Freeze compressed air electric vehicle (EV) fast charging system and method

Abstract

The present disclosure provides an air cooling system for an electric vehicle charging cable, the air cooling system comprising: a compressed air source; at least one filter; at least one dryer; and the subcooler subsystem is used for freezing the compressed air from the compressed air source. A coupler on the charging cable supplies frozen compressed air to the charging cable. The system is configured to maintain an exterior surface of the charging cable below a predetermined temperature during vehicle charging. The system further includes a routing structure that directs the frozen compressed air back to a charging station to maintain the charging cable at a temperature that does not exceed a predetermined temperature. The system may operate in a closed loop mode based on a geo-climate zone. A method for air cooling an electric vehicle charging cable is also disclosed.

Description

[0001] Related Applications

[0002] This application claims priority to U.S. Provisional Application No. 63 / 424,080, filed on November 9, 2022, the content of which is incorporated herein by reference in its entirety. Technical Field

[0003] The present disclosure generally relates to a charging system for an electric vehicle, and more particularly, to a cryogenic compressed air charging system for an electric vehicle, and a method for cooling a fast charging cable for an electric vehicle (EV). Background Art

[0004] Electric vehicles operate on battery power stored in on-board batteries. The batteries are charged using electricity supplied from the power grid. Charging has multiple "levels". Level 1 charging uses standard voltage, e.g., residential electricity (120V), which may take several hours to fully charge the vehicle's battery. Level 2 charging uses 220 - 204V and is typically available at residential charging stations, retail charging stations, and office charging stations. Level 2 charging can fully charge the vehicle on a weekday or overnight. The most efficient charging is Level 3 charging using a "fast charger" that can charge the vehicle to 80% or more in about 30 minutes and fully charge the vehicle in about 60 minutes.

[0005] However, it should be understood that fast chargers operate at high power levels, which requires cooling of the cable between the charging station and the vehicle. Conventional fast charging systems rely on fluid cooling tubes to cool the cable and the connector (the connector between the cable and the vehicle) because power draw generates heat. This allows the cable to be "handled" by a person during charging. Known cooling systems are ethylene glycol-based systems, which are complex and costly to maintain. Additionally, ethylene glycol systems are not necessarily environmentally friendly.

[0006] Furthermore, as the demand for electricity increases, the diameter of the cable must also increase to accommodate the increased electrical demand. However, the cable diameter is limited by the current connector design. Therefore, cooling is crucial.

[0007] Cooling requirements vary depending on many factors. One factor is the current carried by the cable. Another factor is the upper limit of the desired temperature of the cable and connector for user touch. Still another factor is environmental factors. That is, in colder climates, less cooling may be required, while in warmer climates, more cooling may be required. Regardless of the climate factor, the desired temperature of the cable and any associated components does not exceed about 140°F. Nevertheless, again, due to the increased power carried by the cable, cooling is still required.

[0008] U.S. Patent Publication No. 2022 / 0242260, titled "Non-Fluid Cooled Electric Vehicle Fast-Charging Cable" and assigned to the assignee of the present application, which was granted to Shoshani et al., discloses embodiments of a cable that can be used in a fast-charging system and operates without using a liquid cooling fluid.

[0009] Accordingly, there is a need for a system for fast-charging an EV that uses a gaseous cooling medium. Desirably, such a system uses forced air as the cooling medium. More desirably, such a system is flexible and may include multiples of each component to accommodate different and various environmental factors and achieve a predetermined outer temperature of the cable and connectors for ease of touch. SUMMARY OF THE INVENTION

[0010] Aspects of the present disclosure relate to an air-cooling system for an electric vehicle charging cable. The air-cooling system includes: a source of compressed air; at least one filter; at least one dryer; and a subcooler subsystem for refrigerating the compressed air from the source of compressed air. A coupler on the charging cable supplies the refrigerated compressed air to the charging cable. The system is configured to keep the outer surface of the charging cable below a predetermined temperature during vehicle charging. For example, the system is configured to reduce the surface temperature of the EV fast-charging cable and associated components to less than about 140°F by forcing the refrigerated and dried air through cooling channels in the fast-charging cable and through the connector handle for the charging cable. In various embodiments, to achieve this, the dried and compressed air at a desired flow rate is refrigerated and supplied to the cooling channels in the charging cable. In various embodiments, the system further includes a routing structure that guides the refrigerated compressed air back to the charging station to keep the charging cable at a temperature not exceeding the predetermined temperature. In some embodiments, the system may be configured to operate in a closed-loop mode based on the geographical climate zone. A method for air-cooling an electric vehicle charging cable is also disclosed herein.

[0011] In various embodiments, the subcooler subsystem includes a refrigerant cycle. The air-cooling system may further include a heat exchanger. In such embodiments, the heat exchanger includes a refrigerant side and an air side. The heat exchanger may be within the subcooler subsystem.

[0012] In various embodiments, the filter of the air-cooling system may include a hydrocarbon filter, and the dryer may include a desiccant dryer. The system may include multiple filters and / or dryers.

[0013] In some embodiments, an air-cooled electric vehicle charging cable and system may include first and second electric vehicle charging cable portions. Each cable portion may include an insulated conductor carried within a sheath. The sheath may include a wall having an inner surface and defining a cooling channel extending longitudinally along the charging cable between the sheath and the insulated conductor.

[0014] In various embodiments, the system may include: a source of compressed air; one or more filters; one or more dryers; and a subcooler subsystem. The system further includes a coupler on each charging cable portion for supplying chilled air to the air channels of the charging cable portion. In some embodiments, the charging cable cooling channels may be a series of cooling channels. In some embodiments, the series of cooling channels may be formed by a series of inwardly extending fingers extending inwardly from the inner surface. The fingers may be configured to space the insulator from the sheath wall. In some embodiments, the inwardly extending fingers are spaced apart to define an air channel extending longitudinally along the cable between the fingers.

[0015] In some embodiments, the charging cable may further include a connector handle, and the first and second charging cable portions terminate at the connector handle. An exhaust vent may be formed in the connector handle for discharging chilled air from the air channels of the charging cable portion. The exhaust vent may be fixed or movable.

[0016] In yet another aspect, a method for air-cooling an electric vehicle charging cable is disclosed. Such a cable has first and second electric vehicle charging cable portions, each portion including an insulated conductor carried within a sheath having a wall with an inner surface and defining a cooling channel extending longitudinally along the charging cable between the sheath and the insulated conductor.

[0017] The method includes: compressing air to a predetermined pressure; filtering the compressed air; drying the compressed and filtered air; and chilling the compressed, filtered, and dried air in a subcooler having a refrigerant cycle. The compressed, filtered, dried, and chilled air is introduced into the cable cooling channels. The air is discharged from the cooling channels at the connector handle. In the method, the air is compressed to such a pressure that the air exiting the exhaust means or vent is at a noise level not exceeding about -65 dB.

[0018] The method further includes routing the compressed, filtered, dried, and cooled air back to the charging station at a routing structure of the connector handle to keep the charging cable at a temperature not exceeding a predetermined temperature. The method further includes discharging the air from the vehicle according to the protection class requirements of the connector handle.

[0019] These and other objects, features, and characteristics of the present invention disclosed herein will become more apparent upon consideration of the following description and the appended claims in reference to the accompanying drawings, all of which form a part of this specification, wherein like reference numerals designate corresponding parts in the various figures. It is to be expressly understood, however, that the drawings are for the purpose of illustration and description only and are not intended as a definition of the limits of the present invention. As used in the specification and claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The present invention is illustrated by way of example and not limitation in the figures, in which like reference numerals indicate similar elements and in which:

[0021] Figure 1 is a schematic diagram of an air supply system for an EV fast charging system in accordance with one or more aspects described herein;

[0022] Figure 2 depicts a side view of an example fast charging cable and connector handle for use with components of an air supply system in accordance with one or more aspects described herein;

[0023] Figure 3 depicts a side view of an example connector handle for a fast charging cable in accordance with one or more aspects described herein;

[0024] Figures 4A to 4B depicts various views of an example fast charging cable and air coupler in accordance with one or more aspects described herein;

[0025] Figure 5 is a schematic diagram of a subcooler subsystem for an air supply system in accordance with one or more aspects described herein;

[0026] Figure 6 is similar to in accordance with one or more aspects described herein Figure 1 a schematic diagram of an air supply system having two air supply lines from the supply system to two fast charging cables; and

[0027] Figure 7 is a schematic diagram of the air supply system described herein in accordance with one or more aspects when used with an alternative embodiment of a fast charging cable and connector handle.

[0028] These figures are provided for illustrative purposes only and depict only exemplary or sample embodiments. The figures are provided to facilitate understanding by the reader and should not be construed as limiting the breadth, scope, or applicability of the present disclosure. For clarity and simplicity of illustration, the figures are not necessarily drawn to scale. Detailed Description

[0029] In the following description of various examples of the present invention, reference is made to the accompanying drawings, which form a part of the following description, and in which are shown, by way of illustration, various example structures, systems, and steps in which aspects of the present invention may be practiced. However, these aspects are merely indicative of a few of the various ways in which the principles of the present invention may be employed, and the present invention is intended to include all such aspects and their equivalents. It should be understood that other specific arrangements of parts, structures, example devices, systems, and steps may be used without departing from the scope of the present invention, and structural and functional changes may be made. In addition, to some extent, terms such as "top," "bottom," "front," "rear," "side," etc. are used in this specification to describe various example features and elements of the present invention, and these terms are used for convenience herein, e.g., based on the example orientations shown in the figures. Nothing in this specification should be construed as requiring a particular three-dimensional orientation of the structure to fall within the scope of the present invention.

[0030] An embodiment of the air cooling system reduces the surface temperature of an EV fast charging cable and associated components to less than about 140°F by forcing chilled and dry air through cooling channels in the fast charging cable and the connector handle for the charging cable. In the system, dry and compressed air at a desired flow rate is chilled and supplied to the cooling channels in the charging cable. In various embodiments, the chilling of the air will be on demand, that is, when cooling of the cable and components is required (e.g., during charging), the compressed air is chilled. The specific flow rate and cooling load will vary depending on local climate and seasonal temperature variations. The HVAC industry generally recognizes seven defined climate control zones. Thus, the specific components required to achieve the desired cooling and the quantity of each component may vary depending on the location of the EV charging system and the environmental conditions in which it is located.

[0031] Figure 1Schematic diagram of an example embodiment of an air supply system 10 for an EV fast charging system cable in accordance with one or more aspects described herein. For example, the air supply system 10 may be configured for use with a fast charging cable 12 further depicted and described herein. In various embodiments, the air supply system 10 may include: an air compressor 14 or other compressed air source; a compressed air storage tank 16; one or more air dryers 18 (e.g., such as a desiccant dryer); and / or a subcooler 20 that includes a refrigerant-based cooling or refrigeration system for compressed air. In some embodiments, the air supply system 10 may include: one or more filters 22; pipelines / conduits 24 between system components; and / or one or more other components. In various embodiments, compressed air from the air supply system 10 may be combined into the fast charging cable via a compressed air supply pipeline 26, which may be combined downstream of a cable accessory or connector 28 (e.g., as depicted in Figure 2 and Figure 4B and coupled to a power source (not shown).

[0032] In various embodiments, the compressor 14 may include an oil-free compressor, such as an oil-free scroll compressor. Such compressors may not discharge oil into the air system. The storage tank 16 may be any suitable type manufactured for storing pressurized gas (such as pressurized (compressed) air). In an example embodiment, the storage tank 16 may have a capacity of approximately 120 gallons, but appropriately sized tanks will be understood by those skilled in the art. In some embodiments, a 120-gallon tank may reduce the start / stop cycles of the compressor 14 to approximately 5 to 6 cycles per hour. In some embodiments, the storage tank 16 may also provide additional storage time for the compressed air to cool after the compression cycle (compression tends to increase the temperature of the gas leaving the compressor 14).

[0033] In various embodiments, the air supply system 10 includes one or more filters 22. In various embodiments, a first filter downstream of the compressor 14 and the storage tank 16 may include a hydrocarbon filter 22. The hydrocarbon filter 22 may be configured to remove tars, diesel, gasoline, and other hydrocarbon fumes that may be present in the compressed air. In various embodiments, the air supply system 10 may further include: a desiccant dryer 18 downstream of the storage tank 16, and a particulate filter 25 downstream of the desiccant dryer 18 to remove particulates that may be present in the compressed air stream. In some embodiments, the air supply system 10 may include a post-refrigerator (not shown) upstream of the subcooler 20 (e.g., between the desiccant dryer 18 or the particulate filter 25 and the subcooler 20) to further dry the air before the subcooler 20.

[0034] In various embodiments, a desiccant dryer 18 is positioned downstream of the hydrocarbon filter 22 and is used to remove moisture from the compressed air. Such dryers 18 are most useful in cold and / or wet or humid environments. In various embodiments, a subcooler 20, which may include a refrigerant-based cooling or refrigeration system, further reduces the temperature of the compressed air before discharging it into the air supply line 26. The size and capacity of the subcooler 20 may depend on local environmental factors such as local temperature and temperature range, the temperature and humidity of the inlet air, and the like.

[0035] Figure 2 A portion of a representative fast charging cable 12 and a connector handle 30 for use with components of the air supply system 10 in accordance with one or more aspects described herein are shown. As Figure 2 depicted, an air coupler 32 and an electrical terminal 28 may be provided to connect the fast charging cable 12 to the air supply system 10. Briefly referring to Figures 4A to 4B , various views of the fast charging cable 12 and the air coupler 32 are depicted in accordance with one or more aspects described herein. For example, in accordance with one or more aspects described herein, Figure 4A a cross-sectional view of the fast charging cable 12 is depicted, and Figure 4B a perspective view of the air coupler 32 is depicted. In various embodiments, the cable 12 may include a plurality of strands of conductors 34, an insulator 36 surrounding the conductors 34, and a sheath 38 surrounding the insulator 36. In various embodiments, the cable 12 may include an air channel 48 extending parallel to the conductors to move chilled and compressed air longitudinally through the cable 12 from the coupler 32 to the connector handle 30.

[0036] In some embodiments, the sheath 38 of the cable 12 may include a wall 40 having an inner surface 42 and an outer surface 44 and a series of inwardly extending fingers 46 that extend inwardly from the inner surface 42 to the insulator 36 and space the insulator 36 from the sheath 38. In various embodiments, the fingers 46 are spaced apart to define an air channel 48 extending longitudinally along the cable between the fingers 46. It should be understood that the fast charging cable 12 may require two strands of conductors 34 (and thus two portions of the cable 12) and two supply lines 26 from the cooling system 10. For example, Figure 6FIG. 0 provides a schematic illustration of an example of a fast - charging cable 12 in accordance with one or more aspects described herein. The fast - charging cable includes two cable portions 12a and 12b (i.e., two insulated electrical conductors 34 with a sheath (38)) and two air supply lines 26. Examples of such cables are also described in detail in the aforementioned U.S. Patent Publication No. 2022 / 0242260 to Shoshani et al. Other configurations of the cable 12 including air channels will be understood by those skilled in the art and are within the scope and spirit of the present disclosure.

[0037] Figure 4B The example air coupler 32 depicted in FIG. 4 shows the joining in the cable sheath 38 for coupling the air supply line 26 to the fast - charging cable portion 12a. As shown, the insulated conductor 34 may extend longitudinally through the sheath 38, and the joining or coupling of the air supply line 26 to the sheath 38 may cause the air supply line 26 to enter the sheath 38 at an angle with respect to a portion of the cable 12. Figure 4B The exposed portion of the conductor 34 shown in FIG. 6 may be connected to an electrical terminal 28 within a charger (not shown). The air coupler 32 may be configured such that, when manipulating the cable 12 (i.e., removing from the socket at the charger, inserting into a vehicle, and replacing in the charger socket), the coupler 32 does not kink the sheath 38 or the cable 12. In this way, the system may allow air to flow evenly or substantially evenly through the air channel 48 within the sheath 38. In various embodiments, the coupler 32 may be sealed to the cable 12 by a seal, epoxy, etc.

[0038] In various embodiments, Figure 2 and Figure 3The connector handle 30 depicted provides a connection of the cable 12 to a vehicle and also provides an outlet for chilled and compressed air. The connector handle 30 may be configured such that compressed and chilled air travels through and is discharged from the handle 30 to maintain the handle 30 at a temperature not exceeding about 140°F. In various embodiments, the handle 30 may include a body 54, a connector portion 56 for connection to an electric vehicle, a cable receiver 58, a handgrip portion 60, an exhaust port 62, and / or one or more other components. In various embodiments, the fast charging cable 12 may enter the handle 30 at the cable receiver 58, and the conductors 34 terminate at the connector portion 56 for connection to the electric vehicle. The cable sheath 38 may open into the interior of the handle 30 at the cable receiver 58 and provide a path for chilled air from the cable 12 through the handle 30. Air may be discharged from the handle 30 at the exhaust port 62. In various embodiments, the exhaust port 62 may include a vent opening having a series of spaced-apart slats 64 (e.g., shark gills) for discharging air through the spaces between the slats 64. The slats 64 may be fixed or movable. To pass immersion and dust tests, it may be necessary to close the vent 62 (or the slats 64) when the charging system is not operating. Additionally, it may also be necessary to use gaskets, sealants, and / or the like to secure / seal other portions of the interior of the handle 30.

[0039] Figure 5 is a schematic view of a subcooler subsystem 20' for an air supply system 10 in accordance with one or more aspects described herein. The subcooler 20 may take many forms, as will be understood by those skilled in the art. In various embodiments, the subcooler 20 is configured to cool or freeze dry inlet air. For example, in a particular environment or HVAC zone, the subcooler 20 may be configured to freeze dry air from about 45°C (113°F) to about 10°C (50°F). A suitable subcooler 20 may be a refrigerant-based cooling or freezing system to further reduce the temperature of compressed air before discharging it into the air supply line 26. In various embodiments, the air supply system 10 may include a heat exchanger 70 having a refrigerant side or subsystem 70b through which refrigerant circulates and a chilled air side 70a. In some embodiments, the heat exchanger 70 may be incorporated into the subcooler 20 (thereby forming the subcooler subsystem 20'). To maintain the desired outlet chilled air temperature, temperature sensors 84 may be positioned at the inlet air stream 86 and the outlet air stream 88 of the heat exchanger 70 (at the air side 70b of the heat exchanger 70), respectively.

[0040] When implemented, the air supply system 10 can facilitate a method for air-cooling a fast-charging EV cable, such as cable 12 depicted and described herein. In various implementations, the method can include compressing air in compressor 14 to such a pressure that the system will operate at an audio noise level of no more than about -65 dB at the charging handle exhaust or vent 62. The compressed air can be stored, for example, in storage tank 16. The compressed air is then filtered in filter 22. Suitable filters 22 include, for example, at least one hydrocarbon filter to remove tars, diesel, gasoline, and other hydrocarbon fumes that may be present in the compressed air.

[0041] The filtered air is then dried, for example, in desiccant dryer 18 to remove moisture from the compressed air. Desiccant dryer 18 can be most beneficial in cold and / or humid or wet environments. The filtered and dried air can then be filtered in particulate filter 25.

[0042] The filtered and dried air can then be cooled in subcooler 20. A suitable subcooler 20 is a refrigerant-based cooling or refrigeration system to further reduce the temperature of the compressed air before discharging it into air supply line 26.

[0043] Figure 7 Alternative embodiments of the fast-charging cable 12 and connector handle 30 are shown in accordance with one or more aspects described herein. In various embodiments, heated air can be discharged or routed away from the vehicle at vehicle end 39, depending on the protection (e.g., moisture and / or dust) rating requirements of the EV charger. For example, in some embodiments, handle 30 can be configured to provide a connection of cable 12 to the vehicle and further include a routing structure (not shown) within the body 54 of handle 30 for chilled and compressed air. The connector handle is configured such that the compressed and chilled air travels and is directed (i.e., rerouted) at the routing structure of the handle and returns to the charging station to keep the handle at a temperature at or below a predetermined temperature. For example, as Figure 7 depicted, the compressed and chilled air 33 travels from the charging station end 31 of cable 12 through one or more air channels 48 (as Figure 4A depicted) and is redirected (or rerouted) at the routing structure of handle 30 at vehicle end 39 of cable 12. The heated air 37 can return to the charging station end 31 to keep the handle at a temperature not exceeding a predetermined temperature, for example, about 140°F.

[0044] In various embodiments, compressed and chilled air 33 may travel from the charging station end 31 through one or more air channels 48 positioned circumferentially equidistantly spaced around an insulator surrounding an insulated conductor, while heated air 37 may flow back to the charging station end 31, with the remaining air channels 48 positioned circumferentially equidistantly spaced around an insulating layer of the insulated conductor. In some embodiments, compressed and chilled air 33 may travel from the charging station end 31 through one or more air channels 48 positioned circumferentially equidistantly spaced around an insulator surrounding an insulated conductor, while heated air 37 may flow back to the charging station end 31, with additional air channels positioned within the cable. However, it should be understood that one or more air channels 48 may be used with any suitable configuration without departing from the scope of the invention described herein.

[0045] Air returning through the cable may be discharged at the charging station end 31, for example, at the rear side of the air supply system 10 adjacent to the connection for DC power and / or the charger itself. In such embodiments, heated air may be discharged from the vehicle that has been plugged in and is charging. Thus, depending on the protection rating requirements of the EV charger, the heated air may be discharged at the vehicle end 39 or from the vehicle end.

[0046] In some embodiments, the air supply system 10 may be further connected to one or more air extraction devices (e.g., exhaust fans and / or vacuum pumps) to draw the heated air back into the air supply system 10 and further enhance the cooling efficiency.

[0047] In various embodiments, depending on the geographical conditions, the air supply system 10 may be configured to operate in an open-loop or closed-loop mode for heat dissipation. In some embodiments, the air supply system 10 may operate in a closed-loop mode based on geographical climate zones for heating / cooling. For example, compared to the air supply system 10 located in a polar climate zone, the air supply system 10 located in a tropical climate zone may operate in a closed-loop mode optimized for high temperatures. Similarly, compared to the air supply system 10 located in an arid climate zone, the air supply system 10 located in a tropical climate zone may operate in a closed-loop mode optimized for high precipitation. In some embodiments, the closed-loop configuration may further use a heat exchanger 70 (as Figure 5 disclosed) to actively extract heat from the cable 12.

[0048] In some embodiments, the heat from the heat dissipation process may be utilized to keep the air supply system 10 in a walk-in closet (WIC) / outdoor-rated shed at an optimal temperature in low-temperature situations (during cold seasons). Various types of seasonal use of the heated air will be welcomed especially in the northern hemisphere regions.

[0049] In other embodiments, the WIC may include a cooling system to ensure optimal shed temperature in high temperature situations (during hot seasons). In certain embodiments, one or more of the compressed air tanks may be installed underground to take advantage of the low temperature (e.g., a temperature of about 55°F below ground level), and for improving temperature uniformity.

[0050] When implemented, the methods described herein may further include providing filtered and chilled air to an EV fast charging cable 12 having at least a pair of insulated conductors 34, each carried in a sheath 38. One or more air channels 48 are formed between the sheath 38 and the insulated conductors 34, and the method includes forcing chilled and dry air through the air channels 48 to cool the charging cable 12 and the connector handle 30. In various implementations, air exits the cable 12 at the connector handle 30. The handle 30 may include vents 62 through which the air exits.

[0051] It should be understood that the system 10 effectively cools a fast charging EV charging system using cooled or chilled compressed air. Such systems are flexible and may include multiples of each component to accommodate different and various environmental factors and achieve a predetermined external temperature of the cable and connector for ease of touch. In such systems, dry and compressed air at a desired flow rate is chilled or cooled and supplied as needed to the cooling channels in the charging cable. That is, when cooling of the cable and components is required (e.g., during charging), the compressed air is chilled.

[0052] Those skilled in the art will appreciate the advantages of a fast charging EV cable that does not require cooling of the coiled cable, thereby eliminating cooling fluid, fluid connections, and potential leaks. Although certain materials for insulators, adhesives, thermal blankets, and sheaths are disclosed, those skilled in the art will recognize other suitable materials for a fast charging EV cable that are within the scope and spirit of the present disclosure. It should also be recognized that the various materials and layers in any of the disclosed embodiments may be used with other embodiments, and all such embodiments and their variations are within the scope and spirit of the present disclosure.

[0053] It should be understood that the application of the present invention is not limited to the details of the construction and component arrangement set forth herein. The present invention is capable of other embodiments and of being practiced or carried out in various ways. Variations and modifications of the foregoing are within the scope of the present invention. It should be understood that the invention as disclosed and defined herein extends to all alternative combinations of two or more separate features mentioned in the text and / or shown in the drawings or made apparent from the text and / or drawings. All such combinations in different permutations constitute various alternative aspects of the present invention. The embodiments described herein explain the best mode known for practicing the invention and will enable those skilled in the art to utilize the invention.

[0054] Although the preferred embodiments of the present invention have been shown and described, it will be apparent to those skilled in the art that changes and modifications can be made without departing from the spirit of the invention as defined by the scope of this description.

[0055] References in this specification to "one implementation", "an implementation", "some implementations", "various implementations", "certain implementations", "other implementations", "a series of implementations", etc. mean that a particular feature, design, structure, or characteristic described in connection with the implementation is included in at least one implementation of the present disclosure. For example, the phrase "in one implementation" or "in an implementation" that appears in various places in this specification does not necessarily all refer to the same implementation, nor is it a separate implementation or alternative implementation that is mutually exclusive with other implementations. In addition, whether or not the "implementation" and the like are explicitly mentioned, various features are described, and these features can be combined in various ways and included in some implementations, but can also be omitted in various ways in other implementations. Similarly, various features are described, and these features can be preferences or requirements for some implementations, but not for other implementations.

[0056] The language used herein has been selected primarily for readability and guidance purposes and may not have been chosen to depict or limit the subject matter of the present invention. Other implementations, uses, and advantages of the present invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. This specification should be regarded as merely exemplary, and the scope of the present invention is therefore expected to be limited only by the appended claims.

Claims

1. An air cooling system for an electric vehicle charging cable, comprising: Compressed air source; At least one filter; At least one dryer; A subcooler subsystem for freezing compressed air from the compressed air source; And A coupler on the charging cable for supplying frozen compressed air to the charging cable, wherein the system is configured to keep the outer surface of the charging cable below a predetermined temperature during vehicle charging.

2. The air cooling system according to claim 1, wherein the subcooler subsystem includes a refrigerant cycle.

3. The air cooling system according to claim 2, further comprising a heat exchanger.

4. The air cooling system according to claim 3, wherein the heat exchanger includes a refrigerant side and an air side.

5. The air cooling system according to claim 4, wherein the heat exchanger is within the subcooler subsystem.

6. The air cooling system according to claim 1, wherein the filter is a hydrocarbon filter.

7. The air cooling system according to claim 1, wherein the dryer is a desiccant dryer.

8. The air cooling system according to claim 1, wherein the opposite end of the charging cable to the air cooling system terminates at a connector handle configured to connect the charging cable to an electric vehicle.

9. The air cooling system according to claim 8, wherein the connector handle includes a routing structure configured to redirect the chilled compressed air arriving at the connector handle back to the air cooling system.

10. An air-cooled electric vehicle charging cable and system, comprising: First and second electric vehicle charging cable portions, each portion including an insulated conductor carried in a sheath, the sheath having a wall with an inner surface and defining a cooling channel extending longitudinally along the charging cable between the sheath and the insulated conductor; Compressed air source; Filter; Dryer; Subcooler subsystem; A coupler on each charging cable portion for supplying chilled air to the air channels of the charging cable portion.

11. The air-cooled electric vehicle charging cable and system according to claim 10, wherein the cooling channels are a series of cooling channels.

12. The air-cooled electric vehicle charging cable and system according to claim 11, wherein the series of cooling channels are formed by a series of inwardly extending fingers extending inwardly from the inner surface, the fingers spacing the insulator from the sheath wall, and the inwardly extending fingers being spaced apart from each other to define air channels extending longitudinally along the cable between the fingers.

13. The air-cooled electric vehicle charging cable and system according to claim 10, further comprising a connector handle, wherein the first and second charging cable portions terminate at the connector handle.

14. The air-cooled electric vehicle charging cable and system according to claim 13, further comprising an exhaust vent formed in the connector handle for discharging the chilled air from the air channels of the charging cable portions.

15. The air-cooled electric vehicle charging cable and system according to claim 14, wherein the exhaust vent is fixed.

16. The air-cooled electric vehicle charging cable and system according to claim 13, wherein the connector handle includes a routing structure configured to redirect the chilled air reaching the connector handle back through the cable.

17. A method for air-cooling an electric vehicle charging cable, the cable having first and second electric vehicle charging cable portions, each portion including an insulated conductor carried in a sheath, the sheath having a wall with an inner surface and defining a cooling channel extending longitudinally along the charging cable between the sheath and the insulated conductor, the method comprising: Compress air to a predetermined pressure; Filter the compressed air; Dry the compressed and filtered air; Freeze the compressed, filtered and dried air in a subcooler having a refrigerant cycle; and Introduce the compressed, filtered, dried and frozen air into the cooling channel.

18. The method according to claim 17, further comprising discharging the air from the cooling channels at the connector handle.

19. The method according to claim 17, further comprising redirecting the chilled compressed air reaching the connector handle back through the cable towards the air-cooling system.

20. The method according to claim 17, further comprising discharging the air from the vehicle according to the protection class requirements of the connector handle.

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