Approach 1:
The terminal cooling system is segmented into multiple independent cooling channels, each with its own cooling tube and sealed cavity. This segmentation allows each channel to function independently, ensuring effective circulation in each segment rather than relying on a single ineffective cavity system.
Solution Approach 2:
The invention applies hydraulic principles by introducing a liquid cooling medium that circulates through closed-loop cooling tubes. The cooling medium flows continuously through the terminals, utilizing fluid dynamics to achieve efficient heat transfer and dissipation, replacing the ineffective static cavity approach.
2Productivity
If high charging power is used, then charging speed is improved, but heat generation becomes more severe
Solution Approach 1:
The cooling system maintains continuous circulation of the cooling medium through the terminals during the entire charging process. This continuous action ensures that heat is constantly removed from the terminals, allowing high charging power to be sustained without temperature accumulation that would otherwise limit charging speed.
Solution Approach 2:
The cooling medium acts as an intermediary substance that absorbs heat from the terminals during high-power charging. This mediator transfers thermal energy from the charging terminals through the cooling tubes to the cooling system, enabling high charging power while maintaining safe operating temperatures.
3Power
If high temperature is allowed, then charging power can be maintained, but safety hazards and service life are compromised
Solution Approach 1:
The cooling system provides continuous feedback control by monitoring temperature conditions and adjusting cooling medium flow accordingly. This feedback mechanism ensures that terminals remain within safe temperature ranges while maintaining optimal charging power, preventing safety hazards and extending service life through active thermal management.
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 proposed solution effectively reduces terminal temperatures, enhances cooling efficiency, and extends the service life of terminals, while also improving user safety and reducing maintenance costs.
Implementation Method 1
heat can only be dissipated through conduction instead of circulation
Implementation Method 2
effective circulation cannot be formed, so heat can only be dissipated through conduction instead of circulation
Data Source
AI summary
A terminal cooling structure and a cooling system for a direct-current charging device. The terminal cooling structure includes a connecting tube, conductive terminals, and a cooling tube, where the conductive terminals have sealed cavities, and at least one end of the cooling tube is disposed in the sealed cavity; and at least two conductive terminals are provided, each of the conductive terminals is provided with a connecting hole, and the connecting holes communicate with each other by the connecting tube. According to the present application, the cooling tubes are disposed in the conductive terminals, and the sealed cavities are connected to each other by water pipe joints, such that the terminal cooling structure forms a complete loop and may quickly and effectively reduce the temperature of the terminals. With the structure in which cooling liquid enters the sealed cavity from an end opening of the cooling tube and flows out of the sealed cavity from the connecting tube, the contact between the cooling liquid and the inside of the conductive terminal is more sufficient, achieving higher cooling efficiency. With the water pipe joints, the connecting tube can be mounted more conveniently and sealed more completely. A temperature sensor can monitor the cooling effect on the conductive terminals, and can provide a reference for a worker to adjust a cooling liquid supply speed.