Plug Connector Cooling Module for High-Current Weight Reduction
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Solution Overview
Problem
In high-current applications, such as e-mobility, plug connector systems face challenges in balancing high current-carrying capacity with weight reduction due to high thermal loads, where conventional cooling methods require large conductor cross-sections to prevent overheating, making further weight reduction difficult.
Innovation Solution
A cooling module for plug connector parts that integrates the electrical load line into the coolant circuit, allowing for active cooling along the entire length of the cable, reducing the cross-section while maintaining current-carrying capacity, and eliminating the need for separate cooling and electrical line paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductor cross-sections are dimensioned large to carry high current loads, then current-carrying capacity is improved, but weight increases
Solution Approach 1:
The patent merges the cooling function with the electrical connection function by integrating the cooling module directly onto the load contact. The cooling module includes a cooling body with coolant flow paths and a mounting surface for the load contact, combining thermal management and electrical conduction into a single integrated structure. This eliminates the need for separate cooling systems and large conductor cross-sections, reducing weight while maintaining high current-carrying capacity through effective active cooling.
2Reliability
If coolant circuit and electrical lines are spatially separated, then functional requirements are met, but conductor cross-sections must be larger to prevent overheating
Solution Approach 1:
The patent integrates the cooling circuit and electrical lines into a single spatial location by mounting the load contact directly on the cooling module's mounting surface. The load contact is positioned such that it is both electrically connected to the terminal region and thermally coupled to the cooling body with coolant flow paths. This integration allows the electrical current and cooling functions to coexist in the same space, eliminating the need for enlarged conductor cross-sections while maintaining effective thermal management.
3Weight of moving object
If conductor cross-sections are reduced for weight reduction, then weight decreases, but current-carrying capacity and thermal management become problematic
Solution Approach 1:
The patent replaces the mechanical solution of increasing conductor cross-section to handle thermal loads with a thermal management system using active cooling. Instead of relying on large copper cross-sections to conduct heat away passively, the system uses a coolant-circulating cooling module with controlled thermal conduction paths. This substitution allows the use of smaller, lighter conductors while maintaining thermal management effectiveness through active cooling processes.
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 high currents with reduced weight by effectively cooling the load cable, allowing for compact designs and improved thermal management without the need for large conductor cross-sections, thus addressing the weight and thermal load challenges.
Implementation Method 1
at least one opening into the cavity via which a coolant can flow through the cavity
Data Source
AI summary
A cooling module for a plug connector part includes a main body having a cavity in which at least one terminal region is formed for electrical contacting by an electrical load line; at least one opening opening into the cavity via which a coolant can flow through the cavity; and a mounting surface for mounting an electrical load contact.