Liquid-Cooled EV Charging Connector for Terminal Interface Heat
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Solution Overview
Problem
Existing electric vehicle charging connectors and cables face overheating issues due to high charging currents, leading to potential safety hazards and product damage, with existing cooling methods insufficiently addressing heat generation at the interface between the conductor and power terminal.
Innovation Solution
An electric vehicle charging connector and assembly that incorporates a cooling chamber with a cooling fluid to directly cool the conductor connection part and collect the fluid for efficient heat dissipation, using a self-twist and helically wound conductor structure and a collection unit to enhance cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If the diameter of the conductor is increased to minimize heat generated in the electric vehicle charging cable, then the heat generation is reduced, but the weight of the electric vehicle charging cable increases
Solution Approach 1:
A cooling fluid is introduced as an intermediary substance to transfer heat away from the conductor and connector components. The cooling fluid circulates through channels in the connector housing, absorbing heat from the conductor connection parts and carrying it away, thus reducing heat generation effects without requiring larger conductor diameters
Solution Approach 2:
The patent employs a hydraulic cooling system where cooling fluid is pumped through defined channels within the connector structure. This fluid circulation system actively removes heat from high-current components, enabling effective heat management without increasing conductor size or cable weight
2Object-generated harmful factors
If a cooling fluid is circulated in the electric vehicle charging cable to cool the conductor, then heat generated in the cable is reduced, but the structure becomes more complex
Solution Approach 1:
The cooling system is merged with the connector housing structure itself. The housing incorporates internal channels that guide the cooling fluid directly to the conductor connection parts, combining the structural support function with the thermal management function in a single integrated component rather than adding separate cooling apparatus
Solution Approach 2:
The connector housing serves multiple functions: it provides mechanical protection for the electrical components, structurally supports the connection assembly, and simultaneously acts as the cooling system through its integrated fluid channels. This multi-functionality reduces overall system complexity by eliminating the need for separate cooling components
3Temperature
If the cooling chamber accommodates the conductor connection part to cool heat generated at the interface, then cooling efficiency is improved, but the device complexity increases
Solution Approach 1:
The cooling system is designed with local quality by concentrating cooling resources at the specific location where heat is most critical - the conductor connection part interface. The cooling fluid channels are positioned to deliver maximum cooling effect precisely at the heat generation point rather than uniformly cooling the entire connector
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 solution effectively cools the electric vehicle charging cable and connector, preventing overheating, reducing safety risks, and enhancing product reliability by efficiently dissipating heat generated during high-current charging.
Implementation Method 1
a cooling unit configured to cool the conductor and included in the conductor of each of the power units, the cooling unit including a cooling tube and a cooling channel which is included in the cooling tube and in which a cooling fluid flows
Implementation Method 2
a cooling chamber configured to accommodate the conductor connection part of each of the pair of power terminals, cool heat generated in the conductor connection part by using the cooling fluid flowing through the cooling unit
Implementation Method 3
collect the cooling fluid by a collection unit
Data Source
AI summary
The present disclosure relates to an electric vehicle charging connector, which includes a cooling chamber through a cooling fluid passes to cool an electric vehicle charging cable and is configured to connect in the cooling chamber a terminal of the electric vehicle charging connector and a conductor of the electric vehicle charging cable so as to quickly cool heat generated on the terminal of the electric vehicle charging connector and a conductor connection part of the electric vehicle charging cable in the cooling chamber, and to collect the cooling fluid from the cooling chamber to an electric vehicle charger, and an electric vehicle charging assembly.