Electrical Plug Connector with Integrated Gas Cooling Channel
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Solution Overview
Problem
Electrical plug connectors in the automotive industry face thermal challenges due to increasing hybridization and electrification of vehicle drive trains, requiring effective cooling solutions to prevent adverse thermal effects.
Innovation Solution
An electrical plug connector design featuring a connector housing with an outer cooling gas connection that introduces a cooling gas through a cooling gas channel, allowing for the flow of air or inert gases like nitrogen to cool the plug-in connection, eliminating the need for a coolant and simplifying the sealing concept.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a coolant system is used for cooling the plug-in connection, then the cooling effectiveness is improved, but the device complexity and sealing requirements increase
Solution Approach 1:
The patent extracts the cooling function from a complex coolant system and implements it using a simple gas flow channel integrated into the connector housing. The cooling gas channel allows ambient air or inert gas to flow directly through the housing, eliminating the need for sealed coolant circuits, pumps, and complex sealing mechanisms while maintaining effective cooling of the plug-in connection.
Solution Approach 2:
The patent uses pneumatic cooling by introducing a cooling gas (ambient air or inert gas) through a dedicated cooling gas channel in the connector housing. This pneumatic approach replaces liquid coolant systems, simplifying the overall design while maintaining cooling effectiveness through direct gas flow over the electrical contacts.
2Temperature
If a coolant system is used for cooling, then thermal management is improved, but corrosion risks and sealing requirements increase
Solution Approach 1:
The patent employs inert gas (such as nitrogen) or ambient air as the cooling medium instead of liquid coolant. This eliminates corrosion risks associated with liquid coolants coming into contact with electrical contacts and metal components. The inert gas atmosphere prevents oxidative corrosion while effectively managing thermal loads in the plug-in connection.
3Temperature
If active cooling mechanisms are implemented, then thermal management is improved, but the device complexity increases
Solution Approach 1:
The patent merges the cooling function with the connector housing structure by integrating the cooling gas channel directly into the housing design. This eliminates the need for separate cooling components and mechanisms, reducing overall device complexity while maintaining effective thermal management through the combined structural-cooling design.
Solution Approach 2:
The connector housing serves multiple functions: it provides structural support, electrical insulation, and integrated cooling through the built-in cooling gas channel. This multi-functional design eliminates the need for dedicated cooling mechanisms, simplifying the overall device while achieving effective thermal management.
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
This design maintains the temperature of the plug-in connection within a desired working range by effectively dissipating heat through a cooling gas flow, addressing thermal loads without the complexity of coolant systems and corrosion issues.
Implementation Method 1
A cooling gas is brought into the plug connector by the outer cooling gas connection through a cooling gas channel of the connector housing
Implementation Method 2
This design maintains the temperature of the plug-in connection within a desired working range by effectively dissipating heat through a cooling gas flow
Data Source
AI summary
An electrical plug connector includes a connector housing receiving an electrical terminal. The connector housing has an outer cooling gas connection cooling an electrical plug-in connection of the plug connector with a mating plug connector. A cooling gas is brought into the plug connector by the outer cooling gas connection through a cooling gas channel of the connector housing.