Solid-State Cooled Connector Assembly for High-Current EV Wiring
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Solution Overview
Problem
Existing connector assemblies for new energy vehicles face challenges such as high temperature failures, large wire diameters, labor-intensive manual mounting, and ineffective electromagnetic shielding, leading to inefficiencies and safety concerns.
Innovation Solution
A connector assembly with a solid-state cooling medium is introduced, featuring an electrical connection framework with hollow inner cavities filled with a solid-state or semi-solid-state cooling medium, which reduces heat generation and improves electromagnetic shielding through a conductive shielding inner shell.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the diameter of high-voltage cable is increased to meet large-power motor requirements, then the current transmission capacity is improved, but the labor cost and time cost for manual mounting increase
Solution Approach 1:
The high-voltage cable is segmented into multiple smaller sub-cables, each capable of handling a portion of the total current. This segmentation reduces the diameter of individual cables, enabling automated handling and assembly while maintaining the required power transmission capacity through parallel configuration of multiple cables
Solution Approach 2:
The patent introduces a liquid cooling system with cooling channels that flow through the cable assembly. The coolant circulation enables efficient heat removal, allowing the use of multiple smaller cables instead of a single large cable, thereby improving mounting efficiency through automated processes
2Power
If very large current flows through the high-voltage cable, then the power transmission is improved, but excessive heat is generated causing connection failures
Solution Approach 1:
A liquid coolant is introduced as an intermediary substance that absorbs heat from the high-voltage cable and connection joints. The cooling system includes cooling channels and heat dissipation structures that facilitate efficient thermal transfer from the cable to the coolant, preventing excessive temperature rise
Solution Approach 2:
The cooling system utilizes phase transition of the coolant (liquid to vapor and back) to absorb and dissipate large amounts of heat. The evaporative cooling effect provides efficient heat removal from the high-voltage cable, maintaining safe operating temperatures during high current transmission
3Object-affected harmful factors
If a shielding net made of metal wires is used to reduce electromagnetic interference, then the shielding effect is improved, but the equipment price and occupied area increase
Solution Approach 1:
The patent replaces the conventional metal wire braid shielding with a liquid-based electromagnetic shielding system. The conductive liquid coolant flowing through the cable serves as the shielding medium, providing electromagnetic interference protection without requiring additional shielding materials or complex braiding machinery
Solution Approach 2:
The liquid coolant performs multiple functions simultaneously: it provides thermal management by cooling the cable, and it provides electromagnetic shielding by forming a conductive barrier around the high-voltage conductor. This multi-functionality eliminates the need for separate shielding components, reducing equipment complexity and occupied space
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 reduces temperature-related failures, allows for smaller wire diameters, enables automatic production and assembly, and enhances safety and efficiency by improving electromagnetic interference shielding.
Implementation Method 1
The electrical connection framework is provided with at least one hollow inner cavity which is at least partially filled with a solid-state or semi-solid-state cooling medium
Implementation Method 2
the high-voltage cable usually uses a shielding net to shield the electromagnetic interference
Data Source
AI summary
A connector assembly having a solid-state cooling medium, and a vehicle. The connector assembly includes at least one electrical connection framework and connectors The connectors include connection terminals, and two ends of the electrical connection framework are electrically connected to the connection terminals respectively. The electrical connection framework is provided with at least one hollow inner cavity which is at least partially filled with a solid-state or semi-solid-state cooling medium. The present disclosure can reduce the high-temperature failure and the diameter of the electrical connection framework, prolong the service life of the connector assembly and improve the safety of the whole vehicle.