Sealed Charging Connector With Internal Heat Storage for Fast Charging
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Solution Overview
Problem
Existing charging connectors for vehicles face challenges in dissipating heat efficiently, particularly during fast battery charging, which can lead to excessive temperature rises in the terminal, potentially violating safety and quality standards.
Innovation Solution
The connector incorporates a heat storage member made of metal, located within the housing space, which absorbs and dissipates heat generated at the connection portion between the electric wire and the terminal, thereby preventing excessive temperature rises.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the connection portion is sealed with a packing to isolate from outside for waterproofing, then waterproofing is improved, but heat dissipation deteriorates because air in the isolated space acts as heat insulating material
Solution Approach 1:
A heat storage member made of heat-conductive material is introduced as an intermediary substance within the sealed housing space. This member mediates between the connection portion (heat source) and the housing wall (heat sink), providing a thermal conduction path through the insulating air layer. The heat storage member has higher thermal conductivity than air, enabling efficient heat transfer while maintaining the sealed waterproof structure.
2Temperature
If a heat dissipation member is assembled to the outside of the connector, then heat dissipation is improved, but device size increases which is not desirable for miniaturization and limited installation space
Solution Approach 1:
The heat storage member is nested within the existing housing space of the connector, utilizing the internal volume that would otherwise be occupied by air. This nested configuration allows the heat dissipation function to be integrated within the connector's footprint, avoiding any increase in external dimensions. The heat storage member fits inside the sealed housing, making efficient use of internal space.
Solution Approach 2:
Instead of adding heat dissipation capacity in the external direction (increasing connector size), the solution transitions to internal heat management by placing the heat storage member within the three-dimensional housing space. This dimensional reconfiguration allows heat dissipation to occur through the existing external surface area of the connector, effectively utilizing the housing wall as a heat sink without expanding the connector's external dimensions.
3Productivity
If fast battery charging is performed with large current, then charging speed is improved, but temperature rise of terminal per unit time increases making it difficult to maintain operating temperature within standard range
Solution Approach 1:
The heat storage member is pre-positioned within the housing space before charging operation begins. This preliminary arrangement ensures that the thermal management system is ready to immediately absorb heat as soon as charging starts. The heat storage member acts as a thermal buffer that can quickly respond to rapid temperature increases during fast charging, preventing excessive temperature rise from the outset.
Solution Approach 2:
The introduction of the heat storage member changes the thermal parameters of the connector system. It increases the heat capacity and thermal conductivity within the housing space, fundamentally altering the temperature rise characteristics. This parameter change enables the system to withstand higher current loads during fast charging by providing enhanced thermal absorption and dissipation capabilities, thereby controlling the temperature rise rate even under high-power charging conditions.
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 solution effectively manages heat dissipation within the connector, preventing excessive temperature rises and ensuring compliance with safety and quality standards without increasing the connector's size.
Implementation Method 1
a heat storage member made of metal, located within the housing space, which absorbs and dissipates heat generated at the connection portion between the electric wire and the terminal
Implementation Method 2
a temperature of the terminal (so-called operating temperature) increases due to Joule heat generated in the terminal at a time of energization
Data Source
AI summary
A connector includes: an electric wire; a terminal connected to the electric wire; a housing having a housing space to house a connection portion of the electric wire and the terminal; a seal member to seal an opening portion of the housing space to isolate the connection portion housed in the housing space from an outside; and a heat storage member located in the housing space.