Terminal heat exchanger for electrical connector

Abstract

An electrical connector (102) includes a housing (110) extending between a front portion and a rear portion. The housing has a chamber (140) at the rear. The housing has a terminal channel (116) between the front portion and the rear portion. A terminal (114) is coupled to the housing. The terminal includes a mating pin (200) at a front portion (210) of the terminal and a cable connector (202) at a rear portion (212) of the terminal. A mating pin is positioned in the terminal channel for mating with a charging connector. A cable connector is positioned in a chamber at the rear of the housing. A terminal heat exchanger (300) is positioned in the chamber. The terminal heat exchanger is thermally coupled with the cable connector of the terminal. The terminal heat exchanger has a spacer (308) that electrically insulates the terminal heat exchanger from the terminals.

Description

[0001] This application is a divisional application of the invention patent application with application number 202010200987.7, application date March 20, 2020, and invention name “Terminal heat exchanger for electrical connector”. Technical Field

[0002] The subject matter herein relates generally to heat exchangers for electrical connectors. Background Art

[0003] Electrical connectors, such as power connectors, generate heat when current flows through the terminals and cables of the power connector. For example, an electrical connector for a charging inlet assembly of a battery system for an electric vehicle (EV) or a hybrid electric vehicle (HEV) may generate heat through the terminals and cables of the charging inlet assembly during the charging process. The charging connector is configured to mate with the terminals of the charging inlet assembly to charge the battery system of the vehicle. It is desirable to increase the current transmitted through the terminals to charge the battery. However, at higher currents, the terminals and the power cable experience an increase in temperature, which may damage components of the charging inlet assembly.

[0004] There remains a need for an electrical connector having a cooling system for cooling the terminals of the electrical connector. Summary of the invention

[0005] In one embodiment, an electrical connector is provided. The electrical connector includes a housing extending between a front and a rear. The housing has a chamber at the rear. The housing has a terminal channel between the front and the rear. The terminal is connected to the housing. The terminal includes a mating pin at the front of the terminal and a cable connector at the rear of the terminal. The mating pin is positioned in the terminal channel for mating with a charging connector. The cable connector is positioned in the chamber at the rear of the housing. A terminal heat exchanger is positioned in the chamber. The terminal heat exchanger is thermally coupled to the cable connector of the terminal. The terminal heat exchanger has an insulator that electrically insulates the terminal heat exchanger from the terminal. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] The present invention will now be described by way of example with reference to the accompanying drawings:

[0007] Figure 1 is a front perspective view of an electrical connector such as for a charging inlet assembly having a cooling system according to an exemplary embodiment.

[0008] Figure 2 is a side view of a terminal of a charging inlet assembly according to an exemplary embodiment.

[0009] Figure 3 is a side view of a terminal according to an exemplary embodiment.

[0010] Figure 4is a side view of a terminal according to an exemplary embodiment.

[0011] Figure 5 is a cross-sectional view of a charging inlet assembly according to an exemplary embodiment.

[0012] Figure 6 is a rear perspective and partially cutaway view of a portion of a charging inlet assembly showing a terminal heat exchanger according to an exemplary embodiment.

[0013] Figure 7 is a bottom perspective view of a manifold of a terminal heat exchanger according to an exemplary embodiment.

[0014] Figure 8 is a cross-sectional view of a heat transfer element according to an exemplary embodiment.

[0015] Fig. 9 is a cross-sectional view of a terminal heat exchanger according to an exemplary embodiment.

[0016] Fig.10 is a cross-sectional view of a terminal heat exchanger according to an exemplary embodiment.

[0017] Fig.11 is a cross-sectional view of a terminal heat exchanger according to an exemplary embodiment.

[0018] Fig.12 is a cross-sectional view of a portion of a charging inlet assembly according to an exemplary embodiment showing a cooling system interfaced with a terminal heat exchanger.

[0019] Fig.13 is a cross-sectional view of a portion of a charging inlet assembly according to an exemplary embodiment showing a cooling system interfaced with a terminal heat exchanger.

[0020] Fig.14 is a rear perspective view of a portion of a charging inlet assembly showing a terminal heat exchanger coupled to a terminal according to an exemplary embodiment.

[0021] Fig.15 is a rear view of a terminal heat exchanger according to an exemplary embodiment.

[0022] Fig.16 is a side view of one of the terminals according to an exemplary embodiment.

[0023] Fig.17 is a cross-sectional view of a portion of a charging inlet assembly according to an exemplary embodiment showing a cooling system interfaced with a terminal heat exchanger.

[0024] Fig.18is a rear perspective and partially cutaway view of a portion of a charging inlet assembly according to an exemplary embodiment showing a cooling system interfacing with a terminal heat exchanger.

[0025] Fig.19 is a rear perspective view of a portion of a charging inlet assembly showing a terminal heat exchanger according to an exemplary embodiment.

[0026] Fig. 20 is a rear perspective and partially cut-away exploded view of a portion of a charging inlet assembly showing a coupled terminal heat exchanger according to an exemplary embodiment.

[0027] Fig.21 is a schematic diagram of a cooling system according to an exemplary embodiment.

[0028] Fig. 22 is a schematic diagram of a cooling system according to an exemplary embodiment. DETAILED DESCRIPTION

[0029] Figure 1 is a front perspective view of an electrical connector 102 having a cooling system 130 for cooling components of the electrical connector 102 according to an exemplary embodiment. The electrical connector 102 may be a power connector, such as a power connector of a charging inlet assembly 100. Although the electrical connector 102 may be described herein as being part of a charging inlet assembly, it should be appreciated that the electrical connector 102 may be another type of electrical connector.

[0030] The charging inlet assembly 100 is used as a charging inlet for a vehicle such as an electric vehicle (EV) or a hybrid electric vehicle (HEV). The charging inlet assembly 100 includes an electrical connector 102 configured to be received with a charging connector (not shown). In an exemplary embodiment, the electrical connector 102 is configured to mate with a DC fast charging connector (such as an SAE combined CCS charging connector) and further mate with an AC charging connector (such as an SAE J1772 charging connector).

[0031] The charging inlet assembly 100 includes a housing 110 that retains a terminal 114 that forms part of the electrical connector 102. The terminal 114 is electrically connected to a corresponding power cable 118. The terminal 114 is configured to mate with the charging connector. The terminal 114 is received in a terminal channel 116 and is coupled to the housing 110 in the terminal channel 116. In an exemplary embodiment, the charging inlet assembly 100 includes a cooling system 130 for actively cooling the terminal 114. For example, a coolant may be pumped through a line or channel of the cooling system and flow in thermal communication with the terminal 114 to dissipate heat from the terminal 114. The cooling system 130 may additionally be used to actively cool the power cable 118 terminated to the terminal 114.

[0032] The charging inlet assembly 100 includes a mounting flange 120 coupled to the housing 110. The mounting flange 120 is used to couple the charging inlet assembly 100 to the vehicle. The mounting flange 120 includes a mounting tab 122 having an opening 124 that receives a fastener (not shown) for securing the charging inlet assembly 100 to the vehicle. Other types of mounting features may be used to secure the charging inlet assembly 100 to the vehicle. The mounting flange 120 may include a seal for sealing the charging inlet assembly 100 to the vehicle.

[0033] The charging inlet assembly 100 includes a terminal cover 126 hingedly coupled to the mounting flange 120 and / or the housing 110. The cover 126 is used to cover the corresponding terminal 114. The charging inlet assembly 100 may include a rear cover 128 coupled to the rear of the housing 110, the rear cover 128 closing the entrance to the rear of the housing 110. The power cable 118 and / or the coolant supply line 132 and the coolant return line 134 of the cooling system 130 pass through the rear cover 128 and / or the side of the housing 110.

[0034] Figure 2 2 is a side view of a terminal 114 according to an exemplary embodiment. The terminal 114 includes a mating pin 200 at a front portion 210 of the terminal 114 and a cable connector 202 at a rear portion 212 of the terminal 114. The terminal 114 extends along a longitudinal axis 204. The mating pin 200 is configured to mate with a charging connector. The cable connector 202 is configured to electrically connect to a power cable 118 (eg, Figure 1 In an exemplary embodiment, the mating pin 200 and / or the cable connector 202 are configured to be cooled by the cooling system 130 ( Figure 1 For example, the cooling system 130 is configured to be thermally coupled to the mating pin 200 and / or the cable connector 202 at the rear portion 212 of the terminal 114, and the coolant of the cooling system 130 is used to dissipate heat from the terminal 114.

[0035] In various embodiments, the cable connector 202 is separate and discrete from the mating pin 200 and is configured to be mechanically and electrically coupled to the mating pin 200. For example, the cable connector 202 can be press-fit onto the mating pin 200. However, in alternative embodiments, the cable connector 202 can be fixed to the mating pin 200 by other methods, such as friction stir welding, riveting, bolting, etc. In various other embodiments, the cable connector 202 is integral with the mating pin 200, such as being formed together with the mating pin 200. In various embodiments, the cable connector 202 is configured to terminate to the power cable 118 by welding the power cable 118 to the cable connector 202. For example, the cable connector 202 may include a welding piece. In various other embodiments, the cable connector 202 is terminated to the power cable 118 by other methods, such as crimping, welding, etc. For example, the cable connector 202 may include a crimp barrel ( Figure 3 ) or cable drum( Figure 4 ).

[0036] The mating pin 200 is conductive. For example, the mating pin 200 can be made of a metal material such as a copper material. In an exemplary embodiment, the mating pin 200 is a machined screw. The mating pin 200 can be made of a metal alloy (e.g., a copper alloy) having an additive to increase machinability. In an exemplary embodiment, the mating pin 200 is cylindrical. In an exemplary embodiment, the mating pin 200 includes a cap 216 at the end 218 of the mating pin 200. The cap 216 is made of a dielectric material such as a plastic material. The cap 216 makes the terminal 114 contact safe at the front of the housing 110.

[0037] The mating pin 200 includes a mounting head 220 for mounting the mating pin 200 in the housing 110. In the illustrated embodiment, the mounting head 220 has a diameter that is larger than the diameter of the mating pin 200. In an exemplary embodiment, the mounting head 220 includes a latch groove 222 formed circumferentially around the mounting head 220, such as near the front end of the mounting head 220. In an exemplary embodiment, the mounting head 220 includes a sealing groove 226 that accommodates a seal 228. The seal 228 can be located near the rear end of the mounting head 220. The diameter of the seal 228 can be approximately equal to or slightly larger than the diameter of the mounting head 220, so as to abut against the terminal channel 116 ( Figure 1 The interface is sealed on the inner surface of the

[0038] The cable connector 202 is at the rear of the mounting head 220. In an exemplary embodiment, the cable connector 202 includes a mounting shaft 232 extending from the mounting head 220. In the illustrated embodiment, the mounting shaft 232 is integrally formed with the mating pin 200 as a one-piece structure. For example, the mounting shaft 232 can be a machined screw together with the mating pin 200. In various other embodiments, the mounting shaft 232 can be separated and discrete from the mating pin 200 and mechanically coupled to the mating pin 200. The mounting shaft 232 includes an outer surface 234 and extends to the rear flange 230. The outer surface 234 can be cylindrical and can have a diameter similar to or the same as the mounting head 220. In an exemplary embodiment, the outer surface 234 is configured to be actively cooled by the cooling system 130 to reduce the operating temperature of the terminal 114.

[0039] The cable connector 202 extends from and / or is coupled to a mounting shaft 232 at the rear flange 230. In an exemplary embodiment, the mounting shaft 232 includes a rear mounting post 236 (shown in phantom) extending rearwardly from the rear flange 230. The cable connector 202 can be press-fitted onto the rear mounting post 236. The rear mounting post 236 can be cylindrical to allow the cable connector 202 to be rotatably positioned on the mating pin 200. However, in alternative embodiments, the rear mounting post 236 can have other shapes.

[0040] The cable connector 202 includes a cable termination end 240 at the rear portion 212 of the terminal 114. The power cable 118 is configured to be terminated to the cable termination end 240. In the illustrated embodiment, the cable connector 202 includes a weld cap 242 at the rear portion 212 that defines the cable termination end 240. The weld cap 242 is separate and discrete from the mating pin 200 and the mounting shaft 232. In an exemplary embodiment, the weld cap 242 is configured to be actively cooled by the cooling system 130 to reduce the operating temperature of the terminal 114.

[0041] The welding cap 242 includes a base 250 and a welding pad 252 extending from the base 250. In the illustrated embodiment, the welding pad 252 extends from the base 250 perpendicular to the longitudinal axis 204. However, the welding pad 252 may extend at other angles, such as parallel to the longitudinal axis 204, or at other angles, such as approximately 45° relative to the longitudinal axis 204. The welding pad 252 may be rectangular or have other shapes in alternative embodiments. The welding pad 252 may include flat parallel surfaces for welding the power cable 118 to the welding pad 252.

[0042] The base 250 is coupled to the mounting shaft 232 at the rear mounting post 236. In the illustrated embodiment, the base 250 is cylindrical and includes a rectangular pad at the top of the base 250; however, in alternative embodiments, the base 250 may have other shapes. The base 250 has an opening (not shown) that receives the rear mounting post 236. In various embodiments, the base 250 may have a diameter similar to or the same as the diameter of the mounting shaft 232 and / or the mounting head 220. In other various embodiments, the base 250 may be stepped inwardly or outwardly relative to the mounting shaft 232 and / or the mounting head 220. The base 250 includes an outer surface 254. In various embodiments, the outer surface 254 may be axially aligned with the outer surface 234 of the mounting shaft 232, as an extension of the outer surface 234 from the rear flange 230. In an exemplary embodiment, the outer surface 254 is configured to be actively cooled by the cooling system 130 to reduce the operating temperature of the terminal 114.

[0043] Figure 3 is a side view of terminal 114 according to an exemplary embodiment. Figure 3 2. A cable termination end 240 is shown including a crimp contact 244. The crimp contact 244 includes a crimp barrel 246. The crimp barrel 246 is configured to be crimped to a power cable 118 (eg, Figure 1 In an exemplary embodiment, the crimping contact 244 is separate and discrete from the mating pin 200 and is coupled to the mounting shaft 232 at the rear portion 212 of the terminal 114. The crimping contact 244 may be coupled to the welding cap 242 (eg, Figure 2 244 is coupled to the mounting shaft 232 in a similar manner as shown in FIG. 245. For example, the crimp contact 244 may include a base 250 configured to be press-fitted to the rear mounting post 236 (shown in phantom), and the crimp contact may include a pad at the top of the base 250 with the crimp barrel 246 extending from the pad.

[0044] Figure 4 is a side view of terminal 114 according to an exemplary embodiment. Figure 4 The cable termination end 240 is shown including a cable barrel 248 (shown in phantom) at the rear portion 212 of the terminal 114. The cable barrel 248 is open at the rear portion 212 along the longitudinal axis 204. The cable barrel 248 receives the power cable 118 (eg, Figure 1 The power cable 118 can be soldered or welded to the terminal 114 at the cable barrel 248. In the illustrated embodiment, the cable barrel 248 is defined by the mounting axis 232 and is integral with the mating pin 200, rather than being a separate component coupled to the rear end of the terminal 114.

[0045] Figure 5 is a cross-sectional view of a charging inlet assembly 100 according to an exemplary embodiment. Figure 5One of the terminals 114 coupled to the housing 110 is shown. The housing 110 extends to a rear portion 138, and a rear cover 128 is coupled to the housing 110 at the rear portion 138. The housing 110 has a chamber 140 at the rear portion 138. The rear cover 128 is behind the chamber 140 and closes the chamber 140. The rear cover 128 may include a cable outlet (e.g., an opening) that receives the power cable 118 and allows the power cable 118 to exit the chamber 140. The rear cover 128 may include a coolant line outlet (e.g., an opening) or port that allows the supply and return of coolant for a cooling system 130 that actively cools the terminals 114.

[0046] The terminal 114 extends into the cavity 140, and the power cable 118 is terminated to the terminal 114 in the cavity 140. The cooling system 130 interfaces with the terminal 114 in the cavity 140 to provide active cooling for the terminal 114. For example, the terminal heat exchanger 300 is positioned in the cavity 140 to interface with the terminal 114. The terminal heat exchanger 300 is thermally coupled to the terminal 114 to dissipate heat from the terminal 114 and reduce the operating temperature of the terminal 114 to improve the performance of the charging inlet assembly 100 and / or allow higher current to pass through the terminal 114 and / or reduce the risk of damaging the terminal 114.

[0047] The terminal 114 is received in the corresponding terminal channel 116. The mating pin 200 is located in the terminal channel 116 for docking with the charging connector inserted into the housing 110. The housing 110 includes a primary latch 162 extending into the terminal channel 116 to engage the terminal 114 and retain it axially in the terminal channel 116. The primary latch 162 can be a deflectable latch. The primary latch 162 can be integral with the housing 110, for example, co-molded with the housing 110. The primary latch 162 prevents the terminal 114 from being pulled back from the terminal channel 116. The mounting head 220 passes through the terminal channel 116 and engages with the housing 110 by an interference fit to tightly retain the terminal 114 in the terminal channel 116. In an exemplary embodiment, the seal 228 is sealed to the surface of the housing 110 that defines the terminal channel 116.

[0048] In an exemplary embodiment, the terminal 114 is located in the terminal passage 116 so that the cable connector 202 is located immediately behind the terminal passage 116. The cable connector 202 extends into the chamber 140 for electrical connection with the power cable 118 and thermal connection with the cooling system 130. The power cable 118 is coupled to the welding cap 242 within the chamber 140. In an exemplary embodiment, the power cable 118 is ultrasonically welded to the welding pad 252 of the welding cap 242, thereby creating a low resistance butt joint between the terminal 114 and the power cable 118. In various other embodiments, the power cable 118 can be crimped or otherwise mechanically and electrically terminated to the terminal 114. The outer surface 234 of the mounting shaft 232 is located behind the terminal passage 116 in the chamber 140. The outer surface 254 of the base 250 of the welding cap 242 is located behind the terminal passage 116 in the chamber 140. The outer surface 234 and / or the outer surface 254 are positioned in the chamber 140 for interfacing with the terminal heat exchanger 300 of the cooling system 130. In various embodiments, the terminal heat exchanger 300 can be directly thermally coupled to the outer surface 234 and / or the outer surface 254 to directly dissipate heat from the terminal 114. In other various embodiments, the terminal heat exchanger 300 can be indirectly thermally coupled to the outer surface 234 and / or the outer surface 254, such as through a thermal interface material, thermal grease, or another thermal bridge. In other various embodiments, the terminal heat exchanger 300 can be thermally coupled to other portions of the terminal 114, for example, to the solder pad 252.

[0049] The terminal heat exchanger 300 is coupled to the coolant supply line 132 and the coolant return line 134. The coolant flows through the coolant lines 132, 134 to transfer heat from the terminal heat exchanger 300. In an exemplary embodiment, the terminal heat exchanger 300 includes a flow channel 302 in fluid communication with the coolant lines 132, 134. The coolant is directed through the flow channel 302 to dissipate heat from the terminal heat exchanger 300 to cool the terminal 114. In an exemplary embodiment, the terminal heat exchanger 300 includes a manifold 304 and a heat transfer element 306. The heat transfer element 306 is coupled to the terminal 114 to be in thermal communication with the cable connector 202 of the terminal 114. The manifold 304 is coupled to the heat transfer element 306. The manifold 304 forms the flow channel 302, and the coolant in the flow channel 302 is in thermal communication with the heat transfer element 306 to dissipate heat from the heat transfer element 306 and the cable connector 202. In an exemplary embodiment, the terminal heat exchanger 300 includes an isolator 308 that electrically insulates the terminal heat exchanger 300 from the terminal 114. The isolator 308 is a thermally conductive insulator. For example, the isolator 308 can be made of a material that is electrically insulating and highly thermally conductive. The isolator 308 can be a thermally conductive epoxy, a thermoplastic, or a thermosetting material. The isolator can be made of beryllium oxide, aluminum oxide, aluminum nitride, boron nitride silicone, ceramic, Kapton, nylon, polyester, etc. The isolator 308 can be a preformed structure, such as a film, a pad, a sheet, an injection molded part, etc. In various other embodiments, the isolator 308 can be applied in situ, such as grease or paste.

[0050] In various embodiments, the cooling system 130 may include a cable heat exchanger (not shown) in addition to or in place of the terminal heat exchanger 300. The cable heat exchanger is configured to be coupled in thermal communication with the power cable 118 to dissipate heat directly from the power cable 118. The cable heat exchanger may include a manifold and heat transfer elements similar to the manifold 304 and the heat transfer elements 306. The cable heat exchanger may include an insulator similar to the insulator 308.

[0051] Figure 6 is a rear perspective and partially cutaway view of a portion of the charging inlet assembly 100 according to an exemplary embodiment, showing the terminal heat exchanger 300 coupled to the terminal 114. The terminal heat exchanger 300 is coupled to the terminal 114 in thermal communication with the cable connector 202.

[0052] Manifold 304 includes a manifold body 310 extending between an inner surface 312 and an outer surface 314. Inner surface 312 faces heat transfer element 306. Flow channel 302 ( Figure 5314 is defined by a manifold body 310 between an inner surface 312 and an outer surface 314. In the exemplary embodiment, the flow channel 302 opens at the inner surface 312 to directly thermally contact and flow along the heat transfer element 306. In the exemplary embodiment, the manifold 304 includes a manifold inlet 316 and a manifold outlet 318. The flow channel 302 extends between the manifold inlet 316 and the manifold outlet 318. The manifold inlet 316 is configured to be coupled to the coolant supply line 132 (at Figure 5 ). The manifold outlet 318 is configured to couple to the coolant return line 134 (at Figure 5 310 ). For example, the manifold inlet 316 and the manifold outlet 318 may be nozzles or fittings extending from the outer surface 314 of the manifold body 310. The coolant supply line 132 and the coolant return line 134 may be hoses configured to be mounted on the manifold inlet 316 and the manifold outlet 318, respectively. A clamp may be used to secure the hoses in place. Other types of fluid connections may be established between the coolant supply line 132 and the coolant return line 134 and the manifold 304. In the illustrated embodiment, the manifold 304 is used to cool a plurality of terminals 114. In alternative embodiments, each terminal 114 may include a separate terminal heat exchanger 300 and / or manifold 304.

[0053] In one exemplary embodiment, the heat transfer element 306 includes a clip 320 (also located on the cable connector 202) coupled to the terminal 114. Figure 8 304 is coupled to the clip 320. In various embodiments, the manifold 304 can be latchably coupled to the clip 320. In other various embodiments, the manifold 304 can be coupled to the clip 320 using fasteners or other fixing devices. In an exemplary embodiment, a seal 358 ( Fig. 9 ), to prevent coolant from leaking from the flow channel 302 .

[0054] The clip 320 includes a first clip arm 322 having a first hole 324 for receiving one of the cable connectors 202. The clip 320 includes a second clip arm 326 having a second hole 328 for receiving another of the cable connectors 202. The clip 320 is made of a thermally conductive material, such as a metal material or a thermally conductive plastic material. The clip 320 is made of a material having a high convective heat transfer coefficient to transfer heat from the terminal 114 to the coolant flowing through the flow channel 302.

[0055] The clamp arms 322, 326 extend at least partially circumferentially around the cable connector 202. The clamp arms 322, 326 are used to mechanically secure the clip 320 to the terminal 114. In an exemplary embodiment, the clamp arms 322, 326 are thermally coupled to the cable connector 202 to dissipate heat from the cable connector 202. Each of the clamp arms 322, 326 has a large surface area that is in thermal contact with the corresponding cable connector 202. In an exemplary embodiment, the clamp arms 322, 326 are separated from the base 330 of the clip 320 so that each clamp arm 322, 326 has a fixed end and a free end. The clamp arms 322, 326 can be spread apart to load the cable connector 202 into the first hole 324 and the second hole 328. The clamp arms 322, 326 can snap or clip onto the cable connector 202 to physically couple the clip 320 to the cable connector 202. In an exemplary embodiment, the clamp arms 322, 326 are compressed against the cable connector 202 and / or the spacer 308 positioned between the cable connector 202 and the clamp arms 322, 326. In an exemplary embodiment, the fasteners 332 are used to secure and / or fasten the clamp arms 322, 326 against the spacer 308 and the cable connector 202. For example, the fasteners 332 may be threaded fasteners that are threadedly coupled to the base 330 and tightened to compress the clamp arms 322, 326 against the spacer 308 and the cable connector 202.

[0056] The spacer 308 is coupled to the cable connector 202, such as to the outer surface 254, and may be coupled to the outer surface 234 of the mounting shaft 232 (both at Figure 2 306). The spacer 308 is located between the cable connector 202 and the clip 320 of the heat transfer element 306. The spacer 308 forms a thermal bridge between the cable connector 202 and the clip 320 of the heat transfer element 306. The spacer 308 electrically insulates the terminal 114 from the heat transfer element 306. In an exemplary embodiment, the spacer 308 includes a ring 338 having an opening that receives the cable connector 202 corresponding to the terminal 114. In the illustrated embodiment, the ring 338 extends around the cable connector 202 along the entire circumference.

[0057] In the illustrated embodiment, the isolator 308 includes a film 340 wrapped around the terminal 114. The film 340 includes an adhesive layer 342 and an insulating layer 344. The insulating layer 344 is an electrical insulator. The insulating layer 344 is thermally conductive. In an exemplary embodiment, the insulating layer 344 is a thermally conductive thermoplastic sheet. In alternative embodiments, other types of isolators 308 may be provided. In various alternative embodiments, the isolator 308 may be an insert molded around the terminal 114, rather than a film wrapped around the terminal 114.

[0058] Figure 73 is a bottom perspective view of a manifold 304 of a terminal heat exchanger 300 according to an exemplary embodiment. A flow channel 302 is defined by the manifold 304 and opens at an inner surface 312 of a manifold body 310. In the exemplary embodiment, the flow channel 302 is defined by a dividing wall 350 that forms a serpentine path at the inner surface 312 defining the flow channel 302. The flow channel 302 extends from a manifold inlet 316 to a manifold outlet 318. The thickness of the dividing wall 350 controls the height of the flow channel 302, which controls the volume of coolant flowing through the manifold 304.

[0059] In the exemplary embodiment, manifold 304 includes a sealing recess 352 that is configured to receive a gasket, O-ring, or other type of seal (not shown) to seat against heat transfer element 306 ( Figure 6 ) for sealing.

[0060] In alternative embodiments, the manifold 304 may have other shapes or sizes. The manifold 304 may include a securing feature (not shown) for securing the manifold 304 to the heat transfer element 306. For example, the manifold 304 may include a latch, a fastener, or another type of securing feature.

[0061] Figure 8 is a cross-sectional view of a heat transfer element according to an exemplary embodiment. Figure 8 A fastener 332 is shown coupled to the clip 320. The cable connector 202 is shown in the first hole 324 and the second hole 328. The fastener 332 is configured to engage the clamp arms 322, 326 to tighten and compress the clamp arms 322, 326 around the spacer 308 and the cable connector 202. For example, a nut 334 coupled to the fastener 332 can be tightened to engage and compress the clamp arms 322, 326 against the spacer 308 and the cable connector 202. The clamp arms 322, 326 are compressed into thermal engagement with the spacer 308 to provide efficient heat transfer from the cable connector 202 to the clip 320. Figure 8 Isolator 308 is shown including adhesive layer 342 and insulating layer 344 of film 340. In alternative embodiments, separator 308 may include other layers. In other various embodiments, separator 308 may include a single layer.

[0062] Fig. 9 is a cross-sectional view of a terminal heat exchanger 300 according to an exemplary embodiment. Fig. 9 Manifold 304 is shown mounted to heat transfer element 306. Manifold 304 is coupled to base 330 of clip 320. Flow channel 302 is located above heat transfer surface 336 of base 330. Coolant is configured to flow along heat transfer surface 336 to extract heat from heat transfer element 306 to reduce the temperature of heat transfer element 306, and thus reduce the temperature of terminal 114.

[0063] In the exemplary embodiment, the manifold 304 includes a fixing element 354 for fixing the manifold 304 to the clip 320. In the illustrated embodiment, the fixing element 354 includes a latch 356 that is latchably coupled to the base 330 of the clip 320. A seal 358 is provided at an interface between the manifold 304 and the heat transfer element 306. The seal 358 seals the joint of the manifold 304 and the heat transfer element 306 to prevent coolant from leaking from the flow channel 302. When the fixing element 354 is fixed to the heat transfer element 306, the seal 358 can be compressed.

[0064] Fig.10 is a cross-sectional view of a terminal heat exchanger 300 according to an exemplary embodiment. Fig.10 Manifold 304 is shown mounted to heat transfer element 306, with flow channel 302 extending from manifold inlet 316 to manifold outlet 318. In the illustrated embodiment, fixing element 354 includes fasteners 360, such as threaded fasteners, coupled to manifold 304 and base 330 of clip 320. Fastener 360 passes through hole 362 in manifold 304. Hole 362 may be defined by one or more partition walls 350. In the exemplary embodiment, seal 364 is disposed around hole 362 to prevent coolant from leaking from flow channel 302.

[0065] Fig.11 is a cross-sectional view of a terminal heat exchanger 300 according to an exemplary embodiment. Fig.11 A spacer 308 is shown positioned between the heat transfer element 306 and the coolant in the flow channel 302. In the illustrated embodiment, the spacer 308 includes a film 346 extending along the heat transfer surface 336 of the base 330 of the clip 320. The film 346 can be used in addition to or in place of a spacer between the clip 320 and the cable connector 202. The film 346 electrically insulates the clip 320 from the coolant in the flow channel 302. In an exemplary embodiment, the film 346 is thermally conductive, thereby providing efficient heat transfer between the base 330 and the coolant in the flow channel 302.

[0066] Fig.12 is a cross-sectional view of a portion of the charging inlet assembly 100 according to an exemplary embodiment showing the cooling system 130 interfaced with the terminal heat exchanger 300. In the illustrated embodiment, the coolant supply line 132 and the coolant return line 134 are integral with the rear cover 128, rather than separate hoses passing through the rear cover 128, which is separately coupled to the manifold 304.

[0067] The coolant supply line 132 is defined by a supply port 133, and the coolant return line 134 is defined by a return port 135 of the rear cover 128. The supply port 133 and the return port 135 are integral with the rear cover 128, such as molded together with the rear cover 128. The supply port 133 is coupled to the manifold inlet 316 with a sealed interface. The return port 135 is coupled to the manifold outlet 318 at a sealed interface. In an exemplary embodiment, when the rear cover 128 is installed and coupled to the housing 110 (such as Figure 5 ), the supply port 133 and the return port 135 are coupled to the manifold 304. Hoses or other coolant lines may be coupled to the supply port 133 and the return port 135 from the exterior of the rear cover 128.

[0068] Fig.13 is a cross-sectional view of a portion of the charging inlet assembly 100 according to an exemplary embodiment, showing the cooling system 130 docked with the terminal heat exchanger 300. In the illustrated embodiment, the manifold 304 is integral with the rear cover 128. The rear cover 128 includes a manifold body 310, a manifold inlet 316, and a manifold outlet 318. The rear cover 128 is directly coupled to the heat transfer element 306. The rear cover 128 forms a flow channel 302 along a heat transfer surface 336 of the clip 320. A seal 358 is disposed between the rear cover 128 and the clip 320 to seal the flow channel 302.

[0069] Fig.14 is a rear perspective view of a portion of the charging inlet assembly 100 according to an exemplary embodiment, showing the terminal heat exchanger 300 coupled to the terminal 114, and showing various embodiments of the spacer 308. In the illustrated embodiment, the spacer 308 includes a first spacer 370 and a second spacer 372. In other embodiments, the spacer 308 may include the first spacer 370 in both holes 324, 328 or the second spacer 372 in both holes 324, 328.

[0070] The first spacer 370 includes a split ring 374 having a slot 376 extending longitudinally along the split ring 374. In an exemplary embodiment, the split ring 374 is a preformed component, such as a molded component, having an annular shape. The split ring 374 can be clamped onto the cable connector 202. In an exemplary embodiment, when the clamp 320 is tightened around the first spacer 370, the split ring 374 can be compressed around the cable connector 202.

[0071] The second spacer 372 includes a split ring 378 having a gap 380 extending longitudinally along the split ring 378. The split ring 378 includes flanges 382, ​​384 at opposite ends of the split ring 378. The flanges 382, ​​384 are opposed to each other across the area of ​​the gap 380, and the clamp 320 is configured to engage with the flanges 382, ​​384 to compress the second spacer 372 around the cable connector 202 when the clamp 320 is tightened around the second spacer 372.

[0072] Fig.15 1 is a rear view of a terminal heat exchanger 300 according to an exemplary embodiment. In the illustrated embodiment, the clip 320 includes a solid body 390 forming a first hole 324 and a second hole 328. The clip arms 322, 326 are fixed relative to each other and the terminal 114, rather than being compressible. In the exemplary embodiment, the body 390 is an extruded body.

[0073] In an exemplary embodiment, the spacer 308 is formed in an appropriate position between the body 390 of the clip 320 and the terminal 114. The spacer 308 includes a spacer body 394, which forms a thermal bridge between the terminal 114 and the clip 320. For example, the spacer body 394 of the spacer 308 can be injection molded into the first hole 324 and the second hole 328 to fill the space between the outer surface 254 of the cable connector 202 and the inner surface 392 of the holes 324, 328. The spacer body 394 is formed in an appropriate position between the terminal 114 and the clip 320 to completely fill the space between the cable connector 202 and the clip 320 to perform an effective thermal bridge between the cable connector 202 and the clip 320.

[0074] Fig.16 is a side view of one of the terminals 114 according to an exemplary embodiment, showing a corresponding spacer 308 disposed at a rear end of the terminal 114. The spacer 308 is coupled to the outer surface 254 of the cable connector 202 and the outer surface 234 of the mounting shaft 232. In the exemplary embodiment, the spacer 308 includes a ring 400 having a plurality of radial fins 402 separated by fin channels 404. The ring 400 is configured to be in direct thermal contact with a coolant of a cooling system. For example, the coolant flows within the fin channels 404 between the radial fins 402.

[0075] Fig.17 is a cross-sectional view of a portion of a charging inlet assembly 100 according to an exemplary embodiment, showing a cooling system 130 including Fig.17The ring 400 is shown interfacing with the terminal heat exchanger 300. The terminal heat exchanger 300 includes flow channels 302 that allow coolant to flow through the ring 400 of the spacer 308. The flow channels 302 extend through the terminals 114 to allow coolant to flow through the fin channels 404 across the radial fins 402 of the ring 400. In the embodiment shown, the flow channels 302 have an inlet side across one of the terminals 114 and a return side across another of the terminals 114. In alternative embodiments, other arrangements of the flow channels 302 are possible, such as parallel flow rather than series flow.

[0076] Fig.18 is a rear perspective and partially cutaway view of a portion of a charging inlet assembly 100 according to an exemplary embodiment showing a cooling system 130 including Fig.16 The ring shown interfaces with the terminal heat exchanger 300. The terminal heat exchanger 300 includes a flow channel 302 that allows coolant to flow through the ring 400 of the isolator 308. The flow channel 302 extends through the terminal 114 to allow coolant to flow through the fin channels 404 across the radial fins 402 of the ring 400. In the illustrated embodiment, the heat transfer element 306 includes a supply channel 406 and a return channel 408 formed in the heat transfer element 306. The coolant flows from the supply channel 406 to the return channel 408 across the ring 400 of the isolator 308.

[0077] Fig.19 is a rear perspective view of a portion of the charging inlet assembly 100 showing the terminal heat exchanger 300 coupled to one of the terminals 114 . Fig. 20 yes Fig.19 A rear perspective and partially cut-away exploded view of a portion of the charging inlet assembly 100 shown in , showing a terminal heat exchanger 300 coupled to one of the terminals 114. In the illustrated embodiment, the terminal heat exchanger 300 is coupled to the welding pad 252 of the cable connector 202, rather than to the base 250. The terminal heat exchanger 300 is used to dissipate heat directly from the welding pad 252, rather than directly from the base 250. The welding pad 252 provides a large surface area for heat transfer. The welding pad 252 provides a flat surface for mechanically and thermally coupling the terminal heat exchanger 300 to the terminal 114. In an exemplary embodiment, the terminal heat exchanger 300 is coupled to the welding pad 252 using a fastener 420.

[0078] The terminal heat exchanger 300 includes a flow channel 422 ( Fig. 20). The terminal heat exchanger 300 includes a heat transfer element 426 and a spacer 428 between the heat transfer element 426 and the flow channel 422 of the manifold 424. In an exemplary embodiment, the heat transfer element 426 is a thermal pad 430 coupled to the solder pad 252. For example, the thermal pad 430 can be a metal sheet or plate. In alternative embodiments, the thermal pad 430 can be a film or thermal grease. In various other embodiments, the solder pad 252 defines the heat transfer element 426, rather than having a separate heat transfer element 426 disposed on the outer surface of the solder pad 252.

[0079] The spacer 428 electrically insulates the heat transfer element 426 from the coolant in the flow channel 422. The spacer 428 is a thermally conductive insulator. For example, the spacer 428 can be made of a material that is electrically insulating and highly thermally conductive. The spacer 428 can be a thermally conductive epoxy, a thermoplastic material, or a thermosetting material. The spacer 428 can be a preformed structure, such as a film, a pad, a sheet, an injection molded part, etc. In various other embodiments, the spacer 428 can be applied in situ, such as a grease or paste.

[0080] The spacer 428 includes an inner surface 432 and an outer surface 434. The inner surface 432 faces and abuts against the thermal pad 430. The inner surface 432 is in direct physical contact with the thermal pad 430 to ensure effective heat transfer between the thermal pad 430 and the spacer 428. The outer surface 434 faces the flow channel 422. The outer surface defines a heat transfer surface of the spacer 428. The coolant flows along the outer surface 434 to dissipate heat from the spacer 428, thereby dissipating heat from the thermal pad 430 and the welding pad 252. In an exemplary embodiment, the manifold 424 includes a positioning feature 436 extending into the flow channel 422 to engage the spacer 428. The positioning feature 436 presses against the spacer 428 to keep the spacer 428 in direct physical contact with the thermal pad 430 to ensure effective heat transfer between the coolant and the thermal pad 430. The positioning feature 436 prevents the spacer 428 from warping or bending. The positioning feature 436 presses the spacer 428 against the thermal pad 430. The positioning feature 436 can be a post extending into the flow channel 422 so that the coolant is allowed to flow around the post. In other various embodiments, the positioning feature 436 forms a dividing wall that defines a predetermined flow channel 422 through the manifold 424 between the manifold inlet 440 and the manifold outlet 442, such as defining a serpentine path through the manifold 424.

[0081] Fig.21 is a schematic diagram of a cooling system 300 according to an exemplary embodiment. Fig.21A coolant passage 450 is shown between the coolant supply line 132 and the coolant return line 134. The cooling system 130 includes a bypass passage 452 having an exit portion 454 and a return portion 456 relative to the coolant passage 450. The terminal heat exchanger 300 is in fluid communication with the bypass passage 452. The coolant flowing through the bypass passage 452 flows through the flow passage 302 of the terminal heat exchanger 300.

[0082] In an exemplary embodiment, the cooling system 130 includes a venturi 460 in the coolant passage 450. In various embodiments, the cooling system 130 can use a high volume, low pressure (HVLP) coolant flow to cool the terminal 114. The venturi 460 is provided to increase the pressure through the terminal heat exchanger 300. The venturi 460 includes a converging nozzle 462 for reducing the flow area at the cavity contraction of the venturi 460 and a diverging nozzle 464 for increasing the flow area downstream of the venturi 460. The pressure differential generated by the venturi 460 improves the flow through the terminal heat exchanger 300. The inlet of the terminal heat exchanger 300 is connected to the inlet of the venturi 460 (e.g., the coolant supply line 132) at a pressure P1. The outlet of the terminal heat exchanger 300 is connected to the cavity contraction of the venturi 460 at the lowest pressure point at a pressure P2. The pressure differential ( P1 − P2 ) created by the venturi 460 causes the flow rate through the terminal heat exchanger 300 to increase.

[0083] Fig. 22 is a schematic diagram of a cooling system 300 according to an exemplary embodiment. Fig. 22A coolant passage 470 is shown between the coolant supply line 132 and the coolant return line 134. In an exemplary embodiment, the coolant passage 470 supplies a coolant flow to cool the terminal 114, and also supplies a coolant to cool the power cable 118. For example, the cooling system 130 includes a bypass passage 472 for the terminal heat exchanger 300, the bypass passage 472 having an exit portion 474 and a return portion 476 relative to the coolant passage 470. The terminal heat exchanger 300 is in fluid communication with the bypass passage 472. The coolant flowing through the bypass passage 472 flows through the flow channel 302 of the terminal heat exchanger 300. In an exemplary embodiment, the cooling system 130 also includes a cable heat exchanger 480 for cooling the power cable 118. The cable heat exchanger 480 is in direct thermal contact with the power cable 118. The cable heat exchanger 480 includes a flow channel 482 defined by a manifold 484, and the flow channel 482 receives the power cable 118. Manifold 484 may be separate from manifold 304, or alternatively, manifolds 484 and 304 may be integrated as a single unitary manifold. Flow channel 482 extends between inlet 486 and outlet 488. In an exemplary embodiment, an isolator 489 is disposed between power cable 118 and the coolant in flow channel 482. Isolator 489 electrically insulates power cable 118 from the coolant. Isolator 489 is highly thermally conductive to provide efficient heat transfer between power cable 118 and the coolant.

[0084] In an exemplary embodiment, the cooling system 130 includes a venturi 490 in the coolant passage 470, such as in the manifold 484; however, the venturi 490 may be provided separately from the manifold 484. In various embodiments, the cooling system 130 may use a high volume, low pressure (HVLP) coolant flow to cool the terminals 114 and the power cables 118. The venturi 490 is provided to increase the pressure through the terminal heat exchanger 300 and the cable heat exchanger 480. The venturi 490 includes a converging nozzle 492 for reducing the flow area at the cavity contraction of the venturi 490 and a diverging nozzle 494 for increasing the flow area downstream of the venturi 490. The pressure differential created by the venturi 490 improves the flow through the terminal heat exchanger 300 and the cable heat exchanger 480. In an exemplary embodiment, the inlet of the terminal heat exchanger 300 is connected to the inlet of the venturi 490 (e.g., the coolant supply line 132) at a pressure P1. The outlet of the terminal heat exchanger 300 is connected to the cavity contraction of the venturi tube 490 at the lowest pressure point at pressure P2. The pressure differential (P1-P2) generated by the venturi tube 490 causes the flow rate through the terminal heat exchanger 300 to increase.

Claims

1. An electrical connector, comprising: a housing extending between a front portion and a rear portion, the housing having a cavity at the rear portion, the housing having a terminal passage between the front portion and the rear portion; a terminal coupled to the housing, the terminal including a mating pin at a front portion of the terminal and a cable connector at a rear portion of the terminal, the mating pin being positioned in a terminal channel for mating with a charging connector, the cable connector being positioned within the cavity at the rear portion of the housing; and a terminal heat exchanger located in the chamber, the terminal heat exchanger including a heat transfer element thermally coupled to the cable connector of the terminal, the terminal heat exchanger including an insulator electrically insulating the heat transfer exchanger from the terminal, the terminal heat exchanger including a manifold having a flow channel for coolant to flow through the manifold, the flow channel providing the coolant in thermal communication with the heat transfer element.

2. The electrical connector according to claim 1 further includes a cable heat exchanger located in the chamber, the cable heat exchanger is thermally connected to the power cable terminated to the cable connector, the cable heat exchanger includes a second flow channel for coolant to flow through the cable heat exchanger to actively cool the power cable, and the flow channel is flow-connected to the second flow channel.

3. The electrical connector according to claim 1 further includes a cooling assembly, the cooling assembly including a coolant channel between a coolant supply line and a coolant return line, the coolant channel being in fluid communication with the terminal heat exchanger, the cooling assembly including a venturi tube for controlling a coolant flow pressure and controlling a coolant flow rate through the cooling assembly and the terminal heat exchanger.

4. The electrical connector of claim 3, further comprising a cable heat exchanger located in the chamber, the cable heat exchanger being thermally coupled to a power cable terminated to the cable connector, the cable heat exchanger comprising a flow channel in fluid communication with the venturi tube.

5. The electrical connector according to claim 1, wherein: The terminal is a first terminal, and the electrical connector also includes a second terminal connected to the shell, the second terminal includes a mating pin located at the front of the second terminal and a cable connector located at the rear of the second terminal, the cable connector of the second terminal is located in a cavity at the rear of the shell, and the terminal heat exchanger is thermally connected to the cable connector of the second terminal.

6. The electrical connector according to claim 1, wherein: The spacer (308) is a ring (338) having an opening that receives the cable connector (202) of the terminal (114).

7. The electrical connector according to claim 6, wherein: The ring is open at the slot and the ring is compressibly seated against the cable connector.

8. The electrical connector according to claim 6, wherein: The ring includes radial fins separated by fin channels, and the terminal heat exchanger includes flow channels for coolant to flow through the terminal heat exchanger, the flow channels being in flow communication with the fin channels to allow coolant to flow through the ring.

9. An electrical connector, comprising: a housing extending between a front portion and a rear portion, the housing having a cavity at the rear portion, the housing having a terminal passage between the front portion and the rear portion; a terminal coupled to the housing, the terminal comprising a mating pin at a front portion of the terminal and a cable connector at a rear portion of the terminal, the mating pin being located in the terminal channel for mating with the charging connector, the cable connector being located in a cavity at the rear portion of the housing, the cable connector comprising a welding tab having a surface configured to be welded to a power cable; and A terminal heat exchanger is located in the chamber, the terminal heat exchanger is thermally coupled to the welding piece of the cable connector, the terminal heat exchanger includes a manifold, the manifold has a flow channel for coolant to flow through the manifold, and the terminal heat exchanger has an isolation piece between the welding piece and the flow channel for electrically insulating the welding piece from the coolant in the flow channel.

10. The electrical connector according to claim 9 further includes a cooling assembly, the cooling assembly including a coolant channel between a coolant supply line and a coolant return line, the coolant channel being in fluid communication with the terminal heat exchanger, the cooling assembly including a venturi tube for controlling a coolant flow pressure and controlling a coolant flow rate through the cooling assembly and the terminal heat exchanger.

11. The electrical connector of claim 10, further comprising a cable heat exchanger located in the chamber, the cable heat exchanger being thermally coupled to a power cable terminated to the cable connector, the cable heat exchanger comprising a flow channel in fluid communication with the venturi tube.

12. The electrical connector according to claim 1, wherein: The terminal is a first terminal, and the electrical connector also includes a second terminal connected to the shell, the second terminal includes a mating pin located at the front of the second terminal and a cable connector located at the rear of the second terminal, the cable connector of the second terminal is located in a cavity at the rear of the shell, and the terminal heat exchanger is thermally connected to the cable connector of the second terminal.

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