Charging port

Abstract

A charging inlet (1) for interconnecting an external power source with a battery system of an electric vehicle to charge the battery system. The charging inlet (1) typically includes a socket (2) adapted to receive a compatible plug during charging, wherein the socket (2) includes at least one first inlet electrode (3) and at least one second inlet electrode (4) for connection to the external power source via the compatible plug. Typically, a first conductor (5) is electrically and thermally interconnected with the first inlet electrode (3), and a second conductor (6) is electrically and thermally interconnected with the second inlet electrode (4). A cooling member (7) may be thermally interconnected with the first and second conductors (5, 6) to provide a heat sink for the socket (2) and the plug during charging.

Description

Technical Field

[0001] This disclosure relates to the field of charging inlets for electric vehicles. Background Technology

[0002] To charge the battery of an electric vehicle, the battery needs to be connected to an external power source. This can typically be done via a charging port, as is known from existing technology.

[0003] DE102017113920A1, published in December 2018 under the name IAV GmbH Ingenieurgesellschaft Auto und Verkehr, relates to a charging port cooler for a mechanical contact charging port having lead wires from a charging socket and leading to a first cross-section of the charging port cooler, and housed within the housing of the charging port cooler. These lead wires are electrically contacted directly or indirectly via contacts with lead wires from the charging port cooler, which extend out of the housing of the charging port cooler. The lead wires have a second cross-section smaller than the first cross-section of the lead wires. Furthermore, the contacts of the lead wires and the lead wires are surrounded by an electrically insulating and thermally conductive material, and the housing is designed to enclose this material.

[0004] US10377264B2, published in August 2019 under the name of Ford Global Tech LLC, relates to a vehicle conductive charging port. This charging port is configured to conductively transfer charging current from an external source to the vehicle for charging the vehicle's traction battery. A cooling system is configured to cool the charging port based on its temperature. The cooling system uses either a coolant or air to cool the charging port. Summary of the Invention

[0005] As the goal becomes increasingly shorter charging times and therefore higher charging power and consequently higher charging current, several problems arise at the charging inlets of battery systems for connecting external power sources to electric vehicles, as known from existing technologies. On the external power source side, cooling cables are more frequently used; however, this is no longer sufficient to cool the mechanical contacts that conduct the necessary current between the vehicle and the power source.

[0006] Therefore, a first aspect of this disclosure relates to a charging inlet for interconnecting an external power source with a battery system of an electric vehicle to charge the battery system. The charging inlet typically includes a socket adapted to receive a compatible plug during charging. The plug is typically interconnected to the external power source via a cable. The socket typically includes at least one first inlet pole and at least one second inlet pole for connection to the external power source via the compatible plug; however, additional inlet poles are possible. Heat may be generated, particularly when high currents are transmitted via mechanical contacts between the inlet poles and the poles of the plug. To allow for consistently high charging currents, this heat should be dissipated efficiently. The charging inlet according to the disclosure typically includes at least one first conductor and at least one second conductor, the at least one first conductor being electrically and thermally interconnected with the first inlet pole, and the at least one second conductor being electrically and thermally interconnected with the second inlet pole. During charging, the first and second inlet poles are typically electrically and thermally interconnected with their associated poles of the plug for a limited time period.

[0007] Preferably, the cooling component is thermally interconnected with the first and second conductors to provide a heat sink for the socket and the plug during charging. This not only allows heat generated at the inlet poles to dissipate but also provides cooling to the poles of the plug received in the socket during charging. In cases where the socket includes more than two inlet poles, they may also be thermally interconnected with the cooling component. The socket is preferably configured to conform to standards for conductive charging of electric vehicles, such as the international standard IEC 62196. In some variations of the charging inlet, the socket is implemented as a "Combined Charging System" (CCS) type 2 socket.

[0008] The charging port described in this article is suitable for all types of electric vehicles, but it is particularly well-suited for electric trucks. Electric trucks—especially those comprising two or more battery packs—typically have larger battery capacities than, for example, buses, and therefore require particularly high currents during charging to achieve short charging times.

[0009] Depending on the application, the first conductor and the second conductor are interconnected to the battery system via a first cable connection and a second cable connection, respectively. The first cable connection and the second cable connection preferably have a larger cross-sectional area than the corresponding cross-sectional area of ​​the first and second conductors. A larger cross-sectional area generally reduces the conductor's resistance and thus reduces the heat generated when conducting current—especially high current. As a result, the required cooling performance is reduced due to the larger cross-sectional area of ​​the first cable connection and the second cable connection.

[0010] To optimize the electrical coupling and decoupling of the socket from the battery system, each cable connection is interconnected to a corresponding conductor via relays—specifically, a first relay and a second relay. The first and second relays can couple or decouple the corresponding conductor from the corresponding cable connection. Typically, the socket is decoupled from the battery system when no charging is in progress. This increases the safety of the inlet, as the inlet can be substantially voltage-free when no plug is connected to the socket.

[0011] To achieve good protection against environmental influences, the socket, the cooling component, and the first and second conductors are preferably arranged within a housing. The housing may be substantially box-shaped; however, other shapes are possible. To increase heat dissipation, the housing may be at least partially made of a thermally conductive material such as metal; however, other materials are conceivable. The housing is preferably located on the electric vehicle. The socket may be at least temporarily accessible from the outside of the vehicle via an access passage in the housing.

[0012] At least one of the relays is cooled, particularly the first and second relays. In one variation, the relays are thermally interconnected with the housing. Alternatively or additionally, at least one of the relays is preferably interconnected with the cooling member via thermal conduction.

[0013] Depending on the application, at least one of the cable connections is interconnected to a corresponding relay via a sheet metal. The sheet metal preferably has a larger cross-sectional area than the respective first and second conductors. In particular, a busbar can interconnect the cable connection to the corresponding relay. The first and second conductors can be formed as round cables or conductive sheet metal; however, other conductor shapes are conceivable.

[0014] To facilitate installation of the charging port, each cable connection is preferably interconnected with the corresponding relay via at least one connector, specifically at least one connector connecting the corresponding cable connection to the corresponding sheet metal. If suitable, the connector is formed as a quick-connect, for example, a bayonet-type connector or a latch-type connector. Preferably, two connectors are interconnected with the corresponding relay, specifically via the corresponding sheet metal. Depending on the configuration, each cable connection may include at least two substantially parallel cables. These cables can be connected to the connector and, through which, are electrically connected to the relay, specifically via the corresponding sheet metal.

[0015] Although thermally interconnected, the cooling component is preferably electrically isolated from the first and second conductors. This is possible when the first and second conductors are at least partially surrounded by an insulating material (such as a plastic sheath). In a preferred variant, this is achieved when at least one of the conductors is thermally interconnected with the cooling component via a thermally conductive paste-like material—particularly a thermally conductive and electrically insulating material. This ensures good heat transfer from at least one conductor to the cooling component, as a substantially gapless (air) thermal interconnection is possible.

[0016] To provide efficient cooling, the cooling component preferably includes at least one cooling channel. Alternatively or additionally, the thermal component may include at least one cooling fin for passive heat dissipation. Depending on the design, the thermal component may be formed as a separate part or may be included within the housing. If suitable, the thermal component is attached to the interior of the housing. In some variations, the cooling channel forms a closed loop within the thermal component; however, in a preferred variation, the cooling channel is interconnected with a cooling circuit, for example via a cooling channel connector. The cooling channel may include at least one meandering turn, particularly two or three turns. The at least one meandering turn is preferably arranged close to the first conductor and / or the second conductor.

[0017] In some variations, the thermal component includes a body, which is at least partially made of a thermally conductive material. The body may include a groove and a cap, wherein the cap is attached to the body and overlaps the groove, such that together they at least partially form the cooling channel. Alternatively or additionally, the cooling channel may be formed at least partially by a tube accommodated at least partially in the groove of the body. According to embodiments, the body may include at least one recess for thermally interconnecting at least one of the relays. Alternatively or additionally, the body may include at least one indentation for accommodating the first conductor and / or the second conductor.

[0018] To monitor the charging inlet, particularly the temperature, at least one thermal sensor may be thermally interconnected with at least one of the conductors. The thermal sensor is preferably arranged to be connected to one of the relays of the first or second conductor. Good results are possible when the control unit is interconnected with at least one of the relays to control and / or monitor the relays. Specifically, the control unit is configured to switch the relays such that the socket is decoupled from the battery system when no charging is in progress. By design, the control unit is configured to communicate with the vehicle control unit or battery management unit, particularly via a CAN bus (Controller Area Network). For added safety, the control unit may be configured to decouple the battery system from the socket by switching at least one of the relays. Preferably, the control unit is configured to receive thermal data from the at least one thermal sensor and, when a violation of a definable threshold for temperature based on the received temperature data is detected, switch at least one of the relays.

[0019] To protect the socket, and particularly the inlet, from environmental conditions, the housing may include a socket cover disposed between the socket and the exterior of the housing, slidably resisting spring forces, such that the socket is covered when no plug is received in it. The socket cover can slide from a covered position to an open position to allow access to the socket. The socket cover may be formed as a metal plate or the like. As previously described, the control unit is preferably disposed inside the housing; however, the control unit may be incorporated into a vehicle control unit or a battery management unit.

[0020] It should be understood that the foregoing general description and the following detailed description present embodiments and are intended to provide an overview or framework for understanding the nature and characteristics of the disclosure. The accompanying drawings are included to provide further understanding and are incorporated in and form part of this specification. The drawings illustrate various embodiments and, together with the description, serve to explain the principles and operation of the disclosed concepts. Attached Figure Description

[0021] The disclosure described herein will be more fully understood from the detailed description and accompanying drawings given below, which should not be construed as limiting the disclosure described in the appended claims. The drawings show:

[0022] Figure 1 A first variant of the charging port based on publicly available information is shown;

[0023] Figure 2 Shown from a downward perspective in a partially disassembled and disassembled view. Figure 1 The first variant of the charging port; and

[0024] Figure 3 Shown from an upward perspective in a partially disassembled and disassembled view. Figure 1 The first variant of the charging port. Detailed Implementation

[0025] Reference will now be made in detail to certain embodiments illustrated in the accompanying drawings, which show some, but not all, of the features. In fact, the embodiments disclosed herein may be embodied in many different forms and should not be construed as limited to those set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Wherever possible, the same reference numerals will be used to refer to the same parts or components.

[0026] Figure 1 The first variant of charging port 1 is shown. Figure 2 and Figure 3 Shown from two different perspectives in a partially disassembled and disassembled view Figure 1 The first variant.

[0027] like Figure 1 As shown in the first variant, charging port 1 can be used to interconnect an external power source with the battery system of an electric vehicle to charge the battery system. Charging port 1 typically includes a socket 2 adapted to receive a compatible plug (not shown) during charging. The socket 2 of this first variant includes at least one first inlet pole 3 and at least one second inlet pole 4 for connection to an external power source via a plug. Figure 2 As is best seen, the charging port 1 typically includes at least one first conductor 5 and at least one second conductor 6, the at least one first conductor 5 being electrically and thermally interconnected with a first inlet electrode 3, and the at least one second conductor 6 being electrically and thermally interconnected with a second inlet electrode 4. In this way, heat can be transferred away from the inlet electrodes 3 and 4 and the plug interconnected with them, at least during charging, by means of the first conductor 5 and the second conductor 6.

[0028] To achieve good cooling, the cooling component 7 is thermally interconnected with the first conductor 5 and the second conductor 6 to provide a heat sink for the socket 2 and the plug during charging. The illustrated variant of the cooling component 7 includes at least one cooling channel 14 to allow active and therefore efficient cooling. (As shown in...) Figure 3 As is best seen, cooling channel 14 is typically interconnected with a cooling circuit (not shown), particularly via cooling channel connector 23. Cooling channel connector 23 is of the fast-coupled type.

[0029] As in Figure 2 and Figure 3As shown, the cooling member 7 may include a body 20 having a recess for receiving a first conductor 5 and / or a second conductor 6. The recess is preferably shaped substantially in the form of the first conductor 5 and / or the second conductor 6. The body 20 may include a recess 21 and a cover 22, wherein the cover 22 is attached to the body 20 and overlaps with the recess 21 such that they together at least partially form a cooling channel 14. The cooling channel 14 includes at least one bend for increasing heat dissipation. In a first variant, the at least one bend is arranged close to the first conductor 5 and the second conductor 6. In the illustrated variant, the cooling channel 14 includes three bends close to the first conductor 5 and the second conductor 6.

[0030] As in Figure 2 As best seen, the first conductor 5 and the second conductor 6 are interconnected to the battery system (not shown) via a first cable connection 8 and a second cable connection 9, respectively. Each of the first cable connections 8 and 9 has a cross-sectional area larger than that of the corresponding first conductor 5 and second conductor 6. This allows for the omission of active cooling for the first cable connections 8 and 9, as their surface areas are sufficient to dissipate the heat generated during charging. Specifically, the respective cross-sectional areas of the first cable connections 8 and 9 can be approximately twice the cross-sectional areas of the corresponding first conductor 5 and second conductor 6.

[0031] In the variant shown, the first relay 10 is inserted between the first conductor 5 and the first cable connection 8. (As in...) Figure 2 As shown, the second relay 11 is inserted between the second conductor 6 and the second cable connection 9. At least one of the cable connections 8 and 9 is interconnected to the corresponding relay 10 or 11 via sheet metal 12. Figure 2 As can be seen, each of the cable connections 8, 9 is interconnected with a corresponding relay 10, 11 via a sheet metal 12—particularly a busbar. Each sheet metal 12 is thermally interconnected with a cooling member 7. Each cable connection 8, 9 can be interconnected with a corresponding relay 10, 11 via at least one connector 13, particularly at least one quick connector 13 connecting the corresponding cable connection 8, 9 to the corresponding sheet metal 12. In the illustrated variant, two connectors 13 interconnect with the corresponding sheet metal 12. Each cable connection 8, 9 may comprise two substantially parallel cables (not shown) connectable to the corresponding two connectors 13 of the cable connection 8, 9.

[0032] According to one embodiment, the body 20 includes at least one recess for receiving at least one of the relays 10, 11 in a thermally interconnected manner. Figure 3Visible are two generally cylindrical recesses in the body 20 to accommodate the first relay 10 and the second relay 11. Preferably, the cooling member 7 is electrically isolated from the first conductor 5 and the second conductor 6. In the illustrated first variant, conductors 5 and 6 are thermally interconnected with the cooling member 7 via a thermally conductive paste-like material—particularly a thermally conductive and electrically insulating material. For good thermal interconnection, the body 20 preferably includes at least one groove-like recess for accommodating at least one of the first conductor 5 and the second conductor 6. Typically, the body 20 includes one groove-like recess for each conductor 5 or 6.

[0033] The socket 2, cooling component 7, and conductors 5 and 6 are preferably arranged in the housing 18, as in Figure 1 As shown, the housing 18 of the first variant is substantially box-shaped and at least partially made of metal to allow additional heat to dissipate via the outer surface.

[0034] As in Figure 2 As indicated, at least one thermal sensor 15 is typically thermally interconnected with at least one of conductors 5 and 6. In a first variant, at least one thermal sensor 15 is incorporated within a first relay 10 and / or a second relay 11. A control unit 16 is typically interconnected with at least one of relays 10 and 11 for controlling and / or monitoring the relays. Figure 1 As shown, the control unit 16 is preferably arranged in the housing 5. In a first variant, the control unit 16 is interconnected with the vehicle control unit (not shown) via a CAN bus connection.

[0035] More precisely, the terms used in the instruction manual are descriptive rather than restrictive, and it should be understood that various changes may be made without departing from the scope of the disclosed content.

[0036] Name List

[0037] 1 charging port

[0038] 2 sockets

[0039] 3 First Entrance

[0040] 4 Second Inlet Pole

[0041] 5 First conductor

[0042] 6 Second conductor

[0043] 7 Cooling components

[0044] 8 First cable connection

[0045] 9 Second cable connection

[0046] 10 First Relay

[0047] 11 Second Relay

[0048] 12 sheet metal

[0049] 13 Connectors (cable connections) 14 Cooling channels

[0050] 15 thermal sensors

[0051] 16 control units

[0052] 18 shell

[0053] 19 Socket cover; 20 Main body (cooling component); 21 Recess (cooling component); 22 Cover (cooling component)

[0054] 23 Cooling Channel Connector

Claims

1. A charging inlet (1) for interconnecting an external power source with a battery system of an electric vehicle to charge the battery system, the charging inlet (1) comprising: a. A socket (2) adapted to receive a compatible plug during charging, wherein the socket (2) includes at least one first inlet pole (3) and at least one second inlet pole (4) for connection to the external power source via the compatible plug; b. A first conductor (5) and a second conductor (6), wherein the first conductor (5) is electrically and thermally interconnected with the first inlet electrode (3), and the second conductor (6) is electrically and thermally interconnected with the second inlet electrode (4); c. A cooling component (7) thermally interconnected with the first conductor (5) and the second conductor (6) to provide a heat sink for the socket (2) and the plug during charging. The cooling component (7) includes at least one cooling channel (14). The cooling component (7) includes a body (20) having a groove (21) and a cover (22), wherein the cover (22) is attached to the body (20) and overlaps with the groove (21) such that together they at least partially form the cooling channel (14). The first conductor (5) and the second conductor (6) are interconnected with the battery system via a first cable connection (8) and a second cable connection (9), respectively. Each cable connection (8, 9) is interconnected with the corresponding conductor (5, 6) via a first relay (10) or a second relay (11). At least one of the relays (10, 11) is thermally interconnected with the cooling component (7), and The cooling channel (14) includes at least one bend.

2. The charging port (1) according to claim 1, wherein the first cable connection (8) and the second cable connection (9) have a cross-sectional area larger than the cross-sectional area of ​​the corresponding first conductor and second conductor.

3. The charging port (1) according to claim 1, wherein at least one of the relays (10, 11) is cooled.

4. The charging port (1) according to claim 1 or 3, wherein at least one of the cable connections (8, 9) is interconnected with a corresponding relay (10, 11) via a sheet metal (12).

5. The charging port (1) according to claim 4, wherein each cable connection (8, 9) is interconnected with a corresponding relay (10, 11) via at least one connector (13), wherein, At least one quick connector (13) connects the corresponding cable connection (8, 9) to the corresponding sheet metal (12).

6. The charging port (1) according to any one of claims 1 to 3, wherein the cooling member (7) is electrically isolated from the first conductor (5) and the second conductor (6).

7. The charging port (1) according to claim 1 or 3, wherein at least one thermal sensor (15) is thermally interconnected with at least one of the conductors (5, 6).

8. The charging port (1) according to claim 7, wherein the thermal sensor (15) is arranged inside one of the relays (10, 11).

9. The charging port (1) according to claim 1 or 3, wherein the control unit (16) is interconnected with at least one of the relays (10, 11) for controlling and / or monitoring the relays (10, 11).

10. The charging port (1) according to claim 2 or 3, wherein each cable connection (8, 9) comprises at least two substantially parallel cables.

11. The charging port (1) according to claim 2 or 3, wherein at least one of the conductors (5, 6) is thermally interconnected with the cooling member (7) via a thermally conductive paste material.

12. The charging port (1) according to claim 11, wherein the thermally conductive paste material is a thermally conductive and electrically insulating material.

13. The charging port (1) according to claim 2 or 3, wherein the socket (2), the cooling member (7) and the conductors (5, 6) are arranged in the housing (18).

14. The charging port (1) according to claim 13, wherein the housing (18) includes a socket cover (19) disposed between the socket (2) and the exterior of the housing (18) and slidably resisting the force of a spring, such that the socket (2) is covered when no plug is received in the socket (2).

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