Liquid-Cooled Connector Housing for High-Current Charging
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Solution Overview
Problem
High current electrical connectors in electrified vehicles generate significant heat during charging, which poses a challenge for thermal management as vehicle traction batteries increase in size, requiring efficient cooling solutions to maintain high charging rates.
Innovation Solution
The integration of a liquid cooling circuit within the electrical connector housing, featuring a heat exchanger channel with thermally conductive polymers and heat transfer augmentation features, such as axial ribs or lattice structures, to convectively cool bus bars without the need for separate mechanical fasteners, and using a potting compound to enhance thermal conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high current electrical connectors are used in electrified vehicles, then power transfer capability is improved, but heat generation increases
Solution Approach 1:
The cooling circuit is merged with the connector housing to form an integrated thermal management system. The housing itself becomes part of the cooling structure, with cooling channels directly formed within it, eliminating the need for separate cooling components and reducing thermal resistance between the bus bar and cooling fluid.
Solution Approach 2:
A thermally conductive polymer is introduced as an intermediary material between the bus bar and the cooling circuit. This polymer enhances heat transfer from the bus bar to the cooling fluid while maintaining electrical insulation, effectively mediating the thermal interaction between conductive and non-conductive components.
2Temperature
If separate cooling components are added to the connector, then cooling effectiveness is improved, but device complexity increases
Solution Approach 1:
The cooling circuit is integrated directly into the connector housing structure, combining the housing and cooling system into a single component. This eliminates the need for separate cooling components and their associated fasteners, reducing assembly complexity while maintaining effective cooling.
Solution Approach 2:
The connector housing serves dual functions: providing structural support and electrical insulation, while simultaneously acting as a cooling circuit channel. This multi-functionality reduces the total number of components needed while achieving both mechanical and thermal management goals.
3Reliability
If multiple fasteners are used to attach cooling components, then assembly reliability is improved, but manufacturing cost increases
Solution Approach 1:
The cooling circuit is formed as an integral part of the housing structure, eliminating the need for separate fasteners to attach cooling components. This integration reduces assembly steps and manufacturing complexity while maintaining reliable thermal contact through the thermally conductive polymer.
Solution Approach 2:
The use of thermally conductive polymer as a bonding material provides both mechanical attachment and thermal conduction in a single material, replacing multiple fasteners and thermal interface materials. This composite approach simplifies manufacturing while ensuring reliable assembly.
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 solution enables higher charging rates while reducing material and manufacturing costs by actively cooling the connectors, effectively managing heat and improving thermal management in high current electrical connectors.
Implementation Method 1
The heat exchanger channel is configured to receive a fluid for convectively cooling the bus bar
Implementation Method 2
The housing includes a thermally conductive polymer that includes a conductive filler
Implementation Method 3
The heat exchanger channel includes a plurality of heat transfer augmentation features
Data Source
AI summary
This disclosure describes liquid cooled electrical connectors for connecting components of electrified vehicles or components of any other type of power connection/power transfer system. Exemplary electrical connectors include integrated cooling circuits that employ heat exchanger channels for circulating a fluid for convectively cooling bus bars of the connector.