Abstract:
High Voltage cables and terminals are prone to high temperatures and rapid heat generation due to high current ratings, especially in electric vehicles (EVs). If the temperature exceeds a critical limit, danger may be posed to the components which are connected and the overall safety of the passengers. Traditionally, cooling methods are often energy-intensive and rely on active systems, which may not always be practical for high-power applications. Thus, a localized, fast, and reliable passive thermal management methodology that can be retrofitted into existing connector designs through modifications (e.g., enlargement and PCM integration) would provide significant safety enhancement. The material property of phase change materials, which possess high latent heat, has been used to maintain a steady temperature for a period of time. A dual PCM-layer has been incorporated into the design of the high-voltage connector to serve two purposes:1. The first PCM layer (PCM-1), with good conductivity, is used to rapidly absorb heat from the terminals. 2. The second PCM layer (PCM-2), playing a prominent role in heat storage, absorbs excess heat and has a larger heat-absorbing capacity. The objective has been to maintain the terminal temperature below 80°C. An NX-CAD model has been prepared, showcasing the PCM-1 and PCM-2 containers inside the male connector, along with the packaging scenario with the female connector. The “acting time” was theoretically calculated based on varying current ratings for high-voltage applications, ranging from 100A to 150A. The acting time was found to range from 9 minutes to 4 minutes, considering a total of 96g of PCM material.
Conclusion:
The proposed dual-layer PCM design enables efficient, reliable, and sustainable passive heat absorption and buffering for high-voltage connectors.
Key Words: Phase-Change Materials (PCM), dual-layer, safety, Electric vehicles (EVs), high voltage connector, thermal management, sustainable, acting time