Power Connector Heat Exchanger for High-Current Terminal Cooling
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Solution Overview
Problem
Power connectors, such as those in electric vehicle charging inlet assemblies, generate excessive heat during high-current charging, risking damage to components due to inadequate cooling systems.
Innovation Solution
A brazed heat exchanger with a coolant channel is integrated into the power connector, thermally coupled to the terminal pads, using a thermally conductive separator for electrical isolation and a diverter wall to optimize coolant flow and heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If higher current is transmitted through the terminals for charging the battery, then the charging speed and power are improved, but the temperature of the terminals and power cables increases which may damage the components
Solution Approach 1:
The heat exchanger is integrated directly into the power connector housing, merging the cooling function with the existing connector structure. The heat exchanger body is positioned to receive heat directly from the terminal and cable assembly, creating a unified thermal management system that cools the high-current components in situ.
Solution Approach 2:
A thermally conductive separator is introduced as an intermediary component between the terminal/cable assembly and the heat exchanger. This separator facilitates efficient heat transfer from the hot components to the heat exchanger while providing electrical isolation, allowing the cooling system to effectively remove heat without creating electrical shorts.
2Temperature
If a cooling system is added to the power connector, then the temperature control is improved, but the device complexity increases
Solution Approach 1:
The heat exchanger is integrated directly into the power connector housing, merging the cooling function with the existing connector structure. The heat exchanger body is positioned to receive heat directly from the terminal and cable assembly, creating a unified thermal management system that cools the high-current components in situ.
Solution Approach 2:
The heat exchanger serves multiple functions: it acts as a thermal management component, provides structural support within the connector housing, and the thermally conductive separator simultaneously enables heat transfer and provides electrical insulation. This multi-functionality reduces the need for additional separate components.
3Temperature
If a heat exchanger is integrated into the power connector, then the thermal management capability is improved, but the manufacturing complexity increases
Solution Approach 1:
The heat exchanger is integrated directly into the power connector housing, merging the cooling function with the existing connector structure. The heat exchanger body is positioned to receive heat directly from the terminal and cable assembly, creating a unified thermal management system that cools the high-current components in situ.
Solution Approach 2:
The system uses a composite approach combining the heat exchanger body (thermally conductive material) with the thermally conductive separator (electrically insulating but thermally conductive material). This composite material strategy allows efficient heat transfer while maintaining electrical isolation, simplifying the manufacturing process compared to using complex multi-component assemblies.
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 heat exchanger effectively reduces terminal temperatures, enabling higher current transmission while protecting components from overheating.
Implementation Method 1
The heat exchanger is thermally coupled to the pad of the terminal
Implementation Method 2
a coolant channel for coolant flow through the heat exchanger for actively cooling the terminal
Data Source
AI summary
A power connector includes a housing having a terminal channel and a terminal received in the terminal channel including a mating pin at a front of the terminal and a cable connector at a rear of the terminal. The mating pin is positioned in the terminal channel for mating with a charging connector. The cable connector includes a pad configured to be terminated to a power cable. The power connector includes a heat exchanger thermally coupled to the pad of the terminal. The heat exchanger includes a coolant channel for coolant flow through the heat exchanger for actively cooling the terminal. The heat exchanger includes a thermally conductive separator electrically isolating the heat exchanger from the pad of the terminal.