High-Performance Charging Cable and Connector (Plug, Socket)

First of all: the development of a high-performance charging cable only makes sense with the simultaneous development of a corresponding connector. This plug in turn needs a coupling or socket - collectively referred to as a "connector" or power connection.


In order to achieve comparable performance in electromobility (range and tank or charging speed are meant here) you have to transfer and accumulate comparable amounts of energy in comparable time (comparable means 1/3 of the amount of energy as the "fuel" car - because of the high efficiency of the electric motor). So far, the accumulators with high specific power/weight ratio and the charging time are the relevant limitations. The more powerful the accumulators become, the more the charging infrastructure comes into focus, which must provide the required energy in a short time.


Interesting is the benchmark with the traditional system of refueling of gasoline (petrol or diesel). Here are (typically and roughly simplified) about 60 liters of fuel refueled (pumped) in about a minute - so one liter per second. One liter of fuel has about 10 kWh energy content (43,000 kJ per kilogram - converted into the current volume and power unit).

Now, the efficiency of a piston engine in the car is typically about 33% and that of an electric machine higher than 95%. Accordingly, only about 1/3 of the energy needs to be transferred to achieve comparable ranges. In the example mentioned, this would be 20 x 10 kWh, hence 200 kWh.

That means charging 200kW for an hour or, for a charging time of 1 minute, it takes for the same amount of energy:

60 x 200 kW; so 12,000 kW or 12,000,000 watts

This is an enormous flow of energy (energy per time) that has to be transmitted and thus the accumulators, the power grid but also the charging device are confronted with enormous challenges. Even if you use the so-called "high-voltage range" and would transmit, for example, with 1000 volts, it still requires very high currents to transfer this power.

Due to the common formula W = V x A, it quickly becomes clear that 12,000 amperes would have to flow in the given example.

For comparison, a household socket is protected up to a maximum of 16 amps, a one- to three-family house has a backup fuse from 80 to 150 amps - which are typically never used.

Now 12,000 amps would mean huge cable cross-sections and contact areas. Even by a very high-performance cooling, this could not be realistically implemented. So-called superconductors could be the solution if they were available at reasonable costs.


The example makes it clear that the amount of energy for a standard range of 600 km for the electric car can not be charged as fast as a gasoline car. The charging time is also limited by the times in which a battery can still be charged and this amount of energy must be available from the power grid (for the low-voltage grid already a real burden!). For the charging time especially the charging cable and the plug still remain the bottleneck!

We have dedicated ourselves to this "bottleneck" and will present a power connector (plug and socket) with cable and cooling after patenting.