Sprayer Plug Thermal Sensor Layer for EV Charging Safety

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Solution Overview

Problem

Existing devices for conducting electrical energy, such as charging cables for electric cars, face challenges in accurately detecting the temperature of electrical conductors due to the lack of a thermally conductive connection between the temperature sensor and the conductor, leading to delayed and diminished temperature detection, which can result in overheating and safety risks.

Innovation Solution

Incorporating an electrically insulating and thermally conductive first layer between the electrical conductor and the insulating second layer, with the temperature sensor positioned within this layer, ensures rapid and accurate heat transfer from the conductor to the sensor, allowing for timely and precise temperature detection without electrical interference.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the temperature sensor is placed outside the insulating layer (prior art arrangement), then electrical insulation is ensured, but temperature detection accuracy and response time deteriorate due to thermal isolation

Engineering Contradiction:

Improvetemperature detection accuracyVSAvoidthermal connection structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

A thermally conductive intermediate layer is introduced between the electrical conductor and the temperature sensor. This intermediary layer enables efficient heat transfer from the conductor to the sensor while maintaining electrical insulation, thereby resolving the contradiction between detection accuracy and structural complexity.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The solution employs composite material structure combining thermally conductive and electrically insulating properties in the intermediate layer. This composite approach allows simultaneous achievement of thermal coupling for accurate temperature detection and electrical isolation for safety.

Inventive Principle:

Principle #40Composite materials

2Productivity

If the charging current is increased to reduce charging time, then productivity improves, but temperature of the electrical conductor increases causing safety risks

Engineering Contradiction:

Improvecharging speedVSAvoidconductor temperature

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

The temperature sensor provides continuous feedback about the conductor temperature to the control system. This feedback mechanism enables real-time monitoring and control of charging current, allowing the system to maintain high productivity while preventing dangerous temperature increases through adaptive current adjustment.

Inventive Principle:

Principle #23Feedback

3Reliability

If a thermally insulating second layer is used for electrical insulation, then electrical safety is ensured, but temperature detection is delayed due to thermal isolation

Engineering Contradiction:

Improveelectrical safetyVSAvoidtemperature detection delay

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The insulation structure is segmented into multiple functional layers: a thermally conductive intermediate layer for rapid heat transfer to the sensor, and a thermally insulating outer layer for electrical safety. This segmentation allows each layer to perform its specific function optimally without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different thermal conductivity properties are assigned to different regions/layers of the insulation structure. The intermediate layer has high thermal conductivity for sensor coupling, while the outer layer has low thermal conductivity for safety, creating local quality variations that satisfy conflicting requirements.

Inventive Principle:

Principle #3Local quality

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 enables reliable and immediate temperature monitoring, reducing the risk of overheating and enhancing safety by allowing for faster reaction to temperature changes, thus preventing damage and ensuring compliance with safety standards without altering the existing cable or plug structure.

Implementation Method 1

an electrically insulating and thermally conductive first layer (3) in the space between the electrically insulating second layer (4) and the electrical conductor (1), and the temperature sensor (2) is arranged in the region of this electrically insulating and thermally conductive first layer (3)

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentEP2991082B1Sprayer plug in stratified contructions for electric automobiles

Publication Date: 2018.06.06 HEIDELBERGER DRUCKMASCHINEN AG

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AI summary

The invention relates to a device for conducting electrical energy by means of an electrical conductor (1) surrounded by at least one electrically insulating second layer (4), and with at least one temperature sensor (2) for detecting the temperature of the electrical conductor (1), wherein the temperature sensor (2) is arranged between the electrical conductor (1) and the electrically insulating second layer (4). The invention is characterized in that an electrically insulating and thermally conductive first layer (3) is located in the space between the electrically insulating second layer (4) and the electrical conductor (1), and that the temperature sensor (2) is arranged in the region of this electrically insulating and thermally conductive first layer (3).