Passive Cooling Sleeve for Electrical Connectors
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Solution Overview
Problem
Automotive power connector systems face challenges in managing high currents while minimizing weight, bulk, and cost, as well as effectively dissipating heat generated during current transmission, especially in electric and hybrid vehicles.
Innovation Solution
A passive cooling device comprising a sleeve with ducts and radially extending fins that form a convection channel, allowing heat to be dissipated through conduction and convection, which can be integrated into connectors and cables to enhance their performance and longevity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high currents are transmitted through cables and connectors, then charging capacity and power transmission are improved, but heat generation increases and temperature rises
Solution Approach 1:
The invention converts the harmful heat generated by high current transmission into a manageable thermal management challenge by integrating cooling channels directly into the connector housing. The heat generated during power transmission is channeled through dedicated pathways to cooling fins, transforming the harmful thermal effect into a controlled heat dissipation process that enables sustained high-power operation
2Temperature
If active cooling solutions are implemented, then heat dissipation is improved, but device complexity and cost increase
Solution Approach 1:
The cooling system operates passively without requiring external power sources, control systems, or active components. The connector housing itself serves as the heat transfer medium, with integrated channels that rely on natural convection and conduction to move heat from the contact areas to the external fins, allowing the system to self-regulate thermal management
Solution Approach 2:
The cooling function is merged directly into the connector housing structure, eliminating the need for separate cooling components. The housing simultaneously serves as mechanical protection, structural support, and thermal management system through integrated cooling channels and fins
3Weight of stationary object
If connector dimensions are reduced to minimize weight and bulk, then integration and compactness are improved, but heat dissipation capacity decreases
Solution Approach 1:
The invention addresses heat dissipation in compact dimensions by transitioning from volumetric cooling to surface-area-based cooling through integrated fins. The cooling effectiveness is enhanced by extending heat transfer surfaces in the radial direction from the cooling channels, allowing efficient heat dissipation without increasing the overall connector volume or weight
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 passive cooling device enables higher current transmission without increasing dimensions, extends the lifespan of connectors and cables, and allows for reduced cross-sectional areas while maintaining effective heat dissipation, thus improving charging capacity and reducing temperature.
Implementation Method 1
heat produced in cables and/or in contacts may be transmitted via the ducts and fins by conduction through the material from which the sleeve is made
Implementation Method 2
the channel that allows air to flow around each duct and between the fins contributes to removing, by convection, into the environment, the heat transmitted via the ducts and fins
Data Source
Figure 1~6
Figure 2~3
Figure 4~5
AI summary
Passive device for cooling an electrical power connector. This device comprises a sleeve (7) with ducts through each of which passes one cable (5). The ducts guide the cables (5) and contribute, via thermal conduction, to removing the heat produced by the passage of a current in the connector and through the cables (5). The sleeve furthermore comprises fins (13) between which air may flow in order to remove heat by convection. Connection assembly comprising a connector and such a cooling device.