Terminal heat exchanger for electrical connectors

Abstract

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

Description

[0001] This application is a divisional application of the invention patent application with application number 202010200987.7, application date March 20, 2020, and invention title "Terminal Heat Exchanger for Electrical Connectors". Technical Field

[0002] The main topic of this article concerns heat exchangers used in electrical connectors. Background Technology

[0003] Electrical connectors, such as power connectors, generate heat when current flows through the terminals and cables. For example, the electrical connectors of the charging inlet assembly for a battery system in an electric vehicle (EV) or hybrid electric vehicle (HEV) can 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 vehicle's battery system. 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 temperature increases, which can potentially damage components of the charging inlet assembly.

[0004] Electrical connectors with cooling systems are still required, which are used to cool the terminals of the electrical connectors. Summary of the Invention

[0005] In one embodiment, an electrical connector is provided. The electrical connector includes a housing extending between a front portion and a rear portion. The housing has a cavity at the rear portion. The housing has a terminal channel between the front and rear portions. A terminal is coupled to the housing. The terminal includes a mating pin at the front of the terminal and a cable connector at the rear of the terminal. The mating pin is positioned in the terminal channel for mating with a charging connector. The cable connector is positioned in the cavity at the rear of the housing. A terminal heat exchanger is positioned in the cavity. The terminal heat exchanger is thermally coupled to the cable connector of the terminal. The terminal heat exchanger has an insulating element that electrically insulates the terminal heat exchanger from the terminal. Attached Figure Description

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

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

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

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

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

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

[0012] Figure 6 This is a rear perspective and partial sectional view of a portion of the charging inlet assembly, showing a terminal heat exchanger according to an exemplary embodiment.

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

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

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

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

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

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

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

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

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

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

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

[0024] Figure 18This is a rear perspective and partial sectional view of a portion of a charging inlet assembly according to an exemplary embodiment, showing a cooling system docked with a terminal heat exchanger.

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

[0026] Figure 20 This is an exploded view with a rear perspective and partial cutaway of a portion of a charging inlet assembly according to an exemplary embodiment, showing the connected terminal heat exchanger.

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

[0028] Figure 22 This is a schematic diagram of a cooling system according to an exemplary embodiment. Detailed Implementation

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

[0030] The charging inlet assembly 100 serves as a charging inlet for vehicles such as electric vehicles (EVs) or hybrid electric vehicles (HEVs). The charging inlet assembly 100 includes an electrical connector 102 configured to mate with a charging connector (not shown). In an exemplary embodiment, the electrical connector 102 is configured to mate with a DC fast charging connector (such as the SAE Combined CCS charging connector) and also with an AC charging connector (such as the SAE J1772 charging connector).

[0031] The charging inlet assembly 100 includes a housing 110 that holds terminals 114 forming part of an electrical connector 102. Terminals 114 are electrically connected to corresponding power cables 118. Terminals 114 are configured to mate with a charging connector. Terminals 114 are received in a terminal channel 116 and coupled to the housing 110 within the terminal channel 116. In an exemplary embodiment, the charging inlet assembly 100 includes a cooling system 130 for actively cooling the terminals 114. For example, coolant may be pumped through lines or channels of the cooling system and flows in thermal communication with the terminals 114 to dissipate heat from the terminals 114. The cooling system 130 may also be used to actively cool the power cables 118 terminated at the terminals 114.

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

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

[0034] Figure 2 This is a side view of terminal 114 according to an exemplary embodiment. Terminal 114 includes a mating pin 200 at a front portion 210 of terminal 114 and a cable connector 202 at a rear portion 212 of terminal 114. 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 be electrically connected to a power cable 118 (e.g., Figure 1 As shown). In an exemplary embodiment, the mating pin 200 and / or cable connector 202 are configured to be cooled by the cooling system 130 (as shown). Figure 1 (As shown) Active cooling. For example, the cooling system 130 is configured to thermally connect to the mating pin 200 and / or cable connector 202 at the rear 212 of the terminal 114, and the coolant of the cooling system 130 is used to dissipate heat from the terminal 114.

[0035] In various embodiments, the cable connector 202 is separate and independent 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 may be press-fitted onto the mating pin 200. However, in alternative embodiments, the cable connector 202 may be secured to the mating pin 200 by other methods, such as friction stir welding, riveting, bolting, etc. In other various embodiments, the cable connector 202 is integral with the mating pin 200, such as being formed together with the mating pin 200. In various embodiments, the cable connector 202 is configured to terminate 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 other various 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 crimping barrel configured to terminate the power cable 118. Figure 3 ) or cable drum ( Figure 4 ).

[0036] The mating pin 200 is conductive. For example, the mating pin 200 may be made of a metallic material such as copper. 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) with additives to increase machinability. In an exemplary embodiment, the mating pin 200 is cylindrical. In an exemplary embodiment, the mating pin 200 includes a cap 216 at its end 218. The cap 216 is made of a dielectric material such as plastic. The cap 216 securely contacts the terminal 114 at the front of the housing 110.

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

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

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

[0040] Cable connector 202 includes a cable termination 240 at a rear portion 212 of terminal 114. Power cable 118 is configured to terminate at cable termination 240. In the illustrated embodiment, cable connector 202 includes a solder cap 242 at the rear portion 212 defining cable termination 240. Solder cap 242 is separate and independent from mating pin 200 and mounting shaft 232. In an exemplary embodiment, solder cap 242 is configured to be actively cooled by cooling system 130 to reduce the operating temperature of terminal 114.

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

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

[0043] Figure 3 This is a side view of terminal 114 according to an exemplary embodiment. Figure 3 A cable termination 240 including a crimp contact 244 is shown. The crimp contact 244 includes a crimping sleeve 246. The crimping sleeve 246 is configured to crimp to a power cable 118 (e.g., Figure 1 (As shown). In an exemplary embodiment, the press contact 244 is separate and independent from the mating pin 200, and is connected to the mounting shaft 232 at the rear 212 of the terminal 114. The press contact 244 can be coupled to the welding cap 242 (as shown). Figure 2 Connected to the mounting shaft 232 in a similar manner (as shown). For example, the crimp contact 244 may include a base 250 configured to crimp into the rear mounting post 236 (shown in dashed lines), and the crimp contact may include a pad at the top of the base 250, from which the crimp cylinder 246 extends.

[0044] Figure 4 This is a side view of terminal 114 according to an exemplary embodiment. Figure 4 A cable termination 240 is shown, which includes a cable reel 248 (shown in dashed lines) at the rear 212 of terminal 114. The cable reel 248 opens at the rear 212 along the longitudinal axis 204. The cable reel 248 receives the power cable 118 (e.g., ...). Figure 1 The power cable 118 can be brazed or soldered to the terminal 114 at the cable sleeve 248. In the illustrated embodiment, the cable sleeve 248 is defined by the mounting shaft 232 and is integral with the mating pin 200, rather than being a separate component connected to the rear end of the terminal 114.

[0045] Figure 5 This is a cross-sectional view of the charging inlet assembly 100 according to an exemplary embodiment. Figure 5One of the terminals 114 connected to housing 110 is shown. Housing 110 extends to a rear portion 138, and a rear cover 128 is connected to housing 110 at the rear portion 138. Housing 110 has a chamber 140 at the rear portion 138. The rear cover 128 is located behind and closes the chamber 140. The rear cover 128 may include a cable outlet (e.g., an opening) that receives a 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 used to actively cool the terminals 114.

[0046] Terminal 114 extends into chamber 140, and power cable 118 terminates in terminal 114 within chamber 140. Cooling system 130 interfaces with terminal 114 in chamber 140 to provide active cooling for terminal 114. For example, terminal heat exchanger 300 is positioned in chamber 140 to interface with terminal 114. Terminal heat exchanger 300 is thermally coupled to terminal 114 to dissipate heat from terminal 114 and reduce the operating temperature of terminal 114, thereby improving the performance of charging inlet assembly 100 and / or allowing higher current to pass through terminal 114 and / or reducing the risk of damage to terminal 114.

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

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

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

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

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

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

[0053] In one exemplary embodiment, the heat transfer element 306 includes a clip 320 coupled to the cable connector 202 of the terminal 114 (also in... Figure 8 (As shown in the diagram). Manifold 304 is coupled to clip 320. In various embodiments, manifold 304 may be latchably coupled to clip 320. In other various embodiments, manifold 304 may be coupled to clip 320 using fasteners or other securing devices. In an exemplary embodiment, a seal 358 is provided between manifold 304 and clip 320. Figure 9 (as shown), to prevent coolant leakage from flow channel 302.

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

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

[0056] The isolator 308 is connected to the cable connector 202, such as to the outer surface 254, and can also be connected to the outer surface 234 of the mounting shaft 232 (both are in...). Figure 2 (As shown in the diagram). An isolator 308 is located between the cable connector 202 and the clip 320 of the heat transfer element 306. The isolator 308 forms a thermal bridge between the cable connector 202 and the clip 320 of the heat transfer element 306. The isolator 308 electrically insulates the terminal 114 from the heat transfer element 306. In an exemplary embodiment, the isolator 308 includes a ring 338 with an opening that receives the cable connector 202 corresponding to the terminal 114. In the illustrated embodiment, the ring 338 extends around the cable connector 202 along its entire circumference.

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

[0058] Figure 7This is a bottom perspective view of the manifold 304 of a terminal heat exchanger 300 according to an exemplary embodiment. A flow passage 302 is defined by the manifold 304 and opens at the inner surface 312 of the manifold body 310. In the exemplary embodiment, the flow passage 302 is defined by a partition wall 350, which forms a serpentine path at the inner surface 312 defining the flow passage 302. The flow passage 302 extends from a manifold inlet 316 to a manifold outlet 318. The thickness of the partition wall 350 controls the height of the flow passage 302, which in turn controls the volume of coolant flowing through the manifold 304.

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

[0060] In alternative embodiments, manifold 304 may have other shapes or sizes. Manifold 304 may include fixing features (not shown) for securing manifold 304 to heat transfer element 306. For example, manifold 304 may include latches, fasteners, or other types of fixing features.

[0061] Figure 8 This is a cross-sectional view of a heat transfer element according to an exemplary embodiment. Figure 8 A fastener 332 is shown attached to clip 320. Cable connector 202 is shown in a first hole 324 and a second hole 328. Fastener 332 is configured to engage clamping arms 322, 326 to secure and compress clamping arms 322, 326 around isolator 308 and cable connector 202. For example, nut 334 attached to fastener 332 can be tightened to engage and compress clamping arms 322, 326 against isolator 308 and cable connector 202. Clamping arms 322, 326 are compressed to thermally engage with isolator 308 to provide efficient heat transfer from cable connector 202 to clip 320. Figure 8 A spacer 308 is shown, which includes an adhesive layer 342 and an insulating layer 344 of a membrane 340. In an alternative embodiment, spacer 308 may include other layers. In various other embodiments, spacer 308 may include a single layer.

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

[0063] In an exemplary embodiment, manifold 304 includes a retaining element 354 for securing manifold 304 to clip 320. In the illustrated embodiment, retaining element 354 includes a latch 356 latchably coupled to base 330 of clip 320. A seal 358 is disposed at the interface between manifold 304 and heat transfer element 306. Seal 358 seals the junction of manifold 304 and heat transfer element 306 to prevent coolant leakage from flow passage 302. Seal 358 can be compressed when retaining element 354 is secured to heat transfer element 306.

[0064] Figure 10 This is a cross-sectional view of a terminal heat exchanger 300 according to an exemplary embodiment. Figure 10 A manifold 304 is shown mounted to a heat transfer element 306, wherein a flow passage 302 extends from a manifold inlet 316 to a manifold outlet 318. In the illustrated embodiment, a retaining element 354 includes a fastener 360, such as a threaded fastener, which is coupled to the base 330 of the manifold 304 and the clip 320. The fastener 360 passes through a hole 362 in the manifold 304. The hole 362 may be defined by one or more partition walls 350. In an exemplary embodiment, a seal 364 is disposed around the hole 362 to prevent coolant leakage from the flow passage 302.

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

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

[0067] Coolant supply line 132 is defined by supply port 133, and coolant return line 134 is defined by return port 135 of rear cover 128. Supply port 133 and return port 135 are integral with rear cover 128, such as being molded together with rear cover 128. Supply port 133 is coupled to manifold inlet 316 having a sealed interface. Return port 135 is coupled to manifold outlet 318 at the sealed interface. In an exemplary embodiment, when rear cover 128 is installed and coupled to housing 110 (e.g., Figure 5 As shown, supply port 133 and return port 135 are connected to manifold 304. Hose or other coolant lines can be connected from the outside of rear cover 128 to supply port 133 and return port 135.

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

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

[0070] The first isolator 370 includes an open ring 374 having a slot 376 extending longitudinally along the open ring 374. In an exemplary embodiment, the open ring 374 is a pre-formed part having an annular shape, such as a molded part. The open ring 374 can be clamped onto the cable connector 202. In an exemplary embodiment, the open ring 374 can be compressed around the cable connector 202 when the clip 320 is tightened around the first isolator 370.

[0071] The second isolator 372 includes an open ring 378 having a gap 380 extending longitudinally along the open ring 378. The open ring 378 includes flanges 382 and 384 at opposite ends. The flanges 382 and 384 are opposite each other across the gap 380 region, and a clip 320 is configured to engage with the flanges 382 and 384 to compress the second isolator 372 around the cable connector 202 when the clip 320 is tightened around the second isolator 372.

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

[0073] In an exemplary embodiment, an isolator 308 is formed at a suitable location between the body 390 of the clip 320 and the terminal 114. The isolator 308 includes an isolator body 394 that forms a thermal bridge between the terminal 114 and the clip 320. For example, the isolator body 394 of the isolator 308 may be injection molded into a first hole 324 and a second hole 328 to fill the space between the outer surface 254 of the cable connector 202 and the inner surface 392 of the holes 324, 328. The isolator body 394 is formed at a suitable location between the terminal 114 and the clip 320 to completely fill the space between the cable connector 202 and the clip 320, thereby providing effective thermal bridging between the cable connector 202 and the clip 320.

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

[0075] Figure 17 This is a cross-sectional view of a portion of a charging inlet assembly 100 according to an exemplary embodiment, showing a cooling system 130, which includes... Figure 17The ring 400 shown is mated with the terminal heat exchanger 300. The terminal heat exchanger 300 includes a flow channel 302 of the ring 400 that allows coolant to flow through the separator 308. The flow channel 302 extends through the terminals 114 to allow coolant to flow across the radial fins 402 of the annulus 400 and through the fin channels 404. In the illustrated embodiment, the flow channel 302 has an inlet side across one of the terminals 114 and a return side across the other of the terminals 114. In alternative embodiments, other arrangements of the flow channel 302 are possible, such as parallel flow instead of series flow.

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

[0077] Figure 19 This is a rear perspective view of part of the charging inlet assembly 100, showing a terminal heat exchanger 300 connected to one of the terminals 114. Figure 20 yes Figure 19 An exploded rear-view, partially cutaway view of a portion of the charging inlet assembly 100 shown illustrates a terminal heat exchanger 300 coupled to one of the terminals 114. In the illustrated embodiment, the terminal heat exchanger 300 is coupled to a solder pad 252 of the cable connector 202, rather than to a base 250. The terminal heat exchanger 300 dissipates heat directly from the solder pad 252, rather than directly from the base 250. The solder pad 252 provides a large surface area for heat transfer. The solder pad 252 provides a flat surface for mechanically and thermally coupling the terminal heat exchanger 300 to the terminal 114. In an exemplary embodiment, the terminal heat exchanger 300 is coupled to the solder pad 252 using fasteners 420.

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

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

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

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

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

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

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

Claims

1. An electrical connector (102), comprising: A housing (110) extending between a front portion and a rear portion (138), the housing having a chamber (140) at the rear portion and a terminal channel (116) between the front portion and the rear portion. A terminal (114) is connected to the housing, the terminal including a mating pin (200) at the front (210) of the terminal and a cable connector (202) at the rear (212) of the terminal, the mating pin being positioned in the terminal channel for mating with a charging connector, the cable connector being positioned in a cavity at the rear of the housing; and A terminal heat exchanger (300) is positioned in the chamber and is thermally connected to a cable connector of the terminal. The terminal heat exchanger has an insulating element (308) that electrically insulates the terminal heat exchanger from the terminal. The terminal heat exchanger (300) includes a manifold (304), a heat transfer element (306), and a flow channel (302) for allowing coolant to flow through the terminal heat exchanger to actively cool the terminal (114). The manifold (304) has an inner surface (312). A manifold body (310) extending between the inner surface (312) and the outer surface (314), the flow channel (302) being defined by the manifold body (310) between the inner surface (312) and the outer surface (314), the flow channel (302) being open at the inner surface (312) for direct thermal contact with and flow along the heat transfer element (306), the heat transfer element (306) being coupled to the terminal (114) and thermally connected to the cable connector (202) of the terminal; The heat transfer element (306) includes a clip (320) connected to the cable connector (202), the clip being compressed against the isolator (308), the clip including a clamp arm that extends at least partially circumferentially around the cable connector, the clamp arm for securing the clip to the terminal, the clamp arm being compressed against the cable connector and / or the isolator.

2. The electrical connector (102) according to claim 1, wherein, The terminal heat exchanger (300) includes a manifold (304) having a flow channel (302) for providing a coolant flow between the inlet (316) and the outlet (318) of the manifold, and an isolator (308) positioned between the coolant in the flow channel and the cable connector (202) of the terminal (114).

3. The electrical connector (102) according to claim 1, wherein, The heat transfer element (306) includes an inner surface facing the cable connector (202) and an outer surface opposite to the inner surface, the spacer (308) is positioned between the inner surface and the cable connector, and the terminal heat exchanger (300) includes a flow channel (302) for allowing coolant to flow through the terminal heat exchanger to actively cool the outer surface of the heat transfer element.

4. The electrical connector (102) according to claim 1, wherein, The cable connector (202) of the terminal (114) includes a solder tab, the heat transfer element (306) includes a heat pad (430) connected to the solder tab, and the insulating member (308) is connected to the heat pad.

5. The electrical connector (102) according to claim 4, wherein, The flow channel provides coolant in thermal communication with the heat transfer element (306), and the insulating member (308) is positioned between the coolant in the flow channel and the heat pad (430).

6. The electrical connector (102) according to claim 1 further includes a rear cover (128) coupled to the rear portion (138) of the housing (110), the rear cover including a coolant inlet and a coolant outlet, the coolant inlet being in fluid communication with the terminal heat exchanger (300), and the coolant outlet being in fluid communication with the terminal heat exchanger.

7. The electrical connector (102) according to claim 1, wherein, The isolator (308) is a ring (338) with an opening that receives the cable connector (202) of the terminal (114).

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