Electric vehicle charging connector with external passive cooling

Abstract

An electric vehicle charging connector (100) comprises an outer shell (104), an inner shell, and a compartment (102) for power contacts. The outer shell (104) encloses the inner shell (103) and is configured to receive and guide a cable (101) from a rear end (111) of the electric vehicle charging connector (100) to the inner shell (103) at a front end (113) of the electric vehicle charging connector (100). The inner shell (103) comprises the compartment (102) and is configured to provide the cable (101) to the compartment (102). The electric vehicle charging connector (100) further comprises a heat pipe (106) comprising an evaporator (107) and a condenser (109). The evaporator (107) is attached to a heat source in the compartment (102) inside the inner shell (103) and is configured to conduct heat from the heat source via the outer shell (104) to the environment, wherein at least a portion of the heat pipe (106) is arranged outside the outer shell (104).

Description

Technical Field

[0001] This invention relates to electric vehicle charging connectors, charging stations, and the use of heat pipes in electric vehicle charging connectors. Background Technology

[0002] One limiting factor in charging cables used in electric vehicles is the heat generated when high current flows from the charging station through the cable and electrical connectors to the vehicle's battery. Heat can be actively conducted away from the heat source using a liquid. In this way, current ratings exceeding 500A have been achieved. This cooling requires an arrangement that includes the liquid and conducts it from the radiator to the heat source and back. Additional equipment, such as pumps, is required. Alternatively, passive cooling is possible. However, with existing designs, only rated currents up to 200A can be achieved. Passive cooling requires a design that acts as a hollow portion within the housing or housing material, so that heat within the housing is not insulated. This design may be ineffective or result in excessive weight for the charging cable. Summary of the Invention

[0003] The purpose of this invention is to provide an electric vehicle charging connector with an improved IP rating while maintaining thermal performance.

[0004] This problem is addressed by the subject matter of the independent claims. Examples are provided by the dependent claims, the following description, and the accompanying drawings.

[0005] The described embodiments similarly relate to the use of electric vehicle charging connectors, charging stations, and heat pipes in electric vehicle charging connectors. Although different combinations of embodiments may not be described in detail, different combinations of embodiments can produce synergistic effects.

[0006] Technical terms are used according to their common sense. If certain terms are to convey a specific meaning, their definitions will be given below in the context in which they are used.

[0007] According to a first aspect, an electric vehicle charging connector is provided, comprising a housing, an inner housing, and compartments for power contacts. The housing surrounds the inner housing and is configured to receive and guide a cable from a rear end to a front end of the electric vehicle charging connector. The inner housing includes compartments and is configured to provide cables to the compartments. The electric vehicle charging connector also includes a heat pipe comprising an evaporator and a condenser. The evaporator is attached to a heat source in a compartment inside the inner housing and is configured to conduct heat from the heat source through the housing to the environment, wherein at least a portion of the heat pipe is disposed outside the housing.

[0008] The inner and outer shells protect the electric vehicle charging connector from environmental influences. However, during the charging process, such as when charging a vehicle's battery, heat is generated in the compartment as high current flows through the cables and power contacts within the compartment. This heat must be dissipated. This is achieved using a heat pipe that includes an evaporator that receives heat from a heat source in the compartment and conducts it through the inner and outer shells to the environment. At least a portion of the heat pipe is disposed outside the outer shell and is at least a part of the heat-conducting and / or heat-dissipating portion, i.e., a condenser. The condenser may include fins to expand its surface area, thereby enhancing its thermal performance. If at least a portion of the heat pipe is outside the outer shell, the thermal performance of the heat pipe is higher, and therefore the thermal performance of the electric vehicle charging connector is higher.

[0009] According to one embodiment, the electric vehicle charging connector may further include a structure disposed outside the housing, such that the structure, together with the housing, forms a protected space for the portion of the heat pipe outside the housing. The structure may be made of the same or similar material as the housing, or it may be composed of a different material. That is, the structure may be a component of the housing, or it may be a separate part that can be mounted to the housing. The structure may have a flat shape or an outwardly curved shape, thereby improving the mechanical stability of the arrangement.

[0010] According to one embodiment, the portion of the heat pipe outside the housing is the condenser. That is, the complete condenser is on the outside, with the thermal bridge between the condenser and the evaporator forming an interface between the inside and outside of the housing relative to the housing.

[0011] According to one embodiment, the portion of the heat pipe outside the housing is part of the condenser. That is, unlike the previous embodiment, the condenser is not entirely external, but only a portion of it. This embodiment is highly advantageous because, in this case, the portion between the evaporator and condenser is moved inside the housing. Since the temperature of the thermal bridge element can be significantly higher than the ambient temperature, the user can be protected from the effects of this element. Furthermore, some heat is already dissipated inside the housing, making the external condenser portion a cooler section than the other parts.

[0012] According to one embodiment, the inner and outer shells are sealed to provide a high IP rating protection. The outer shell provides a medium IP rating protection. For example, the inner shell has an IP rating of IP67, and the outer shell has an IP rating of IP44. If the outer shell has only an opening, it may not be able to achieve IP44 with the same thermal performance.

[0013] According to one embodiment, the electric vehicle charging connector includes more than one heat pipe. Therefore, there can also be more than one condenser. For example, there are two heat pipes, and the condensers can be arranged on the left and right sides of the connector.

[0014] These and other features, aspects, and advantages of the invention will be better understood with reference to the accompanying drawings and the following description. In principle, identical or equivalent elements have the same reference numerals. Attached Figure Description

[0015] Figure 1 A diagram showing the interior of the electric vehicle charging connector on which the embodiment may be based is illustrated;

[0016] Figure 2 The embodiments shown may be based on additional heat pipes. Figure 1 A diagram of the interior of an electric vehicle charging connector;

[0017] Figure 3a A diagram showing the exterior of an electric vehicle charging connector according to an embodiment is provided.

[0018] Figure 3b A cross-sectional view of an electric vehicle charging connector according to an embodiment is shown;

[0019] Figure 3c A diagram showing a cross-sectional view of an electric vehicle charging connector according to another embodiment; and

[0020] Figure 4 A schematic diagram of a charging station connected to a vehicle is shown. Detailed Implementation

[0021] Figure 1 The design of the charging connector on which the arrangement of the present invention is based is illustrated. The electric vehicle charging connector 100 includes a housing 104, an inner housing, and a compartment 102 for power contacts. The housing 104 surrounds the inner housing 103 and is configured to receive and guide a cable 101 from the rear end 111 to the front end 113 of the electric vehicle charging connector 100. The inner housing 103 includes the compartment 102 and is configured to provide the cable 101 to the compartment 102. The inner housing 103 functions to ensure electrical insulation, mechanical strength, and protection against water and dirt contamination. For this purpose, the housing 103 is largely hermetically sealed and, in some designs, almost completely encapsulated. The contact holder 102 can also be treated in this manner. The combination of components 102 and 103 is further enclosed within the housing 104. The connector may include an additional “latch element” 115. This element is a lever for locking the connector to the vehicle and facilitates communication between the vehicle and the charging station to initiate a charging session.

[0022] The overall design aims to provide triple mechanical protection for the contacts (guaranteed by the contact holder 102, inner housing 103, and outer housing 104) and dual IP protection (guaranteed by the contact holder 102 and inner housing 103). Another reason for separating housings 103 and 104 is weight. The stringent functional requirements of the inner housing 103 resulted in a rather robust and heavy design, which may also be "sealed for life." On the other hand, the larger outer housing 104 is constructed in a relatively lightweight manner, with an emphasis on weight reduction and increased comfort.

[0023] Figure 2 The embodiment shown may be based on an additional heat pipe 106. Figure 1 A diagram of an electric vehicle charging connector. Figure 2 The electric vehicle charging connector 100 in the middle has a connection with Figure 1 The design is basically the same as that of the electric vehicle charging connector 100; however, a heat pipe 106, which acts as a heat conductor, is shown arranged inside the housings 103 and 104. The heat receiving portion (i.e., Figure 2 The evaporator 107 of the heat pipe is attached in a manner that brings it into close thermal contact with the heat source or hot spot, particularly near the contacts of the connector. The heat pipe then extracts heat from the inner housing 103, which is highly sealed for electrical, water, dust, and mechanical protection of the contacts and associated components. Heat is then transferred from the evaporator through section 112 and via seal 110 to the condenser 109, which has condenser fins 108. The outer housing 104 requires lower protection and primarily serves as the interface with the user. The heat pipe 106 dissipates heat into the environment within region 109 of the condenser 109, which includes the heat pipe 106. Each phase may have one or more heat pipes.

[0024] If the condenser or a portion thereof is exposed to air, for example, inside housing 104, this would allow water to penetrate the outer housing or housing 104. This means that the IP rating of this arrangement would be IPX0 (the water ingress classification would be 0 regardless of the dust ingress classification represented by X), indicating that water enters the housing. This is highly undesirable and could pose problems with (a) safety and (b) third-party certification of the connector according to existing standards (i.e., IEC 62196-3), which state that the minimum IP rating for the housing in such products is IP44. The proposed arrangement addresses this problem.

[0025] exist Figure 3a In this configuration, the condenser 109 appears as element 108 externally to the connector 100 on the housing 104. The condenser is exposed to air. (See below.) Figure 3b and 3c A cross-sectional view of the front side, indicated by the symbol AA, is shown.

[0026] Figure 3b A front cross-sectional view of connector 100 is shown. Connector 100 includes a housing 104, which includes an inner housing 103, which in turn includes a contact element compartment 102. In this cross-section, a key element in the arrangement of the cooling system is the condenser 109, which is exposed to fresh air outside the housing 104. The condenser 109 may be protected by an optional structure or a mesh 304. The condenser 109 contacts the contact element 102 by means of a thermal bridge 112, such as... Figure 2 As shown in the cross-section, thermal bridge 112 can be a heat pipe element.

[0027] exist Figure 3c Different embodiments are shown in the diagram. Here, a portion of the condenser 109 is located inside the housing 104 but outside the inner housing 103, such that only a portion of the condenser 109 is exposed to fresh air. Circle 306 indicates that portion 112 is inside the housing 104. The advantage of this configuration is that portion 112, which would be at a higher temperature compared to ambient temperature, is less exposed to potential contact by the end user, thus improving safety. In this configuration, some fins 108 may be located inside the housing 104.

[0028] Figure 4 A schematic diagram is shown as an example of a charging station 400 connected to a vehicle 402 via an electric vehicle charging connector 100. The connection between the electric vehicle charging connector 100 and the charging station 400 is fixed, such that the electric vehicle charging connector 100 is part of the charging station 400.

[0029] Therefore, a sufficient IP rating was achieved while ensuring the thermal performance of the connector.

[0030] By studying the accompanying drawings, the disclosure, and the appended claims, those skilled in the art can understand and implement other variations of the disclosed embodiments in practicing the claimed invention. In the claims, the word "comprising" does not exclude other elements or steps, and the indefinite article "a" or "an" does not exclude a plurality. The fact that certain measures are recited only in mutually different dependent claims does not mean that a combination of these measures cannot be used advantageously. Any reference numerals in the claims should not be construed as limiting the scope of the claims.

Claims

1. An electric vehicle charging connector (100) includes a housing (104), an inner housing (103), and a compartment (102) for power contacts. The outer shell (104) surrounds the inner shell (103) and is configured to receive and guide the cable (101) from the rear end (111) of the electric vehicle charging connector (100) to the front end (113) of the electric vehicle charging connector (100). The inner housing (103) includes the compartment (102) and is configured to supply the cable (101) to the compartment (102). The electric vehicle charging connector (100) further includes a heat pipe (106) including an evaporator (107) and a condenser (109), wherein the evaporator (107) is attached to a heat source in the compartment (102) inside the inner shell (103) and is configured to conduct heat from the heat source to the environment via the outer shell (104), wherein at least a portion of the heat pipe (106) is disposed outside the outer shell (104); The inner shell (103) is sealed to the outer shell and provides a higher IP rating protection than the outer shell.

2. The electric vehicle charging connector (100) according to claim 1, wherein the electric vehicle charging connector (100) further comprises a structure (304) disposed outside the housing such that the structure (304) together with the housing forms a protected space for the portion of the heat pipe outside the housing.

3. The electric vehicle charging connector (100) according to claim 1 or 2, wherein the portion of the heat pipe (106) outside the housing is the condenser (109).

4. The electric vehicle charging connector (100) according to claim 1 or 2, wherein the portion of the heat pipe (106) outside the housing (104) is part of the condenser (109).

5. The electric vehicle charging connector (100) according to claim 1 or 2, wherein the inner housing (103) provides high IP rating protection; and wherein the outer housing provides medium IP rating protection, wherein the high IP rating is IP67 and the medium IP rating is IP44.

6. The electric vehicle charging connector (100) according to claim 1 or 2, wherein the electric vehicle charging connector (100) includes more than one heat pipe.

7. A charging station (400) comprising an electric vehicle charging connector (100) according to any one of claims 1 to 6.

8. Use of a heat pipe (106) in an electric vehicle charging connector (100) according to any one of claims 1 to 6.

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