Cooling system for charging inlet assembly of electric vehicle

Abstract

A power connector (102) includes a housing (110) housing a charging terminal (104) and a power conductor (118) terminated to a cable connector of the charging terminal. A cooling module (130) is thermally coupled to the charging terminal. The cooling module includes a carrier (132) having recesses (142) and phase change elements (134) housed in the respective recesses, the phase change elements being thermally coupled to the respective cable connectors to reduce the operating temperature of the charging terminals.

Description

Technical Field

[0001] The subject matter herein relates generally to charging inlet assemblies. Background Art

[0002] 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.

[0003] There remains a need for a cooling system for cooling a power connector, such as for a charging inlet assembly. Summary of the invention

[0004] In one embodiment, a power connector is provided, and the power connector includes a housing extending between a front and a rear. The housing has a terminal channel between the front and the rear. The power connector includes a charging terminal connected to the housing. Each charging terminal includes a mating pin at the front of the charging terminal and a cable connector at the rear of the charging terminal. The mating pin is positioned in a corresponding terminal channel for mating with the charging connector. The cable connector is positioned at the rear of the housing. The power connector includes a power conductor terminated to the cable connector of the corresponding charging terminal. The power connector includes a cooling module thermally coupled to the charging terminal. The cooling module includes a carrier having a recess. The cooling module includes a phase change element received in the corresponding recess and held relative to each other by the carrier. The phase change element is thermally coupled to the corresponding cable connector to reduce the operating temperature of the charging terminal during charging. BRIEF DESCRIPTION OF THE DRAWINGS

[0005] The present invention will now be described by way of example with reference to the accompanying drawings, in which:

[0006] Figure 1 is a front perspective view of a power connector having a cooling module for cooling components of the power connector according to an exemplary embodiment.

[0007] Figure 2 is a rear perspective view of a power connector and a cooling module according to an exemplary embodiment.

[0008] Figure 3 is a perspective view of a portion of a power connector (with a housing removed) showing a cooling module coupled to charging terminals 104 and power conductors according to an exemplary embodiment.

[0009] Figure 4 is an exploded view of a portion of a power connector according to an exemplary embodiment.

[0010] Figure 5 is a perspective view of a phase change element according to an exemplary embodiment.

[0011] Figure 6 is a perspective view of a phase change element according to an exemplary embodiment.

[0012] Figure 7 is a rear perspective view of a portion of a cooling module showing a phase change element received in a carrier according to an exemplary embodiment.

[0013] Figure 8 is a front perspective view of a portion of a cooling module showing a phase change element received in a carrier according to an exemplary embodiment.

[0014] Fig. 9 is a front perspective view of a portion of a cooling module showing a thermal interface component coupled to a carrier according to an exemplary embodiment.

[0015] Fig.10 is a perspective view of a cooling module thermally coupled to a charging terminal according to an exemplary embodiment.

[0016] Fig.11 is a graph showing the charging temperature of uncooled terminals (terminals without cooling modules) versus the charging temperature of cooled terminals (terminals with cooling modules). DETAILED DESCRIPTION

[0017] Figure 1 is a front perspective view of the power connector 102 having a cooling module 130 for cooling components of the power connector 102 according to an exemplary embodiment. Figure 2 1 is a rear perspective view of a power connector 102 and a cooling module 130 according to an exemplary embodiment. The power connector 102 is part of a power system and includes a terminal 104 configured to transmit power. In various embodiments, the power connector 102 is used in a battery system. The power connector 102 can be used to charge the battery. For example, the terminal 104 can be a charging terminal, such as an AC charging terminal or a DC charging terminal. In other embodiments, the power connector 102 can be used to power components such as motors or other electrical components. In the illustrated embodiment, the power connector 102 and the cooling module 130 are part of a charging inlet assembly 100 for an electric vehicle. However, it should be appreciated that the power connector 102 and the cooling module 130 can be another type of electrical connector and / or can be used in another type of system or application.

[0018] 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 in cooperation with a charging connector (not shown). The charging terminals 104 are configured to mate with the charging connector. In the illustrated embodiment, the charging terminals 104 include an AC charging terminal and a DC charging terminal. In an exemplary embodiment, the power connector 102 is configured to mate with a DC fast charging connector (such as an SAE combo CCS charging connector) or other types of connectors (such as an SAE J1772 charging connector).

[0019] The charging inlet assembly 100 includes a housing 110 that holds a charging terminal 104. The housing 110 and the charging terminal 104 form part of the power connector 102. The housing 110 extends between a front portion 112 and a rear portion 114. The front portion 112 defines a mating end of the power connector 102. The charging terminal 104 is disposed at the front portion 112 to interface with the charging connector. The charging terminal 104 is received in a terminal channel 116 and is coupled to the housing 110 in the terminal channel 116. The terminal channel 116 extends between the front portion 112 and the rear portion 114. The charging terminal 104 is electrically connected to a corresponding power conductor 118. The power conductor 118 may be a power cable, a bus bar, or another type of conductor. The power conductor 118 extends from the rear portion 114.

[0020] In an exemplary embodiment, the power connector 102 and the charging inlet assembly 100 include a cooling module 130 for reducing the charging temperature of the charging terminal 104 and the power conductor 118 during charging. For example, the cooling module 130 includes a phase change material (PCM) that absorbs energy / heat upon phase change to provide relative or equivalent cooling (e.g., operating at a reduced temperature compared to use without the PCM). The PCM absorbs energy during a phase change (e.g., from solid to liquid) at a phase change temperature (PCT). For example, the PCM absorbs a large amount of heat at a nearly constant temperature until all the material melts at the PCT to absorb heat during the charging process. By melting (e.g., changing from solid to liquid) at the phase change temperature (PCT), the PCM is able to store a large amount of energy compared to sensible heat storage. The PCM may be a latent heat storage (LHS) material. In various embodiments, the PCM may be an organic PCM, including hydrocarbons such as paraffins, lipids, sugar alcohols, etc. In other various embodiments, the PCM may be an inorganic PCM, including hydrated salts. In other embodiments, the PCM may be a solid-solid PCM that undergoes a solid / solid phase transition, whereby the material changes crystal structure from one lattice configuration to another at a fixed and well-defined temperature.

[0021] 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 to seal the charging inlet assembly 100 to the vehicle.

[0022] The charging inlet assembly 100 includes a terminal cover 126 hingedly coupled to the mounting flange 120 and / or the housing 110 ( Figure 1 The terminal cover 126 is used to cover the corresponding charging terminal 104. The housing 110 may include a rear cover 128 ( Figure 2 ), the rear cover closes access to the rear of the housing 110. The rear cover 128 can be clipped to the main portion of the housing 110, for example using clips or latches. Other types of fixing features, such as fasteners, can be used in alternative embodiments.

[0023] Figure 3 is a perspective view of a portion of the power connector 102 (with the housing removed) showing the cooling module 130 coupled to the charging terminals 104 and the power conductors 118 . Figure 4 is an exploded view of a portion of the power connector 102. The cooling module 130 is used for lower operating temperatures of the charging terminals 104. In the illustrated embodiment, the power connector 102 includes a pair of charging terminals 104 and corresponding power conductors 118. However, the power connector 102 may include more or fewer charging terminals 104 and power conductors 118. In the illustrated embodiment, the cooling module 130 operates on multiple charging terminals 104. However, in alternative embodiments, multiple cooling modules 130 (e.g., separate and discrete cooling modules) may be provided, such as separate cooling modules 130 for separate charging terminals 104. The separate cooling modules 130 may be coupled together to form a unified or united structure.

[0024] Each charging terminal 104 includes a mating pin 200 at a front portion 210 of the charging terminal 104 and a cable connector 202 at a rear portion 212 of the charging terminal 104. The mating pin 200 is configured to mate to the charging connector. The cable connector 202 is configured to electrically connect to the power conductor 118. During charging, the temperature of the mating pin 200 and the cable connector 202 increases. In an exemplary embodiment, the rate of temperature increase is mitigated or slowed by the cooling module 130.

[0025] 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 processes, such as welding, riveting, bolting, etc. In other various embodiments, the cable connector 202 is integral with the mating pin 200, such as formed together with the mating pin 200. In various embodiments, the cable connector 202 is configured to terminate to the power conductor 118 by welding the power conductor 118 to the cable connector 202. For example, the cable connector 202 can include a welding tab. In other various embodiments, the cable connector 202 is terminated to the power conductor 118 by other processes (such as crimping, welding, etc.). For example, the cable connector 202 can include a crimp barrel configured to terminate to the power conductor 118.

[0026] 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 screw-machined. The mating pin 200 may be made of a metal alloy (e.g., a copper alloy) with 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 interfacial sealing against the inner surface of the terminal channel 116 (e.g., Figure 1 as shown).

[0027] The cable connector 202 extends from and / or is coupled to the rear end of the mating pin 200. The cable connector 202 may be press-fitted onto the mating pin 200. The cable connector 202 includes a cable termination end 240 at the rear 212 of the charging terminal 104. The power conductor 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 defining the cable termination end 240 at the rear 212. In alternative embodiments, the welding pad 242 may be rectangular or have other shapes. The welding pad 242 may include parallel surfaces for welding the power conductor 118 to the plane of the welding pad 242. In alternative embodiments, the cable termination end 240 may include a crimp barrel (not shown) instead of the welding pad 242. In an exemplary embodiment, the cable connector 202 includes a thermal interface 244. The cooling module 130 is configured to be thermally connected to the thermal interface 244. The thermal interface 244 may be disposed along the solder pad 242 , such as along a planar surface of the solder pad 242 opposite the power conductor 118 .

[0028] The cooling module 130 includes a carrier 132 and one or more phase change elements 134. The phase change element 134 is configured to be thermally coupled to the charging terminal 104. The phase change element 134 dissipates heat from the charging terminal 104 so as to slow down the temperature rise in the charging terminal during the charging process. In various embodiments, the cooling module 130 includes a thermal interface element 136 that provides an interface between the phase change element 134 and the charging terminal 104. However, in alternative embodiments, the phase change element 134 can be directly thermally coupled to the charging terminal 104 without using the thermal interface element 136. In various embodiments, the cooling module 130 includes a housing 138 that holds the carrier 132, the phase change element 134, and the thermal interface element 136. However, in alternative embodiments, components of the cooling module 130 can be coupled to the charging terminal 104 via other devices or fixing elements.

[0029] The carrier 132 holds the phase change elements 134. In various embodiments, the carrier 132 holds all phase change elements 134 (e.g., a pair of phase change elements 134). However, in alternative embodiments, a plurality of carriers 132 may be provided, each holding a corresponding phase change element 134. In an exemplary embodiment, the carrier 132 includes a body 140 made of an electrically insulating material. For example, the body 140 of the carrier 132 may be made of a plastic material. Such as to dissipate heat from the phase change elements 134 and / or the charging terminal 104.

[0030] The carrier 132 includes one or more recesses 142 that receive the phase change elements 134. In the illustrated embodiment, the carrier 132 includes a pair of recesses 142. In alternative embodiments, the carrier 132 may include more or fewer recesses 142. The carrier 132 includes partition walls 144 between the recesses 142. The partition walls 144 isolate the recesses 142, and thus isolate the phase change elements 134 from each other.

[0031] The carrier 132 extends between the front 146 and the rear 148. The carrier 132 includes a side wall 150 extending between the front 146 and the rear 148. The side wall 150 surrounds the periphery of the carrier 132. The recess 142 can be open along the side wall 150 to allow the phase change element 134 to interface with the corresponding charging terminal 104. In an exemplary embodiment, the recess 142 is open at the front 146 to receive the phase change element 134. For example, the phase change element 134 can be front loaded into the recess 142. Optionally, the recess 142 can be closed at the rear 148. However, in alternative embodiments, the recess 142 can be open at the rear 148, for example to receive the phase change element 134 or to allow a heat sink or other heat dissipation element to engage with the phase change element 134. In an exemplary embodiment, the carrier 132 includes a first side 152 and a second side 154. The carrier 132 includes a first end 156 and a second end 158. The sidewall 150 extends along a first side 152 and a second side 154 and a first end 156 and a second end 158. In the illustrated embodiment, the first side 152 and the second side 154 are generally planar. For example, the first side 152 and the second side 154 may be oriented parallel to each other. However, in alternative embodiments, the first side 152 and the second side 154 may be curved. In an exemplary embodiment, the first end 156 and the second end 158 are curved between the first side 152 and the second side 154. However, in alternative embodiments, the first end 156 and the second end 158 may include flat portions that are parallel to each other. In alternative embodiments, the carrier 132 may have other shapes.

[0032] In an exemplary embodiment, carrier 132 has a volume defined by sidewalls 150 between front portion 146 and rear portion 148. In an exemplary embodiment, recess 142 occupies a majority of the volume of carrier 132, such that phase change element 134 may occupy a majority of the volume, such as greater than 50% of the volume. In various embodiments, phase change element 134 may occupy greater than 75% of the volume. In some embodiments, phase change element 134 may occupy greater than 90% of the volume. In an exemplary embodiment, carrier 132 includes features that position and / or retain phase change element 134 in recess 142. For example, carrier 132 may include compression ribs and / or positioning ribs and / or tabs, bottoms, or other protrusions extending into recess 142 to interface with phase change element 134. In other various embodiments, carrier 132 may include wells, slots, grooves, or other features extending into body 140 of carrier 132 to receive them and position phase change element 134 in recess 142. Other types of securing features may be used to secure phase change element 134 within recess 142 , such as latches, clips, fasteners, adhesives, covers, and the like.

[0033] Additional references Figure 5 and Figure 6 , Figure 5 and Figure 6 1 is a perspective view of phase change elements 134 according to an exemplary embodiment, each of which includes an enclosure 160 surrounding a phase change material (PCM) 162. Encapsulation 160 may be a film, a sheet, a molded body, or another type of enclosure that surrounds and contains phase change material 162. Encapsulation 160 is sized and shaped to fit within recess 142. For example, phase change element 134 may have a shape that is complementary to the shape of recess 142. Encapsulation 160 may include a positioning feature 164 for positioning phase change element 134 within recess 142.

[0034] Phase change element 134 extends between front portion 166 and rear portion 168. Phase change element 134 includes sidewall 170 located between front portion 166 and rear portion 168. Phase change element 134 includes inner portion 172 and outer portion 174. Outer portion 174 forms thermal interface 176 configured to face charging terminal 104. In an exemplary embodiment, thermal interface 176 is planar. Thermal interface 176 is a large surface area configured to face charging terminal 104 for efficient heat transfer between charging terminal 104 and phase change element 134.

[0035] The PCM 162 is a material configured to absorb a large amount of heat at a nearly constant temperature until the material changes phase / state. For example, the PCM 162 is made of a material that undergoes a solid / liquid phase transition at a phase transition temperature. In an exemplary embodiment, the PCM 162 includes a hydrocarbon, such as a paraffin, a lipid, a sugar alcohol, etc. In various other embodiments, the PCM 162 includes a hydrated salt. In other embodiments, the PCM 162 includes a material that undergoes a solid / solid phase transition, whereby the material changes the crystal structure from one lattice configuration to another lattice configuration at a fixed and well-defined temperature. The phase change element 134 allows a lower operating temperature of the charging terminal 104 by absorbing heat from the charging terminal 104 during the charging process, thereby effectively extending the charging time and / or reducing the charging temperature of the charging terminal 104 during the charging cycle (e.g., compared to use without the PCM). The PCM 162 absorbs energy during the phase transition (e.g., from solid to liquid) at the phase transition temperature (PCT). For example, the phase change element 134 absorbs a large amount of heat at a nearly constant temperature until all of the PCM 162 melts at the phase change temperature to absorb heat during the charging process. By melting (e.g., changing from solid to liquid) at the phase change temperature (PCT), the PCM 162 is able to store a large amount of energy compared to sensible heat storage. The PCM 162 may be a latent heat storage (LHS) material.

[0036] Return to reference Figure 3 and Figure 4, the thermal interface element 136 can be disposed between the phase change element 134 and the charging terminal 104 to enhance the thermal coupling between the phase change element 134 and the charging terminal 104. In an exemplary embodiment, the thermal interface element 136 is a thermal interface sheet, such as a film or a tape. For example, the thermal interface sheet can be a metal sheet with high thermal conductivity and low thermal interface resistance. In an alternative embodiment, the thermal interface element 136 can be a thermally conductive pad. In various other embodiments, the thermal interface element 136 can be a thermal paste or thermal adhesive used between the phase change element 134 and the charging terminal 104.

[0037] In an exemplary embodiment, the thermal interface component 136 is flexible to conform between the surface of the phase change element 134 and the charging terminal 104. The thermal interface component 136 includes an inner interface 180 and an outer interface 182, wherein the inner interface 180 is configured to face and interface with the corresponding phase change element 134, and the outer interface 182 is configured to face and interface with the corresponding charging terminal 104. The interfaces 180, 182 can be generally planar. However, in other embodiments, the interfaces 180, 182 can be non-planar to conform to and engage the phase change element 134 and the charging terminal 104.

[0038] In the illustrated embodiment, a single thermal interface component 136 is provided for covering two phase change elements 134. However, in alternative embodiments, a plurality of thermal interface components 136 may be provided, such as providing one thermal interface component 136 at each of the phase change elements 134. In an exemplary embodiment, the thermal interface component 136 wraps around a portion of the carrier 132 to cover the phase change element 134. For example, the thermal interface component 136 may wrap around a portion of the side wall 150. The thermal interface component 136 may wrap from the front 146 and / or the rear 148. In an exemplary embodiment, the thermal interface component 136 may be adhered or otherwise fixed to a portion of the carrier 132, such as the rear 148 and / or the front 146 and / or the side wall 150. In various embodiments, the thermal interface component 136 may cover the recess 142 to hold the phase change element 134 in the recess 142. In an exemplary embodiment, the thermal interface component 136 is made of a thermally conductive and electrically insulating material to avoid forming an electrical path between the charging terminals 104. For example, thermal interface component 136 may be a glass fiber reinforced silicone having a glass fiber sheet coated with a thermally conductive silicone rubber, or may be a polyimide film coated with a ceramic filled high temperature silicone rubber.

[0039] The housing 138 serves as a housing to hold the components of the cooling module 130 together. The housing 138 may be used to support the charging terminal 104. The housing 138 includes a chamber 190. The carrier 132, the phase change element 134, the thermal interface element 136, and the charging terminal 104 are received in the chamber 190. In an exemplary embodiment, the phase change element 134 and the thermal interface element 136 are thermally coupled to the charging terminal 104 in the chamber 190. The housing 138 may be used to position the charging terminals 104 relative to each other, such as at a fixed position or spaced relative to each other, such as for loading into a charging inlet housing.

[0040] In an exemplary embodiment, the housing 138 is a multi-piece structure. For example, the housing 138 includes a first housing member 192 and a second housing member 194. The first shaft member 192 and the second shaft member 194 are coupled together, such as using fasteners. The chamber 190 is defined between the first and second shaft members 192, 194. Optionally, the first shaft member 192 and the second shaft member 194 can be similar to each other, such as mirrored halves.

[0041] In an exemplary embodiment, the first housing member 192 includes a first terminal recess 196, and the second housing member 194 includes a second terminal recess 198. The terminal recesses 196, 198 receive corresponding charging terminals 104. The terminal recesses 196, 198 may include positioning features for positioning or arranging the charging terminals 104 relative to the housing 138. The housing 138 may be open at the front to allow the pins 200 of the charging terminals 104 to extend forward of the housing 138. The housing 138 may be open at the rear to allow the power conductors 118 to extend rearward from the housing 138. In alternative embodiments, the housing 138 may include a cable outlet at a location other than the rear, such as at the side, to allow the power conductors 118 to leave the housing 138 by 90°.

[0042] In an exemplary embodiment, the housing 138 includes a front wall 199 at the front for supporting the carrier 132 and / or the phase change element 134. For example, the front wall 199 can be used to hold the phase change element 134 in the recess 142 of the carrier 132. In alternative embodiments, the housing 138 can have other sizes or shapes. When assembled, the carrier 132 and the phase change element 134 are received in the cavity 190 of the housing 138. In an exemplary embodiment, the first and second shaft members 192, 194 receive the charging terminals 104 on opposite sides of the cavity 190, wherein the carrier 132 and the phase change element 134 are located between the charging terminals 104. When the first housing member 192 and the second housing member 194 are coupled together, the housing members 192, 194 press the charging terminals 104 into thermal contact with the phase change element 134 and / or the thermal interface element 136. For example, when the fastener is tightened, the charging terminal 104 is pressed inwardly into physical contact with the phase change element 134 and / or the thermal interface element 136. The direct physical contact allows for efficient heat transfer between the charging terminal 104 and the phase change element 134 and / or the thermal interface element 136. The heat generated in the charging terminal 104 is absorbed by the phase change element 134 through the thermal interface element 136, thereby reducing the temperature in the charging terminal 104 or slowing down the temperature rise in the charging terminal 104 during the charging process.

[0043] Figure 7 is a rear perspective view of a portion of cooling module 130 showing phase change element 134 housed in carrier 132 according to an exemplary embodiment. Figure 8 is a front perspective view of a portion of cooling module 130 showing phase change element 134 received in carrier 132 according to an exemplary embodiment.

[0044] During assembly, the phase change element 134 is received in the recess 142 of the carrier 132, such as by the front portion 146. The phase change element 134 may bottom out against the rear wall at the rear portion 148 of the carrier 132. The partition wall 144 is located between the recesses 142. The partition wall 144 separates the phase change elements 134 from each other. The body 140 of the carrier 132 may have air pockets to enhance the cooling of the carrier 132 and thus reduce the overall temperature of the cooling module 130. Optionally, the carrier 132 may include interference ribs in the recess 142 that retain the phase change element 134 in the recess 142 by an interference fit. Other types of positioning and / or fixing features may be provided in alternative embodiments. The carrier 132 may be shaped to retain the phase change element 134 in the recess 142. For example, the sidewall 150 at the recess 142 may have a dovetail shape to prevent the phase change element 134 from being withdrawn through the sidewall 150. In an exemplary embodiment, an outer portion 174 of the phase change element 134 includes a thermal interface 176. The thermal interface 176 may be generally coplanar with the sides 152, 154 of the carrier 132. However, in alternative embodiments, the thermal interface 176 may protrude from the carrier 132 to interface with the charging terminal 104.

[0045] Fig. 9 1 is a front perspective view of a portion of a cooling module 130 according to an exemplary embodiment showing a thermal interface element 136 coupled to a carrier 132. In an exemplary embodiment, the thermal interface element 136 wraps around a portion of the carrier 132. For example, a portion of the thermal interface element 136 may be secured to a rear portion 148 of the carrier 132 and wrapped around the sidewalls 150 and the front portion 146. The thermal interface element 136 may be adhered to the rear portion 148 and / or the sidewalls 150 and / or the front portion 146. The thermal interface element 136 covers the recess 142 and the phase change element 134 located in the recess 142. The thermal interface element 136 is configured to interface with the charging terminal 104 to transfer heat between the charging terminal 104 and the phase change element 134.

[0046] Fig.10 1 is a perspective view of a cooling module 130 thermally coupled to a charging terminal 104 according to an exemplary embodiment. In the illustrated embodiment, the cooling module 130 is provided without a thermal interface element 136 ( Fig. 9 ) and no housing 138 ( Figure 3 ). The phase change element 134 is located in the recess 142 of the carrier 132. The phase change element 134 directly interfaces with the charging terminal 104. For example, the thermal interface 176 of the phase change element 134 directly interfaces with the thermal interface 244 of the cable connector 202 of the charging terminal 104.

[0047] Fig.113 is a graph showing a charging temperature 300 of an uncooled terminal (a terminal without a cooling module 130) versus a charging temperature 302 of a cooled terminal (a terminal with a cooling module 130). The charging temperature 302 of the cooled terminal is lower than the charging temperature 300 of the uncooled terminal. The cooling module reduces the operating temperature of the terminal by absorbing heat from the terminal. The graph shows an operating temperature 304 of the cooling module of the phase change element (e.g., an operating temperature of the phase change material). The phase change element absorbs latent heat at a substantially constant temperature until a phase change temperature 306 is reached. The cooled terminal can be charged for a longer charging cycle at a lower temperature than the uncooled terminal.

Claims

1. A power connector (102), comprising: a housing (110) extending between a front portion (112) and a rear portion (114), the housing having a terminal passage (116) between the front portion and the rear portion; Charging terminals (104) coupled to the housing, each charging terminal comprising a mating pin (200) at a front portion of the charging terminal and a cable connector (202) at a rear portion of the charging terminal, the mating pin being positioned in a corresponding terminal channel to mate with the charging connector, the cable connector being positioned at a rear portion of the housing; power conductors (118) terminated in cable connectors to corresponding charging terminals; and A cooling module (130) is thermally coupled to the charging terminal, the cooling module comprising a carrier (132) having recesses (142), the cooling module comprising phase change elements (134) received in respective recesses and held relative to each other by the carrier, the phase change elements being thermally coupled to respective cable connectors to reduce an operating temperature of the charging terminal during charging.

2. The power connector (102) of claim 1, wherein the carrier (132) comprises partition walls (144) between the recesses (142) to isolate the phase change elements (134) from each other.

3. The power connector (102) according to claim 1, wherein the recess (142) is open at the side (152, 154) of the carrier (132) to allow the phase change element (134) to interface with the charging terminal (104).

4. The power connector (102) according to claim 1, wherein: The carrier (132) has a volume, and the phase change element (134) occupies at least 50% of the volume.

5. The power connector (102) according to claim 1, wherein: The phase change element (134) is configured to directly engage the charging terminal (104).

6. The power connector (102) according to claim 1, wherein: The cooling module (130) also includes at least one thermal interface element (136) between the phase change element (134) and the charging terminal (104).

7. The power connector (102) according to claim 6, wherein: The at least one thermal interface component (136) is secured to the carrier (132) to cover (126) a corresponding recess (142).

8. The power connector (102) of claim 1, wherein each phase change element (134) includes a cover (126) enclosing a phase change material (162), the cover having a shape complementary to a shape of the recess (142).

9. The power connector (102) according to claim 1, wherein: The cooling module (130) also includes a housing (138) having a cavity (190) in which the carrier (132) is received, the housing being configured to be coupled to the charging terminal (104) to secure the cooling module to the charging terminal.

10. The power connector (102) according to claim 9, wherein: A cable connector (202) of the charging terminal (104) is received in the chamber (190).

11. The power connector (102) according to claim 9, wherein: The housing (138), the carrier (132), the phase change element (134), and the charging terminal (104) are configured to be loaded into and removed from the housing (110) as a unit.

12. The power connector (102) according to claim 9, wherein: The housing (138) includes a first housing member (192) and a second housing member (194) coupled together to compress a thermal interface between the phase change element (134) and the charging terminal (104).

13. The power connector (102) of claim 1, wherein the carrier (132) extends between a front portion (146) and a rear portion (148), the carrier having a side wall (150) between the front portion and the rear portion, the side wall extending along a first side (152), a second side (154), a first end (156), and a second end (158), the recess (142) comprising a first recess at the first side and a second recess at the second side, the carrier comprising a partition wall between the first recess and the second recess.

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