Cable heat exchanger for power connector

Abstract

A power connector (102) includes a housing (110) having a terminal channel (116) that holds a terminal (114). The terminal includes a mating pin at a front portion (210) of the terminal and a cable connector at a rear portion (212, 316) of the terminal. A mating pin (200) is positioned in the terminal channel for mating with the charging connector. The power connector includes a power cable (118) including a conductor terminated to a cable connector (202) at a rear of a terminal. The power connector includes a cable heat exchanger (300) thermally coupled to a conductor of the power cable. The cable heat exchanger includes coolant channels (302) for flowing coolant through the cable heat exchanger to actively cool conductors of the power supply cable. The thermally conductive isolator electrically insulates the cable heat exchanger from a conductor (180) of the power cable.

Description

[0001] This application is a divisional application of the invention patent application with application date of March 26, 2020, application number 202010221862.2, and invention name “Cable heat exchanger for power connector”. Technical Field

[0002] The subject matter herein relates generally to heat exchangers for power 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, a power 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 power cables experience increased temperatures, which may damage components of the charging inlet assembly.

[0004] The technical problem to be solved by the present invention is to provide a cooling system for cooling a power connector, the power connector being used for a charging inlet assembly, for example. Summary of the invention

[0005] The above technical problems are solved by a power connector, which includes a shell extending between a front and a rear, and has a chamber and a terminal channel between the front and the rear of the shell. The power connector includes a terminal connected to the shell, the terminal including 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 the charging connector. The cable connector is positioned in the chamber at the rear of the shell. The power connector includes a power cable, which includes a conductor terminated to the cable connector at the rear of the terminal. The power connector includes a cable heat exchanger positioned in the chamber, which is thermally connected to the conductor of the power cable. The cable heat exchanger includes a coolant channel for flowing a coolant through the cable heat exchanger to actively cool the conductor of the power cable. The thermally conductive isolator electrically insulates the cable heat exchanger from the conductor of the power cable.

[0006] The above technical problem is also solved by a power connector, which includes: a shell extending between a front and a rear, the shell having a chamber at the rear, the shell having a terminal channel between the front and the rear; a terminal connected to the shell, the terminal including a mating pin at the front of the terminal and a cable connector at the rear of the terminal, the mating pin being positioned in the terminal channel for mating with a charging connector, the cable connector being positioned in the chamber at the rear of the shell; a power cable terminated to the cable connector at the rear of the terminal, the power cable including a conductor; and a cable heat exchanger located in the chamber, the cable heat exchanger being thermally coupled to the conductor of the power cable, the cable heat exchanger including a coolant channel for flowing a coolant through the cable heat exchanger, thereby actively cooling the conductor of the power cable; and a second terminal and a second power cable terminated to the second terminal, the cable heat exchanger being thermally coupled to the conductor of the second power cable, the coolant channel flowing adjacent to the power cable and the second power cable for actively cooling the conductor of the power cable and the conductor of the second power cable.

[0007] The above technical problem is also solved by a power connector, which includes: a shell extending between a front and a rear, the shell having a chamber at the rear, the shell having a terminal channel between the front and the rear; a terminal connected to the shell, the terminal including a mating pin at the front of the terminal and a cable connector at the rear of the terminal, the mating pin being positioned in the terminal channel for mating with a charging connector, the cable connector being positioned in the chamber at the rear of the shell; a power cable terminated to the cable connector at the rear of the terminal, the power cable including a conductor; and a cable heat exchanger located in the chamber, the cable heat exchanger a cooling assembly comprising a cooling adapter coupled to a housing of a charging inlet assembly, the cooling adapter comprising an adapter body forming a cavity, the adapter body having a cable outlet for a power cable of the charging inlet assembly, the cooling adapter comprising a supply port and a return port, a coolant supply line coupled to the supply port, and a coolant return line coupled to the return port, wherein the supply port is coupled to an inlet of the coolant channel, and the return port is coupled to an outlet of the coolant channel. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The present invention will now be described by way of example with reference to the accompanying drawings:

[0009] Figure 1 is a front perspective view of a power connector of a charging inlet assembly with a cooling system according to an exemplary embodiment.

[0010] Figure 2 is a rear perspective view of a charging inlet assembly and cooling system according to an exemplary embodiment.

[0011] Figure 3 is a side view of a terminal of a power connector according to an exemplary embodiment.

[0012] Figure 4 is a cross-sectional view of a charging inlet assembly according to an exemplary embodiment.

[0013] Figure 5 is a partial cross-sectional view of a portion of a charging inlet assembly according to an exemplary embodiment.

[0014] Figure 6 is a partial cross-sectional view of a portion of a charging inlet assembly showing a cooling adapter and a cable heat exchanger of a cooling system according to an exemplary embodiment.

[0015] Figure 7 is a partial cross-sectional view of a portion of a charging inlet assembly showing a cooling adapter and a cable heat exchanger according to an exemplary embodiment.

[0016] Figure 8 is a cross-sectional view of a cable heat exchanger according to an exemplary embodiment.

[0017] Fig. 9 is a cross-sectional view of a cable heat exchanger according to an exemplary embodiment.

[0018] Fig.10 is a cross-sectional view of a cable heat exchanger according to an exemplary embodiment. DETAILED DESCRIPTION

[0019] Figure 1 is a front perspective view of the power connector 102 of the charging inlet assembly 100 having a cooling system 130 for cooling components of the power connector 102 . Figure 2 is a rear perspective view of the charging inlet assembly 100 and the cooling system 130 according to an exemplary embodiment. Although the power connector 102 may be described herein as being part of a charging inlet assembly, it should be appreciated that the power connector 102 may be another type of electrical connector.

[0020] 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 a power connector 102 configured to be received with a charging connector (not shown). In an exemplary embodiment, the power 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).

[0021] The charging inlet assembly 100 includes a housing 110 that holds a terminal 114 that forms part of the power 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 power cable 118 to cool the terminal 114. For example, a coolant may be pumped through a line or channel of the cooling system 130 and flow in thermal communication with the power cable 118 to dissipate heat from the power cable 118, which further dissipates heat from the terminal 114. For example, the power cable 118 is electrically and thermally coupled to the terminal 114. The power cable can be used to absorb and dissipate heat from the terminal using the cooling system 130.

[0022] 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.

[0023] The charging inlet assembly 100 includes a terminal cover 126 ( Figure 1 The terminal cover 126 is used to cover the corresponding terminal 114. The housing 110 includes a rear cover 128 ( Figure 2 ), a rear cover 128 closes access to the rear of the housing 110. The rear cover 128 can be clamped to the main portion of the housing 110, for example, using clips or latches. In alternative embodiments, other types of fixing features, such as fasteners, can be used.

[0024] In an exemplary embodiment, the cooling system 130 includes a cooling adapter 131 ( Figure 2), which is connected to the rear cover 128, for example. Seals can be provided at interfaces between the cooling adapter 131 and the main body of the housing 110 and / or between portions of the cooling adapter 131. For example, the cooling adapter 131 can be a multi-piece adapter. The cooling adapter 131 includes an adapter body 133 that forms a cavity 135. The adapter body 133 forms a portion of the housing 110 to surround a rear chamber of the housing 110. The cavity 135 leads to the rear chamber of the housing 110. The cooling components of the cooling system 130 are thermally coupled to the power cable 118 in the cavity 135 and / or the rear chamber of the housing 110. The adapter body 133 includes a cable outlet 137 for the power cable 118. The cooling adapter 131 includes a supply port 138 and a return port 139 (at Figure 5 13). The coolant supply line 132 is coupled to the supply port 138. The coolant return line 134 is coupled to the return port 139. In the illustrated embodiment, the supply port 138 and the return port 139 are arranged on opposite sides of the adapter body 133; however, the ports 138, 139 may be in other locations. In an alternative embodiment, the supply port 138 and / or the return port 139 may be located at the rear of the adapter body 133, such as adjacent to the cable outlet 137, so that the coolant supply line 132 and the coolant return line 134 extend from the rear (e.g., parallel to the power cable 118).

[0025] Figure 3 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 2 In an exemplary embodiment, the mating pin 200 and / or the cable connector 202 are configured to be cooled by using a cooling system 130 (eg, Figure 2 As shown, the temperature of the power cable 118 is reduced and the power cable 118 is cooled.

[0026] 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 welding, riveting, bolting, etc. In various other embodiments, the cable connector 202 is integral with the mating pin 200, such as formed 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 tab. 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 configured to terminate to the power cable 118.

[0027] The mating pin 200 is electrically conductive. For example, the mating pin 200 may 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 may 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, a seal 228 is coupled to the mating pin 200 near the rear end of the mating pin 200 for abutting against the terminal channel 116 ( Figure 1 The interface is sealed on the inner surface of the device (as shown).

[0028] The cable connector 202 extends from and / or is coupled to the rear end of the mating pin 200. The cable connector 202 can be press-fitted onto the mating pin 200. 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 welding pad 242 at the rear portion 212, which defines the cable termination end 240. The welding pad 242 can be rectangular or have other shapes in alternative embodiments. The welding pad 242 may include a flat parallel surface for welding the power cable 118 to the welding pad 242. In an alternative embodiment, the cable termination end 240 may include a crimp barrel (not shown) instead of the welding pad 242.

[0029] Figure 4 is a cross-sectional view of a charging inlet assembly 100 according to an exemplary embodiment. Figure 4One of the terminals 114 coupled to the housing 110 is shown. The housing 110 has a chamber 140 located at the rear of the housing. A rear cover 128 is behind 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 power cable 118 and the terminals 114.

[0030] 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 power cable 118 in the cavity 140 to provide active cooling for the power cable 118 and the terminal 114. For example, the cooling system 130 includes a cable heat exchanger 300, which is positioned in the cavity 140 to interface with the power cable 118. The cable heat exchanger 300 is thermally coupled to the power cable 118 to dissipate heat from the power cable 118, and thereby dissipate heat from the terminal 114. The cooling system 130 reduces the operating temperature of the terminal 114 to improve the performance of the charging inlet assembly 100 and / or allow higher currents to pass through the terminal 114 and / or reduce the risk of damaging the terminal 114.

[0031] 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 backward from 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.

[0032] In an exemplary embodiment, the terminal 114 is located in the terminal channel 116 so that the cable connector 202 is located immediately behind the terminal channel 116. The cable connector 202 extends into the chamber 140 for electrical connection with the power cable 118 and thermal connection with the power cable 118. The power cable 118 is coupled to the welding pad 242 within the chamber 140. In an exemplary embodiment, the power cable 118 is ultrasonically welded to the welding pad 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 cooling system 130 is thermally coupled to the power cable 118 immediately behind the cable connector 202 to define a small connection between the cooling system 130 and the power cable 118. In various embodiments, the cable heat exchanger 300 can be directly thermally coupled to the outer surface of the power cable 118. In other various embodiments, the cable heat exchanger 300 may be indirectly thermally coupled to the outer surface of the power cable 118 , such as through a thermal interface material, thermal grease, or another thermal bridge.

[0033] Figure 5 is a partial cross-sectional view of a portion of a charging inlet assembly 100 according to an exemplary embodiment. Figure 5 A pair of power cables 118 terminated to a pair of terminals 114 are shown. Figure 5 1 shows a cooling adapter 131, which shows a cable heat exchanger 300 in a cavity 135 of an adapter body 133 thermally coupled to a power cable 118 in the cavity 135. The cooling adapter 131 may include one or more interface seals 136 for interfacing with the housing 110 ( Figure 2 The cable heat exchanger 300 is connected to the supply port 138 and the return port 139 to connect the cable heat exchanger 300 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 cable heat exchanger 300.

[0034] Figure 6 is a partial cross-sectional view of a portion of charging inlet assembly 100 according to an exemplary embodiment, illustrating cooling adapter 131 and cable heat exchanger 300 . Figure 7 is a partial cross-sectional view of a portion of charging inlet assembly 100 according to an exemplary embodiment, illustrating cooling adapter 131 and cable heat exchanger 300 .

[0035] The power cables 118 extend into the cooling adapter 131 to be terminated to the terminals 114. Each power cable 118 includes a conductor 180 and a jacket 182 surrounding the conductor 180. The conductor 180 is terminated to the welding pad 242 of the cable connector 202. The conductor 180 can be a stranded conductor or a solid conductor 180. At the termination end 184 of the power cable 118, a portion of the jacket 182 is removed to expose the conductor 180 for termination to the terminal 114. In an exemplary embodiment, the cable heat exchanger 300 is coupled to the exposed portion of the conductor 180 of the power cable 118 (e.g., in front of the end of the jacket 182). In this way, the cable heat exchanger 300 is thermally coupled to the conductor 180 to effectively dissipate heat from the conductor 180, which dissipates heat from the terminal 114.

[0036] In an exemplary embodiment, the power cable 118 includes a thermally conductive spacer 186 surrounding the conductor 180. The spacer 186 is made of an electrically insulating but thermally conductive material. In this way, the spacer 186 effectively transfers heat between the conductor 180 and the cable heat exchanger 300. The thermally conductive spacer 186 is relatively thin to allow effective heat transfer between the conductor 180 and the cable heat exchanger 300. The spacer 186 also electrically insulates the cable heat exchanger 300 from the conductor 180 of the power cable 118 to prevent a short circuit of the power cable 118 and / or shock or damage caused by accidental contact with the cable heat exchanger 300. In an exemplary embodiment, the thermally conductive spacer 186 is coaxial with the conductor 180 of the power cable 118. For example, the thermally conductive spacer 186 is wrapped around the conductor 180. The spacer 186 can be made of an electrically insulating and highly thermally conductive material. The spacer 186 can be a thermally conductive epoxy, a thermoplastic material, or a thermosetting material. The insulator 186 can be made of beryllium oxide, aluminum oxide, aluminum nitride, boron nitride silicone, ceramic, Kapton, nylon, polyester, etc. The insulator 186 can be a pre-formed structure, such as a film, a pad, a sheet, a tube, an injection molded part, etc. In other various embodiments, the insulator 186 can be applied in situ, such as a grease or paste. In various embodiments, the thermally conductive insulator 186 is a heat shrink tubing applied to the outer surface of the conductor 180 of the power cable 118. The thermally conductive insulator 186 can be made of a doped polymer material, such as a plastic material having a thermally conductive material added to the plastic material to increase thermal conductivity. In alternative embodiments, other types of thermally conductive, electrically insulating materials can be used. In an exemplary embodiment, the insulator 186 is secured to the power cable 118 using a fastener 188, such as a band, a clip, an adhesive, etc.

[0037] In an exemplary embodiment, the cable heat exchanger 300 includes a manifold 304 having a coolant passage 302 therethrough and a back plate 306 coupled to the manifold 304. The power cable 118 is configured to be compressed between the manifold 304 and the back plate 306 when the back plate 306 is coupled to the manifold 304. The back plate 306 may be secured to the manifold 304 using fasteners, clips, latches, or other securing features. The spacer 186 is located between the manifold 304 and the conductor 180 and may be positioned between the back plate 306 and the conductor 180. The spacer 186 electrically insulates the manifold 304 and the back plate 306 from the conductor 180 of the power cable 118 to prevent the power cable 118 from shorting.

[0038] The manifold 304 extends between the supply side 310 and the return side 312. The manifold 304 includes a front portion 314 and a rear portion 316. The manifold 304 includes an outer end 318 and an inner end 320 opposite the outer end 318. The inner end 320 faces the power cable 118. In an exemplary embodiment, the manifold 304 includes a manifold receiving portion 322 at the inner end 320, which receives the power cable 118. For example, the manifold receiving portion 322 is concave, and its radius of curvature is similar to the radius of curvature of the power cable 118. In this way, the inner end 320 has a large surface area for docking with the power cable 118. The manifold receiving portion 322 can be shaped to engage around the power cable 118 at approximately 180°. In an exemplary embodiment, the back plate 306 includes a back plate receiving portion 324 aligned with the manifold receiving portion 322 to receive the power cable 118. In various embodiments, the back plate 306 and the inner end 320 of the manifold 304 may surround approximately 360° around each power cable 118. When the cable heat exchanger 300 is assembled, the power cables 118 are compressed between the back plate 306 and the inner end 320 of the manifold 304.

[0039] The coolant passage 302 is configured to be in fluid communication with the supply port 138 and the return port 139 and the supply coolant line 132 and the return coolant line 134. The coolant is directed through the coolant passage 302 to dissipate heat from the manifold 304 of the cable heat exchanger 300 to cool the power cable 118, thereby cooling the terminal 114. In various embodiments, the coolant passage 302 has a circular cross-section. The coolant passage 302 extends between an inlet 330 of the supply side 310 and an outlet 332 of the return side 312. Optionally, the inlet 330 can be threaded (e.g., internal or external) to be threadedly coupled to the supply coolant line 132, such as being threadedly coupled to a fluid coupler 334 at the end of the supply coolant line 132. The outlet 332 can be threaded (e.g., internal or external) to be threadedly connected to the return coolant line 134, such as being threadedly coupled to a fluid coupler 336 at the end of the return coolant line 134. In the exemplary embodiment, the coolant passage 302 extends along the longitudinal axis. However, the coolant passage 302 may extend along a non-linear path, such as a curved or serpentine path in alternative embodiments. Optionally, a seal 338 may be provided at the supply side 310 and / or the return side 312 to interface between the manifold 304 and the fluid couplings 334, 336 and / or the cooling adapter 131.

[0040] Figure 8 3 is a cross-sectional view of a cable heat exchanger 300 according to an exemplary embodiment. The inner end 320 of the manifold 304 faces the power cable 118 and docks with the power cable 118. The cable heat exchanger 300 includes a volume displacement element 350 positioned in the coolant channel 302 to reduce the volume of the coolant channel 302 along a section 352 of the coolant channel 302 (e.g., along a center section aligned with the power cable 118). In the reduced volume section 352 of the coolant channel 302, the flow rate of the coolant is increased. For example, in the space 354 between the volume displacement element 350 and the inner wall 356 of the coolant channel 302, the flow rate is increased. The increased flow rate increases the heat transfer between the manifold 304 and the coolant, thereby reducing the temperature of the manifold 304, and also reducing the temperature of the power cable 118 and the terminal 114.

[0041] In the exemplary embodiment, the volume displacement element 350 is located approximately in the center of the coolant passage 302, forming approximately equal spaces 354 on opposite sides of the volume displacement element 350. However, in alternative embodiments, other locations are also possible. The volume displacement element 350 can have a ramp surface 358 at the leading and trailing ends of the volume displacement element 350 to reduce turbulence in the coolant passage 302.

[0042] Fig. 93 is a cross-sectional view of a cable heat exchanger 300 according to an exemplary embodiment. The cable heat exchanger 300 includes a nozzle 360 ​​in a coolant channel 302. The nozzle 360 ​​has a reduced size (e.g., a reduced width) compared to an upstream section 362 and / or a downstream section 364 of the coolant channel 302. The nozzle 360 ​​reduces the area of ​​the coolant channel 302 to increase the flow rate of the coolant through the nozzle 360. In an exemplary embodiment, the nozzle 360 ​​is aligned with the power cable 118. The increased flow rate increases the heat transfer between the manifold 304 and the coolant, thereby reducing the temperature of the manifold 304, and also reducing the temperature of the power cable 118 and the terminal 114.

[0043] Fig.10 300 is a cross-sectional view of a cable heat exchanger 300 according to an exemplary embodiment. The cable heat exchanger 300 includes a heat exchange fin 370 positioned in a coolant channel 302. The heat exchange fin 370 is thermally coupled to the manifold 304 and transfers heat from the manifold 304 to the coolant. For example, the heat exchange fin 370 can be integrated with the manifold 304. The heat exchange fin 370 increases the surface area of ​​the cable heat exchanger 300 in thermal contact with the coolant to increase the thermal efficiency of the cable heat exchanger 300. In an exemplary embodiment, the heat exchange fin 370 extends parallel to the coolant flow direction through the coolant channel 302. In an exemplary embodiment, the heat exchange fin 370 can be spaced approximately equidistantly, thereby forming a space with approximately equal width on the opposite sides of the heat exchange fin 370 between them. However, in alternative embodiments, other positions and orientations are feasible. The heat exchanging fins 370 may have sloped surfaces at leading and trailing ends of the heat exchanging fins 370 to reduce turbulence in the coolant passages 302 .

[0044] CROSS-REFERENCE TO RELATED APPLICATIONS

[0045] This application claims the benefit of U.S. Provisional Application No. 62 / 824,430, filed on March 27, 2019, the subject matter of which is incorporated herein by reference in its entirety.

Claims

1. A power 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 the terminal channel for mating with a charging connector, the cable connector being positioned within the cavity at the rear portion of the housing; a power cable terminated to the cable connector at a rear portion of the terminal, the power cable comprising a conductor; and a cable heat exchanger located in the chamber, the cable heat exchanger being thermally coupled to the conductor of the power cable, the cable heat exchanger comprising a coolant passage for flowing a coolant through the cable heat exchanger to actively cool the conductor of the power cable; and A second terminal and a second power cable terminated to the second terminal, the cable heat exchanger is thermally coupled to a conductor of the second power cable, and the coolant channel flows adjacent to the power cable and the second power cable for actively cooling the conductor of the power cable and the conductor of the second power cable.

2. The cable connector (102) according to claim 1, wherein: The cable heat exchanger (300) includes a manifold (304) forming the coolant channel (302), the coolant channel having an inlet (330) and an outlet (332), the manifold providing a coolant flow between the inlet and the outlet.

3. The cable connector (102) according to claim 1, wherein: The cable heat exchanger (300) includes a manifold (304) having a coolant channel (302) passing through the manifold, the manifold having an inner end (320), the inner end (320) including a manifold receiving portion (322) receiving the power cable and the second power cable, the cable heat exchanger includes a back plate (306) coupled to the inner end of the manifold, the back plate including a back plate receiving portion (324) aligned with the manifold receiving portion and receiving the power cable and the second power cable, the power cable and the second power cable being pressed between the back plate and the inner end of the manifold.

4. The cable connector (102) according to claim 1, wherein: The cable heat exchanger (300) includes a manifold (304) forming a coolant passage (302) therethrough, the manifold defining a heat sink to dissipate heat from the conductors (180) of the power cable (118) and the conductors of the second power cable into coolant flowing through the manifold.

5. The cable connector (102) according to claim 1, wherein: The cable heat exchanger (300) includes a thermally conductive spacer (186) that electrically insulates the cable heat exchanger from a conductor (180) of the power cable (118) and a conductor of the second power cable, respectively.

6. The cable connector (102) according to claim 5, wherein: A first one of the thermally conductive isolators (186) is coaxial with the conductor (180) of the power cable (118), and a second one of the thermally conductive isolators is coaxial with the conductor of the second power cable.

7. The cable connector (102) according to claim 5, wherein: The thermally conductive spacer (186) is a heat shrink tubing applied to the outer surface of the conductor (180) of the power cable (118) and the conductor of the second power cable.

8. The cable connector (102) according to claim 5, wherein: The power cable (118) includes a first jacket surrounding a conductor (180) of the power cable, a termination end (184) of the power cable having a section of the first jacket removed to expose the conductor of the power cable, a first of the thermally conductive insulators being coupled to the conductor of the power cable, a thickness of the first thermally conductive insulator being thinner than a thickness of the first jacket, and / or The second power cable includes a second sheath surrounding a conductor of the second power cable, a termination end of the second power cable having a section of the second sheath removed to expose the conductor of the second power cable, a second thermally conductive insulator in the thermally conductive insulator being connected to the conductor of the second power cable, a thickness of the second thermally conductive insulator being thinner than a thickness of the second sheath.

9. The cable connector (102) according to claim 1, wherein: The cable heat exchanger (300) includes a volume displacement element (350) positioned in the coolant channel (302) to reduce the volume of the coolant channel and increase the coolant flow rate through the coolant channel along the volume displacement element.

10. The cable connector (102) according to claim 1, wherein: The cable heat exchanger (300) comprises heat exchange fins (370) extending into the coolant channel (302) to increase the surface area of ​​the cable heat exchanger in thermal contact with the coolant, the heat exchange fins extending parallel to the coolant flow direction and passing through the coolant channel.

11. A power 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 the terminal channel for mating with a charging connector, the cable connector being positioned within the cavity at the rear portion of the housing; a power cable terminated to the cable connector at a rear portion of the terminal, the power cable comprising a conductor; and a cable heat exchanger located in the chamber, the cable heat exchanger being thermally coupled to the conductor of the power cable, the cable heat exchanger comprising a coolant passage for flowing a coolant through the cable heat exchanger to actively cool the conductor of the power cable; and A cooling assembly, comprising a cooling adapter coupled to a housing of a charging inlet assembly, the cooling adapter comprising an adapter body forming a cavity, the adapter body having a cable outlet for a power cable of the charging inlet assembly, the cooling adapter comprising a supply port and a return port, a coolant supply line coupled to the supply port, a coolant return line coupled to the return port, wherein the supply port is coupled to an inlet of the coolant channel, and the return port is coupled to an outlet of the coolant channel.

12. The cable connector (102) according to claim 11, wherein: The cable heat exchanger (300) includes a manifold (304) forming the coolant channel (302), the coolant channel having an inlet (330) and an outlet (332), the manifold providing a coolant flow between the inlet and the outlet.

13. The cable connector (102) according to claim 11, wherein: The cable heat exchanger (300) includes a manifold (304) having a coolant channel (302) passing through the manifold, the manifold having an inner end (320), the inner end (320) including a manifold receiving portion (322) receiving the power cable (118), the cable heat exchanger including a back plate (306) coupled to the inner end of the manifold, the back plate including a back plate receiving portion (324) aligned with the manifold receiving portion and receiving the power cable, the power cable being compressed between the back plate and the inner end of the manifold.

14. The cable connector (102) according to claim 11, wherein: The cable heat exchanger (300) includes a manifold (304) forming a coolant passage (302) therethrough, the manifold defining a heat sink to dissipate heat from conductors (180) of the power cable (118) into coolant flowing through the manifold.

15. The cable connector (102) according to claim 11, wherein: The cable heat exchanger (300) includes a thermally conductive spacer (186) that electrically insulates the cable heat exchanger from a conductor (180) of the power cable (118).

16. The cable connector (102) according to claim 15, wherein: The thermally conductive spacer (186) is coaxial with the conductor (180) of the power cable (118).

17. The cable connector (102) according to claim 15, wherein: The thermally conductive spacer (186) is a heat shrink tubing applied to the outer surface (188) of the conductor (180) of the power cable (118).

18. The cable connector (102) according to claim 15, wherein: The power cable (118) includes a jacket (182) surrounding a conductor (180) of the power cable, a termination end (184) of the power cable having a section of the jacket removed to expose the conductor of the power cable, the thermally conductive insulator (186) coupled to the conductor of the power cable, the thickness of the thermally conductive insulator being thinner than the thickness of the jacket.

19. The cable connector (102) according to claim 11, wherein: The cable heat exchanger (300) includes a volume displacement element (350) positioned in the coolant channel (302) to reduce the volume of the coolant channel and increase the coolant flow rate through the coolant channel along the volume displacement element.

20. The cable connector (102) of claim 11, wherein: The cable heat exchanger (300) comprises heat exchange fins (370) extending into the coolant channel (302) to increase the surface area of ​​the cable heat exchanger in thermal contact with the coolant, the heat exchange fins extending parallel to the coolant flow direction and passing through the coolant channel.

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