Optimization of thermal conduction of high-voltage charging sockets through thermal simulation to reduce the charging time of electric vehicles

In Europe, charging with the CCS (Combined Charging System) charging standard is the most widespread variant for charging electric vehicles. This applies equally to passenger cars and commercial vehicles. Electric commercial vehicles in particular, with their large energy storage system, can achieve charging capacities that reach the limits of the CCS standard through the further development of the charging components. The goal of rapid charging of electric vehicles is to maintain a high charging current for as long as possible in order to be able to store as much electrical energy as possible in a specified time. The heat losses resulting from rapid charging must not exceed a limit value of 90°C in the charging socket. The charging socket must be thermally optimised in order to delay this point in time as long as possible. One way to improve thermal optimization is to adjust the thermal conductivity of the materials in the charging socket so that they dissipate the waste heat better.In this paper, a thermal Matlab/Simscape model developed in-house is used to optimise components at the CCS charging socket through better heat conduction and compare the results. Comparisons of the thermal test results from the current CCS socket and the version with optimization approaches show slower heating. The improved heat dissipation during charging extends the time to charge with higher current before the permissible limit temperature is reached. This can reduce the total charging time.