Vehicle Charging Connector PCB Heat Sensing at Power Contacts
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Solution Overview
Problem
The increased electric current for faster charging of electric or hybrid vehicles poses a risk of overheating, which can lead to fires, necessitating effective temperature monitoring at the power contacts.
Innovation Solution
A connection device with a housing containing power contacts and a printed circuit board equipped with temperature sensors, where metal pads ensure optimal thermal conductivity and contact, allowing for rapid detection of abnormal temperature rises.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the electric current intensity is increased to reduce charging time, then the charging power is improved, but the risk of overheating and fire increases
Solution Approach 1:
Temperature sensors are installed on the power contacts before charging operations begin, enabling proactive temperature monitoring. The system is prepared in advance to detect temperature rises and trigger safety mechanisms before overheating causes damage or fire.
Solution Approach 2:
Temperature sensors continuously monitor the temperature of power contacts during charging and provide real-time feedback to the control system. This feedback loop enables the system to detect abnormal temperature rises and respond by interrupting the charging process, preventing overheating and fire hazards.
2Reliability
If temperature monitoring is implemented at power contacts, then safety is improved, but the device complexity increases
Solution Approach 1:
Temperature sensors are selectively installed only at the power contacts where temperature monitoring is most critical. This localized approach provides targeted safety monitoring at the specific locations where overheating risks are highest, without requiring comprehensive temperature monitoring throughout the entire device.
Solution Approach 2:
The patent replaces complex mechanical temperature monitoring systems with electronic temperature sensors that provide more precise and reliable temperature detection. This substitution simplifies the overall system while improving safety through more accurate temperature measurement and control.
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 monitors temperature at power contacts, preventing overheating and potential fires by ensuring rapid detection and triggering safety measures, thus ensuring safe and efficient high-current charging.
Implementation Method 1
a first metal pad which is compressed between the printed circuit board and an axial surface of the rear section of the first power contact
Data Source
AI summary
A connection device for electrical connection of a vehicle to a charging cord provided with a charging socket includes a housing, a power contact disposed within the housing, and a printed circuit board mounted in the housing having a first face provided with a first metal pad which is compressed between the printed circuit board and a surface of the power contact, and a second face provided with a first temperature sensor which is arranged opposite the first metal pad. A method of electrical connection of a vehicle to a charging cord provided with a charging socket is also provided.