Plug-in Connector Cooling Jacket with Polymeric Insulation
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Solution Overview
Problem
Existing plug-in connectors face challenges in effectively dissipating heat generated by high electrical currents, which can lead to safety hazards and reduced efficiency due to inadequate cooling mechanisms.
Innovation Solution
A plug-in connector design featuring a cooling jacket made of polymeric material, integrated with fluid ports and a connecting sleeve, allowing for the circulation of coolant to efficiently remove heat from both the contact element and electrical wires, while an insulating sheath ensures electrical insulation and safety by preventing direct contact between conductive coolants and current-carrying parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a cooling facility is integrated into the plug-in connector, then heat dissipation is improved, but device complexity increases
Solution Approach 1:
The cooling facility is merged with the plug-in connector by integrating the cooling jacket as an integral component that encompasses the contact element. The cooling jacket includes fluid ports and a connecting sleeve, combining cooling functionality with the connector structure itself rather than adding separate cooling systems.
Solution Approach 2:
The cooling jacket serves multiple functions: it provides thermal management by dissipating heat from the contact element, offers mechanical protection through the connecting sleeve that accommodates the contact element, and enables fluid circulation through integrated fluid ports. This multi-functionality reduces the need for additional separate components.
2Temperature
If coolant flows directly over contact elements, then cooling efficiency is improved, but electrical safety deteriorates
Solution Approach 1:
An insulating sheath is introduced as an intermediary layer between the conductive coolant and the current-carrying contact elements. This sheath allows the coolant to flow directly over the contact elements for efficient heat dissipation while simultaneously providing electrical insulation to prevent hazardous current flow through the coolant.
3Temperature
If multiple components are used for cooling, then cooling performance is improved, but manufacturing complexity increases
Solution Approach 1:
The cooling jacket, connecting sleeve, and fluid ports are merged into a single integrated component that can be manufactured as one piece. This reduces the number of separate parts that need to be assembled while maintaining the complex cooling functionality required for effective heat dissipation.
Solution Approach 2:
The cooling jacket is made from elastomeric material that can be molded into a single piece incorporating the connecting sleeve and fluid ports. This flexible material allows for complex geometries to be formed in one manufacturing process rather than requiring assembly of multiple rigid components.
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 provides effective heat dissipation, enhances safety by preventing electrical hazards, and allows for the use of conductive coolants, thereby improving the reliability and performance of connectors handling high currents.
Implementation Method 1
the cooling jacket being adapted for conveying a coolant through an interior of the cooling jacket
Implementation Method 2
the coolant passes the cooling jacket's interior, with the coolant impinging on the at least one terminal connector
Implementation Method 3
an insulating sheath ensures electrical insulation and safety by preventing direct contact between conductive coolants and current-carrying parts
Data Source
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AI summary
A plug-in connector is described. The plug-in connector comprises a contact element with a connector element and at least one terminal connector and a cooling jacket with a first fluid port adapted for fluidically connecting the cooling jacket with a first tube and a second fluid port adapted for fluidically connecting the cooling jacket with a second tube. The cooling jacket further comprises a connecting sleeve for accommodating the contact element, wherein the cooling jacket is manufactured in one piece and wherein the cooling jacket is made of a polymeric material. An outer surface of the contact element is encompassed by the connecting sleeve in a fluid-tight manner, wherein the connector element is at least partly exposed to the outside of the cooling jacket and wherein the at least one terminal connector is at least partly disposed in the interior of the cooling jacket. The at least one terminal connector is configured for being electrically connected with at least one electrical wire that is introducible into the cooling jacket via at least one of the fluid ports.