Vehicle charging system including a phase change material for absorbing heat during a charging event

Abstract

The present disclosure provides "Vehicle charging systems including phase change material for absorbing heat during charging events." A charging system for an electrified vehicle includes a charging component and a phase change material positioned relative to the charging component and configured to absorb heat from the charging component. The charging component can include a vehicle outlet assembly, a charging cord, a charging connector, a high voltage cable, etc.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to a vehicle charging system that passively cools one or more charging components during a charging event with a phase change material. BACKGROUND

[0002] The desire to reduce fuel consumption and emissions of motor vehicles is well documented. As a result, vehicles that reduce or completely eliminate the reliance on internal combustion engines are being developed. To this end, electrified vehicles are currently being developed. Generally, an electrified vehicle is different from a conventional motor vehicle in that the electrified vehicle is selectively driven by one or more electric motors powered by a battery pack. In contrast, a conventional motor vehicle relies solely on an internal combustion engine to propel the vehicle.

[0003] Conductive charging systems generally connect an electrified vehicle to an external power source, such as a wall outlet or a charging station, to charge the vehicle's battery pack. Plug-in hybrid electric vehicles and battery electric vehicles, for example, include a vehicle receptacle assembly having a port for receiving a connector from a charging station. Some components of the charging system generate heat during a charging event. During certain charging events, such as a direct current (DC) fast charging event, it can be necessary to cool these components to avoid overheating. SUMMARY

[0004] A charging system of an electrified vehicle according to an example aspect of the present disclosure includes, among other things, a charging component and a phase change material positioned relative to the charging component and configured to absorb heat from the charging component.

[0005] In further non-limiting embodiments of the foregoing charging system, the charging component is a vehicle receptacle assembly.

[0006] In further non-limiting embodiments of any of the foregoing charging systems, the phase change material is encapsulated on a back face of a housing of the vehicle receptacle assembly.

[0007] In further non-limiting embodiments of any of the foregoing charging systems, the phase change material is a ring positioned within a channel formed in the back face of the housing.

[0008] In further non-limiting embodiments of any of the foregoing charging systems, a contact point around a mating terminal of the vehicle receptacle assembly is made of the phase change material.

[0009] In further non-limiting embodiments of any of the foregoing charging systems, the phase change material is a nanostructured phase change material.

[0010] In further non-limiting embodiments of any of the foregoing charging systems, the charging component is a charging connector having a charging wire extending within the charging connector.

[0011] In further non-limiting embodiments of any of the foregoing charging systems, the charging wire includes a housing and a wire within the housing.

[0012] In further non-limiting embodiments of any of the foregoing charging systems, the phase change material is received within a cavity within the housing.

[0013] In further non-limiting embodiments of any of the foregoing charging systems, the phase change material is positioned radially between an outer tube wall and an inner tube wall of the housing.

[0014] In further non-limiting embodiments of any of the foregoing charging systems, the phase change material is configured in a plurality of sheets disposed within the charging component.

[0015] In further non-limiting embodiments of any of the foregoing charging systems, the plurality of sheets are disposed within a housing of the charging component.

[0016] In further non-limiting embodiments of any of the foregoing charging systems, the charging component is a high voltage cable.

[0017] A charging system of an electrified vehicle, according to another exemplary aspect of the present disclosure, includes, among other things, a battery pack; a vehicle outlet assembly; a high voltage cable connecting the battery pack and the vehicle outlet assembly; a charging connector attached to a charging wire and connectable to the vehicle outlet assembly; and a phase change material adapted to absorb heat from at least one of the vehicle outlet assembly, the high voltage cable, the charging connector, and the charging wire during charging.

[0018] In further non-limiting embodiments of the foregoing charging system, the charging is a direct current (DC) fast charging event.

[0019] In further non-limiting embodiments of any of the foregoing charging systems, each of the vehicle outlet assembly, the high voltage cable, the charging connector, and the charging wire includes the phase change material.

[0020] In further non-limiting embodiments of any of the foregoing charging systems, the phase change material is disposed about a port of the vehicle outlet assembly.

[0021] In further non-limiting embodiments of any of the foregoing charging systems, the phase change material is disposed within a housing of the high voltage cable or within the charging wire.

[0022] In a further non-limiting embodiment of any of the foregoing charging systems, a portion of the vehicle inlet assembly is made from the phase change material.

[0023] In a further non-limiting embodiment of any of the foregoing charging systems, the portion is a contact point surrounding a mating terminal of a port of the vehicle inlet assembly.

[0024] The embodiments, examples and alternatives in the preceding paragraphs, claims or the following description and drawings, including any of their various aspects or individual features, may be taken independently or in any combination. Features described in conjunction with one embodiment are applicable to all embodiments, unless such features are incompatible.

[0025] The various features and advantages of the present disclosure will become apparent to those skilled in the art from the following detailed description. The drawings accompanying the detailed description can be briefly described as follows. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 A powertrain system for an electrified vehicle is schematically shown.

[0027] Figure 2 An electrified vehicle is schematically shown while being charged at a charging station.

[0028] Figure 3 An exemplary charging system for charging an electrified vehicle is shown.

[0029] Figure 4 It is a front view of the vehicle inlet assembly of the charging system.

[0030] Figure 5 yes Figure 4 Rear view of the vehicle socket assembly.

[0031] Figure 6 Shown for cooling Figure 4 and Figure 5 A first phase change material configuration is provided for a portion of a vehicle inlet assembly.

[0032] Figure 7 Shown for cooling Figure 4 and Figure 5 A second phase change material configuration is provided for a portion of the vehicle inlet assembly.

[0033] Figure 8 A side view of the charging system's charging cable and connector.

[0034] Figure 9 Shown for cooling Figure 8 Portions of the charging cable and connector are configured with a first phase change material.

[0035] Figure 10 A second phase change material configuration for cooling portions of a charging cord and connector is shown. Figure 8

[0036] A high voltage cable of a charging system is shown. Figure 11

[0037] A first phase change material configuration for cooling portions of a high voltage cable is shown. Figure 12 Figure 11

[0038] Figure 13 A second phase change material configuration for cooling portions of a high voltage cable is shown. Figure 11 DETAILED DESCRIPTION

[0039] The present disclosure describes example conductive charging systems for charging an energy storage device (e.g., a battery pack) of an electrified vehicle. The example charging systems include charging components (e.g., a vehicle receptacle assembly, a charging cord, a charging connector, a high voltage cable, etc.) and a phase change material for passively cooling the charging components during a charging event. These and other features are discussed in greater detail in the following paragraphs of this DETAILED DESCRIPTION.

[0040] Figure 1 A powertrain system 10 of an electrified vehicle 12 is schematically shown. The electrified vehicle 12 can be, for example, a battery electric vehicle (BEV) or a plug-in hybrid electric vehicle (PHEV). Thus, although not shown in this embodiment, the electrified vehicle 12 can be equipped with an internal combustion engine that can be used alone or in combination with other energy sources to propel the electrified vehicle 12.

[0041] In the illustrated embodiment, the electrified vehicle 12 is a full electric vehicle that is propelled solely by electric power, such as by an electric machine 14, without any assistance from an internal combustion engine. The electric machine 14 can operate as an electric motor, a generator, or both. The electric machine 14 receives electric power and provides a rotational output power. The electric machine 14 can be connected to a gear box 16 for adjusting the output torque and speed of the electric machine 14 at a predetermined gear ratio. The gear box 16 is connected to a set of drive wheels 18 through an output shaft 20. A voltage bus 22 electrically connects the electric machine 14 to a battery pack 24 through an inverter 26. The electric machine 14, the gear box 16, and the inverter 26 can be collectively referred to as a transmission 28.

[0042] ​​​The battery pack 24 is an exemplary electrical storage battery for an electrified vehicle. The battery pack 24 can be a high-voltage traction battery pack that includes a plurality of battery assemblies 25 (i.e., battery arrays or battery cell groups) capable of outputting electrical power to operate the electric motor 14 and / or other electrical loads of the electrified vehicle 12. Other types of energy storage and / or output devices can also be used to provide electrical power to the electrified vehicle 12.

[0043] The electrified vehicle 12 is also equipped with a charging system 30 for charging the energy storage devices (e.g., battery cells) of the battery pack 24. As described in greater detail below, the charging system 30 can include charging components located on and external to the electrified vehicle 12. The charging system 30 can be connected to an external power source for receiving and distributing electrical power received from the external power source throughout the electrified vehicle 12.

[0044] Figure 1 The powertrain 10 of FIG. 1 is highly schematic and is not intended to limit the present disclosure. Alternatively or additionally, the powertrain 10 can employ various additional components within the scope of the present disclosure. Moreover, the teachings of the present disclosure can be incorporated into any type of electrified vehicle, including but not limited to automobiles, trucks, sport utility vehicles, boats, airplanes, etc.

[0045] Figure 2 The electrified vehicle 12 is shown parked proximate to a conductive charging station 32 for charging. The electrified vehicle 12 can employ the powertrain 10 shown in FIG. 1 or any similar electrified powertrain. Figure 1

[0046] The charging station 32 is powered by an external power source 34 (shown schematically). In one embodiment, the external power source 34 includes a utility grid power source. In another embodiment, the external power source 34 includes an alternative energy source, such as solar, wind, etc. In yet another embodiment, the external power source 34 includes a combination of a utility grid power source and an alternative energy source.

[0047] The charging station 32 can include, among other things, a housing 36 and a charging cord 38. Generally, the housing 36 houses various internal components of the charging station 32. The size, shape, and configuration of the housing 36 are not intended to limit the present disclosure. The housing 36 can additionally include an output display 40 for displaying information to an occupant 42 of the electrified vehicle 12.

[0048] Referring now to Figure 2 and Figure 3 ​The charging cord 38 can extend outside the housing 36 to connect to the electrified vehicle 12. For example, the charging cord 38 can include a charging connector 44 configured to connect to a vehicle receptacle assembly 46 of the electrified vehicle 12. Power sourced from the external power source 34 can be delivered from the charging station 32 to the vehicle receptacle assembly 46 for use in charging the battery pack 24 of the electrified vehicle 12 via the charging connector 44 attached to the charging cord 38. A high-voltage cable 48 connects between the vehicle receptacle assembly 46 and the battery pack 24 for delivering power received by the vehicle receptacle assembly 46 to the battery pack 24 to replenish the energy of the battery cells of the battery pack 24.

[0049] The charging system 30 can include a plurality of heat-generating charging components. In one embodiment, the charging cord 38, the charging connector 44, the vehicle receptacle assembly 46, the high-voltage cable 48, and the battery pack 24 make up the charging system 30 of the electrified vehicle 12. Thus, the charging system 30 can include components located on the electrified vehicle 12 and located outside the electrified vehicle 12.

[0050] The charging system 30 can be configured to deliver power to the battery pack 24 using any type of charging (e.g., AC, DC, etc.). In one embodiment, the charging system 30 is capable of performing a direct current (DC) fast charging event. A DC fast charging event is a relatively immediate fast charging event that typically lasts about thirty minutes or less. As one non-limiting example, the charging system 30 employs DC fast charging by delivering a power level greater than 50 kW (as opposed to the power output of a standard AC charger) to fast charge the battery pack 24.

[0051] Because the current exchanged during a DC fast charging event is relatively large, a relatively significant amount of heat can be generated in some charging components of the charging system 30. It is generally desirable to dissipate this heat during a charging event. Exemplary charging components including features for dissipating heat generated during a charging event are described in further detail below.

[0052] With continued reference to Figures 1 to 3 , Figures 4 to 5 An exemplary vehicle receptacle assembly 46 of the charging system 30 is shown. The vehicle receptacle assembly 46 includes a housing 50. The housing 50 is permanently mounted to a vehicle body 51 and is therefore considered to be on the electrified vehicle 12.

[0053] The housing 50 includes a front face 52 (see Figure 4 ) and a back face 54 (see Figure 5 ). The front face 52 of the housing 50 faces outward of the electrified vehicle 12 (i.e., faces toward the charging station 32), and the back face 54 faces inward of the electrified vehicle 12.

[0054] A first port 56 and a second port 58 are disposed on the front face 52 of the housing 50. The first port 56 includes a plurality of mating terminals 60 for carrying alternating current during a charging event when the charging connector 44 is coupled to the vehicle outlet assembly 46, and the second port 58 includes mating terminals 62 for carrying direct current during a charging event when the charging connector 44 is coupled to the vehicle outlet assembly 46.

[0055] A phase change material 64 can be disposed at the back face 54 of the housing 50 for absorbing heat generated at the vehicle outlet assembly 46 during a charging event, such as a DC fast charging event. The phase change material 64 can take various configurations for incorporation into the housing 50. In one embodiment, the phase change material 64 is configured as a ring 65 that is received against the back face 54 such that it circumscribes the second port 58 (i.e., the port carrying direct current) (see, e.g., Figure 5 ). In another embodiment, the phase change material 64 is received within a channel 66 formed in the back face 54 of the housing 50 (see, e.g., Figure 6 ). In yet another embodiment, contact points 68 around the mating terminals 62 of the second port 58 are made of the phase change material 64 (see, e.g., Figure 7 ).

[0056] The phase change material 64 is adapted to passively absorb heat from the vehicle outlet assembly 46 during a charging event by changing its phase (e.g., a phase change from a solid phase to a liquid phase or a phase change from a liquid phase to a solid phase). In one embodiment, the phase change material 64 is a nanostructured phase change material. The term "nanostructured" describes the size of the phase change material (PCM) crystalline structure, which affects the efficiency of heat transfer during a phase change. The smaller the crystalline structure, the more efficient and consistent the phase change. In another embodiment, the phase change material 64 includes paraffin. However, other phase change materials are also contemplated within the scope of the present disclosure. For example, the phase change material 64 can be any phase change material with a melting point great enough to absorb heat generated during a DC fast charging event. In one embodiment, the phase change material 64 is capable of absorbing temperatures of at least 150°F (65.6°C).

[0057] With continued reference to Figures 1 to 3 , Figures 8 to 10 An exemplary charging connector 44 is shown attached to a charging cord 38 of the charging system 30. One section of the charging cord 38 can extend into the charging connector 44. The end of the charging cord 38 opposite the charging connector 44 is attached to the charging station 32 (see Figure 2 ).

[0058] The charging cord 38 can include a housing 70 that surrounds the wire 72. The housing 70 can include an outer tube wall 74 and an inner tube wall 76. The outer tube wall 74 circumscribes the inner tube wall 76. A cavity 78 can be formed inside the housing 70 at a location radially between the outer tube wall 74 and the inner tube wall 76.

[0059] The phase change material 64 can be disposed within the cavity 78 for passively absorbing heat from the charging connector 44 during a charging event, such as a DC fast charging event. The phase change material 64 can take various configurations for incorporation into the housing 70 of the charging cord 38. In one embodiment, the phase change material 64 is configured as a ring 65 that is received within the cavity 78 such that it circumscribes the inner tube wall 76 (see, e.g., Figure 9 ). Other non-ring shapes are also contemplated within the scope of the present disclosure. For example, the housing 70 and the phase change material 64 can include any shape, and the shape is not intended to be limited to the particular shape shown in Figure 8 and Figure 9 .

[0060] In another embodiment, the phase change material 64 is configured as a plurality of strips 80 that are circumferentially spaced apart from one another and positioned within the housing 70 (see, e.g., Figure 10 ). The plurality of strips 80 provide discrete areas or segments of the phase change material 64 within the housing 70.

[0061] In yet another embodiment, the phase change material 64 is only disposed in a section of the charging cord 38 that extends within the charging connector 44. That is, in one embodiment, the length of the phase change material 64 can be less than the overall length of the charging cord 38.

[0062] With continued reference to Figures 1 to 3 , Figures 11 to 13 an example high voltage cable 48 of the charging system 30 is shown. The high voltage cable 48 is connected between the vehicle receptacle assembly 46 and the battery pack 24 (see Figure 3 ) for delivering power to the battery pack 24.

[0063] The high voltage cable 48 can include a housing 82 that surrounds a wire 84. The housing 82 can include an outer tube wall 86 and an inner tube wall 88. The outer tube wall 86 circumscribes the inner tube wall 88. A cavity 90 can be formed inside the housing 82 at a location radially between the outer tube wall 86 and the inner tube wall 88.

[0064] The phase change material 64 can be disposed within the cavity 90 for passively dissipating heat from the high voltage cable 48 during a charging event, such as a DC fast charging event. The phase change material 64 can take various configurations for incorporation into the housing 82 of the high voltage cable 48. In one embodiment, the phase change material 64 is configured as a ring 65 that is received within the cavity 90 such that it circumscribes the inner tube wall 88 (see, e.g.,Figure 12 Other non-circular shapes are also contemplated within the scope of the present disclosure. For example, the housing 82 and phase change material 64 can comprise any shape, and the shape is not intended to be limited to Figure 11 and Figure 12 the particular shapes shown.

[0065] In another embodiment, the phase change material 64 is configured as a plurality of strips 92 that are circumferentially spaced apart from one another within the housing 82 (see, e.g., Figure 13 The plurality of strips 92 provide discrete areas or segments of phase change material 64 within the housing 82.

[0066] In yet another embodiment, the phase change material 64 extends only within discrete segments of the high voltage cable 48. That is, in one embodiment, the length of the phase change material 64 can be less than the overall length of the high voltage cable 48.

[0067] Although shown separately in Figures 4 to 13 , each of the vehicle outlet assembly 46, the charging connector 44, and the high voltage cable 48 can be equipped with the phase change material 64 for absorbing heat generated within each of these components during a charging event.

[0068] The electrified vehicle charging system of the present disclosure employs a phase change material that is capable of passively cooling one or more heat-generating charging components of the charging system. A cooling system that circulates coolant to actively cool the charging components can thus be eliminated, reducing cost and simplifying packaging.

[0069] Although different non-limiting embodiments are shown with particular components or steps, embodiments of the present disclosure are not limited to those specific combinations. Some of the components or features from any of the non-limiting embodiments can be used with features or components from any of the other non-limiting embodiments.

[0070] It should be understood that like reference numerals identify corresponding or analogous elements throughout the several figures. It should be understood that although a particular arrangement of components has been disclosed in these example embodiments, other arrangements can also benefit from the teachings of the present disclosure.

[0071] The foregoing description should be interpreted as illustrative of the present disclosure and not in a limiting sense. Those of ordinary skill in the art will understand that certain modifications can fall within the scope of the present disclosure. For these reasons, the following claims should be studied to determine the true scope and content of the present disclosure.

[0072] According to the present invention, there is provided a charging system for an electrified vehicle having: a charging component; and a phase change material positioned relative to the charging component and configured to absorb heat from the charging component.

[0073] According to one embodiment, the charging component is a vehicle outlet assembly.

[0074] According to one embodiment, the phase change material is encapsulated on a back face of a housing of the vehicle outlet assembly.

[0075] According to one embodiment, the phase change material is a ring positioned within a channel formed in the back face of the housing.

[0076] According to one embodiment, contact points around mating terminals of the vehicle outlet assembly are made of the phase change material.

[0077] According to one embodiment, the phase change material is a nanostructured phase change material.

[0078] According to one embodiment, the charging component is a charging connector having a charging cord extending within the charging connector.

[0079] According to one embodiment, the charging cord includes a sheath and a wire within the sheath.

[0080] According to one embodiment, the phase change material is received within a cavity within the sheath.

[0081] According to one embodiment, the phase change material is positioned radially between an outer tube wall and an inner tube wall of the sheath.

[0082] According to one embodiment, the phase change material is configured in a plurality of sheets disposed within the charging component.

[0083] According to one embodiment, the plurality of sheets are disposed within a housing of the charging component.

[0084] According to one embodiment, the charging component is a high voltage cable.

[0085] According to the present invention, there is provided a charging system for an electrified vehicle having: a battery pack; a vehicle outlet assembly; a high voltage cable connecting the battery pack and the vehicle outlet assembly; a charging connector attached to a charging cord and connectable to the vehicle outlet assembly; and a phase change material adapted to absorb heat from at least one of the vehicle outlet assembly, the high voltage cable, the charging connector and the charging cord during charging.

[0086] According to one embodiment, the charging is a direct current (DC) fast charging event.

[0087] According to one embodiment, each of the vehicle outlet assembly, the high voltage cable, the charging connector and the charging cord includes the phase change material.

[0088] According to one embodiment, the phase change material is disposed about a port of the vehicle outlet assembly.

[0089] According to one embodiment, the phase change material is disposed within a housing of the high voltage cable or within the charging cord.

[0090] According to one embodiment, a portion of the vehicle outlet assembly is made of the phase change material.

[0091] According to one embodiment, the portion is a contact point about a mating terminal of a port of the vehicle outlet assembly.

Claims

1. A charging system for an electric vehicle, comprising: Charging components; as well as a phase change material positioned relative to the charging member and configured to absorb heat from the charging member; wherein the charging component is a vehicle socket assembly; The phase change material is configured as a ring, which is encapsulated on the back of the housing of the vehicle socket assembly and externally connected to the DC port of the vehicle socket assembly. 2 . The charging system of claim 1 , wherein contact points surrounding mating terminals of the vehicle inlet assembly are made of the phase change material.

3. The charging system of claim 1, wherein the phase change material is a nanostructured phase change material.

4. The charging system of claim 1 , wherein the charging system includes a charging connector having a charging cord extending within the charging connector, and the charging cord includes a housing and a wire within the housing. 5 . The charging system of claim 4 , wherein the phase change material is received in a cavity within the housing or positioned radially between an outer tube wall and an inner tube wall of the housing. 6 . The charging system according to claim 1 , wherein the phase change material is configured in a plurality of sheets provided within the charging member, and wherein the plurality of sheets are provided within a housing of the charging member.

7. The charging system of claim 1, wherein the charging system comprises a high voltage cable.

8. A charging system for an electrified vehicle, comprising: Battery pack; Vehicle socket assembly; a high-voltage cable connecting the battery pack and the vehicle socket assembly; a charging connector attached to the charging cable and connectable to the vehicle inlet assembly; as well as a phase change material adapted to absorb heat from at least one of the vehicle inlet assembly, the high voltage cable, the charging connector, and the charging cord during charging; The phase change material is configured as a ring, which is encapsulated on the back of the housing of the vehicle socket assembly and externally connected to the DC port of the vehicle socket assembly.

9. The charging system of claim 8, wherein the charging is a direct current (DC) fast charging event. 10 . The charging system of claim 8 , wherein each of the vehicle inlet assembly, the high voltage cable, the charging connector, and the charging cord comprises the phase change material. 11 . The charging system according to claim 8 , wherein the phase change material is provided in a housing of the high-voltage cable or in the charging line.

12. The charging system of any one of claims 8 to 10, wherein a portion of the vehicle inlet assembly is made of the phase change material, and wherein the portion is a contact point surrounding a mating terminal of a port of the vehicle inlet assembly.

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