Liquid-Cooled EV Charging Connector for High-Current Contacts
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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, leading to inefficiencies and increased weight, and active cooling systems require additional components like pumps.
Innovation Solution
A charging connector design featuring contact elements with integrated cooling tubes and channels, allowing for forced cooling of both the contact elements and cables, utilizing a liquid coolant to manage high current rates and reduce weight by optimizing the connector's structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If passive cooling designs are used in charging connectors, then the connector structure is simpler, but the current rating is limited to up to 200 A and cooling effectiveness is insufficient
Solution Approach 1:
The patent applies hydraulic cooling by integrating a cooling tube with liquid coolant circulation through the contact element. The cooling tube receives coolant at an inlet and dissipates heat through the contact element body, enabling effective cooling for high current ratings exceeding 200 A while maintaining a relatively simple connector structure without requiring additional pump components.
2Reliability
If active cooling systems with pumps are used, then high current rates over 500 A are achieved, but additional devices such as pumps are necessary increasing device complexity
Solution Approach 1:
The patent implements hydraulic cooling through an integrated cooling tube that circulates liquid coolant through the contact element. This approach achieves effective cooling for high current ratings over 500 A while avoiding the need for additional pump devices, as the coolant circulation is designed to function without active pumping components.
Solution Approach 2:
The cooling tube is merged with the contact element structure, where the cooling tube is arranged to receive coolant and is in thermal contact with the contact element body. This integration combines the electrical contact function and cooling function into a single unified component, reducing overall device complexity while maintaining high cooling effectiveness.
3Temperature
If hollows are created in the enclosure for passive cooling, then cooling is possible, but the connector weight increases and insulation effectiveness may be reduced
Solution Approach 1:
The patent replaces passive hollow cooling structures with an active hydraulic cooling system using a cooling tube that circulates liquid coolant. This approach provides effective cooling for high current applications without requiring large hollow spaces in the enclosure, thereby avoiding increased cable weight while maintaining proper insulation characteristics.
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 operation at higher current rates while maintaining safe temperature ranges, reducing charging time for heavy load vehicles, and minimizing connector weight and space requirements.
Implementation Method 1
The cooling tube being fluidically 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 the block portion and the contact fingers are cooled by the cooling fluid
Implementation Method 2
A charging connector design featuring contact elements with integrated cooling tubes and channels, allowing for forced cooling of both the contact elements and cables, utilizing a liquid coolant to manage high current rates
Data Source
Figure 1~2
Figure 3a~4
AI summary
The present invention relates to an electric vehicle charging connector (10) comprising contact elements (26). The contact elements (26) are electrically connected to a cable (22), wherein the contact elements (26) comprise a block portion (34) and at least one contact finger (38) extending from the block portion (34), wherein the electric charging connector (10) further comprises a cooling tube (42) for forced cooling, comprising a liquid coolant for cooling at least the contact element (26). The cooling tube (42) being fluidically connected to an internal cooling channel (30) of the contact element (26), wherein the cooling channel (30) extending from the block portion (34) into the contact finger (38), so that both parts are cooled by the cooling fluid.