Split Cooling Channel Assembly for EV Charging Connector Lines
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In electric vehicle charging systems, the current-carrying components on the electric vehicle side are undersized, leading to increased heating due to thermal energy transfer from undersized electric lines to the plug connector part, which can exceed permissible temperature limits and cause excessive heating.
Innovation Solution
A cooling device with a modular design featuring two separate housing assemblies that connect to form a cooling channel for coolant flow, allowing for efficient heat absorption and dissipation at the electric line, thereby preventing excessive heating from being transferred to the plug connector part.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If current-carrying components are oversized to reduce heating, then temperature control is improved, but device complexity and cost increase
Solution Approach 1:
The cooling device is divided into two separate housing assemblies that can be manufactured independently and then connected. Each housing assembly contains cooling channels that work together to provide comprehensive cooling of the plug connector part, allowing for simplified manufacturing while achieving effective temperature control.
Solution Approach 2:
A coolant is introduced as an intermediary substance that absorbs heat from the plug connector part through the cooling channels. The coolant circulates between the two housing assemblies, transferring thermal energy away from the heated components without requiring direct contact or complex thermal management systems.
2Temperature
If active cooling is added to counteract heating, then temperature control is improved, but device complexity increases
Solution Approach 1:
The cooling function is merged with the structural housing of the plug connector part. The two housing assemblies serve both as structural enclosures and as carriers for the cooling channels, eliminating the need for separate cooling components and reducing overall device complexity.
Solution Approach 2:
The housing assemblies perform multiple functions: they provide structural support, enclose the connector components, and serve as the cooling system itself through integrated cooling channels. This multi-functionality reduces the number of separate components needed in the system.
3Ease of manufacture
If modular housing assemblies are used for the cooling device, then ease of manufacture is improved, but connection complexity increases
Solution Approach 1:
The cooling device is segmented into two housing assemblies that can be manufactured using standard manufacturing processes. This segmentation allows each housing to be produced independently with simpler tooling and assembly requirements, improving overall ease of manufacture.
Solution Approach 2:
The cooling channels are nested within the housing assemblies themselves, with the channels formed as integral parts of the housing structure. When the two housings are connected, the cooling channels align and connect automatically, minimizing the complexity of connections required.
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 cooling device effectively absorbs and dissipates heat from the electric lines, reducing the risk of excessive heating at the plug connector part and ensuring compliance with temperature limits, even during high-current charging processes.
Implementation Method 1
a cooling channel through which a coolant can flow
Implementation Method 2
a cooling channel through which a coolant can flow
Data Source
AI summary
A cooling device for cooling at least one electric line which is connected to a plug connector part includes: a cooling module disposable on the at least one electric line and having a cooling channel for flowing coolant therethrough, the cooling module having two housing assemblies, each of which has a respective connection section and a flow opening molded onto the connection section, the two housing assemblies being separate in a preassembly state and being connectable together to be placed on the at least one electric line such that the at least one electric line is received between the housing assemblies. The flow openings of the connection sections of the two housing assemblies are fluidically connected together to form the cooling channel.