ABB Advances EV Charging Connector Thermal Management with External Passive Cooling Patent
Time:2026-11-02 Browse: 2
ABB EV Charging Patent Highlights a Heat Pipe-Based Cooling Design for Charging Connectors
ABB is advancing its research into electric vehicle (EV) charging technology with a patent covering an electric vehicle charging connector featuring external passive cooling. The technology focuses on managing heat generated inside the connector while maintaining enclosure protection, addressing an important engineering challenge in high-current EV charging applications.
According to the patent publication, the design uses a heat pipe to transfer thermal energy from the power contact compartment to the surrounding environment. Part of the heat pipe is positioned outside the connector's external enclosure, allowing heat to dissipate without relying entirely on conventional internal cooling arrangements.
Heat Pipe Technology for Improved Thermal Management
Heat generation is a significant consideration in EV charging connectors. When high electrical currents pass through charging cables and power contacts, electrical resistance produces heat. If this heat is not effectively managed, it can affect connector temperature, operating reliability, and component service life.
ABB's patented design incorporates several key structural elements:
Inner enclosure: Houses and protects the power contact compartment and associated electrical components.
External enclosure: Surrounds the inner enclosure and provides an additional protective structure.
Heat pipe: Transfers thermal energy away from internal heat sources.
Evaporator: Connects to a heat source inside the power contact compartment and absorbs heat.
Condenser: Releases the transferred heat into the surrounding environment, with at least part of the heat pipe positioned outside the external enclosure.
The heat pipe works through a phase-change heat transfer process. Heat absorbed at the evaporator is transported toward the condenser, where it can be released into the ambient air. This arrangement provides a passive approach to thermal management without requiring a dedicated liquid circulation pump.
Balancing Cooling Performance and Enclosure Protection
One of the technical challenges addressed by the patent is balancing heat dissipation with environmental protection.
Charging connectors must protect electrical contacts and internal components against moisture, dust, and mechanical damage. However, opening the enclosure or exposing internal cooling structures directly to the environment may compromise its protective performance.
ABB's design separates the protective and thermal management functions through an inner and outer enclosure structure. The heat pipe provides a thermal path from the internal contact compartment to an externally exposed cooling section.
The patent also describes configurations in which an external protective structure helps shield the exposed portion of the heat pipe. Depending on the embodiment, either the entire condenser or only part of it may be located outside the external enclosure.
This design approach aims to improve heat dissipation while maintaining the required enclosure protection. The patent discusses IP protection as an important consideration, although actual protection ratings must be established through product testing and certification.
Why Passive Cooling Matters for EV Charging Infrastructure
As EV charging infrastructure develops, connector thermal management remains an important engineering consideration. High-current charging places greater thermal demands on electrical contacts, cables, insulation materials, and connector housings.
Compared with liquid-cooled solutions, passive cooling can offer potential advantages in system simplicity because it does not require a dedicated coolant circulation pump. It may also reduce the number of active cooling components that need maintenance.
However, passive cooling performance depends on factors such as ambient temperature, heat pipe design, thermal contact resistance, condenser surface area, and airflow conditions. It should therefore be evaluated according to the intended charging current and operating environment.
For charging equipment manufacturers and industrial component suppliers, this patent illustrates the importance of combining electrical connection design, thermal engineering, and enclosure protection in next-generation EV charging systems.
Patent Information
The patent publication identifies the invention as "Electric Vehicle Charging Connector with External Passive Cooling." The Chinese application number is CN202111368486.0, and the application was filed on November 18, 2021. The corresponding Chinese publication number is CN114521092A, published on May 20, 2022.
The patent application lists ABB Schweiz AG as the original applicant and identifies six inventors: Francisco Garcia-Ferre, Jaroslav Hemrle, Elise Fahy, Pedram Kheiri, Ali Ugur, and Wojciech Wysocki.
The patent describes a charging connector structure, a charging station incorporating the connector, and the use of a heat pipe for thermal management.
Industry Outlook
Thermal management will continue to play an important role in the development of high-power EV charging equipment. Solutions that combine effective heat transfer, compact connector structures, and reliable environmental protection may contribute to more practical and maintainable charging infrastructure.
As charging technology evolves, innovations in connectors, power electronics, cooling systems, and electrical protection will remain relevant to manufacturers and suppliers across the industrial automation and EV charging sectors.
