Electric vehicle conductive charge couplers

Abstract

The overall performance of listed Electric vehicle conductive charge couplers varies greatly based on engineering observations. In the field, excessive temperature rise at the connection between the charging station cord and the vehicle inlet has been noted. The temperature rise can be severe enough to damage the plastic coupler housings on both sides of the connection, and can occur in products that have been in the field for less than a year. In a laboratory environment, the variation can be measured more precisely with temperature and voltage drop across the connection. Laboratory results show resistance and temperature can increase rapidly with low cycling if the right conditions are present. The conditions can include intermixed contact technologies, insufficient crimping processes, thermal cycling, and elevated ambient temperatures. Changes may be needed to the standards that govern EV coupler connector design to better reflect these situations. A more demanding standard would help deliver charging systems that maintain low resistance and interchangeability across manufacturers, end of life safeguards, and increased longevity.