Liquid-Cooled EV Charging Connector for High-Current Heat Dissipation
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Solution Overview
Problem
Existing electric vehicle charging connectors are limited to current ratings of up to 200 A due to ineffective passive cooling designs, which lead to heat management issues and increased weight, preventing the achievement of higher current ratings without significant design modifications.
Innovation Solution
The electric vehicle charging connector incorporates a cooling tube with a liquid coolant that connects to an internal cooling channel extending from a block portion to contact fingers, allowing for forced cooling and reducing the connector's weight by creating a gap between outer and inner casings, enabling higher current ratings and efficient heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If passive cooling designs are used, then the connector structure is simpler, but the current rating is limited to 200 A and heat dissipation is ineffective
Solution Approach 1:
The patent applies hydraulic cooling by integrating a cooling tube with liquid coolant circulation through the contact elements. The cooling tube extends into the contact finger, and coolant flows through channels to actively remove heat generated during high-current charging operations, enabling current ratings exceeding 500 A.
Solution Approach 2:
The cooling tube is nested within the connector housing and extends into the contact elements. The cooling channels are integrated within the contact finger structure, creating a compact nested arrangement that provides effective cooling without increasing overall connector dimensions.
2Reliability
If active cooling with liquid coolant is implemented, then current ratings over 500 A are achieved, but additional devices such as pumps and cooling tubes are required
Solution Approach 1:
The cooling tube is merged with the connector housing structure, and the cooling channels are integrated within the contact elements themselves. This combining of cooling functions with existing structural components reduces the number of separate parts and simplifies the overall system while maintaining high current rating capability.
Solution Approach 2:
The contact elements serve dual functions: electrical conduction and heat transfer. The same contact finger that conducts charging current also contains cooling channels that dissipate heat, eliminating the need for separate cooling components and reducing system complexity.
3Reliability
If cooling channels are integrated into contact elements, then heat dissipation is improved, but manufacturing complexity increases
Solution Approach 1:
The contact finger is designed with specific geometric parameters including cooling channels with optimized cross-sections and dimensions. The channel size, shape, and positioning are carefully controlled to balance cooling efficiency with manufacturability, allowing effective heat dissipation while maintaining ease of fabrication.
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 allows for higher current ratings without exceeding temperature limits, reducing charging time for heavy-load vehicles and minimizing cable diameter and space requirements, while ensuring human safety and efficient cooling.
Implementation Method 1
The cooling tube is fluidly connected to an internal cooling channel of the contact element, wherein the cooling channel is extending from the block portion into the contact finger, so that both parts are cooled by the cooling fluid.
Data Source
AI summary
An electric vehicle charging connector includes contact elements that are electrically connected to a cable. The contact elements comprise a block portion and at least one contact finger extending from the block portion, and a cooling tube for forced cooling that includes a liquid coolant for cooling at least one of the contact elements. The cooling tube is fluidly connected to an internal cooling channel of the contact element. The cooling channel extends from the block portion into the contact finger so that both parts are cooled by the cooling fluid.