Liquid-cooled charging system for vehicle

Abstract

To provide a liquid-cooled charging system for a vehicle, which can dissipate heat generated during charging (including fast charging) of an electrically powered vehicle thereby reducing a risk of damaging a charging assembly.SOLUTION: In a vehicle 10, a liquid-cooled charging system 100 includes a charging assembly having an interface assembly configured to support a charging plug of a charging station and an energy transfer assembly configured to electrically couple the charging station to a battery of the vehicle during charging. A fluid circuit extends along components of the charging assembly. A coolant system of the liquid-cooled charging system is connected to the fluid circuit, allowing a coolant of the coolant system to flow through the fluid circuit to dissipate heat from the charging assembly components during charging of the vehicle.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present disclosure generally relates to a charging system configured for use in an electric vehicle. Although electric vehicles have numerous advantages, one obstacle that such vehicles face is that it takes longer to fully charge the battery of an electric vehicle compared to the time it takes to fill the fuel of a vehicle of equivalent size powered by an internal combustion engine.

Background Art

[0002] DC rapid charging has emerged as one option for reducing the time required to charge an electric vehicle. However, the large amount of heat generated as a result of the high rate of power (and current) used during such charging can increase the resistance of the vehicle's charging system to the flow of current (and thus increase the time required to charge the vehicle), and, more seriously, can pose a risk of damaging the vehicle's charging components. Given the limitations of existing rapid charging systems, it would be desirable to provide a charging system for an electric vehicle that can dissipate and / or mitigate the heat generated during such rapid charging of the vehicle.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Patent Document 2

Patent Document 3

Patent Document 4

Patent Document 5

Summary of the Invention

[0004] In one embodiment of the present disclosure, a housing for a charging system includes a mounting plate. A first opening and a second opening are each defined by and extend through the mounting plate. A charging port includes a port outer portion and a port inner portion. The port outer portion extends around the first and second openings and outwardly from the front face of the mounting plate. The port outer portion is configured to engage and support a charging plug of a charging station. The port inner portion extends around each of the first and second openings and outwardly from the rear face of the mounting plate. The port inner portion includes a mounting body. From a rear portion of the mounting body, a first passage is defined by and extends through the mounting body. The first passage is in fluid communication with the first opening. From a rear portion of the mounting body, a second passage is defined by and extends through the mounting body. The second passage is in fluid communication with the second opening. A channel is defined by and extends through the mounting body. A first end of the channel is in fluid communication with the first passage, and a second end of the channel is in fluid communication with the second passage.

[0005] In some aspects, the mounting plate includes a mounting structure configured to attach the housing to a vehicle. In some aspects, the port outer portion is configured to be accessible from outside the vehicle when the mounting plate is securely fixed to the vehicle via the mounting structure. In some aspects, the port outer portion is configured to engage and support a charging plug used for DC fast charging. In some aspects, each of the first and second openings in the mounting plate is configured to receive and support a contact terminal such that the contact terminal extends into the port outer portion and is accessible from outside the vehicle.

[0006] In one embodiment of the present disclosure, a charging assembly kit includes a housing having a mounting plate and first and second energy transfer assemblies. A port structure extends outwardly from the front face of the mounting plate. A mounting body extends outwardly from the rear face of the mounting plate. The mounting body includes a first passage extending from a rear portion of the mounting body and defined by and extending through the mounting body. A second passage is defined by and extends through the mounting body from a rear portion of the mounting body. A channel is defined by and extends through the mounting body. The channel fluidly connects the first passage and the second passage. Each of the first energy transfer assembly and the second energy transfer assembly includes an electrical connector that defines a channel therethrough and is formed of a conductive material. The channel of the first electrical connector is configured to be fluidly coupled with the first passage, and the channel of the second electrical connector is configured to be fluidly coupled with the second passage.

[0007] In some aspects, the charging assembly kit further includes a first contact terminal and a second contact terminal each extending within the port structure. The first contact terminal is configured to be electrically coupled to the first electrical connector, and the second contact terminal is configured to be electrically coupled to the second electrical connector. In some aspects, the first terminal body is configured to be received within the first passage, and the second terminal body is configured to be received within the second passage.

[0008] In some embodiments, each of the first terminal body and the second terminal body includes sidewalls that define a hollow chamber. A first aperture extends through the sidewall of the first terminal body, and a second aperture extends through the sidewall of the second terminal body. In some embodiments, the first aperture is configured to be in fluid communication with a first end of a channel that extends through the mounting body when the first terminal connector is received within the first passage. The second aperture is configured to be in fluid communication with a second end of a channel that extends through the mounting body when the second terminal connector is received within the second passage.

[0009] In some embodiments, the channel of the first electrical connector is configured to be in fluid communication with the channel of the second electrical connector when a first end of the first electrical connector is attached to the first terminal body and a first end of the second electrical connector is attached to the second terminal body.

[0010] In some embodiments, the second end of the first electrical connector and the second end of the second electrical connector are each configured to be fluidly connected to a refrigerant source. In some embodiments, the second end of each of the first electrical connector and the second electrical connector is configured to be electrically connected to a battery of a vehicle. In some embodiments, the first terminal connector electrically connects a first contact terminal to the first electrical connector, and the second terminal connector electrically connects a second contact terminal to the second electrical connector.

[0011] In some embodiments, the charging assembly further includes an enclosed body having a first receiving structure configured to receive the first electrical connector, a second receiving structure configured to receive the second electrical connector, and a body portion configured to surround and attach to at least a portion of the outer surface of the mounting body.

[0012] In one embodiment of the present disclosure, a charging housing is provided that includes a first surface configured to be accessible from outside the vehicle and a second surface configured to be inaccessible from outside the vehicle. A charging port configured to engage a charging plug of a charging station is provided on the first surface of the housing, and a mounting body is provided on the rear surface of the housing. A first end of a first energy transfer assembly is arranged within the charging port of the housing such that it is accessible from outside the vehicle. A first end of a second energy transfer assembly is arranged within the charging port of the housing such that it is accessible from outside the vehicle. A second end of the first energy transfer assembly and a second end of the second energy transfer assembly are each fluidly coupled to a refrigerant source. The seconds of the first energy transfer assembly and the second energy transfer assembly are electrically coupled to a battery of the vehicle.

[0013] In some aspects, the step of fluidly coupling the second end of the first energy transfer assembly to the refrigerant source includes fluidly coupling a refrigerant source of the vehicle to a first channel extending through at least a portion of the first energy transfer assembly. The step of fluidly coupling the second end of the second energy transfer assembly to the refrigerant source includes fluidly coupling a refrigerant source of the vehicle to a second channel extending through at least a portion of the second energy transfer assembly.

[0014] In some embodiments, to define a return fluid path, a first channel of a first energy transfer assembly is fluidly coupled with a second channel of a second energy transfer assembly. In some embodiments, the step of fluidly coupling the first channel of the first energy transfer assembly and the second channel of the second energy transfer assembly includes coupling the first channel of the first energy transfer assembly to a first end of a fluid channel defined by and extending through a mounting body; and coupling the second channel of the second energy transfer assembly to a second end of the fluid channel of the mounting body. In some embodiments, voltage isolation is provided between the first energy transfer assembly and the second energy transfer assembly.

[0015] More specifically, the present invention provides the following. [1] A mounting plate; A first opening and a second opening, each defined by and extending through the mounting plate; A port external portion extending around the first and second openings and outward from the front surface of the mounting plate, the port external portion configured to engage and support a charging plug of a charging station; and A port internal portion extending around each of the first and second openings and outward from the rear surface of the mounting plate, A first passage extending from a rear portion of the mounting body, defined by and extending through the mounting body, the first passage being in fluid communication with the first opening; A second passage extending from the rear portion of the mounting body, defined by and extending through the mounting body, the second passage being in fluid communication with the second opening; and A channel defined by and extending through the mounting body; Comprising A mounting body in which a first end of the channel is in fluid communication with the first passage and a second end of the channel is in fluid communication with the second passage. Including a port internal part A charging port having A housing for a charging system having [2] The housing of [1], wherein the mounting plate includes a mounting structure configured to attach the housing to a vehicle. [3] The housing of [2], wherein the port external part is configured to be accessible from outside the vehicle when the mounting plate is securely fixed to the vehicle via the mounting structure. [4] The housing of [1], wherein the port external part is configured to engage and support a charging plug used for DC rapid charging. [5] The housing of [4], wherein each of the first and second openings in the mounting plate is configured to receive and support the contact terminal such that the contact terminal extends into the port external part and is accessible from outside the vehicle. [6] A mounting plate; A port structure extending outwardly from the front surface of the mounting plate; and A mounting body extending outwardly from the rear surface of the mounting plate, A first passage defined by and extending through the mounting body from a rear portion of the mounting body; A second passage defined by and extending through the mounting body from a rear portion of the mounting body; and A channel defined by and extending through the mounting body, the channel fluidly connecting the first passage and the second passage Comprising a mounting body A housing having An electrical connector that defines a channel therethrough and is formed of a conductive material, with first and second energy transfer assemblies, each of the first and second energy transfer assemblies including comprising configured such that the channel of the first electrical connector is in fluid communication with the first passageway and the channel of the second electrical connector is in fluid communication with the second passageway A charging assembly kit. [7] Further comprising a first contact terminal and a second contact terminal, each configured to extend into a port structure, the first contact terminal configured to be electrically connected to the first electrical connector and the second contact terminal configured to be electrically connected to the second electrical connector, the charging assembly kit of [6]. [8] The charging assembly kit of [7], further comprising a first terminal body configured to be received within the first passageway and a second terminal body configured to be received within the second passageway. [9] Each of the first terminal body and the second terminal body includes a sidewall that defines a hollow chamber, wherein a first aperture extends through the sidewall of the first terminal body and a second aperture extends through the sidewall of the second terminal body, the charging assembly kit of [8].

[10] The first aperture is configured to be in fluid communication with a first end of a channel extending through the mounting body when the first terminal connector is received within the first passageway; and the second aperture is configured to be in fluid communication with a second end of the channel extending through the mounting body when the second terminal connector is received within the second passageway, the charging assembly kit of [9].

[11] The channel of the first electrical connector is configured to be in fluid communication with the channel of the second electrical connector when a first end of the first electrical connector is attached to the first terminal body and a first end of the second electrical connector is attached to the second terminal body, the charging assembly kit of

[10] .

[12] The charging assembly kit of

[11] , wherein the second end of the first electrical connector and the second end of the second electrical connector are each configured to be fluidly connected to a refrigerant source.

[13] The charging assembly kit of

[12] , wherein the second end of each of the first electrical connector and the second electrical connector is configured to be electrically connected to a battery of the vehicle.

[14] The charging assembly kit of [8], wherein the first terminal connector electrically connects the first contact terminal to the first electrical connector, and the second terminal connector electrically connects the second contact terminal to the second electrical connector.

[15] A sealed body having a first receiving structure configured to receive the first electrical connector, a second receiving structure configured to receive the second electrical connector, and a body portion configured to surround and be attached to at least a portion of an outer surface of the mounting body. The charging assembly kit of

[14] , further comprising a

[16] A method comprising the following steps: Providing a charging housing having a first surface configured to be accessible from the outside of the vehicle and a second surface configured to be inaccessible from the outside of the vehicle, wherein: Providing a charging port configured to engage a charging plug of a charging station on the first surface of the housing and providing a mounting body on the rear surface of the housing; Arranging a first end of a first energy transfer assembly within the charging port of the housing so as to be accessible from the outside of the vehicle; Arranging a first end of a second energy transfer assembly within the charging port of the housing so as to be accessible from the outside of the vehicle; Fluidly connecting a second end of the first energy transfer assembly and a second end of the second energy transfer assembly to a refrigerant source; and Electrically connecting the second of the first energy transfer assembly and the second energy transfer assembly to the battery of the vehicle.

[17] The step of fluidly connecting the second end of the first energy transfer assembly to a refrigerant source includes fluidly connecting the refrigerant source of the vehicle to a first channel extending through at least a portion of the first energy transfer assembly; and the step of fluidly connecting the second end of the second energy transfer assembly to the refrigerant source includes fluidly connecting the refrigerant source of the vehicle to a second channel extending through at least a portion of the second energy transfer assembly, the method of

[16] .

[18] The method of

[17] , further comprising the step of fluidly connecting the first channel of the first energy transfer assembly and the second channel of the second energy transfer assembly to define a return fluid path.

[19] The step of fluidly connecting the first channel of the first energy transfer assembly and the second channel of the second energy transfer assembly is Connecting the first channel of the first energy transfer assembly to a first end of a fluid channel defined by and extending through a mounting body; and Connecting the second channel of the second energy transfer assembly to a second end of the fluid channel of the mounting body The method of

[18] including.

[20] The method of

[18] , further including providing a voltage isolation between the first energy transfer assembly and the second energy transfer assembly.

Brief Description of the Drawings

[0016]

Figure 1

Figure 2A

Figure 2B

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7A

Figure 7B

Figure 8A

Figure 8B

Figure 9A

Figure 9B

DETAILED DESCRIPTION

[0017] Detailed Description While referring to the drawings, a liquid-cooled charging system 100 configured to dissipate heat generated during charging of a vehicle 10 that is fully electric or partially electric (or during any other use of the vehicle 10) will be described based on various aspects. Generally, as shown in FIG. 1, the liquid-cooled charging system 100 includes a charging assembly 200 through which an energy storage component (e.g., battery 11) of the vehicle 10 can be electrically connected to an external power source (e.g., through a charging station 20). The liquid-cooled charging system 100 also includes a refrigerant system 110 fluidly connected to one or more fluid circuits 290 of the charging assembly 200; the fluid circuits 290 extend along, through, around, or adjacent to one or more of the components that define the charging assembly 200.

[0018] The liquid-cooled charging system 100 may be configured to be used for both AC charging and DC charging of the vehicle 10 according to any number of different charging conditions and / or modes (e.g., Level 1, Level 2, Level 3, etc.). In various aspects, the liquid-cooled charging system 100 may be configured to be used for DC fast charging (e.g., Level 3 charging; or other charging conditions where power in excess of 20 kW, more specifically in excess of about 50 kW, and even more specifically in excess of 150 kW is provided to the vehicle 10 and / or a current in excess of 50 A, more specifically in excess of 100 A, and / or a VDC in excess of 200 V, more specifically in excess of 400 V is used). This is because the increased heat dissipation rate that the liquid-cooled charging system 100 can provide by flowing refrigerant through the fluid circuits 290 of the charging assembly 200 from the refrigerant system 110 to absorb heat from the charging assembly 200 may be particularly advantageous in mitigating the effects of the high levels of heat generated during charging of the vehicle 10 under such conditions.

[0019] Since the liquid-cooled charging system 100 is incorporated exclusively in the vehicle 10 (as opposed to being provided as part of and / or incorporated into the charging station 20), the ability of the liquid-cooled charging system 100 to minimize the risk of heat-related damage associated with charging (particularly under DC fast charging conditions) does not depend on the type and / or characteristics of the charging station 20 used to supply energy to the vehicle 10. Thus, the liquid-cooled charging system 100 is configured to enable the vehicle 10 to be charged quickly and safely regardless of the type of charging (e.g., DC fast charging) and / or whether the charging station 20 used to charge the vehicle 10 includes features for heat dissipation.

[0020] As shown in FIG. 1, in various aspects, the refrigerant system 110 of the liquid-cooled charging system 100 includes a pump 112 (or any other suitable fluid transfer device), a refrigerant source 114, and a cooling assembly 116. In some aspects, the various components of the refrigerant system 110 may be defined by components of an existing vehicle refrigerant system configured to dissipate heat from other components of the vehicle 10. For example, the refrigerant source 114 may be configured to supply refrigerant to both the electric motor 13 of the vehicle 10 and components of the charging assembly 200 of the liquid-cooled charging system 100. Thus, as will be appreciated, the liquid-cooled charging system 100 may be advantageously incorporated into the vehicle 10 without adding significant additional components and / or weight to the vehicle 10. And it may also be possible to retrofit the vehicle 10 to include a liquid-cooled charging system 100 as described herein without requiring significant redesign and / or modification of the vehicle 10. Alternatively, in other aspects, some or all of the components of the refrigerant system 110 may be discrete and separate components from the existing components of the refrigerant system of the vehicle 10. For example, the refrigerant source 114 of the refrigerant system 110 may be separate from an additionally provided refrigerant source used for cooling other components of the vehicle 10.

[0021] The pump 112 is configured to transfer a fluid refrigerant (in the form of a liquid and / or a gas) between the refrigerant source 114 of the charging assembly 200, the cooling assembly 116, and the fluid circuit(s) 290. The cooling assembly 116 may include any number or any combination of heat dissipation devices (such as radiators, fans, etc.) configured to cool the refrigerant as the fluid refrigerant circulates between and through the refrigerant system 110 and the charging assembly 200. Although the refrigerant system 110 illustrated in FIG. 1 is shown as including only a single pump 112, it should be understood that any number of pumps 112 may be used. Additionally, although the refrigerant system 110 illustrated in FIG. 1 is shown as including only a single refrigerant source 114, it should be understood that any number of refrigerant sources 114 may be used.

[0022] As shown in FIG. 1, the charging assembly 200 of the liquid-cooled charging system 100 includes a liquid-cooled energy transfer assembly 210 through which energy from the charging station 20 is supplied to the battery 11 to charge the vehicle 10; an interface assembly 250 configured to both support the liquid-cooled energy transfer assembly 210 with respect to the vehicle 10 and support the charging plug of the charging station 20 with respect to the vehicle 10; and a fluid circuit 290 through which the refrigerant provided by the refrigerant system 110 may flow to dissipate heat generated during charging of the vehicle 10 and / or during other use of the vehicle 10 and thereby mitigate the effects of heat. The charging assembly 200 according to one exemplary embodiment is shown in FIGS. 2A - 9B and will be described with reference to these drawings.

[0023] Figures 2A and 2B respectively illustrate a front view and a rear view of an assembled charging assembly 200 according to one exemplary embodiment. As shown in FIG. 2A, the mounting plate 261 of the interface assembly 250 includes a front surface 261a from which an external portion 263a of the liquid-cooled charging port extends. As will be described in more detail below, the mounting plate 261 is configured to be attached to the vehicle 10 such that the external portion 263a of the liquid-cooled charging port is accessible from outside the vehicle 10. The external portion 263a of the liquid-cooled charging port is configured to be physically engaged by a charging plug of the charging station 20, which enables the charging plug to be supported relative to the vehicle 10 during charging. As shown in FIG. 2B, an internal portion 263b of the liquid-cooled charging port is provided on the rear surface 261b of the mounting plate 261. As will be described in more detail below, in addition to supporting components of one or more liquid-cooled energy transfer assemblies 210 relative to the vehicle 10, the internal portion 263b of the liquid-cooled charging port defines a part of the fluid circuit 290 of the charging assembly 200.

[0024] During charging of the vehicle 10, energy from the charging station 20 is transferred to the battery 11 of the vehicle 10 via the liquid-cooled energy transfer assembly 210. As shown in FIG. 2A, each liquid-cooled energy transfer assembly 210 comprises a first and outer end defined by a contact terminal 211 supported within the liquid-cooled charging port 263 so as to be accessible from outside the vehicle 10. As illustrated by FIG. 2B, an electrical connector extending internally and comprising a hollow and tubular conductive tube 213 defining the second and inner end of each liquid-cooled energy transfer assembly 210 extends from the inner portion 263b of the liquid-cooled charging port and is electrically connected to each contact terminal 211. During charging, the conductive tube 213 is configured to transfer energy received by the contact terminal 211 from the charging plug of the charging station 20 to the battery 11, and the conductive tube 213 is electrically connected to the battery 11 via the attachment connector 215. As an alternative to the structure of the hollow and tubular conductive tube 213 defining the electrical connector of the embodiment of the liquid-cooled charging system 100 shown in FIG. 2B, in other embodiments, the electrical connector may be defined by various other structures configured to electrically connect the contact terminal 211 to the battery 11 of the vehicle 10, such as, for example, an electric wire.

[0025] As shown in the embodiments of the charging assembly 200 of FIGS. 2A-9B, in various embodiments, the first and second liquid-cooled energy transfer assemblies 210 may be included in the charging assembly 200 such that when the charging plug of the charging station 20 is in electrical (and optionally physical) contact with the contact terminal 211, the first and second liquid-cooled energy transfer assemblies 210 define an electrical circuit through which electricity can flow. The first liquid-cooled energy transfer assembly 210 is electrically connected to the negative terminal of the battery 11 via the first attachment connector 215, and the second liquid-cooled energy transfer assembly 210 is electrically connected to the positive terminal of the battery 11 via the second attachment connector 215.

[0026] As will be described in more detail below, in various aspects (such as the aspects described with reference to FIGS. 2A-9B), in addition to defining a portion of the liquid-cooled energy transfer assembly 210, the conductive tube 213 may additionally define a channel 214 that defines a portion of the fluid circuit 290 of the charging assembly 200. Therefore, the attachment connector 215 may be additionally configured to fluidly connect the conductive tube 213 to the refrigerant system 110 of the liquid-cooled charging system 100 in addition to electrically connecting the conductive tube 213 to the battery 11.

[0027] As shown in FIGS. 2A and 2B, in various aspects, the interface assembly 250 may include one or more charging ports 264 in addition to the liquid-cooled charging port 263, where the charging assembly 200 additionally includes an energy transfer assembly 216 supported for each of the additionally provided charging ports 264. In some aspects, some or all of the additionally provided charging ports 264 and energy transfer assemblies 216 may be defined as and / or include a liquid-cooled charging port 263 and / or a liquid-cooled energy transfer assembly 210 that defines and / or includes a fluid circuit 290 (such as described with reference to any aspect of the liquid-cooled charging port 263 and / or the liquid-cooled energy transfer assembly 210 disclosed herein). In other aspects, the additional charging ports 264 and / or energy transfer assemblies 216 included in the charging assembly 200 may be defined by any number of other configurations and arrangements.

[0028] Referring to FIG. 3, a exploded view of the charging assembly 200 is shown, illustrating various components of the liquid-cooled energy transfer assembly 210 and the interface assembly 250, based on one exemplary embodiment. As will be described in more detail below, for each liquid-cooled energy transfer assembly 210 of the embodiments of the charging assembly 200 of FIGS. 2A-9B, it includes a contact terminal 211 (including a body 211a and an optional plug 211b), a terminal body 220, a conductive tube 213, and a mounting connector 215, while each interface assembly 250 includes a housing 260 and an optional sealed body 270.

[0029] Referring to FIGS. 4-6, based on one exemplary embodiment, components of the liquid-cooled energy transfer assembly 210 are shown. Based on one exemplary embodiment, the contact terminal 211 is shown in FIG. 5. The contact terminal 211 is configured to electrically and physically engage with the charging plug of the charging station 20 during charging of the vehicle 10. Thus, as illustrated by FIGS. 2B and 9A, the contact terminal 211 is configured to extend through an opening 265 in the mounting plate 261 of the housing 260 of the interface assembly 250 and into the external portion 263a of the liquid-cooled charging port such that at least a portion of the contact terminal 211 is accessible from outside the vehicle 10. The contact terminal 211 is defined by a rigid body 211a formed of a conductive material. In some embodiments, a non-conductive plug 211b may be integrally or removably attached to the front portion of the contact terminal 211.

[0030] As also shown in FIGS. 5 and 9A, each contact terminal 211 may be mounted to the housing 260 of the charging assembly 200 via a terminal body 220 and electrically connected to a conductive tube 213. A rear threaded portion 211c of the contact terminal 211 may be configured to removably attach the contact terminal 211 to a threaded opening 227 of the terminal body 220. In other embodiments, the contact terminal 211 and the terminal body 220 may be removably engaged via any other number of engagement structures. In some embodiments, the contact terminal 211 may alternatively be fixedly and non-removably connected to the terminal body 220, such as by forming the contact terminal 211 and the terminal body 220 as an integral or monolithic structure.

[0031] As illustrated by FIG. 5, a side wall 221 forming the terminal body 220 defines a hollow chamber 223, and an aperture 225 formed in the side wall 221 provides fluid communication between the exterior and interior of the chamber 223. Referring to FIGS. 9A and 9B, each terminal body 220 is configured to be at least partially received within a passage 268 extending within a mounting body 267 defined by a liquid-cooled charging port inner portion 263b. As shown in FIGS. 9A and 9B described below, the aperture 225 of the side wall 221 is sized and spaced along the terminal body 220 such that the aperture 225 can be aligned with a channel 266 defined by the mounting body 267 when the terminal body 220 is mounted within the passage 268 of the mounting body 267.

[0032] In some embodiments, a positioning structure, such as a slotted positioning ring 228 formed around the outer surface of the side wall 221 of the terminal body 220 as shown in FIG. 5 for example, is optionally included in the terminal body 220 and is configured to orient the terminal body 220 relative to the mounting body 267 such that the aperture 225 of the terminal body 220 is aligned with the channel 266 of the mounting body 267 when the charging assembly 200 is assembled. Also as shown in FIG. 5, in some embodiments, an optional O-ring receiving groove 229 may be defined by a portion of the side wall 221 that extends above and / or below the aperture 225. An optionally included O-ring 275 positioned within the groove 229 is configured to sealingly engage a portion of the mounting body 267 that defines a passage 268 in which the terminal body 220 is received to minimize or prevent leakage of the fluid refrigerant flowing through the fluid circuit 290 defined by the hollow chamber 223 and the channel 266 during assembly of the charging assembly 200.

[0033] The front end of a conductive tube 213 is connected to the rear end of the terminal body 220 and is configured to electrically connect the contact terminal 211 to the battery 11 of the vehicle 10. As illustrated by FIGS. 6 and 9A, the conductive tube 213 defines a hollow and tubular conduit formed of a conductive material 213a having an outer surface and an inner surface that defines a channel 214. In various embodiments, a portion or all of the outer surface and / or inner surface of the conductive tube 213 may be coated with an insulating coating 213b. As shown in FIGS. 9A and 9B, the front end of each conductive tube 213 is attached to the rear end of the terminal body 220 (e.g., via soldering; use of a compression nut, flare end, and nut; welding, etc.) such that the channel 214 of the conductive tube 213 is in fluid communication with the chamber 223 of the terminal body 220 and thus also defines a portion of the fluid circuit 290.

[0034] Referring to FIG. 6, an attachment connector 215 configured to connect the rear end of the conductive tube 213 to the refrigerant system 110 and the battery 11 of the vehicle 10 is shown based on one exemplary embodiment. The attachment connector 215 is shown as a discontinuous component configured to releasably engage the rear end of the conductive tube 213 (as illustrated by the assembly drawing of FIG. 6), but in other embodiments, the attachment connector 215 may be a component provided integrally with the conductive tube 213. In other embodiments, any number of other attachment components and / or methods (e.g., welding, screwing, adhesive materials, etc.) configured to electrically connect the conductive tube 213 to the battery 11 and / or fluidly connect the conductive tube 213 to the refrigerant system 110 may be used. In some embodiments, by physically connecting the rear end of the conductive tube 213 to the battery 11 via the attachment connector 215, both electrically connecting the conductive tube 213 to the battery 11 and fluidly connecting the channel 214 of the conductive tube 213 to the refrigerant system 110 are performed, and the refrigerant system 110 may be partially or wholly defined by the refrigerant system components of the battery 11 of the vehicle 10.

[0035] Referring to FIGS. 7A and 7B, front and rear views of the housing 260 of the interface assembly 250 are shown respectively based on one exemplary embodiment. As shown in FIGS. 7A and 7B, the housing 260 includes a mounting plate 261 from which a liquid-cooled charging port 263 (and optionally one or more additional charging ports 264) extends. The mounting plate 261 may be formed to have any shape (e.g., rectangular, circular, square, etc.). And it may include and / or define any number or combination of different attachment structures through which the housing 260 can be mounted to the vehicle 10. For example, in some embodiments, the attachment structure may define an aperture 262 through which any number of different fastening elements may be inserted to securely fix the housing 260 to the vehicle 10.

[0036] As described above, the liquid-cooled charging port external portion 263a extending from the front surface 261a of the mounting plate 261 around one or more openings 265 extending through the mounting plate 261 defines a physical interface with which a charging plug of the charging station 20 can engage during charging in order to support the charging plug with respect to the vehicle 10. Thus, in various aspects, the configuration of the liquid-cooled charging port external portion 263a may be defined by arrangements, sizes, dimensions, etc. corresponding to any number of different charging plug configurations used for AC charging and / or DC charging, such as those described with reference to, for example, "SAE International Standards for Electrical Connectors for Electric Vehicles", or any other number of different standards applicable to the charging plug configuration. In various aspects, the liquid-cooled charging port external portion 263a may be advantageously configured to engage a charging plug that can be used to provide DC fast charging.

[0037] Referring to FIG. 7B, based on one exemplary aspect, the liquid-cooled charging port internal portion 263b is illustrated. As shown in FIG. 7B, the liquid-cooled charging port internal portion 263b is defined by a mounting body 267 that is sealingly engaged with, integrally attached to, and / or monolithically formed with the rear surface 261b of the mounting plate 261 around one or more openings 265 extending through the mounting plate 261. A plurality of discontinuous passages 268 extend through the mounting body 267, and each passage 268 extends between a rear opening defined at the rear surface of the mounting body 267 and one of the openings 265 extending through the mounting plate 261. As described above, the passages 268 of the mounting body 267 are each sized and shaped to support the terminal body 220 therein and are accompanied by channels 266 that define a portion of a fluid circuit 290 that fluidly connects each of the passages 268.

[0038] As shown in FIG. 7B, in various embodiments, an alignment structure may optionally be provided on the mounting body 267. Similar to the positioning features of the terminal body 220 that are optionally provided, the alignment structure is configured to orient the terminal body 220 relative to the mounting body 267 such that the aperture 225 of the terminal body 220 aligns with the channel 266 of the mounting body 267 during assembly of the charging assembly 200. In some embodiments, the alignment structure of the mounting body 267 (such as the positioning strut 269 shown in FIG. 7B) may be configured to interact with the positioning features (such as the slotted positioning ring 228) of the terminal body 220 to facilitate alignment of the terminal body 220 within the passage 268 of the mounting body 267.

[0039] As shown in FIGS. 8A and 8B, in various embodiments, the interface assembly 250 may optionally further include a sealed body 270 configured to be attached to the liquid-cooled charging port inner portion 263b, for example, to ensure physical attachment of the conductive tube 213 and the terminal body 220 to each other and / or to the mounting body 267 (e.g., by applying radial and / or longitudinal compressive forces to the conductive tube 213 and / or the terminal body 220 via the engagement between the sealed body 270 and the liquid-cooled charging port inner portion 263b). Additionally, the engagement between the sealed body 270 and the outside of the liquid-cooled charging port inner portion 263b may be configured to form a sealed cavity that substantially prevents fluid refrigerant from migrating from the junction between the channel 214 of the conductive tube 213 and the chamber 223 of the terminal body 220 and / or from the junction between the chamber 223 of the terminal body 220 and the channel 266 of the mounting body 267 to the external environment. As shown in FIGS. 9A and 9B, in various embodiments, one or more O-rings 275 may optionally be provided between the sealed body 270 and the interface of the liquid-cooled charging port inner portion 263b to further enhance protection against leakage of the refrigerant fluid.

[0040] As also shown in FIGS. 8A and 8B, based on one exemplary embodiment, a unitary structure may be defined by the sealed body 270 that includes a body portion 271 and two receiving structures 273 through which the conductive tube 213 is configured to be inserted. The sealed body 270 may be slid to cover the attachment portion between the terminal body 220 and the conductive tube 213, and may be configured to engage with the inner portion 263b of the liquid-cooled charging port (e.g., via snap fit, interference fit, cam fit, etc.) through the engagement of one or more attachment structures (e.g., openings 272) with one or more corresponding structures provided around the outside of the inner portion 263b of the liquid-cooled charging port. In other embodiments, the sealed body 270 may be defined by any number of other engagement structures and / or arrangements through which the sealed body 270 may be attached to the inner portion 263b of the liquid-cooled charging port.

[0041] Next, referring to FIGS. 9A and 9B, an assembly diagram of a charging assembly 200 and a fluid circuit 290 of the charging assembly 200 is shown based on an exemplary embodiment. As shown in FIGS. 9A and 9B, when the terminal body 220 is inserted into the passage 268 of the mounting body 267 of the housing 260 and the front end of the conductive tube 213 is attached to the terminal body 220, a channel 214 defined by the conductive tube 213, the chamber 223 and the aperture 225 of the terminal body 220, and the channel 266 of the mounting body 267 defines the fluid circuit 290. When the rear end of the conductive tube 213 is fluidly connected to the refrigerant system 110 (e.g., via an attachment connector 215), the fluid circuit 290 may define a return fluid path through which refrigerant from the refrigerant system 110 can flow, as indicated by the arrow in FIG. 9A. Since the refrigerant from the refrigerant source 114 is passed through the fluid circuit 290 by the pump 112 of the refrigerant system 110, the heat from various components of the charging assembly 200 (e.g., as a result of DC rapid charging of the battery 11 of the vehicle 10) can be dissipated at an increased rate. As described above, the increased heat dissipation ability provided by the fluid circuit 290 may advantageously allow for the use of higher power and / or larger current during battery charging, and thus the battery 10 may be charged more rapidly.

[0042] In various embodiments, the dimensions of the fluid path defined by the fluid circuit 290 (e.g., the radius and length of the channel 213, the chamber 223, the aperture 225, and / or the channel 266), and the desired flow rate of the fluid refrigerant through the fluid circuit 290 may vary depending on any number of different factors, such as the type of vehicle 10 in which the liquid-cooled charging system 100 is used, the desired degree / rate of heat dissipation, etc. In embodiments where more than one fluid circuit 290 is defined and / or included within the charging assembly 200, the flow of refrigerant may optionally be controlled independently for each of the fluid circuits 290.

[0043] In the embodiment of the charging system 200 described with reference to FIGS. 2A-9B, the fluid circuit 290 is described as being defined by respective components of the interface assembly 250 (i.e., the channel 266 of the housing 260), as well as the energy transfer assembly 210 (i.e., the channel 214 of the conductive tube 211 and the chambers 223 and apertures 225 of the terminal body 220). However, in other embodiments, the charging system 200 may be defined by any number of other configurations of the fluid circuit 290. By way of non-limiting example, in other embodiments, the fluid circuit 290 may be defined entirely by only one or more components of the interface assembly 250, only one or more components of the energy transfer assembly 210, other combinations of components of the energy transfer assembly 210 and the interface assembly 250, and so on.

[0044] For example, instead of a return portion of a return path of a fluid circuit 290 defined by one of the energy transfer assemblies 210 (e.g., the portion indicated by the arrow in FIG. 9A showing the flow of refrigerant exiting the energy transfer assembly 210), in some embodiments, each energy transfer assembly 210 may be individually and optionally separately connected to an additional (one or more) channel defined by and / or included in the charging assembly 200 that defines a return path through which the refrigerant entering each energy transfer assembly 210 can return through it to the refrigerant system 110. In some such embodiments, the additional channel may be defined, for example, within a portion of the wall defining the conductive tube 213 (such that each of the conductive tubes 213 defines a multi-chamber structure). In other such embodiments, the additional “return” channel may be defined, for example, by one or more additional conduits fluidly coupled to the channel 266 of the mounting body 267 of the housing 260. In other embodiments, the refrigerant system 110 may optionally be fluidly connected between the sealed body 270 and the outside of the liquid-cooled charging portion inner portion 263b through an inlet port and an outlet port provided on the sealed body 270 (not shown in the figure) in a chamber defined therebetween.

[0045] In yet other aspects, fluid circuit 290 may be defined in its entirety by one or more components additionally included in charging system 200, provided separately from the various components of charging system 200 described herein with reference to FIGS. 2A-9B. For example, in some aspects, an additionally included fluid conduit (not shown in the figures) that is fluidly coupled to refrigerant system 110 and defines a return fluid path may be disposed around or otherwise arranged around the outer surfaces of some or all of the components of charging assembly 200. For example, a coiled conduit fluidly connected to refrigerant system 110 at an inlet end and an outlet end may be disposed around and surround the outside of each energy transfer assembly 210. As will be appreciated, in some such aspects, the components of energy transfer assembly 210 and / or interface assembly 250 may be formed without channels, chambers, apertures, etc. that define a fluid circuit 290 through which refrigerant can flow. For example, in some such aspects, the energy transfer assembly may be defined by a solid wire extending between battery 11 and an externally accessible contact terminal.

[0046] It should be noted that the term "exemplary" and variations thereof used herein to describe the various aspects are intended to indicate that such aspects are possible examples, representations, or illustrations of possible aspects (and such terms are not intended to imply that such aspects are necessarily special or the best examples).

[0047] As used herein, the term "coupled" and variations thereof mean joining two members directly or indirectly to each other. Such connections may be static (e.g., permanent or fixed) or movable (e.g., removable or releasable). Such connections may be achieved by the two members being directly coupled to each other; by using another intervening member and any additional intermediate members coupled to each other, the two members are coupled to each other; or by using an intervening member integrally formed as a single unitary body with one of the two members, the two members are coupled to each other. When "coupled" or variations thereof are modified by additional terms (e.g., directly coupled, etc.), the general definition of "coupled" provided above is modified by the ordinary meaning of that additional term (e.g., "directly coupled" means the joining of two members without another intervening member), resulting in a definition narrower than the general definition of "coupled" provided above. Such connections may be mechanical, electrical, or fluidic.

[0048] As used herein, the term "or" is used in its inclusive sense (and not in its exclusive sense), so when used to connect a list of elements, the term "or" means one, several, or all of the elements in the list. Connective words such as "at least one of X, Y, and Z" are understood to convey that the elements may be any of X, Y, Z; X and Y; X and Z; Y and Z; or X, Y, and Z (i.e., any combination of X, Y, and Z), unless otherwise specifically stated. Thus, unless otherwise presented, such connective words generally do not imply that a particular aspect requires the presence of at least one of X, at least one of Y, and at least one of Z, respectively.

[0049] References to the position of elements in this specification (e.g., "top", "bottom", "above", "below") are used only to describe the orientation of the various elements within the drawings. It should be noted that the orientation of the various elements may be different in other exemplary embodiments and such variations are intended to be encompassed by this disclosure.

Description of the Reference Numerals

[0050] 10 Vehicle 11 Battery 13 Electric motor 20 Charging station 100 Liquid-cooled charging system 110 Refrigerant system 112 Pump 114 Refrigerant source 116 Cooling assembly 200 Charging assembly 210 Liquid-cooled energy transfer assembly 211 Contact terminal 211a Body 211b Plug 211c Rear threaded portion 213 Conductive tube 213a Conductive material 213b Insulating coating 214 Channel 215 Mounting connector 216 Energy transfer assembly 220 Terminal body 221 Side wall 223 Chamber 225 Aperture 227 Threaded opening 228 Slotted positioning ring 229 O-ring receiving groove 250 Interface assembly 260 Housing 261 Mounting plate 261a Front surface 261b Rear surface 262 Aperture 263 Liquid-cooled charging port 263a External part of the liquid-cooled charging port 263b Internal part of the liquid-cooled charging port 264 Charging port 265 Opening 266 Channel 267 Mounting body 268 Passage 269 Positioning strut 270 Sealed body 271 Body part 272 Opening 273 Receiving structure 275 O-ring 290 Fluid circuit

Claims

1. A mounting plate; A first opening and a second opening, each defined by and extending through the mounting plate; A port external portion extending around the first and second openings and outward from the front face of the mounting plate, configured to engage and support a charging plug of a charging station; and A port internal portion extending around each of the first and second openings and outward from the rear face of the mounting plate, A first passage defined by and extending through a mounting body from a rear portion of the mounting body, the first passage being in fluid communication with the first opening and through which a pump transfers refrigerant to a heat dissipation device; A second passage defined by and extending through the mounting body from the rear portion of the mounting body, the second passage being in fluid communication with the second opening and through which the pump transfers refrigerant to the heat dissipation device; and A channel defined by and extending through the mounting body; Comprising A mounting body in which a first end of the channel is in fluid communication with the first passage and a second end of the channel is in fluid communication with the second passage Including a port internal portion A charging port comprising A housing for a charging system comprising.

2. The housing according to claim 1, wherein the mounting plate includes a mounting structure configured to attach the housing to a vehicle.

3. The housing according to claim 2, wherein the port external portion is configured to be accessible from outside the vehicle when the mounting plate is securely fixed to the vehicle via the mounting structure.

4. The housing according to claim 1, wherein the port external portion is configured to engage and support a charging plug used for DC rapid charging.

5. The housing according to claim 4, wherein each of the first and second openings in the mounting plate is configured to receive and support the contact terminal such that the contact terminal extends into the port external portion and is accessible from outside the vehicle.

6. A mounting plate; A port structure extending outward from the front face of the mounting plate; and A mounting body extending outward from the rear surface of the mounting plate, A first passage defined by and extending through the mounting body from a rear portion of the mounting body, through which a pump transfers refrigerant to a heat dissipation device; A second passage defined by and extending through the mounting body from a rear portion of the mounting body, through which the pump transfers refrigerant to the heat dissipation device; and A channel defined by and extending through the mounting body, fluidly connecting the first passage and the second passage A mounting body comprising A housing comprising A first electrical connector and a second electrical connector respectively, each of the first energy transfer assembly and the second energy transfer assembly including the first electrical connector and the second electrical connector that define a channel therethrough and are formed of a conductive material Comprising The channel of the first electrical connector is configured to be fluidly connected to the first passage, and the channel of the second electrical connector is configured to be fluidly connected to the second passage. A charging assembly kit.

7. The charging assembly kit according to claim 6, further comprising a first contact terminal and a second contact terminal each configured to extend into a port structure, the first contact terminal being configured to be electrically connected to the first electrical connector, and the second contact terminal being configured to be electrically connected to the second electrical connector.

8. The charging assembly kit according to claim 7, further comprising a first terminal body configured to be received in the first passage and a second terminal body configured to be received in the second passage.

9. The charging assembly kit according to claim 8, wherein each of the first terminal body and the second terminal body includes side walls defining a hollow chamber, wherein a first aperture extends through the side walls of the first terminal body, and a second aperture extends through the side walls of the second terminal body.

10. When the first terminal connector is received within the first passageway, a first aperture is configured to be in fluid communication with a first end of a channel extending through the mounting body; and when the second terminal connector is received within the second passageway, a second aperture is configured to be in fluid communication with a second end of the channel extending through the mounting body. The charging assembly kit according to claim 9.

11. When a first end of the first electrical connector is attached to the first terminal body and a first end of the second electrical connector is attached to the second terminal body, the channel of the first electrical connector is configured to be in fluid communication with the channel of the second electrical connector. The charging assembly kit according to claim 10.

12. The second end of the first electrical connector and the second end of the second electrical connector are each configured to be fluidly coupled to a refrigerant source. The charging assembly kit according to claim 11.

13. The second end of each of the first electrical connector and the second electrical connector is configured to be electrically coupled to a battery of a vehicle. The charging assembly kit according to claim 12.

14. The first terminal connector electrically couples a first contact terminal to the first electrical connector, and the second terminal connector electrically couples a second contact terminal to the second electrical connector. The charging assembly kit according to claim 8.

15. A sealed body having a first receiving structure configured to receive the first electrical connector, a second receiving structure configured to receive the second electrical connector, and a body portion configured to surround and be attached to at least a portion of an outer surface of the mounting body is further provided. The charging assembly kit according to claim 14.

16. Providing a charging housing having a first surface configured to be accessible from outside the vehicle and a second surface configured to be inaccessible from outside the vehicle, comprising the steps of: providing a charging port configured to engage a charging plug of a charging station on the first surface of the housing, and providing the mounting body on a rear surface of the housing; arranging a first end of a first energy transfer assembly within the charging port of the housing such that it is accessible from outside the vehicle; Arranging a first end portion of a second energy transfer assembly within the charging port of the housing such that it is accessible from outside the vehicle; Fluidly connecting a second end portion of the first energy transfer assembly and a second end portion of the second energy transfer assembly to a refrigerant source; and Electrically connecting second end portions of the first energy transfer assembly and the second energy transfer assembly to the vehicle's battery comprising a method, wherein the mounting body from a rear portion of the mounting body, a first passage defined by and extending through the mounting body, through which a pump transfers refrigerant to a heat dissipation device, the first passage; from the rear portion of the mounting body, a second passage defined by and extending through the mounting body, through which the pump transfers refrigerant to the heat dissipation device, the second passage including, method. [

17. ] The step of fluidly connecting a second end portion of the first energy transfer assembly to a refrigerant source includes fluidly connecting a refrigerant source of the vehicle to a first channel extending through at least a portion of the first energy transfer assembly; and the step of fluidly connecting a second end portion of the second energy transfer assembly to a refrigerant source includes fluidly connecting the refrigerant source of the vehicle to a second channel extending through at least a portion of the second energy transfer assembly, the method according to claim 16. [

18. ] The method according to claim 17, further comprising fluidly connecting a first channel of the first energy transfer assembly and a second channel of the second energy transfer assembly to define a return fluid path. [

19. ] The step of fluidly connecting a first channel of the first energy transfer assembly and a second channel of the second energy transfer assembly connecting the first channel of the first energy transfer assembly to a first end portion of a fluid channel defined by and extending through the mounting body via the first passage; and connecting the second channel of the second energy transfer assembly to a second end portion of the fluid channel of the mounting body via the second passage including, the method according to claim 18. [

20. ] The method of claim 18, further comprising providing a voltage isolation between the first energy transfer assembly and the second energy transfer assembly.

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