Sealed Charging Connector with Heat Storage for Terminal Cooling
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Solution Overview
Problem
Existing vehicle charging connectors face challenges in managing terminal operating temperatures, particularly during rapid charging, due to heat insulation from sealing materials, which can lead to excessive temperature rises and safety concerns.
Innovation Solution
Incorporating a deformable heat storage member within the connector's accommodation space that surrounds the connection portion between the electric wire and terminal, allowing for efficient heat absorption and dissipation while maintaining a compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the connection portion is sealed by a packing to isolate from outside for waterproofing, then waterproofing is improved, but heat radiation capability deteriorates due to heat insulation from air in the sealed space
Solution Approach 1:
A heat storage member made of metal mesh is introduced as an intermediary substance between the sealed connection portion and the external environment. This mesh structure serves dual functions: it maintains the waterproof seal while providing thermal conduction pathways for heat to escape from the connection portion, thereby resolving the contradiction between waterproofing and heat radiation capability
Solution Approach 2:
The heat storage member is constructed from metal mesh with a porous structure. This porous configuration allows the material to function as both a thermal conductor (providing heat radiation pathways) and a space-filling seal maintainer within the enclosed space, enabling heat to be conducted away while preserving the waterproof enclosure
2Device complexity
If natural heat radiation is used to manage terminal temperature, then device complexity is kept simple, but temperature control becomes insufficient during rapid charging due to excessive temperature rise
Solution Approach 1:
The heat storage member made of metal mesh provides self-service thermal management by passively conducting heat away from the connection portion through its inherent thermal conductivity. No active control systems, motors, or complex mechanisms are required - the structure itself performs the heat dissipation function, maintaining simplicity while improving temperature control during rapid charging
Solution Approach 2:
The introduction of the metal mesh heat storage member changes the thermal parameters of the sealed space. It transforms the space from being purely insulating (air-filled) to having enhanced thermal conductivity, thereby improving heat radiation capability without requiring complex active thermal management systems
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 effectively prevents rapid temperature increases in the terminal during charging, ensuring the operating temperature remains within safety standards without increasing the connector's size, by utilizing a heat storage member with high thermal capacity that elastically expands and contracts to contact both the housing and connection surfaces.
Implementation Method 1
a heat storage member disposed in the accommodation space to surround the connection portion
Implementation Method 2
a temperature of a terminal (so-called operating temperature) rises due to Joule heat generated in the terminal at the time of energization
Implementation Method 3
The heat storage member is deformable to elastically expand and contract in accordance with a shape of the accommodation space
Data Source
AI summary
There is provided a connector including: an electric wire; a terminal connected to the electric wire; a housing having an accommodation space inside the housing, the accommodation space accommodating a connection portion between the electric wire and the terminal; a seal member configured to seal an opening portion of the accommodation space to isolate the connection portion accommodated in the accommodation space from outside; and a heat storage member disposed in the accommodation space to surround the connection portion. The heat storage member is deformable to elastically expand and contract in accordance with a shape of the accommodation space. A first part of the heat storage member is in contact with an inner surface of the housing defining the accommodation space, and a second part of the heat storage member is in contact with an outer surface of the connection portion.