Charging device

Abstract

The utility model discloses a charging device, and relates to the technical field of charging. The charging equipment comprises a pile body, the pile body is provided with a pile end connector, the pile end connector is used for being connected with an electric vehicle, and the electric vehicle is provided with a battery cavity; and the heat management module is constructed to be communicated with the battery cavity to form a battery heat exchange branch under the condition that the pile end interface is connected with the electric vehicle, so that insulation heat exchange fluid in the heat management module flows in the battery heat exchange branch and is charged into the battery cavity. The charging equipment provided by the utility model provides a heat management function for the battery pack on the electric vehicle, so that the fast charging speed can be further improved.

Description

Technical Field

[0001] The utility model relates to the technical field of charging, in particular to a charging device. Background Art

[0002] With the popularization of electric vehicles such as new energy vehicles, eVTOL (Electric Vertical Takeoff and Landing, electric vertical take-off and landing aircraft), and new energy ships that are mainly powered by electricity, charging equipment such as charging piles are playing an increasingly important role and have increasingly higher indicators, such as the continuous improvement of charging speed requirements.

[0003] In the related art, when a charging pile is rapidly charging a battery pack of an electric vehicle, the battery pack generates a large amount of heat, thereby affecting the charging speed. Utility Model Content

[0004] The main purpose of the utility model is to provide a charging device, which aims to solve the technical problem in the related art that a battery pack generates a large amount of heat and affects the charging speed.

[0005] To achieve the above-mentioned purpose, the present invention provides a charging device, which includes:

[0006] A pile body having a pile end interface for connecting to an electric vehicle, wherein the electric vehicle has a battery cavity; and

[0007] The thermal management module is constructed to communicate with the battery cavity to form a battery heat exchange branch when the pile end interface is connected to the electric vehicle, so that the insulating heat exchange fluid in the thermal management module can flow in the battery heat exchange branch and fill the battery cavity.

[0008] In one embodiment, the thermal management module further includes an air-filling and fluid-exchanging component;

[0009] Among them, the inflation and fluid exchange component is connected to the battery heat exchange branch, and is used to input non-combustible gas into the battery cavity to discharge the insulating heat exchange fluid from the battery cavity; the non-combustible gas includes one or more of inert gas, nitrogen, carbon dioxide and sulfur hexafluoride.

[0010] In one embodiment, the gas-inflating and liquid-exchanging assembly includes a gas-inflating branch circuit, which includes a gas storage device and a gas circuit valve connected in sequence through a pipeline;

[0011] Among them, the output end of the inflation branch is connected to the pipeline between the heat exchanger and the pile end interface, and a switch valve is provided on the pipeline between the heat exchanger and the output end of the inflation branch; among them, the gas circuit valve is a pressure reducing valve.

[0012] In one embodiment, the battery cavity is filled with a battery heat exchange medium to form immersion cooling for the battery cell group in the battery cavity, and the material of the battery heat exchange medium is consistent with the material of the insulating heat exchange fluid.

[0013] In one embodiment, the insulating heat exchange fluid is made of deionized water, electronic fluorinated liquid, hydrocarbons, esters, or silicone oils.

[0014] In one embodiment, the charging device also includes a charging power device, a device cavity is provided in the pile body, the charging power device is arranged in the device cavity, the thermal management module is connected to the device cavity to form a device heat exchange branch, so that the insulating heat exchange fluid in the thermal management module flows in the device heat exchange branch and enters the device cavity to form immersion cooling of the charging power device.

[0015] In one embodiment, the thermal management module includes a main circuit, which includes a medium storage box, a pump, and a heat exchanger connected in sequence through pipelines. The thermal management module is arranged inside or outside the pile body.

[0016] In one embodiment, the device heat exchange branch and the battery heat exchange branch are connected in parallel and then in series to the main circuit to form a circulation loop; or, the device heat exchange branch, the battery heat exchange branch and the main circuit are connected in series to form a circulation loop.

[0017] In one embodiment, the heat exchanger comprises a direct evaporation refrigeration cycle device or a semiconductor refrigeration device; and / or

[0018] The main circuit also includes a positive temperature coefficient PTC heater, or the heat exchanger is connected to a heat pump system, and the heat pump system switches between cooling mode and heating mode.

[0019] In one embodiment, the thermal management module includes:

[0020] a first thermal management submodule, the first thermal management submodule being in communication with a device heat exchange branch;

[0021] The second thermal management submodule is connected to the battery heat exchange branch.

[0022] In one embodiment, the charging device further includes a charging gun, which includes:

[0023] A charging gun head having a fluid interface; and

[0024] A charging gun cable, one end of which is connected to the charging gun head, and the other end of which is connected to the thermal management module. A fluid conduit is provided in the charging gun cable for the insulating heat exchange fluid to flow through, and the fluid conduit is connected to the fluid interface;

[0025] When the charging gun head is connected to the electric vehicle, the pile end interface and the battery cavity are connected through the fluid interface and the fluid pipeline to form a battery heat exchange branch.

[0026] In one embodiment, the charging gun cable includes:

[0027] At least one core group, the core group including at least one core and an insulating layer sleeved on the radial outside of the at least one core, with gaps between adjacent core groups;

[0028] a protective layer mounted on the radially outer sides of all the core groups, the protective layer being spaced apart from the core groups; and

[0029] A cable phase change module, which is filled in the gap between the wire core group and the protective layer and the gap between adjacent wire core groups, and the material of the cable phase change module includes phase change material;

[0030] Wherein, a fluid pipeline is provided in the cable phase change module.

[0031] The thermal management module in the charging device of the technical solution of the present invention can be connected to the battery cavity in the electric vehicle to form a battery heat exchange branch, so that during the charging process of the electric vehicle, the battery cells in the battery pack are immersed in cooling by an insulating heat exchange fluid, thereby providing a thermal management function for the battery pack to support higher power charging, thereby further improving the fast charging speed.

[0032] In addition, the thermal management module can also achieve immersion cooling of the charging power devices in the device cavity through the device heat exchange branch, thereby providing thermal management functions for the battery pack and the charging pile itself to support higher power charging, thereby further improving the fast charging speed.

[0033] In addition, the insulating heat exchange fluid can also perform immersion cooling on the wire core and charging terminals. Compared with air cooling and liquid cooling, its heat dissipation area is larger and the heat dissipation effect is better, so the charging equipment can support greater charging power.

[0034] In addition, the filler of the charging gun cable is constructed as a cable filling module made of phase change material, and a fluid pipe for the circulation of coolant is also provided in the cable phase change module. In the process of the coolant flowing through the fluid pipe, the coolant can cool the cable phase change module, thereby improving the heat storage capacity of the cable phase change module, so that the cable phase change module can absorb more heat emitted by the core. That is, under the same cross-sectional area, the temperature rise of the charging gun cable is smaller. In this way, under the premise that the charging power of the charging gun is determined, that is, the heat generation is determined, the cooling purpose of the charging gun cable can be achieved by a smaller amount of phase change material, thereby reducing the outer diameter of the charging gun cable and reducing the weight of the charging gun cable. In other words, charging gun cables with the same outer diameter or weight can support higher power charging. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on the structures shown in these drawings without paying any creative work.

[0036] Figure 1 A schematic diagram showing the connection of the charging device provided by the present invention;

[0037] Figure 2 A schematic diagram of an embodiment of a charging device provided by the present utility model;

[0038] Figure 3 A schematic diagram of another embodiment of the charging device provided by the present invention;

[0039] Figure 4 A schematic diagram of another embodiment of the charging device provided by the present invention;

[0040] Figure 5 A schematic diagram of the connection between the charging device provided by the present invention and the electric vehicle;

[0041] Figure 6 This is a structural diagram of an embodiment of a charging gun in the charging device provided by the utility model;

[0042] Figure 7 This is a cross-sectional schematic diagram of an embodiment of a charging gun cable in a charging device provided by the present invention;

[0043] Figure 8 This is a schematic diagram of a pipeline in an embodiment of a charging gun cable in a charging device provided by the present invention;

[0044] Figure 9A schematic diagram of the fluid flow direction of another embodiment of a charging gun in the charging device provided by the present invention;

[0045] Figure 10 This is a schematic diagram of a pipeline for another embodiment of a charging gun cable in the charging device provided by the present invention.

[0046] Description of Figure Numbers:

[0047] 01. Device heat exchange branch; 02. Battery heat exchange branch; 10. Insulated heat exchange fluid; 11. First tee; 12. Second tee; 100. Charging device; 110. Pile body; 111. Device cavity; 1111. First device hole; 1112. Second device hole; 112. Pile end interface; 120. Charging power device; 130. Thermal management module; 130a. First thermal management submodule; 130b. Second thermal management submodule; 131. Medium storage box; 1311. Medium return pipe; 132. Pump; 133. Heat exchanger; 1331. Medium pump outlet pipe; 140. Gas charging branch; 141. Gas storage device; 142. Gas circuit valve; 150. Charging gun; 151. Charging gun head; 1511. Gun head body; 1512, charging terminal; 1511a, liquid outlet cooling chamber; 1511b, liquid inlet cooling chamber; 1513, fluid interface; 1514, fluid flow channel; 152, charging gun cable; 1521, wire core group; 1522, protective layer; 1523, cable phase change module; 1523a, second sub-phase changer; 1523b, third sub-phase changer; 1524, fluid pipeline; 1524a, liquid outlet pipe; 1524b, liquid inlet pipe; 1525a, first cable cooling channel; 1525b, second cable cooling channel; 1511c, gun head cooling chamber; 160, medium channel cable; 200, electric vehicle; 210, battery cavity; 211, first battery cavity hole; 212, second battery cavity hole; 220, battery cell.

[0048] The realization of the purpose, functional features and advantages of the present invention will be further explained in conjunction with embodiments and with reference to the accompanying drawings. DETAILED DESCRIPTION

[0049] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the embodiments described are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts shall fall within the scope of protection of the present invention.

[0050] It should be noted that if the embodiments of the present invention involve directional indications (such as up, down, left, right, front, back, etc.), the directional indications are only used to explain the relative position relationship, movement status, etc. between the components in a certain specific posture. If the specific posture changes, the directional indications will also change accordingly.

[0051] In addition, if there are descriptions involving "first", "second", etc. in the embodiments of the present invention, the descriptions of "first", "second", etc. are only for descriptive purposes and cannot be understood as indicating or implying their relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features limited to "first" and "second" may explicitly or implicitly include at least one of such features. In addition, if "and / or" or "and / or" appears in the full text, its meaning includes three parallel schemes. Taking "A and / or B" as an example, it includes scheme A, or scheme B, or a scheme in which A and B are satisfied at the same time. In addition, the technical solutions between the various embodiments can be combined with each other, but it must be based on the ability of ordinary technicians in this field to implement. When the combination of technical solutions is mutually contradictory or cannot be implemented, it should be deemed that such a combination of technical solutions does not exist and is not within the scope of protection required by the present invention.

[0052] With the increasing popularity of battery-powered electric vehicles, such as new energy vehicles (NEVs), eVTOLs, and new energy ships, charging equipment such as charging piles is becoming increasingly important and demanding. Specifically, the increasing demand for fast charging in electric vehicles is driving the increasing power of individual charging pile guns. This means that the weight and size of charging piles and charging guns are also increasing along with the power output.

[0053] In order to solve the problem of size and weight of charging piles and charging guns, the following technical routes exist in related technologies:

[0054] One is to adopt a high-voltage system, increasing the voltage at the same power to reduce the charging current. This can reduce the size of components such as cables and charging gun heads to reduce weight and volume.

[0055] The second approach is to use liquid-cooled charging piles. Compared to air-cooled charging piles, liquid-cooled charging piles have higher heat exchange efficiency and are smaller in size. Furthermore, the charging gun and charging gun cable also use liquid cooling technology, achieving a smaller size while outputting greater power.

[0056] However, when charging an electric vehicle, especially during fast charging, the battery pack of the electric vehicle will also generate a large amount of heat during the fast charging process, which will have a significant impact on the battery temperature state and thermal management efficiency. Therefore, how to dissipate heat from the battery pack during charging using charging equipment has become a technical problem that technical personnel in this field urgently need to solve.

[0057] To this end, the present application provides a solution in which the charging equipment provides immersion cooling for the battery pack through an insulating heat exchange fluid 10, thereby providing thermal management function for the battery pack to support higher power charging, thereby achieving faster charging.

[0058] The technical concept of the present invention is further described below with reference to some specific embodiments.

[0059] See also Figure 1 and Figure 2 The present invention provides a charging device 100 for charging an electric vehicle 200 having a battery chamber 210. Specifically, the electric vehicle 200 may be a new energy vehicle, a battery-powered vehicle, a drone, an eVTOL, or a new energy vessel. The following description uses an eVTOL as an example.

[0060] As can be understood, eVTOL has a battery pack. The battery pack not only provides electrical energy to the power unit of the eVTOL, but also provides electrical energy to airborne systems such as the onboard environmental control system and the onboard lighting system. The battery pack includes a module shell having a battery cavity 210 and a battery cell group installed in the battery cavity 210. The module shell has a first battery cavity hole 211 and a second battery cavity hole 212 connected to the battery cavity 210, wherein the first battery cavity hole 211 is for the insulating heat exchange fluid 10 to flow in, and the second battery cavity hole 212 is for the insulating heat exchange fluid 10 to flow out. The first battery cavity hole 211 and the second battery cavity hole 212 are both arranged on the upper part of the top wall or side wall of the module shell. In addition, the module shell is a shell structure with a sealed design, so that the battery cavity 210 inside it can be used to fill the insulating heat exchange fluid 10. When the battery cavity 210 is filled with the insulating heat exchange fluid 10, the insulating heat exchange fluid 10 can completely submerge the battery pack, thereby contacting and exchanging heat with the battery cells 220 of the battery pack. This transfers heat from the battery cells 220 to the module housing, where it then exchanges heat with the external environment, thereby improving the heat dissipation efficiency of the battery cells 220. It is understood that the battery cells 220 can be configured in a variety of structural forms, such as one or more of a soft-pack cell, a prismatic cell, and a cylindrical cell. Furthermore, the battery cavity 210 can be a single cell cavity or a connected cavity formed by connecting multiple cells via a pipeline. Furthermore, the eVTOL also has a machine-side interface, which includes a machine-side medium inlet hole connected to the first battery cavity hole 211 and a machine-side medium outlet hole connected to the second battery cavity hole 212. Of course, this machine-side interface can be integrated into the charging socket on the eVTOL that mates with the charging gun, thereby avoiding a significant increase in the weight of the eVTOL and wasting space within the eVTOL body.

[0061] In one possible embodiment, the battery cavity 210 can also be filled with a non-combustible gas. When the battery cavity 210 is filled with the non-combustible gas, the battery cells come into contact with the non-combustible gas. This reduces the contact area between the battery cells and oxygen. In the event of thermal runaway, the non-combustible gas can suppress combustion. Notably, the filling of the non-combustible gas reduces water vapor within the battery cavity 210, thus reducing the risk of condensation within the battery cavity 210 and preventing insulation failure in the battery pack.

[0062] In one possible embodiment, a phase change module is further disposed within the battery cavity 210. In this case, the battery cells 220 can directly exchange heat with the phase change module, thereby improving the heat dissipation efficiency of the battery cells 220. If a phase change module is disposed between two adjacent battery cells 220, heat between the two adjacent battery cells 220 can be dissipated through the phase change module, preventing heat accumulation between the two adjacent battery cells 220, thereby improving the heat dissipation efficiency of the battery pack.

[0063] In this embodiment, the charging device 100 includes a charging station 110 and a thermal management module 130. The charging station 110 has a charging terminal interface 112 for connecting to an electric vehicle 200. The thermal management module 130 is configured to communicate with the battery cavity 210 to form a battery heat exchange branch 02 when the charging station 110 is connected to the electric vehicle 200. This allows the insulating heat exchange fluid 10 to flow through the battery heat exchange branch 02 and fill the battery cavity 210.

[0064] The pile body 110 is the main body of the charging device 100, such as a charging pile. It includes, but is not limited to, housing the internal charging circuit, providing the human-machine interface panel required for charging, and carrying the charging gun and charging gun cable. It should be noted that the pile body 110 can be a charging pile body of a ground charging station. In addition, the pile body 110 can also be integrated into a vehicle with land, air, water, or underwater navigation capabilities, such as a mobile charging vehicle, an aircraft ground handling vehicle, or an aircraft maintenance vessel with service functions.

[0065] The thermal management module 130 is used to provide thermal management functions for the battery pack of the eVTOL during charging. The thermal management module 130 can be arranged inside the pile body 110, and can also be arranged outside the pile body 110. As in one example, the thermal management module 130 is arranged inside the pile body 110, and the pile body 110 can include an above-ground part and an underground part, and the thermal management module 130 can be installed inside the above-ground part of the pile body 110. Or as in one example, the pile body 110 is a ground charging pile, and the main part of the thermal management module 130 is located underground below the ground charging pile, and only the pipeline components such as the pipe for the insulating heat exchange fluid 10 to circulate to the device cavity 111 are located inside the ground charging pile, thereby reducing the volume of the above-ground part of the charging pile, making the charging pile more miniaturized.

[0066] In this embodiment, the thermal management module 130 is used to provide an insulating heat exchange fluid 10 and includes heat exchange components that drive the insulating heat exchange fluid 10 through the battery heat exchange branch 02 and the device heat exchange branch 01. The insulating heat exchange fluid 10 is a coolant, which can remove heat generated by the battery cells 220 during its flow. Because the heat of the battery pack comes from the heat generated by the battery cells 220, this embodiment provides immersion cooling for the battery pack's battery cells 220, improving thermal management efficiency.

[0067] When the pile body 110 is connected to the eVTOL via the pile end interface 112, the thermal management module 130 communicates with the battery cavity 210 on the eVTOL, thereby forming a battery heat exchange branch 02 for the insulating heat exchange fluid 10 to flow through the battery heat exchange branch 02. After the insulating heat exchange fluid 10 enters the battery cavity 210 through the first battery cavity hole 211, it can directly contact the battery cells in the battery cavity 210, thereby performing thermal management on the battery cells, and then flows out through the second battery cavity hole 212.

[0068] The insulating heat exchange fluid 10 is an insulating, flash-free coolant. In one embodiment, the insulating heat exchange fluid 10 is made of deionized water, electronic fluorinated liquid, hydrocarbons, esters, or silicone oils. In this way, the insulating heat exchange fluid 10 has the characteristics of high insulation, high specific heat capacity, high thermal conductivity, non-flammability, no flash point, non-toxicity, and low chemical activity. In addition, even if the insulating heat exchange fluid 10 in this embodiment leaks, safety issues can be avoided. Optionally, in one embodiment, the electronic fluorinated liquid is configured as hydrofluoroether or hydrofluoroolefin. Optionally, in one embodiment, the hydrocarbon is configured as mineral oil or synthetic hydrocarbon oil, such as transformer oil. Optionally, in one embodiment, the lipid is configured as triglyceride or synthetic ester. Optionally, in one embodiment, the silicone oil is configured as dimethyl silicone oil.

[0069] It's worth noting that the insulating heat exchange fluid 10 within the battery pack can also be introduced into the battery pack by the thermal management module 130 only during charging of the eVTOL. This allows the insulating heat exchange fluid 10 to directly contact the battery cells 220 within the battery pack, generating heat exchange and thereby changing the battery pack temperature. Alternatively, in one feasible embodiment, the battery pack is also filled with a battery heat exchange medium to provide immersion cooling for the battery cells within the battery cavity, thereby forming an immersion-cooled battery pack. In this way, during flight, the battery heat exchange medium cools the battery cells within the immersion-cooled battery pack. Furthermore, the material of the battery heat exchange medium is consistent with that of the insulating heat exchange fluid 10, making the charging device 100 provided in this embodiment compatible with immersion-cooled battery packs. Specifically, once the thermal management module 130 is connected to the battery cavity 210, the insulating heat exchange fluid 10 and the battery heat exchange medium can be directly mixed and used, eliminating the need to first drain the battery heat exchange medium from the battery cavity 210 before introducing the insulating heat exchange fluid 10. This improves maintenance convenience and reduces maintenance difficulty.

[0070] It is not difficult to see that in this embodiment, the thermal management module 130 in the charging device can be connected to the battery cavity 210 in the electric vehicle to form a battery heat exchange branch 02, so that in the process of charging the electric vehicle, the battery cells 220 in the battery pack are immersed in cooling through the insulating heat exchange fluid 10, thereby providing a thermal management function for the battery pack to support higher power charging, thereby further improving the fast charging speed.

[0071] Also, see Figure 1 and Figure 2 In one embodiment, the pile body 110 has a device cavity 111, and the charging power device 120 is arranged in the device cavity 111; the thermal management module 130 is connected to the device cavity 111 to form a device heat exchange branch 01, so that the insulating heat exchange fluid 10 can flow in the device heat exchange branch 01 and enter the device cavity.

[0072] The pile body 110 has a device cavity 111 therein, and the device cavity 111 is used to install a charging circuit that provides charging services. It is understandable that the charging circuit includes but is not limited to a fast charging circuit and / or a slow charging circuit, and a charging control circuit that controls the fast charging circuit and / or the slow charging circuit to provide charging services. The fast charging circuit is used to provide fast charging services, while the slow charging circuit is used to provide ordinary charging services. In one example, the charging circuit also includes a detection circuit and an isolation circuit. The detection circuit is used to monitor the operating status of the charging circuit itself and send it to the charging control circuit or other control center. When the fast charging circuit and the slow charging circuit are switched in state, or when the fast charging circuit and the slow charging circuit are switched in state, the isolation circuit quickly discharges the residual energy in the circuit when the state is switched, thereby improving the safety of the charging circuit.

[0073] The charging circuit is composed of various charging power devices 120, including but not limited to a DC-DC converter, an AC-DC converter, a battery, capacitors, inductors, induction coils, a rectifier bridge, a high-voltage busbar, a switching tube, a fuse protector, a diode, and various cables. It is understood that when all charging power devices 120 of the charging circuit are integrated into a single chamber, the device chamber 111 can be a single chamber. Alternatively, when all charging power devices 120 of the charging circuit are distributed across multiple chambers, the device chamber 111 can also be a connected body composed of multiple chambers connected by pipes, although this embodiment is not limited to this. It is worth noting that the device chamber 111 is a sealed chamber, thereby isolating the internal environment from the external environment to prevent leakage of the insulating heat exchange fluid 10 from the device chamber 111 as it flows within the device chamber 111. Furthermore, the sealed chamber structure of the device chamber 111 also allows the insulating heat exchange fluid 10 to completely fill the device chamber 111, completely submerging the various charging power devices 120. The device cavity 111 can be filled with the insulating heat exchange fluid 10. Of course, the insulating heat exchange fluid 10 can also be used to submerge all the charging power devices 120. The insulating heat exchange fluid 10 exchanges heat with each charging power device 120 in the device cavity 111 to cool down each charging power device 120. Figure 2 As can be understood, the pile body 110 has a first device hole 1111 and a second device hole 1112 in communication with the device cavity 111. The first device hole 1111 is for the insulating heat exchange fluid 10 to flow in, and the second device hole 1112 is for the insulating heat exchange fluid 10 to flow out. Of course, in order to allow the insulating heat exchange fluid 10 to completely submerge the charging power device 120, the first device hole 1111 and the second device hole 1112 are also both provided on the top wall or the upper part of the side wall of the device cavity 111. In addition, a corresponding flow channel or guide structure may be provided inside the pile body 110 to ensure that the insulating heat exchange fluid 10 circulates to each charging power device 120 to ensure the immersion effect.

[0074] Since the heat of the charging pile itself comes from the heat generated by the charging power device 120 during charging, and since the heat of the battery pack comes from the heat generated by the battery cells 220, this embodiment provides immersion cooling for both the charging power device 120 in the device cavity 111 and the battery cells 220 of the battery pack to improve thermal management efficiency.

[0075] Specifically, the thermal management module 130 communicates with the device cavity 111, thereby forming a device heat exchange branch 01. At this point, the cooled insulating heat exchange fluid 10 enters the device cavity 111 through the first device hole 1111 and directly contacts each charging power device 120 within the device cavity 111, thereby removing heat generated by the charging power devices 120 and increasing its temperature. The heated insulating heat exchange fluid 10 then exits the device cavity 111 through the second device hole 1112 and continues along the device heat exchange branch 01, removing heat from the device cavity 111.

[0076] See also Figure 2 Specifically, the pile body 110 is detachably connected to the electric vehicle 200 via a pipe: the pile end interface 112 on the pile body 110 is connected to a dedicated pipe or a universal pipe, and the dedicated pipe or universal pipe is plugged into the machine end interface provided on the electric vehicle 200. Therefore, when the charging device 100 charges the electric vehicle 200, the two are plugged into each other to achieve communication between the pipe for supplying the insulating heat exchange fluid 10 in the pile body 110 and the electric vehicle 200, establishing a channel for providing the insulating heat exchange fluid 10 to enter the battery cavity 210. In this way, when charging the eVTOL, it is necessary not only to connect the charging gun to the electric vehicle 200, but also to connect the pile end interface 112 to the corresponding machine end interface of the eVTOL through a pipe, thereby establishing a battery heat exchange branch. Of course, the pipe connected to the pile end interface 112 can be integrated into the charging gun, so that the pipe connected to the pile end interface 112 in this case is the charging gun cable, which will be explained in detail later.

[0077] It is not difficult to see that in this embodiment, the thermal management module 130 not only communicates with the device cavity 111, where the charging power device 120 is installed, to form the device heat exchange branch 01, but also communicates with the battery cavity 210 in the electric vehicle 200 to form the battery heat exchange branch 02. Thus, during the charging process of the electric vehicle 200, the charging power device 120 in the device cavity 111 is immersed in the insulating heat exchange fluid 10, and the battery cells 220 in the battery pack are also immersed in the cooling. In this way, during fast charging and other charging processes, the battery pack can be kept within a certain temperature range, meeting the requirements of fast charging while maintaining uniform temperature of the battery pack.

[0078] Furthermore, compared to the strict space and weight requirements of eVTOLs, charging equipment 100, such as charging piles, has sufficient space and weight to accommodate a higher-power thermal management module 130, thereby improving thermal management of the battery pack. Furthermore, since the thermal management function of the battery pack during charging is provided by the thermal management module 130 on the charging equipment 100, the eVTOL's own thermal management equipment can only provide thermal management services during battery discharge and does not need to be activated during charging. This means that the eVTOL can carry less powerful thermal management equipment than in related technologies, thereby reducing the space and weight occupied by the thermal management equipment on the eVTOL. Furthermore, since the eVTOL's own thermal management equipment does not need to be activated during charging, it can also make the eVTOL more energy-efficient.

[0079] In addition, in addition to providing immersion cooling for the battery pack, the charging device of this embodiment uses immersion cooling technology to directly immerse and cool components such as power modules, which has a better cooling effect and a simpler structure. It also solves complex problems in traditional liquid cooling technology, such as low indirect cooling efficiency and the need for liquid leakage prevention and insulation design in specific structural design.

[0080] See also Figure 2 In one embodiment, thermal management module 130 may include a first thermal management submodule 130a and a second thermal management submodule 130b. First thermal management submodule 130a communicates with device heat exchange branch 01, while second thermal management submodule 130b communicates with battery heat exchange branch 02. Each of first and second thermal management submodules 130a and 130b has an independent heat exchange system, independently adjusting the temperature of the insulating heat exchange fluid 10 in its corresponding branch. This allows independent temperature control in battery heat exchange branch 02 and device heat exchange branch 01, without affecting each other. This improves safety and reduces the complexity of the temperature control process.

[0081] Alternatively, see Figure 3In one embodiment, the thermal management module 130 includes a main circuit, which includes a medium storage box 131, a pump 132, and a heat exchanger 133, which are connected in sequence through pipes. Among them, the medium storage box 131 can be constructed as an expansion water tank, which stores the insulating heat exchange fluid 10. The capacity of the expansion water tank needs to be determined based on the fluid usage of the device heat exchange branch 01 and the fluid usage in the battery heat exchange branch 02, and a certain margin should be reserved. The pump 132 is used to drive the insulating heat exchange fluid 10 to flow in the battery heat exchange branch 02 and / or the device heat exchange branch 01. The power of the pump 132 is calculated based on the flow resistance. The pump 132 can be integrated into the heat exchanger 133. The heat exchanger 133 is used to exchange heat for the insulating heat exchange fluid 10. When the insulating heat exchange fluid 10 flows through the heat exchanger 133, the temperature of the insulating heat exchange fluid 10 is reduced under the action of the heat exchanger 133, so that the temperature difference between the insulating heat exchange fluid 10 and the battery cell 220 and / or the charging power device 120 is large, so that they can be cooled.

[0082] In an optional embodiment, heat exchanger 133 comprises a direct evaporative refrigeration cycle device. In this manner, heat exchanger 133 can regulate the temperature of the insulating heat exchange fluid 10, thereby regulating the temperature of the battery pack and device cavity 111. However, this embodiment is not limited thereto. In other embodiments, heat exchanger 133 regulates the temperature of the insulating heat exchange fluid 10 using an indirect water circulation refrigeration device, an absorption refrigeration device, or a semiconductor refrigeration device.

[0083] Understandably, in some low-temperature environments, such as those at high latitudes, the lower temperatures inevitably affect the normal operation of the battery pack and / or the charging power device 120. For example, in one optional embodiment, the main circuit also includes a PTC (Positive Temperature Coefficient) heater (not shown). Alternatively, in another optional embodiment, the heat exchanger 133 is connected to a heat pump system that switches between cooling and heating modes. In this way, the insulating heat exchange fluid 10 flowing through the main circuit can be heated by the PTC heater, or when the heat pump system is in heating mode. This helps improve the thermal management module 130's ability to heat the insulating heat exchange fluid 10, thereby adapting to various temperature conditions and, in other words, improving the environmental adaptability of the charging device 100. Of course, in other optional embodiments, the eVTOL battery pack is equipped with a phase change module and a heat exchange module in heat exchange connection with the phase change module, so that the eVTOL can use the battery pack as a heat source for the aircraft's temperature control system to control the cabin temperature. At this point, the phase change module in the battery pack is preheated or cooled by switching the PTC heater and / or heat pump system, allowing the phase change material to transition to the phase required for the flight mission. This allows the phase change material to exchange heat with the refrigerant in the aircraft's temperature control system during flight, either storing heat transferred from the cabin or transferring pre-stored heat back to the cabin. This allows the phase change material in the battery pack to meet various eVTOL temperature control scenarios, improving the aircraft's reliability and adaptability.

[0084] Specifically, the expansion tank has a first tank port and a second tank port. The first tank port is connected to the pump 132 via a pipeline. The outlet of the pump 132 is connected to the heat exchanger 133 via a pipeline. The heat exchanger 133 has a medium pump outlet pipe 1331. The second tank port is connected to the medium return pipe 1311. In this case, the medium return pipe 1311, the expansion tank, the pump 132, the heat exchanger 133, and the medium pump outlet pipe 1331 are connected in series to form the main circuit of this embodiment.

[0085] As an optional implementation, the device heat exchange branch 01 and the battery heat exchange branch 02 are connected in parallel and then connected in series to the main circuit to form a circulation loop. Figure 4The medium pump outlet pipe 1331 is connected to a first three-way pipe 11, one interface of the first three-way pipe 11 is connected to the pile end interface 112 through a pipeline, and the other interface of the first three-way pipe 11 is connected to the device cavity 111 through a pipeline. Similarly, the medium return pipe 1311 is connected to a second three-way pipe 12, one interface of the second three-way pipe 12 is connected to the pile end interface 112 through a pipeline, and the other interface of the second three-way pipe 12 is connected to the device cavity 111 through a pipeline. In this way, when the pile body 110 is connected to the eVTOL, one interface of the first three-way pipe 11, the battery cavity 210, and one interface of the second three-way pipe 12 constitute the battery heat exchange branch 02, while the other interface of the first three-way pipe 11, the device cavity 111, and the other interface of the second three-way pipe 12 constitute the device heat exchange branch 01.

[0086] In this embodiment, when the pile-end interface 112 is connected to the eVTOL, the device heat exchange branch 01 and the battery heat exchange branch 02 are connected in parallel and then in series to the main circuit to form a circulation loop. At this time, the pump 132 delivers the insulating heat exchange fluid 10 to the heat exchanger 133 for cooling. After cooling, the insulating heat exchange fluid 10 passes through the medium pump outlet pipe 1331 and is divided into two paths at the first tee pipe 11:

[0087] Device heat exchange branch 01: The insulating heat exchange fluid 10 passes through the first device hole 1111 and enters the device cavity 111, where it directly contacts each charging power device 120 for heat exchange, thereby increasing its temperature. The heated insulating heat exchange fluid 10 then passes through the second device hole 1112 and the pipeline and returns to the second T-piece 12. It then returns to the expansion water tank through the medium return pipe 1311.

[0088] Battery heat exchange branch 02: The insulating heat exchange fluid 10 enters the battery cavity 210 through the pile end interface 112 and directly contacts the battery cell 220 for heat exchange and heat rises. The heated insulating heat exchange fluid 10 passes through the second battery cavity hole 212 and the pile end interface 112 and returns to the second three-way pipe 12, and then returns to the expansion water tank through the medium return pipe 1311.

[0089] In this embodiment, the device heat exchange branch 01 and the battery heat exchange branch 02 are connected in parallel to the same main circuit. In this way, the insulating heat exchange fluid 10 transported from the main circuit is divided into two paths and enters the device heat exchange branch 01 and the battery heat exchange branch 02, so that the insulating heat exchange fluid 10 cooled by the heat exchanger 133 can enter the device heat exchange branch 01 or the battery heat exchange branch 02 as soon as possible for heat exchange. The insulating heat exchange fluids 10 in the two branches do not affect each other, and the cooling effects of the insulating heat exchange fluids 10 in the two branches can be ensured.

[0090] Alternatively, as another optional implementation, the device heat exchange branch 01, the battery heat exchange branch 02 and the main circuit are connected in series to form a circulation loop.

[0091] See also Figure 3 As an option in this embodiment, the medium pump outlet pipe 1331 communicates with the first battery cavity hole 211 of the battery cavity 210 through the pipeline and the pile end interface 112. A return pipe is provided at the pile end interface 112. The battery cavity 210 communicates with the first device hole 1111 of the device cavity 111 through the second battery cavity hole 212, the pile end interface 112, and the return pipe, while the second device hole 1112 of the device cavity 111 communicates with the medium return pipe 1311. In this case, the main circuit, the battery heat exchange branch 02, and the device heat exchange branch 01 are connected in series, forming a circulation loop. The insulating heat exchange fluid 10 pumped from the main circuit first enters the battery heat exchange branch 02, then enters the device heat exchange branch 01, and finally flows into the main circuit.

[0092] Alternatively, as another option in this embodiment, the medium return pipe 1311 communicates with the second battery cavity hole 212 of the battery chamber 210 via a pipeline and the pile-end interface 112. A delivery pipe is provided at the pile-end interface 112. The first battery cavity hole 211 of the battery chamber 210 communicates with the second device hole 1112 of the device chamber 111 via the pile-end interface 112 and the delivery pipe, while the first device hole 1111 of the device chamber 111 communicates with the medium pump-out pipe 1331. In this case, the main circuit, the device heat exchange branch 01, and the battery heat exchange branch 02 are connected in series, forming a circulation loop. The insulating heat exchange fluid 10 pumped from the main circuit first enters the device heat exchange branch 01.

[0093] It is not difficult to see that the series connection of the pipes is simpler than the parallel connection. It should be noted that since the temperature that the charging power device 120 can withstand is higher than the temperature that the battery cell 220 in the battery pack can withstand, it is better to connect the battery heat exchange branch 02 in series upstream of the device heat exchange branch 01. In this way, the insulating heat exchange fluid 10 that has been cooled by the heat exchanger 133 first flows through the battery heat exchange branch 02 to cool the battery cell, and then flows through the device heat exchange branch 01 to cool the various charging power devices 120. In this way, the parameters of the insulating heat exchange fluid 10 can be designed accordingly based only on the cooling requirements of the battery cell 220, without fully considering the cooling requirements of the battery cell 220 and the cooling requirements of the charging power device 120. This not only ensures the cooling effect of the battery, but also reduces the complexity of the temperature control of the insulating heat exchange fluid 10.

[0094] In this embodiment, the device heat exchange branch 01 and the battery heat exchange branch 02 are both temperature-controlled by the heat exchanger 133 on the same main circuit, which reduces the number of components in the thermal management module 130 and can also reduce the volume and weight of the thermal management module 130, thereby facilitating the miniaturization of the charging device 100 and further facilitating the integration of the charging device 100 into maintenance equipment such as ground vehicles.

[0095] It is understandable that after charging the battery pack, it may be necessary to discharge the insulating heat exchange fluid 10 from the battery cavity 210. Therefore, in one embodiment, the thermal management module 130 further includes a gas-filled fluid exchange component, which is connected to the battery heat exchange branch 02 and is used to input non-flammable gas into the battery cavity 210 to discharge the insulating heat exchange fluid 10 from the battery cavity 210.

[0096] In this way, when the temperature of the battery pack is adjusted to a preset temperature or is fully charged, the eVTOL can introduce non-flammable gas into the battery heat exchange branch 02 through the inflation and fluid exchange assembly during the flight takeoff preparation stage. After the non-flammable gas enters the battery cavity 210 through one of the first battery cavity hole 211 and the second battery cavity hole 212, the insulating heat exchange fluid 10 therein is squeezed out of the battery cavity 210 through the other of the first battery cavity hole 211 and the second battery cavity hole 212. On the one hand, the insulating heat exchange fluid 10 in the battery cavity 210 is discharged, and on the other hand, during the flight of the eVTOL, the battery cavity 210 is filled with non-flammable gas to suppress battery combustion when thermal runaway occurs in the battery cavity 210.

[0097] Alternatively, when the circuit in the device cavity 111 needs to be repaired and maintained, or when the insulating heat exchange fluid 10 needs to be discharged for other reasons, the insulating heat exchange fluid 10 in the device cavity 111 also needs to be discharged. To this end, in one embodiment, the thermal management module 130 further includes a gas-filled fluid exchange component, which is connected to the device heat exchange branch 01 and is used to input non-combustible gas into the device cavity 111 to discharge the insulating heat exchange fluid 10 from the device cavity 111.

[0098] Specifically, when the insulating heat exchange fluid 10 needs to be discharged, non-combustible gas can be introduced into the device heat exchange branch 01 through the inflation and liquid exchange component. After the non-combustible gas enters the device cavity 111 through one of the first device hole 1111 and the second device hole 1112, the insulating heat exchange fluid 10 therein is squeezed out of the device cavity 111 through the other of the first device hole 1111 and the second device hole 1112, thereby discharging the insulating heat exchange fluid 10 in the device cavity 111.

[0099] Of course, in some feasible embodiments, when the battery heat exchange branch 02 and the device heat exchange branch 01 are connected in series, the insulating heat exchange fluid 10 in the battery cavity 210 and the device cavity 111 can be discharged simultaneously through an inflation and drainage component. It should be noted that when the inflation and drainage component is working, the insulating heat exchange fluid 10 can return to the expansion tank under the action of non-flammable gas. In some examples, both the device heat exchange branch 01 and the battery heat exchange branch 02 are connected to a drainage branch connected to the outside world through a drainage switch valve, so that when the insulating heat exchange fluid 10 in the battery cavity 210 or the device cavity 111 is discharged through the inflation and drainage component, the drainage branch is opened and the expansion tank is closed, and the battery cavity 210 or the device cavity 111 can be connected to the outside world, thereby providing a discharge channel for the insulating heat exchange fluid 10.

[0100] The non-combustible gas in this embodiment refers to the gas other than the combustible gas and the combustion-supporting gas. In one embodiment, the non-combustible gas includes one or more of an inert gas, nitrogen, carbon dioxide, and sulfur hexafluoride.

[0101] See also Figure 3 In one example, the gas-inflating and liquid-exchanging assembly includes a gas-inflating branch 140, which includes a gas storage device 141 and a gas circuit valve 142, which are sequentially connected via pipelines. The output end of the gas-inflating branch 140 is connected to the pipeline between the heat exchanger 133 and the pile-end interface 112, and a switch valve (not shown) is provided between the heat exchanger 133 and the output end of the gas-inflating branch 140. Specifically, the medium pump outlet pipe 1331 of the heat exchanger 133 is connected to a switch valve, which is connected to a multi-way pipe (a four-way pipe when the device heat exchange branch 01 and the battery heat exchange branch 02 are connected in parallel, or a three-way pipe when the device heat exchange branch 01 and the battery heat exchange branch 02 are connected in series). One of the pipe ends of the multi-way pipe is connected to a gas circuit valve 142 via a pipeline, and the gas circuit valve 142 is connected to the gas storage device 141 via a pipeline. The gas storage device 141 can be a high-pressure gas storage device 141, and the gas circuit valve 142 is a pressure reducing valve. In this way, the air pressure within the gas storage device 141 is relatively high. Under the action of the high air pressure, the non-combustible gas will flow along the pipeline through the pile end interface 112 and into the battery cavity 210 within the eVTOL. After entering the battery cavity 210, the non-combustible gas squeezes the insulating heat exchange fluid 10, causing the insulating heat exchange fluid 10 to be discharged from the battery cavity 210. In addition, under the action of the pressure reducing valve, the high-pressure non-combustible gas within the gas storage device 141 can be reduced in pressure and released to prevent the pipeline from being subjected to excessive air pressure, thereby preventing damage to the pipeline, the battery cells 220 in the battery cavity 210, and the charging power device 120 in the device cavity 111. The on-off valve provided between the heat exchanger 133 and the charging branch 140 is used to switch to a closed state after the charging branch 140 begins operation, thereby preventing the non-combustible gas from entering the heat exchanger 133 first, thereby improving the working efficiency of the charging and draining components.

[0102] Of course, in other embodiments, the inflation branch 140 may also be provided with a pump to provide power for the flow of the non-combustible gas. Alternatively, in other embodiments, the inflation and drainage assembly may also be provided in the battery pack or in the device cavity 111 .

[0103] It is understood that after the pile body 110 is connected to the eVTOL, not only a charging channel for power transmission needs to be established between the charging device 100 and the eVTOL, but also a medium channel for the flow of the insulating heat exchange fluid 10 needs to be established. Figure 5 The medium channel can be an independent medium channel cable 160. In this case, during charging, not only the charging gun 150 needs to be connected to the eVTOL, but also the independent medium channel cable 160 needs to be connected to the eVTOL.

[0104] Alternatively, the medium channel may be fully or partially integrated into the charging gun 150 of the charging pile. Figure 6 and Figure 7 The charging device 100 also includes a charging gun 150, which includes a charging gun head 151 and a charging gun cable 152. The charging gun head 151 has a fluid interface 1513. One end of the charging gun cable 152 is connected to the charging gun head 151, and the other end of the charging gun cable 152 is connected to the thermal management module 130. The charging gun cable 152 is provided with a fluid conduit 1524 for the insulating heat exchange fluid 10 to flow through. The fluid conduit 1524 is correspondingly connected to the fluid interface 1513. When the charging gun head 151 is connected to the electric vehicle 200, the thermal management module 130 and the battery cavity 210 are connected through the fluid interface 1513 and the fluid conduit 1524 to form a battery heat exchange branch 02.

[0105] In this embodiment, the charging gun head 151, in addition to the charging port, also provides a fluid port 1513. The charging gun head 151 is connected to the charging gun cable 152, which is in communication with the thermal management module 130 via the terminal port 112. In addition to the existing wire core, the charging gun cable 152 also provides a fluid conduit 1524, which communicates with the fluid port 1513. In order to avoid a significant increase in the volume and weight of the charging gun cable 152 compared to the charging gun cable 152 in the related art, the number of fluid interfaces 1513 and fluid pipes 1524 can both be one. At this time, the fluid pipe 1524 in the charging gun cable 152 is only one of the channels for the insulating heat exchange fluid 10 to flow out of the charging device 100 and enter the eVTOL and the channels for the insulating heat exchange fluid 10 to flow through the battery cavity 210 and return to the charging device 100. The other of the channels for the insulating heat exchange fluid 10 to flow out of the charging device 100 and enter the eVTOL and the channels for the insulating heat exchange fluid 10 to flow through the battery cavity 210 and return to the charging device 100 can be provided by a medium channel cable 160 additionally provided on the charging device 100.

[0106] Alternatively, in order to reduce the number of components of the charging device 100 and improve the operational convenience during eVTOL charging, the channel through which the insulating heat exchange fluid 10 flows out of the charging device 100 and enters the eVTOL and the channel through which the insulating heat exchange fluid 10 returns to the charging device 100 after flowing through the battery cavity 210 are both integrated on the charging gun cable 152. In this case, the number of fluid interfaces 1513 and fluid pipes 1524 is at least 2, that is, at least one inlet and one outlet.

[0107] Furthermore, to prevent blockage of the fluid conduits 1524 , a backup can be provided for the fluid conduits 1524 in either direction. Therefore, the number of fluid interfaces 1513 and fluid conduits 1524 can both be greater than two. Alternatively, when multiple battery packs are connected in parallel (e.g., battery packs are provided on both wings of an eVTOL, and the battery packs are connected in parallel), the number of fluid interfaces 1513 and fluid conduits 1524 can both be greater than two, thereby providing media channels for the corresponding battery packs through different fluid conduits 1524 .

[0108] It is worth mentioning that the fluid conduit 1524 and the fluid interface 1513 can be connected to each other in a one-to-one correspondence. Alternatively, the fluid conduit 1524 and the fluid interface 1513 can also be connected to each other in a one-to-many manner. To avoid the cross-sectional area of the fluid conduit 1524 being too large and affecting the structural strength of the charging gun cable, one fluid interface 1513 can be connected to multiple fluid conduits 1524 with smaller cross-sectional areas. Alternatively, when the battery pack includes multiple battery packs, each battery pack is connected to a fluid interface 1513. In this case, a fluid conduit 1524 can be connected to multiple fluid interfaces 1513, thereby providing insulating heat exchange fluid 10 to multiple battery packs at the same time.

[0109] It is not difficult to see that in this embodiment, by integrating the medium channel for the circulation of the insulating heat exchange fluid 10 into the charging gun cable 152, the charging gun 150 has the functions of transmitting both electrical energy and transmitting the insulating heat exchange fluid 10. The charging gun and the eVTOL are plugged in at one time to complete the establishment of the power channel and the medium channel, thereby reducing the plug-in steps during charging of the eVTOL and thereby improving the charging efficiency of the eVTOL.

[0110] See also Figure 7 In one embodiment, the charging gun cable 152 includes at least one core group 1521, a protective layer 1522 radially outside all the core groups 1521, and a cable phase change module 1523. The core group 1521 includes at least one core and an insulating layer radially outside at least one core, and there is a gap between adjacent core groups, and the core group 1521 is spaced apart from the protective layer 1522; the cable phase change module 1523 fills the gap between the core group 1521 and the protective layer 1522 and the gap between adjacent core groups 1521, and the material of the cable phase change module 1523 includes phase change material; wherein, a fluid pipe 1524 is provided in the cable phase change module 1523.

[0111] In this embodiment, an insulating layer wraps at least one bundle of wire cores to form a wire core group 1521. The wire cores can be at least one of a positive battery charging wire, a negative battery charging wire, a positive low-voltage power supply wire, a negative low-voltage power supply wire, and a signal wire. Of course, the signal wires can be of various types. There can be multiple wire core groups 1521, with gaps between adjacent wire core groups 1521. It is understood that the gaps between adjacent wire core groups 1521 can be achieved by separating them from each other, or by tangently connecting the outer surfaces of wire core groups 1521 with curved outer surfaces, such as circular cross-sections, to form a gap between the non-tangent portions of their outer surfaces. A cable phase change module 1523 is used to fill the gaps between the wire core groups 1521 and the protective layer 1522 of the outer wall of the charging gun cable 152, as well as between adjacent wire core groups 1521. The protective layer 1522 is constructed as a metal layer, a plastic layer, or a plastic layer with a metal braid. In one example, the protective layer 1522 is constructed as a plastic layer with a metal braided mesh, thereby providing better mechanical performance while meeting the cable weight index.

[0112] The material of the cable phase change module 1523 includes phase change material. During the charging process, compared with the use of plastic or polymer materials to fill the gap between the wire core and the protective layer 1522 in related technologies, the phase change material can absorb the heat generated by the wire core, thereby effectively reducing the temperature of the charging gun cable 152 and avoiding overheating of the charging gun cable 152 during charging.

[0113] Furthermore, in this embodiment, the cable phase change module 1523 is also provided with the aforementioned fluid conduit 1524. Specifically, the fluid conduit 1524 extends along the routing direction of the charging gun cable 152 and penetrates the charging gun cable 152. As the insulating heat exchange fluid 10 flows through the fluid conduit 1524, it cools the cable phase change module 1523. It is readily apparent that the flowing insulating heat exchange fluid 10 cools the cable phase change module 1523, thereby increasing the heat storage capacity of the cable phase change module 1523 and allowing it to absorb more heat dissipated by the cable core. In other words, given the same cross-sectional area, the temperature rise of the charging gun cable 152 in this embodiment is smaller. Thus, given a fixed charging power (i.e., heat generation) of the charging gun, cooling the charging gun cable 152 can be achieved with a smaller amount of phase change material, thereby reducing the outer diameter and weight of the charging gun cable 152.

[0114] Furthermore, a portion of the surface of the core assembly 1521 may form the wall of the fluid conduit 1524, or the core assembly 1521 may be completely disposed within the fluid conduit 1524. In this case, the insulating heat exchange fluid within the fluid conduit 1524 can directly immerse the core assembly in cooling. It is readily apparent that, compared to air cooling and liquid cooling, immersion cooling of the core assembly 1521 provides a larger heat dissipation area and a better heat dissipation effect.

[0115] The fluid conduit 1524 can be constructed as a cavity extending along the wiring direction of the charging gun cable 152. The inner diameter of the cavity is uniform and free of protrusions, which facilitates the rapid passage of the insulating heat exchange fluid 10 through the charging gun cable 152. Alternatively, in one embodiment, the cable phase change module 1523 includes a plurality of first sub-phase change fillers arranged in sequence and spaced apart along the wiring direction of the charging gun cable 152. The first sub-phase change fillers have first through-holes, so that the cavities between any two adjacent first sub-phase change fillers in the plurality of first sub-phase change fillers are connected through the first through-holes to form the fluid conduit 1524.

[0116] Thus, for each fluid conduit 1524, in the areas where the phase-change material forms the first sub-phase-change filler, the phase-change material secures the inner core and outer protective layer 1522, absorbing heat generated by the core during charging. In areas not filled with phase-change material, the outer walls of the core assembly 1521, the inner walls of the protective layer 1522, and the opposing sidewalls of the two first sub-phase-change fillers together enclose a cavity for the insulating heat exchange fluid 10 to flow through. Adjacent cavities are connected via first through-holes reserved in the first sub-phase-change fillers. Consequently, under the pressure provided by the main pump 132, the insulating heat exchange fluid 10 fills each cavity in the charging gun cable 152, providing structural support for the charging gun cable 152 itself and effectively securing the inner core and outer protective layer 1522. Of course, the spacing between the segments of the first sub-phase-change filler should be appropriate. Excessive spacing may make the charging gun cable 152 structurally unsustainable, causing the inner core to wobble during charging.

[0117] It is not difficult to see that in this embodiment, the phase change material is arranged at intervals in the wiring direction of the cable, which significantly reduces the weight and improves the heat dissipation effect of the cable compared to ordinary charging gun cables.

[0118] See also Figure 8In one embodiment, at least two fluid pipes 1524 are provided in the cable phase change module 1523, and two of the at least two fluid pipes 1524 form a group, one of the fluid pipes 1524 in a group is a liquid inlet pipe 1524b, and the other is a liquid outlet pipe 1524a; wherein, the cable phase change module 1523 includes a plurality of second sub-phase change filling bodies 1523a arranged in sequence along the wiring direction of the charging gun cable 152, and the second sub-phase change filling bodies 1523a have a second through hole, so that the cavities between any two adjacent second sub-phase change filling bodies 1523a in the plurality of second sub-phase change filling bodies 1523a are connected through the second through hole to form a liquid inlet pipe 1524b, and a liquid outlet pipe 1524a with a pipe structure is provided in the cable phase change module 1523.

[0119] In this embodiment, the fluid conduits 1524 within the cable phase change module 1523 are arranged in pairs, with one of the conduits being a liquid outlet 1524a. Liquid outlet 1524a is used to flow the insulating heat exchange fluid 10 into the eVTOL. Liquid outlet 1524a is constructed as a pipe that extends through the charging gun cable 152 along its routing direction. Its inner wall surface is free of protrusions, facilitating rapid passage of the insulating heat exchange fluid 10 through the charging gun cable 152 and into the eVTOL. As will be readily understood, the faster the flow rate of the insulating heat exchange fluid 10, the less heat exchange occurs between the insulating heat exchange fluid 10 and other components within the charging gun cable 152. This effectively prevents significant temperature changes in the insulating heat exchange fluid 10 as it flows through the charging gun cable 152, ensuring that the temperature difference between the insulating heat exchange fluid 10 and the battery cells 220 after entering the battery cavity 210 meets heat exchange requirements.

[0120] The other is a liquid inlet pipe 1524b, which is used to return the insulating heat exchange fluid 10 flowing through the battery cavity 210 from the eVTOL to the thermal management module 130. As before, for any liquid inlet pipe 1524b, in the area where the phase change material forms the second sub-phase change filling body 1523a, the phase change material can fix the internal core and the external protective layer 1522, and absorb the heat generated by the core during charging. In the area where the phase change material is not filled: the inner wall of the insulating layer and protective layer 1522 of the core group 1521 and the opposite side walls of the two second sub-phase change filling bodies 1523a together enclose a cavity, which is used for the insulating heat exchange fluid 10 to flow through, and adjacent cavities are connected through the second through-hole reserved in the second sub-phase change filling body 1523a. Thus, under the pressure provided by the main circuit pump 132, the insulating heat exchange fluid 10 will fill each cavity in the charging gun cable 152, thereby providing support for the cable structure and effectively fixing the internal wire core and the external protective layer 1522. Compared to the inner wall of the liquid outlet pipe 1524a, which has no protrusions, the adjacent second sub-phase change filling bodies 1523a are connected through the second through-holes. As a result, the flow channel cross-section of the liquid inlet pipe 1524b shrinks at each second through-hole, resulting in a more drastic change in the flow channel cross-section in the direction of fluid flow in the liquid inlet pipe 1524b. This will effectively slow the flow rate of the insulating heat exchange fluid 10 in the liquid inlet pipe 1524b, allowing the insulating heat exchange fluid 10 to fully exchange heat with the wire core.

[0121] It is easy to understand that in this embodiment, the liquid outlet pipe 1524a allows the insulating heat exchange fluid 10 to quickly pass through the charging gun cable 152 and enter the eVTOL to ensure the thermal management effect in the battery cavity 210, and the liquid inlet pipe 1524b allows the insulating heat exchange fluid 10 to circulate slowly in the charging gun cable 152 and fully absorb the heat of the wire core, thereby ensuring the thermal management effect of the charging gun cable 152 itself.

[0122] In order to further reduce the heat exchange between the insulating heat exchange fluid 10 in the liquid outlet pipe 1524a and the wire core, in one embodiment, the liquid outlet pipe 1524a is made of a polymer thermal insulation material.

[0123] See also Figure 6In one embodiment, the charging gun head 151 includes a gun head body 1511 and a charging terminal 1512. The gun head body 1511 has a liquid inlet cooling chamber 1511b and a liquid outlet cooling chamber 1511a. There are at least two fluid interfaces 1513, at least one of which is in communication with the liquid inlet cooling chamber 1511b, and at least one of which is in communication with the liquid outlet cooling chamber 1511a. The charging terminal 1512 is disposed on the gun head body 1511, and the charging terminal 1512 passes through the liquid inlet cooling chamber 1511b or the liquid outlet cooling chamber 1511a and is connected to the corresponding wire core group 1521, or the charging terminal 1512 extends into the liquid inlet cooling chamber 1511b or the liquid outlet cooling chamber 1511a and is connected to the corresponding wire core group 1521. The liquid inlet pipe 1524b is in communication with the liquid inlet cooling chamber 1511b, and the liquid outlet pipe 1524a is in communication with the liquid outlet cooling chamber 1511a.

[0124] The gun head body 1511 is the main part of the charging gun head 151, which includes a tail portion connected to the charging gun cable 152, and a head portion provided with a fluid interface 1513 and a charging interface. All the charging terminals 1512 form the aforementioned charging interface in a preset layout. The charging terminal 1512 is assembled in the gun head body 1511, and one end of the charging terminal 1512 is exposed from the head portion, and the other end extends to the tail portion to be connected to the wire core. It can be understood that the charging terminal 1512 can be connected to the wires of the wire core group 1521 for power transmission, or it can be connected to the signal line of the wire core group 1521 for information transmission. In a feasible embodiment, the tail portion of the gun head body 1511 also has a gun head phase change module constructed of phase change material. The structure of the gun head phase change module is consistent with the structure of the cable phase change module 1523, so that the two can cooperate.

[0125] In this embodiment, a liquid inlet cooling chamber 1511b and a liquid outlet cooling chamber 1511a are defined within the gun tip body 1511. The liquid inlet cooling chamber 1511b and the liquid outlet cooling chamber 1511a are arranged side by side on a radial plane of the gun tip body 1511. One end of the liquid inlet cooling chamber 1511b is connected to the fluid interface 1513 corresponding to the liquid inlet pipe 1524b among all the fluid interfaces 1513, and the other end is connected to the liquid inlet pipe 1524b. Meanwhile, one end of the liquid outlet cooling chamber 1511a is connected to the fluid interface 1513 corresponding to the liquid outlet pipe 1524a among all the fluid interfaces 1513, and the other end is connected to the liquid outlet pipe 1524a. In this way, the insulating heat exchange fluid 10 is temporarily retained in the liquid outlet cooling chamber 1511a before entering the eVTOL. After leaving the eVTOL, the insulating heat exchange fluid 10 enters the fluid interface 1513 and is temporarily retained in the liquid inlet cooling chamber 1511b.

[0126] A portion of the multiple charging terminals 1512 pass through the liquid inlet cooling cavity 1511b and are connected to the corresponding wire core group 1521, while another portion of the charging terminals 1512 pass through the liquid outlet cooling cavity 1511a and are connected to the corresponding wire core group 1521, so that each charging terminal 1512 in the charging gun head 151 is directly in contact with the insulating heat exchange fluid 10 during operation and is cooled.

[0127] Alternatively, a portion of the plurality of charging terminals 1512 extends into the liquid inlet cooling cavity 1511b, and the corresponding wire core groups 1521 also extend into the liquid inlet cooling cavity 1511b, and the two are connected within the liquid inlet cooling cavity 1511b. Similarly, another portion of the plurality of charging terminals 1512 extends into the liquid outlet cooling cavity 1511a, and the corresponding wire core groups 1521 also extend into the liquid outlet cooling cavity 1511a, and the two are connected within the liquid outlet cooling cavity 1511a.

[0128] It is not difficult to see that the battery cells in the battery cavity 210, the charging power device 120 in the device cavity 111 in the pile body 110, the wire core in the charging gun cable 152, and the charging terminal 1512 of the charging gun head 151 are all cooled by the insulating heat exchange fluid 10. Therefore, this embodiment provides cooling measures for each key component that generates heat during the eVTOL charging process, thereby significantly improving the heating phenomenon of each key component during the eVTOL charging process. In this way, through the cooling solution provided by this embodiment, the charging device 100 can support a higher charging power rate and reduce charging time, that is, it can support faster fast charging technology.

[0129] In addition, in this embodiment, the insulating heat exchange fluid 10 will directly contact the battery cells in the battery cavity 210, the charging power device 120 in the device cavity 111 in the pile body 110, the wire cores in the charging gun cable 152, and the charging terminal 1512 of the charging gun head 151. Therefore, at the same power, since there is no need to design isolation measures (isolation of coolant and heat dissipation components), the pile body 110, the charging gun cable 152 and the charging gun head 151 are smaller in size and lighter in weight, which improves the convenience of personnel operation.

[0130] Of course, since the cross-sectional shape of the charging gun head 151 is generally constructed as a symmetrical figure, in this embodiment, the liquid inlet cooling cavity 1511b and the liquid outlet cooling cavity 1511a can be constructed as a symmetrical structure, thereby fully utilizing the internal space of the charging gun head 151.

[0131] In one embodiment, to ensure the structural strength of the charging gun cable 152, the phase change material is a solid-solid phase change material. It should be noted that, in the solid state, a solid-solid phase change material can absorb or release heat during the process of transforming from one crystal structure (phase) to another. During the phase change process, this material remains in a solid state with relatively little volume change, thereby not only storing heat but also ensuring structural support for the charging gun cable 152. In one example, the solid-solid phase change material can be an organic polymer phase change material such as high-density polyethylene. Alternatively, in another example, the solid-solid phase change material can be a composite phase change material of an organic polymer and paraffin wax.

[0132] See also Figure 7 In one embodiment, a first cable cooling channel 1525a and a second cable cooling channel 1525b are further provided in the charging gun cable 152. The first cable cooling channel 1525a and the second cable cooling channel 1525b are both used to allow the insulating heat exchange fluid 10 to flow through; one end of the first cable cooling channel 1525a is connected to the thermal management module 130, and the other end of the first cable cooling channel 1525a is connected to one end of the second cable cooling channel 1525b, and the other end of the second cable cooling channel 1525b is connected to the device heat exchange branch, so that the thermal management module 130, the first cable cooling channel 1525a, the second cable cooling channel 1525b and the device heat exchange branch form a circulation loop.

[0133] The first cable cooling channel 1525a and the second cable cooling channel 1525b are channels within the charging gun cable 152, arranged parallel to the fluid conduit 1524. Both extend along the routing direction of the charging gun cable 152 and penetrate the charging gun cable 152. Unlike the fluid conduit 1524, the first cable cooling channel 1525a and the second cable cooling channel 1525b together form a U-shaped channel within the charging gun 150, with one end closed and the other open, connecting to the charging end interface 112. In this manner, the insulating heat exchange fluid 10 within the thermal management module 130 first enters the device cavity 111, then enters the charging gun cable 152 through the first cable cooling channel 1525a, flows unidirectionally through the entire length of the charging gun cable 152, and then enters the second cable cooling channel 1525b. There, it flows in the opposite direction, returning to the charging body 110 and ultimately returning to the expansion tank. Of course, this embodiment is not limited thereto. The insulating heat exchange fluid 10 leaving the heat exchanger 133 may first enter the charging gun cable 152 and then enter the device cavity 111 .

[0134] In this embodiment, during fast charging, since the charging gun cable 152 generates a large amount of heat, the insulating heat exchange fluid 10 entering the eVTOL does not intentionally cool the charging gun cable 152 when flowing through the fluid pipe 1524 in the charging gun cable 152. Instead, the charging gun cable 152 is cooled by the first cable cooling channel 1525a and the second cable cooling channel 1525b additionally provided in the charging gun cable 152, thereby ensuring the cooling effect of the battery cavity 210 and the charging gun cable 152.

[0135] See also Figure 9 In one embodiment, the charging gun head 151 includes: a gun head body 1511 and a charging terminal 1512. The gun head body 1511 has a gun head cooling cavity 1511c and a fluid flow channel 1514. One end of the fluid flow channel 1514 is connected to the fluid interface 1513, and the other end of the fluid flow channel 1514 is connected to the fluid pipeline 1524; the charging terminal 1512 is arranged on the gun head body 1511, and the charging terminal 1512 passes through the gun head cooling cavity 1511c and is connected to the wire core group 1521, or the charging terminal 1512 extends into the gun head cooling cavity 1511c and is connected to the wire core group 1521; the other end of the first cable cooling channel 1525a is connected to one end of the second cable cooling channel 1525b through the gun head cooling cavity 1511c.

[0136] In this embodiment, the gun head body 1511 is not provided with a liquid inlet cooling cavity 1511b and a liquid outlet cooling cavity 1511a, but only has one gun head cooling cavity 1511c. At this time, all charging terminals 1512 pass through the gun head cooling cavity 1511c and communicate with the core group 1521. Alternatively, the core group 1521 extends into the gun head cooling cavity 1511c, and all charging terminals 1512 extend into the gun head cooling cavity 1511c and communicate with the core group 1521. The first cable cooling channel 1525a and the second cable cooling channel 1525b are both connected to the gun head cooling cavity 1511c to achieve mutual communication. In this way, on the one hand, the insulating heat exchange fluid 10 used to cool the charging terminal 1512 is the fluid in the device heat exchange branch 01, rather than the insulating heat exchange fluid 10 after heat exchange with the battery cell 220 in the battery heat exchange branch 02, thereby ensuring the cooling effect of each charging terminal 1512. On the other hand, the connection point between the first cable cooling channel 1525a and the second cable cooling channel 1525b is not in the charging gun cable 152, but at the charging gun head 151, thereby simplifying the structure of the charging gun cable 152 and reducing manufacturing costs.

[0137] In addition, a fluid flow channel 1514 is defined in the gun head body 1511, and the fluid flow channel 1514 is connected to the fluid interface 1513 and the corresponding fluid pipeline 1524. Figure 9In one example, the gun tip body 1511 defines two fluid interfaces 1513, one inlet and one outlet. At this time, two side-by-side fluid flow channels 1514 are also defined in the gun tip body 1511. One fluid flow channel 1514 connects one fluid interface 1513 with the liquid inlet pipe 1524b, and the other fluid flow channel 1514 connects the other fluid interface 1513 with the liquid outlet pipe 1524a.

[0138] It is easy to understand that compared with the gun head body 1511 provided in the previous embodiment with the liquid inlet cooling cavity 1511b and the liquid outlet cooling cavity 1511a, the structure of the gun head body 1511 in this embodiment is simpler and more reliable.

[0139] As previously mentioned, the first cable cooling channel 1525a and the second cable cooling channel 1525b in this embodiment can be constructed as tubular structures with smooth inner walls. In this case, the tubular structure can be made of metal to conduct heat more quickly, thereby cooling the wire core and / or phase change material more rapidly. For example, in one embodiment, the first cable cooling channel 1525a is constructed as a thin-walled metal tube with a wall thickness b, where b satisfies the following: 0.3 mm ≤ b ≤ 1 mm.

[0140] Alternatively, the first cable cooling channel 1525a and the second cable cooling channel 1525b in this embodiment can also be constructed as a cavity structure formed by the aforementioned phase change filling bodies being arranged at intervals. Figure 10 In one embodiment, the cable phase change module 1523 further includes a plurality of third sub-phase change filling bodies 1523b arranged in sequence along the wiring direction of the charging gun cable 152, and the third sub-phase change filling bodies 1523b have a third through hole, so that the cavities between any two adjacent third sub-phase change filling bodies 1523b in the plurality of third sub-phase change filling bodies 1523b are connected through the third through hole to form a second cable cooling channel 1525b.

[0141] In this way, when the first cable cooling channel 1525a is constructed as a thin-walled metal tube and the insulating heat exchange fluid 10 flows into the charging gun head 151, and the second cable cooling channel 1525b is constructed as a cavity structure formed by the third sub-phase change filler 1523b being spaced apart and the insulating heat exchange fluid 10 returns to the pile body 110, the insulating heat exchange fluid 10 can enter the gun head cooling cavity 1511c more quickly to cool the charging terminal 1512 with a larger heat generation, and then return to cool the charging gun cable 152, thereby improving the cooling effect.

[0142] It should be noted that each pipe in the pile body 110 can be configured as a soft pipe or a hard pipe, and this embodiment does not limit this.

[0143] For ease of understanding, two specific examples are shown below:

[0144] Example 1:

[0145] See also Figure 2 and Figure 4 The pile body includes a first thermal management submodule 130a and a second thermal management submodule 130b. The thermal management modules comprise four pipes, two inlet and two outlet, forming two circulation loops. Each of the first and second thermal management submodules 120a and 130b has a main circuit formed by an expansion tank, a pump 132, and a heat exchanger 133, connected in sequence via pipes.

[0146] The first circulation loop is as follows: under the driving force provided by the first thermal management submodule 130a, the insulating heat exchange fluid 10 flows out of the first thermal management submodule 130a and reaches the pile end interface 112 through the pipeline. The pile end interface 112 is connected to the charging gun cable 152, and the insulating heat exchange fluid 10 enters the charging gun cable 152 through the first cable cooling channel 1525a. The first cable cooling channel 1525a is constructed as a pipe structure with no protrusions on the inner wall of the cable phase change module 1523, so that the insulating heat exchange fluid 10 quickly enters the gun head cooling cavity 1511c of the charging gun head 151 to cool the charging terminal 1512. The insulating heat exchange fluid 10 then enters the second cable cooling channel 1525b. Multiple third sub-phase-change fillers 1523b are spaced apart along the wiring direction of the charging gun cable 152. Each of these third sub-phase-change fillers 1523b has a third through-hole. This allows the cavities between any two adjacent third sub-phase-change fillers 1523b to connect through the third through-hole, forming a second cable cooling channel 1525b. This significantly reduces the flow rate of the insulating heat exchange fluid 10 within the second cable cooling channel 1525b, allowing it to fully absorb the heat generated by the cable core. The insulating heat exchange fluid 10 then passes through the pile end interface 112 and returns to the pile body 110. It then passes through the first device hole 1111 via a pipe and enters the device cavity 111. The device cavity 111 is filled with the insulating heat exchange fluid 10, allowing it to directly contact and cool each charging power device 120. The insulating heat exchange fluid 10 then exits the device cavity 111 through the second device hole 1112 and returns to the first thermal management sub-module 130a via a pipe.

[0147] The second circulation pipeline is as follows: Under the driving force provided by the second thermal management submodule 130b, the insulating heat exchange fluid 10 flows out of the second thermal management submodule 130b, through the pipeline to the charging head interface 112, and then into the liquid outlet pipe 1524a of the charging gun cable 152. The liquid outlet pipe 1524a is constructed as a thin-walled metal tube made of polymer thermal insulation material. This allows the insulating heat exchange fluid 10 to pass through the liquid outlet pipe 1524a quickly and heat-insulatingly to the charging gun head body 1511. The insulating heat exchange fluid 10 enters the eVTOL through the fluid interface 1513 and then passes through the pipeline and the first battery cavity hole 211 into the battery cavity 210. The insulating heat exchange fluid 10 fills the battery cavity 210, thereby directly cooling the battery cells. The insulating heat exchange fluid 10 then leaves the battery cavity 210 through the second battery cavity hole 212 and enters the liquid inlet pipe 1524b through another fluid interface 1513 on the charging gun head. Similar in structure to the second cable cooling channel 1525b, multiple second sub-phase-change fillers 1523a are spaced apart along the routing direction of the charging gun cable 152. Each second sub-phase-change filler 1523a has a second through-hole. This allows the cavities between any two adjacent second sub-phase-change fillers 1523a to connect through the second through-hole, forming a liquid inlet pipe 1524b. This significantly reduces the flow rate of the insulating heat exchange fluid 10 within the liquid inlet pipe 1524b, absorbing heat generated by the cable core. The insulating heat exchange fluid 10 then passes through the pile end interface 112 and returns to the second thermal management sub-module 130b through the pipeline.

[0148] As can be seen, in this example, the battery pack cooling and the charging module cooling are independent and do not affect each other. In this example, since the battery pack cooling and the charging circuit cooling are independent, the second thermal management sub-module 130b can be used to increase the temperature of the battery cavity 210. Specifically, the eVTOL battery pack is equipped with a phase change module and a heat exchange module connected to the phase change module for heat exchange. This allows the eVTOL to use the battery pack as a heat source for the aircraft's temperature control system to control the cabin temperature. In this case, the second thermal management sub-module generates heat, pre-heating the phase change module in the battery pack, causing the phase change material to transition to the phase required for the flight mission. This allows the phase change material to exchange heat with the refrigerant in the aircraft's temperature control system during flight, transferring the pre-stored heat to the refrigerant. This allows the phase change material in the battery pack to meet various temperature control scenarios of the eVTOL, thereby improving the aircraft's reliability and adaptability.

[0149] In this example, an on-off valve is installed in the pipeline connecting the second thermal management submodule 130b to the pile-end interface. Downstream of the on-off valve is an air filling branch, which includes a high-pressure gas storage device and a pressure-reducing valve, connected in sequence via pipelines. When the battery pack temperature reaches a preset level or is fully charged, the on-off valve closes and the pressure-reducing valve opens. Under the influence of high pressure, non-combustible gas flows through the pile-end interface along the pipeline and into the battery cavity 210 within the eVTOL. Once inside, the non-combustible gas squeezes the insulating heat exchange fluid 10, forcing it out of the battery cavity 210. This not only removes the insulating heat exchange fluid from the battery cavity 210, but also ensures that the battery cavity 210 is filled with non-combustible gas, thereby suppressing combustion in the event of thermal runaway. The discharged insulating heat exchange fluid 10 can return to the expansion tank of the second thermal management submodule 130b. Excess non-combustible gas can also enter the expansion tank and then be discharged to the outside through the expansion tank's exhaust port.

[0150] See also Figure 3 Example 2: The pile body includes a thermal management module 130. At this time, the thermal management module 130 includes two pipes, one inlet and one outlet, forming a circulation loop.

[0151] The thermal management module 130 includes a main circuit formed by an expansion water tank, a pump 132, and a heat exchanger 133, which are connected in sequence through pipelines. The heat exchanger has a medium pump outlet pipe 1331, and the expansion water tank has a medium return pipe 1311. The medium pump outlet pipe 1331 is connected to the pile end interface 112 through a pipeline. The insulating heat exchange fluid 10 reaches the pile end interface 112 through the pipeline and enters the liquid outlet pipe 1524a of the charging gun cable 152. The liquid outlet pipe 1524a is made of a polymer thermal insulation material. In this way, the insulating heat exchange fluid 10 passes through the liquid outlet pipe 1524a quickly and heat-insulatingly to the gun head body 1511 of the charging gun. A liquid outlet cooling chamber 1511a is provided in the gun head body 1511. The insulating heat exchange fluid 10 cools the charging terminal 1512 passing through the liquid outlet cooling chamber 1511a in the liquid outlet cooling chamber 1511a. The insulating heat exchange fluid 10 then passes through the fluid interface 1513 of the charging gun head and enters the eVTOL, and in turn passes through the pipe and the first battery cavity hole 211 into the battery cavity 210. The insulating heat exchange fluid 10 fills the battery cavity 210, thereby directly cooling the battery cell 220. The insulating heat exchange fluid 10 then leaves the battery cavity 210 from the second battery cavity hole 212 and enters the liquid inlet cooling cavity 1511b through another fluid interface 1513 on the charging gun head. The insulating heat exchange fluid 10 cools the charging terminal 1512 that passes through the liquid inlet cooling cavity 1511b in the liquid inlet cooling cavity 1511b. The insulating heat exchange fluid 10 then enters the liquid inlet pipe 1524b of the charging gun cable 152. Multiple second sub-phase-change fillers 1523a are spaced apart along the wiring direction of the charging gun cable 152. Each of these second sub-phase-change fillers 1523a has a second through-hole. This allows the cavities between any two adjacent second sub-phase-change fillers 1523a to connect through the second through-hole, forming a liquid inlet pipe 1524b. This significantly reduces the flow rate of the insulating heat exchange fluid 10 within the liquid inlet pipe 1524b, absorbing heat generated by the cable core. The insulating heat exchange fluid 10 then passes through the terminal interface 112 and, in sequence, through the pipeline and the second device hole 1112, into the device cavity 111. The device cavity 111 is then filled with the insulating heat exchange fluid 10. This allows the insulating heat exchange fluid 10 to directly contact and cool each charging power device 120. The insulating heat exchange fluid 10 then exits the device cavity 111 through the second device hole 1112 and returns to the medium return pipe 1311 via the pipeline.

[0152] It's worth noting that the flow rate of a single outlet pipe 1524a or a single inlet pipe 1524b is limited. Increasing the cross-sectional area of a single outlet pipe 1524a or a single inlet pipe 1524b to increase the flow rate may result in insufficient structural strength of the charging gun cable 152. Therefore, in this example, the charging gun cable 152 is provided with two outlet pipes 1524a and two inlet pipes 1524b.

[0153] In this example, an on-off valve is also installed on the pipeline connecting the medium pump outlet pipe 1331 and the pile-end interface 112. Downstream of the on-off valve, an air filling branch is provided. This branch includes a high-pressure gas storage device and a pressure-reducing valve, which are sequentially connected through pipelines. When the battery pack is fully charged, the on-off valve can be closed and the pressure-reducing valve opened. Under the action of high pressure, non-combustible gas flows through the pipeline and into the battery cavity within the eVTOL. Once inside, it squeezes the insulating heat exchange fluid 10, forcing it out of the battery cavity 210. This not only removes the insulating heat exchange fluid 10 from the battery cavity 210, but also ensures that the battery cavity 210 is filled with non-combustible gas, thereby suppressing combustion in the event of thermal runaway. The discharged insulating heat exchange fluid 10 can be returned to the expansion tank via the pipeline. Excess non-combustible gas can also enter the expansion tank and be discharged to the outside through the expansion tank's exhaust port.

[0154] From the above two examples, it is not difficult to see that:

[0155] (1) Ordinary liquid cooling systems composed of ethylene glycol and water or refrigerants (Freon) are not compatible with submerged battery packs because their conductivity may involve safety issues. The above two examples use insulating, flash-point-free insulating heat exchange fluids that are compatible with submerged battery packs. Insulating heat exchange fluids such as deionized water, electronic fluoride liquid, hydrocarbons, esters or silicone oils will not cause safety problems even if they leak due to their high insulation properties. In addition, the battery pack on the electric vehicle can be directly provided with coolant through the charging gun, so the thermal management device of the electric vehicle does not need to be started during charging. During the charging process, it can ensure that the battery cools down quickly while maintaining the temperature uniformity of the battery system, which is more convenient and energy-saving.

[0156] At the same time, since the heat generated by most electric vehicles during discharge is less than that generated by fast charging (especially fast charging within 30 minutes), their built-in thermal management devices can only be responsible for the heat dissipation function during discharge, so their design power can be smaller, and their volume and weight can also be smaller.

[0157] In addition to the above two examples, when the electric vehicle eVTOL is in a low-temperature environment, the heat exchanger 133 may include a PTC heater, which can also provide a heated insulating heat exchange fluid to heat the battery pack, which is faster and more convenient than traditional heating methods.

[0158] (2) Compared with air cooling and traditional liquid-cooled plate cooling, the above two examples use immersion cooling, which has a larger heat dissipation area and better heat dissipation effect, so it can support a larger charging power. Compared with the traditional liquid-cooled plate cooling system, since there is no need to consider the insulation problem caused by leakage, the immersion cooling system design is simpler and more reliable. Under the same power, since there is no need to design isolation measures (isolation of coolant and heat dissipation components), the charging pile, charging gun cable and charging gun are smaller and lighter, which improves the convenience of personnel operation.

[0159] (3) It can provide insulating heat exchange fluid to the battery pack, and is compatible with traditional liquid-cooled plate battery packs and immersion battery packs. During fast charging, due to the high heat generated by the battery pack, the general onboard thermal management system cannot provide the required cooling capacity. However, ground charging equipment can support higher charging power, thereby reducing charging time.

[0160] (4) The charging gun cable uses phase change material, which is wrapped around the outside of various functional wire cores to fix and absorb the heat of the wire cores. The phase change material is set in sections, which reduces the weight of the cable. The space between the phase change material, the wire core and the protective layer of the cable outer wall becomes an insulating heat exchange fluid immersion space, which greatly increases the heat dissipation rate of the cable. Therefore, this cable is lighter than traditional cables and has better heat dissipation effect.

[0161] The above are merely exemplary embodiments of the present invention and are not intended to limit the patent scope of the present invention. All equivalent structural transformations made using the contents of the present invention specification and drawings under the technical concept of the present invention, or direct / indirect applications in other related technical fields, are included in the patent protection scope of the present invention.

Claims

1. A charging device, characterized in that: The charging device includes: A pile body, the pile body having a pile end interface, the pile end interface being used to connect to an electric vehicle, and the electric vehicle having a battery cavity; and a thermal management module, wherein the thermal management module is configured to communicate with the battery cavity to form a battery heat exchange branch when the pile end interface is connected to the electric vehicle, so that the insulating heat exchange fluid in the thermal management module can flow through the battery heat exchange branch and fill the battery cavity; The thermal management module includes a main circuit, which includes a medium storage box, a pump and a heat exchanger connected in sequence through pipelines. The insulating heat exchange fluid is stored in the medium storage box. The heat exchanger includes a medium pump outlet pipe, which is connected to the pile end interface.

2. The charging device according to claim 1, wherein: The thermal management module also includes an air filling and fluid replacement component; The gas-filling and fluid-exchanging assembly is connected to the battery heat exchange branch, and is used to input non-combustible gas into the battery cavity to discharge the insulating heat exchange fluid from the battery cavity; the non-combustible gas includes one or more of inert gas, nitrogen, carbon dioxide and sulfur hexafluoride.

3. The charging device according to claim 2, wherein: The gas filling and liquid exchange assembly includes a gas filling branch, and the gas filling branch includes a gas storage device and a gas circuit valve connected in sequence through a pipeline; Wherein, the gas circuit valve is a pressure reducing valve.

4. The charging device according to claim 1, wherein: The battery cavity is filled with a battery heat exchange medium to form immersion cooling for the battery cell group in the battery cavity, and the material of the battery heat exchange medium is consistent with the material of the insulating heat exchange fluid.

5. The charging device according to claim 1, wherein: The insulating heat exchange fluid is made of deionized water, electronic fluorinated liquid, hydrocarbons, esters or silicone oils.

6. The charging device according to claim 1, wherein: The charging device also includes a charging power device. A device cavity is provided in the pile body, and the charging power device is arranged in the device cavity. The thermal management module is connected to the device cavity to form a device heat exchange branch, so that the insulating heat exchange fluid in the thermal management module can flow in the device heat exchange branch and enter the device cavity to form immersion cooling for the charging power device.

7. The charging device according to claim 6, wherein: The thermal management module is arranged inside or outside the pile body.

8. The charging device according to claim 7, wherein: The device heat exchange branch and the battery heat exchange branch are connected in parallel and then in series to the main circuit to form a circulation loop; or, the device heat exchange branch, the battery heat exchange branch and the main circuit are connected in series to form a circulation loop.

9. The charging device according to claim 7, wherein: The heat exchanger includes a direct evaporation refrigeration cycle device or a semiconductor refrigeration device; and / or The main circuit further includes a positive temperature coefficient (PTC) heater, or the heat exchanger is connected to a heat pump system, which switches between a cooling mode and a heating mode.

10. The charging device according to claim 6, wherein: The thermal management module includes: a first thermal management submodule, the first thermal management submodule being in communication with the device heat exchange branch; A second thermal management submodule is connected to the battery heat exchange branch.

11. The charging device according to any one of claims 1 to 10, characterized in that: The charging device further includes a charging gun, which includes: a charging gun head having a fluid connection; and a charging gun cable, one end of which is connected to the charging gun head, and the other end of which is in communication with the thermal management module; a fluid conduit provided in the charging gun cable for allowing the insulating heat exchange fluid to flow through, and the fluid conduit being in communication with the fluid interface; Wherein, when the charging gun head is connected to the electric vehicle, the pile end interface and the battery cavity are communicated through the fluid interface and the fluid pipeline to form the battery heat exchange branch.

12. The charging device according to claim 11, wherein: The charging gun cable includes: At least one core group, the core group comprising at least one core and an insulating layer sleeved radially outside the at least one core, with gaps between adjacent core groups; a protective layer sleeved on the radial outside of all the core groups, wherein the protective layer is spaced apart from the core groups; and a cable phase change module, the cable phase change module filling the gap between the wire core group and the protective layer and the gap between adjacent wire core groups, and the material of the cable phase change module includes phase change material; Wherein, the fluid pipeline is provided in the cable phase change module.

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