Multi-Strip Charging Contacts for Fast EV Charging Without Overheating
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Solution Overview
Problem
Existing rapid charging systems for electric vehicles, particularly electric buses, suffer from long charging times and overheating of components due to high current densities, necessitating costly infrastructure upgrades to improve charging efficiency and safety.
Innovation Solution
A rapid charging system with a contact device and charging contact device featuring at least four strip-shaped charging contact elements and contact elements, allowing for multiple power contacts to distribute current, reducing heating and enabling fast, safe charging without complete infrastructure replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high current density is used for rapid charging, then charging speed is improved, but components overheat and exceed permissible temperature limits
Solution Approach 1:
The charging contact device divides the current path into multiple parallel conductive strips (at least four strip-shaped charging contact elements), distributing the high charging current across multiple segments rather than concentrating it in a single contact path, thereby reducing current density and heat generation in each individual strip
Solution Approach 2:
The charging contact elements are arranged in a spatial distribution pattern (at least four strips arranged relative to contact elements) that utilizes two-dimensional space to create multiple parallel current paths, effectively increasing the cross-sectional area for current flow and reducing resistance-induced heating
2Productivity
If existing charging infrastructure is replaced with improved rapid charging system, then charging efficiency is improved, but investment costs increase significantly
Solution Approach 1:
The charging contact device is designed with a universal interface that maintains compatibility with existing contact devices while enabling improved rapid charging performance, allowing the same charging station infrastructure to serve both legacy and enhanced charging requirements without complete replacement
Solution Approach 2:
The system improves charging efficiency by changing key parameters such as the number of contact elements (at least four strip-shaped elements), their geometric arrangement, and material properties, rather than requiring complete infrastructure replacement, thereby achieving performance enhancement at lower cost
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 system enables efficient, high-current charging without overheating, supporting gradual infrastructure upgrades and reducing initial investment costs by maintaining compatibility with existing systems.
Implementation Method 1
the contact elements in the contact position can each be electrically contacted with the charging contact elements to form contact pairs
Implementation Method 2
charging a vehicle takes a comparatively long time and, during longer charging times, components on the charging contact device or the contact device become so hot as a result of the charging process that permissible temperature limits for these components can be exceeded
Data Source
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AI summary
The invention relates to a rapid charging system (46) for electrically powered vehicles, in particular electric buses or the like, and to a method for forming an electrically conductive connection between a vehicle and a stationary charging station, comprising a contact device (47), a charging contact device (43), and a positioning device, wherein the contact device or the charging contact device can be arranged on a vehicle, wherein the contact device can be electrically contacted with the charging contact device in a contact position, wherein the contact device can be positioned relative to the charging contact device and brought into the contact position by means of the positioning device, wherein the charging contact device has a charging contact element carrier (44) with charging contact elements (45), wherein the charging contact elements are each strip-shaped,wherein the contact device comprises a contact element carrier (48) with contact elements (49), wherein the contact elements can be electrically contacted in the contact position with the charging contact elements to form contact pairs, wherein the contact pairs can be formed for at least two power contacts of the rapid charging system, wherein the charging contact element carrier has at least four charging contact elements (45) and/or wherein the contact element carrier has at least four contact elements (49), wherein the charging contact elements are arranged relative to the contact elements such that in the contact position at least two power contacts can be formed between two charging contact elements and two contact elements.