High-output charging system

Abstract

The present invention relates to a high-output charging system which includes a cooling system for cooling a high-output power line for rapid charging of an electric vehicle and in which a power line in the form of a bare wire is inserted into a cooling unit and exposed to a low-temperature refrigerant environment, thereby undergoing heat-exchange, the high-output charging system being characterized by comprising: a connector for charging an electric vehicle; a power supply unit including a power line for supplying electricity to the connector; and a cooling system including a cooling unit through which a refrigerant for cooling the power line flows, wherein the power line is configured in the form of an uncoated bare wire, the cooling unit is formed in a structure in which the bare wire is directly inserted into a refrigerant pipe through which the refrigerant flows, and the cooling system forms a vapor compression refrigeration cycle including a compressor and a condenser.

Description

High-power charging system

[0001] The present invention relates to a system for effectively cooling heat generated during high-power charging of an electric vehicle, and in particular, to a power-refrigerant integrated high-power charging system that simultaneously secures cooling efficiency and stability by including an expansion means and a vortex-prevention flow path, wherein the power line is inserted into the refrigerant pipe in the form of a bare wire and heat exchange is achieved by direct contact with the refrigerant.

[0002] As high-current charging becomes commonplace to increase the charging speed of electric vehicles, the problem of heat generation in charging cables and connectors is becoming serious. To address this, various methods for cooling power lines have been proposed; however, these methods have limitations, such as complex structures and large volumes resulting from the separate arrangement of refrigerant pipes and wires, as well as low cooling efficiency.

[0003] The present invention aims to provide a stable and reliable high-output charging system by maximizing cooling efficiency through a structure that integrates power lines and refrigerant pipes, improving the cooling efficiency of wires that generate heat during the charging process by adjusting the installation position of the expansion means, and integrating expansion and flow control functions at the connector end, a vortex prevention structure, etc.

[0004] The high-power charging system of the present invention comprises: a connector for charging an electric vehicle; a power supply unit including a power line for supplying electricity to the connector; and a cooling system including a cooling unit through which a refrigerant flows to cool the power line; wherein the power line is configured in the form of an uninsulated bare wire, the cooling unit is formed in a structure in which the bare wire is directly inserted into a refrigerant pipe through which the refrigerant flows, and the cooling system forms a vapor compression refrigeration cycle including a compressor and a condenser.

[0005] At this time, the cooling system forms a closed-loop structure connecting a compressor, a condenser, an expansion valve, and a cooling section through which refrigerant flows to cool the power line, wherein the refrigerant in the refrigerant pipe passes through the expansion valve and is supplied in a low-temperature, low-pressure liquid state to come into direct contact with the bare wire, and during charging, at least a portion of the refrigerant undergoes a phase change from liquid to gas through heat exchange to absorb latent heat and directly cool the bare wire, and the refrigerant pipe extends to the connector.

[0006] In addition, the cooling system is characterized by including an insulating part at least at either before or after the refrigerant flows into the cooling part.

[0007] In addition, the power line comprises a positive ray and a negative ray, and the cooling unit comprises a positive ray refrigerant pipe for cooling the positive ray; a negative ray refrigerant pipe for cooling the negative ray; and a connecting pipe connecting the positive ray refrigerant pipe and the negative ray refrigerant pipe, wherein the positive ray refrigerant pipe and the negative ray refrigerant pipe are characterized by being made of an insulating and thermal insulating material having lower thermal conductivity than the refrigerant pipe through which the refrigerant flows in the entire cooling system.

[0008] In addition, the above-mentioned connecting pipe is characterized by including an insulating portion.

[0009] In addition, the power line includes a positive electrode and a negative electrode, and the cooling system is characterized by cooling the positive electrode or the negative electrode separately in multiple ways.

[0010] Meanwhile, the above connector has a power supply terminal for connecting to the charging terminal of an electric vehicle.

[0011] The cooling unit is characterized by including a sub-refrigerant pipe for cooling the power supply terminal by bypassing the flow of some refrigerant.

[0012] At this time, the refrigerant is selected from one of R404A, R507, 1234yf, 1234ze, and R134a as a cryogenic cooling refrigerant, and is characterized in that some or more of the refrigerant undergoes a liquid evaporation phase change through heat exchange in the cooling section.

[0013] On the other hand, the high-power charging system of the present invention is characterized in that the vapor compression refrigeration cycle further includes an expansion means for depressurizing the refrigerant, and the expansion means is an orifice or a nozzle instead of an expansion valve.

[0014] At this time, the orifice or nozzle is characterized by replacing the expansion valve or being installed in an insulating part provided inside the connector or before the power line is inserted into the cooling part.

[0015] In addition, the cooling unit is characterized by including an anode refrigerant pipe for cooling an anode ray, a cathode refrigerant pipe for cooling a cathode ray, and a third refrigerant pipe through which the refrigerant flows.

[0016] At this time, the ground wire is inserted inside the third refrigerant pipe.

[0017] In addition, the refrigerant is characterized by being introduced to the connector side through the third refrigerant pipe, and then the refrigerant, whose temperature has been lowered through the expansion means, is branched out to the positive refrigerant pipe and the negative refrigerant pipe.

[0018] Meanwhile, the connector is characterized by further including a cover to prevent vortices that may occur due to an instantaneous increase in flow rate in the section where the refrigerant flows into the connector and to uniformly control the refrigerant flow.

[0019] According to the present invention, the power line and the refrigerant pipe are configured as a single integrated structure to serve as a cooling unit, thereby enabling more effective control of heat generated during charging. Due to a structure in which the bare wire comes into direct contact with the refrigerant inside the refrigerant pipe, the heat transfer path is shortened and heat exchange efficiency is improved, allowing the wire temperature to be maintained stably even in high-output charging environments.

[0020] In addition, the orifice or nozzle applied instead of the expansion valve simplifies the structure and reduces the possibility of failure, and by being placed within the connector terminal or the inlet insulation, it facilitates the rapid arrival of the refrigerant in the cooling section after expansion.

[0021] By forming a circulation cover inside to prevent vortices or uneven cooling that may occur due to a sudden increase in flow rate when refrigerant flows into the connector, the overall refrigerant flow can be stabilized and consistency of cooling can be ensured.

[0022] By including the ground line within the cooling loop, heat generation issues in the ground line can be mitigated in addition to the power line, and both electrical safety and thermal stability are ensured. In particular, the flow path design, in which the refrigerant flows in through the third refrigerant pipe, passes through an expansion means, and then branches into positive and negative refrigerant pipes, ensures a balance of heat dissipation, thereby reducing cooling deviations in each power line and contributing to increased reliability during high-speed charging.

[0023] As such, the present invention can significantly improve the performance and reliability of electric vehicle charging infrastructure by providing a charging cooling system capable of stable and efficient cooling even in high-power environments.

[0024] FIG. 1 is a basic conceptual diagram of the present invention.

[0025] FIG. 2 Detailed view of a cooling section of another embodiment having a sub-cooling section of the present invention

[0026] FIG. 3 Enlarged view of portion A of FIG. 1 of the present invention

[0027] FIG. 4 Conceptual diagram of another embodiment having a plurality of cooling systems of the present invention

[0028] FIG. 5 Conceptual diagram of another embodiment of the expansion means of the present invention

[0029] FIG. 6a is an enlarged view of the Z portion of FIG. 5 of the present invention.

[0030] FIG. 6b. Exploded perspective view of the insulation part and refrigerant pipe broken to be applied in the present invention

[0031] FIG. 6c is a broken, exploded perspective view of a valve and a refrigerant pipe of a cooling system applied to the present invention.

[0032] FIG. 7 is a conceptual diagram illustrating another embodiment having a third refrigerant pipe of the present invention.

[0033] FIGS. 8(a) and (b) are conceptual diagrams illustrating the connector side of another embodiment having a third refrigerant pipe of the present invention.

[0034] FIG. 9 is a conceptual diagram of another embodiment showing the connector side of another embodiment having a third refrigerant pipe of the present invention.

[0035] FIG. 10 is a conceptual cross-sectional view of an embodiment showing the connector side of another embodiment having a third refrigerant pipe of the present invention.

[0036] Hereinafter, an embodiment of the present invention will be described in detail with reference to the drawings.

[0037] The present invention is capable of various modifications and may have various embodiments, and specific embodiments are illustrated in the drawings and described in detail in the detailed description. This is not intended to limit the present invention to specific embodiments, and it should be understood that it includes all modifications, equivalents, and substitutions that fall within the spirit and scope of the invention. Furthermore, it should be noted that the drawings presented below are not limited and may be embodied in other forms, and that throughout the specification, the same reference numerals indicate the same components, and that the same components in the drawings are indicated by the same reference numerals wherever possible.

[0038]

[0039] Referring to FIG. 1, the high-power charging system of the present invention includes a connector (100), a power supply unit (200), and a cooling system (300).

[0040] The power supply unit (200) is configured to supply direct current electricity for rapid charging of the electric vehicle (10) and is equipped with a power line including a positive electrode (210a) and a negative electrode (210b). In the present invention, the power line may be provided as a metal wire such as copper, aluminum, or an alloy thereof in the form of a bare wire without a separate sheath or insulation. The bare wire may be provided as a single wire or a stranded wire, and since it is not sheathed, it is directly exposed to the environment, but the overall volume is reduced and a relatively lightweight charging system can be constructed.

[0041]

[0042] Referring to FIGS. 1 and 2, the connector (100) is configured to connect the electric vehicle (10) and the charging system. By connecting the power supply terminal (101) provided in the connector (100) to the charging terminal (11) of the electric vehicle (10), electricity supplied by the power line of the power supply unit (200) is supplied to the electric vehicle (10) to charge it.

[0043]

[0044] A cooling system (300) is provided to manage the heat of a charging system, such as by removing Joule heat generated during the transmission of electricity, such as power lines (210a, 210b) and power supply terminals (101), thereby reducing electrical resistance. The cooling system (300) is provided as a closed loop constituting a cooling cycle including a compressor (CP), a condenser (CD), an expansion valve (EV), and a cooling unit (310), and an insulating refrigerant flows within the closed loop and circulates through the entire cooling cycle.

[0045] Referring to FIG. 3, which is an enlarged view of section 'A' in FIG. 1, the cooling section (310) may be provided in the form of a refrigerant pipe through which an insulating refrigerant flows to directly cool the positive or negative wire (210a, 210b). The positive and negative wires (210a, 210b) in the form of bare wires are inserted into the cooling section (310) and are exposed directly to a low-temperature insulating refrigerant environment. The bare metal wires without coating come into direct contact with the refrigerant flowing in the direction of the arrow inside the refrigerant pipe, and heat exchange is performed quickly and efficiently.

[0046] As shown in FIGS. 1 and 2, the cooling section (310) may include a positive ray refrigerant pipe (310a) for cooling a positive ray (210a), a negative ray refrigerant pipe (310b) for cooling a negative ray (210b), and a connecting pipe (313) connecting the positive ray refrigerant pipe (310a) and the negative ray refrigerant pipe (310b). The refrigerant flows in the cooling section (310) along the positive ray refrigerant pipe (310a) → connecting pipe (313) → negative ray refrigerant pipe (310b) or in the opposite direction.

[0047]

[0048] The positive refrigerant pipe (310a), connecting pipe (313), and negative refrigerant pipe (310b) are parts of a refrigerant pipe (P) made of the same material as the copper pipe, provided for the flow of refrigerant throughout the cooling system (300), such as the compressor (CP), condenser (CD), and expansion valve (EV) in the cooling system (300), and can be provided with a heat exchange material such as the same metal. That is, a refrigerant pipe with a positive ray (210a) and a negative ray (210b) embedded therein is provided to the connector (100) in a form where the positive ray (210a) and the negative ray (210b) are directly inserted in a part of the refrigerant pipe, respectively, so that heat management is achieved. By using the connected refrigerant pipe as a cooling part (310), the cooling system (300) can be easily provided, and the risk of refrigerant leakage can be reduced because there is no separate joint or connecting tool.

[0049] At this time, in order to maintain the low temperature of the refrigerant as much as possible and increase the efficiency of cooling, additional components for insulation, such as an external covering, may be provided on more than a part of the cooling section (310).

[0050]

[0051] Meanwhile, some of the positive ray refrigerant pipe (310a), connecting pipe (313), and negative ray refrigerant pipe (310b) forming the cooling section (310) may be made of a thermal insulation and insulating material, such as a polymer material, which has a relatively lower thermal conductivity than the refrigerant pipes, such as metal, flowing in other configurations in the cooling system (300). In this case, the material of the refrigerant pipe forming the cooling cycle closed loop in the section where the positive ray (210a) and the negative ray (210b) are inserted into the cooling section (310) and heat exchange takes place is changed, and a separate joint or connecting tool may be provided for this purpose.

[0052] Meanwhile, the positive ray refrigerant tube (310a), the connecting tube (313), and the negative ray refrigerant tube (310b) may be in the form of tubes, and may be provided in various shapes such as the diameter of the tube, circular, or rectangular, taking into consideration cooling capacity and efficiency.

[0053]

[0054] Referring to FIG. 3, in the present invention, the cooling system (300) includes an insulating section (315) at least at one of the locations before and after the refrigerant flows into the cooling section (310) in a closed loop connecting the compressor (CP), condenser (CD), expansion valve (EV), and cooling section (310) to prevent electrical short circuits caused by condensation or leakage of the refrigerant that may occur due to the low-temperature refrigerant. For example, referring to FIG. 1, an insulating section (400) may be provided at two locations before the positive electrode (210a) is inserted into the cooling section (310) and before the negative electrode (210b) is inserted into the cooling section (310). The insulating section (315) may be provided to have a hollow structure and may be arranged to house a refrigerant pipe inside.

[0055] The insulating part (315) may be provided as a non-conductive material comprising at least one selected from the group consisting of PFA (perfluoroalkoxy), FEP (fluorinated ethylene), PTFE (Poly Tetra Fluoro Ethylene), PEEK (Polyether Ether Ketone), high heat-resistant plastic, nylon, silicone, and urethane. In particular, PEEK (Polyether Ether Ketone) may be used to maintain the insulating function even in a low-temperature environment with a refrigerant, and PEEK is a semicrystalline thermoplastic plastic that has excellent chemical resistance and mechanical strength, low moisture absorption rate, robust fire resistance, and excellent dimensional stability over a wide temperature range.

[0056] Referring to FIG. 2, in order to prevent an electrical short circuit caused by condensation or leakage of the refrigerant that may occur due to the low-temperature refrigerant in the cooling system (300) of the present invention, the connecting pipe (313) of the cooling section (310) may include another insulating section (400). For example, as shown in FIG. 2, a hollow insulating section (400) may be placed on the outer surface of the connecting pipe (313) connecting the positive refrigerant pipe (310a) and the negative refrigerant pipe (310b). In another embodiment, the insulating section (400) may be provided by using a non-conductive material for the connecting pipe (313) itself.

[0057]

[0058] In the present invention, the cooling section (310) is primarily intended to directly exchange heat with the positive ray (210a) and the negative ray (210b), but as shown in FIG. 2, a part of the cooling section (310) may be bypassed to additionally provide a sub-refrigerant pipe (314). The sub-refrigerant pipe (314) may be provided by configuring a small refrigerant pipe through which a portion of the refrigerant can flow, selected as needed from the positive ray refrigerant pipe (310a), the connecting pipe (313), and the negative ray refrigerant pipe (310b), and the sub-refrigerant pipe (314) may perform heat management of the power supply terminal (101) that may be required at the connector (100). When rapid charging, the power supply terminal (101) can also exchange heat with the sub-refrigerant pipe (314) to reduce the heat generated when connected to the charging terminal (11) of the electric vehicle (10). Unlike the power lines (210a, 210b) of the present invention, the sub-refrigerant pipe (314) can be provided near the power supply terminal (101) to allow for indirect heat exchange with the refrigerant. The refrigerant that has flowed through the sub-refrigerant pipe (314) is recovered back into the closed-loop cooling system (300).

[0059]

[0060] In order to provide a cryogenic cooling environment in the present invention, the refrigerant may be selected from one of R134a, R404A, R507, 1234yf, and 1234ze as a cryogenic cooling refrigerant. The refrigerant supplied to the cooling unit (310) in a low-temperature, low-pressure liquid state after passing through the expansion valve in the cooling system (300) may undergo a phase change into a low-temperature, low-pressure gaseous state through heat exchange with the power line in the cooling unit (310). By utilizing the heat of evaporation of the refrigerant, there is an effect of increasing cooling efficiency.

[0061] FIG. 3 illustrates a cooling connection part (500) for bringing a refrigerant flowing inside a refrigerant pipe (P) into contact with a positive ray (210a) or a negative ray (210b).

[0062] The cooling connection part (500) is equipped with a current-carrying part (510) to which the supplied positive or negative power is connected, and a refrigerant inlet part (530) to allow the refrigerant flowing inside the refrigerant pipe (P) to flow in. The refrigerant flowing in flows along the empty space inside the cooling connection part (500) and meets the positive refrigerant pipe (310a) or the negative refrigerant pipe (310b). The positive wire (210a) or negative wire (210b) provided inside is electrically connected at the power-joining part (520) provided on one side of the cooling connection part (500) and is electrically connected to the current-carrying part (510) supplied from the outside. The power-joining part (520) and the positive wire (210a) or negative wire (210b) can be electrically connected through strong external compression. It is finished with a cap (540) to prevent refrigerant leakage.

[0063] Meanwhile, as shown in FIG. 3, even though an insulating refrigerant is used, current flowing along the positive or negative line may flow back into the refrigerant flow line along the refrigerant pipe (copper pipe). To prevent this, an insulating part (315) may be provided at one end of the refrigerant pipe. The insulating part (315) may be connected to both ends of the insulating part (315) by cutting a portion of the refrigerant pipe (copper pipe) and connecting them by means such as screw connection.

[0064]

[0065] Meanwhile, referring to FIG. 4, it is possible to increase cooling performance by configuring two or more cooling systems (300) and, in particular, to configure a closed loop of the cooling cycle so that different cooling systems (300) separate and cool the positive electrode (210a) and the negative electrode (210b) respectively. In this case, not only is the cooling performance increased, but the possibility of a short circuit caused by condensation due to the temperature difference or refrigerant leakage can be significantly reduced, and there is the effect of not having to provide a separate insulation part (400).

[0066]

[0067] Referring to FIG. 5, another embodiment of the high-power charging system of the present invention includes a cooling unit (310) in which power lines (210a, 210b) are inserted inside the cooling unit (310) and the power lines (210a, 210b) and the refrigerant pipe (360) are integrated in flow, thereby including a vapor compression refrigeration cycle-based cooling system for effectively controlling high heat generated during charging.

[0068] As illustrated in FIG. 5, the high-power charging system according to the present invention comprises a power supply unit (200), a cooling system (300) including a compressor (320) and a condenser (330), and a connector (100). The cooling unit (310) is configured such that a power line in the form of a barred wire is inserted inside and comes into direct contact with the refrigerant. As described above, the power line is not a conductor with an insulating sheath, but rather the insulating sheath is removed so that the metal conductor is directly exposed and comes into direct contact with the refrigerant to perform high-speed heat exchange. As a result, the cooling medium can effectively respond to the heat generated by the power line, and the thermal resistance of the entire system is significantly reduced.

[0069] Referring to FIGS. 5, 6a, 6b, and 6c, the cooling system is configured as a vapor compression refrigeration cycle, and high-temperature, high-pressure refrigerant passes through a condenser (330) to be converted into a liquid state, and then expands to a low-temperature, low-pressure state through an orifice or nozzle (350a) applied instead of an expansion valve. The expanded refrigerant then flows back into the compressor (320) and flows into the condenser (330) in a compressed state. Positive and negative rays (210a, 210b) are inserted into a portion of the interior of this closed-loop refrigerant tube to cool it.

[0070] Referring to FIGS. 5 and 7, the expansion means may replace the expansion valve (EV) shown in FIGS. 1 and 4, or may be selectively positioned at least one of the following: inside the connector (100), an insulating part (B, 340) provided on the refrigerant pipe inlet side, or a separate refrigerant pipe or a ground-side refrigerant pipe (C). Each may be combined with an insulating part to serve as an electrical shielding function.

[0071] In particular, in the embodiment illustrated in FIG. 6a, positive / negative wires (210a, 210b) in the form of bare wires electrically connected to power lines are inserted inside a cooling section (310) connected to the end of a refrigerant pipe (360), and these positive / negative wires (210a, 210b) are arranged on the same axis within the same flow path as the refrigerant. The refrigerant flows around each of the positive / negative wires (210a, 210b), and when heat is transferred, it is rapidly removed by the latent heat of evaporation of the refrigerant.

[0072] Meanwhile, as illustrated in FIGS. 6a and 6b, external power supply is provided by a power supply unit (200) connected to a cooling unit (310) through a conductive unit (370), and an insulating unit (340) is formed in the refrigerant pipe (360) to communicate with the conductive unit (370), thereby ensuring that power is not transmitted to the cooling system (300) while stably supplying power to the connector (100). In FIGS. 6a to 6c of the present invention, the power line supplying power from the outside and the positive / negative lines (210a, 210b), which are power lines provided in the cooling unit (310), are named separately, but this is merely to aid in understanding the invention and is not limited thereto.

[0073] To elaborate, the conductive part (370) is made of a conductive material and a flow path is formed to transfer the refrigerant of the refrigerant pipe (360) to the cooling part (310). Positive / negative rays (210a, 210b) are arranged in this flow path, and a power supply part (200) that supplies power from the outside is provided to be electrically connected to the positive / negative rays (210a, 210b). A fixing end (371) is formed at the end of the conductive part (370) to fix the end of the positive / negative rays (210a, 210b), thereby stably positioning the end of the positive / negative rays (210a, 210b). Additionally, an inlet (372) through which refrigerant flows is formed on the outside of the fixing end (371), allowing refrigerant to flow from the refrigerant pipe (360) into the insulation part (340).

[0074] Meanwhile, the refrigerant pipe (360) is composed of a non-conductive Teflon tube. Since the non-conductive Teflon tube is a material that is both insulating and flexible, it provides insulation to the entire connecting pipe between the refrigerant pipe (360) and the cooling system (300), while also allowing it to be installed in various locations. Additionally, the refrigerant pipe (360) may include a protective pipe (361) composed of a non-conductive woven fabric that surrounds the outer surface, thereby protecting the refrigerant pipe (360) from the external environment and improving internal pressure.

[0075] As described above, the insulation part (340) can be formed by configuring the refrigerant pipe (360) with a non-conductive material, and as a result, the refrigerant pipe (360) and the cooling part (310) are connected in an electrically shielded state, so that the supply of power and the flow of refrigerant can be stably carried out.

[0076] Meanwhile, as illustrated in FIGS. 6a and 6c, an expansion means (350a) is further provided between the cooling system (300) and the conductive part (370) to increase cooling efficiency. To elaborate, a valve (V) that controls the supply of refrigerant is formed on the cooling system (300) side, and a nozzle (350a) is provided on the refrigerant pipe (360) connected between the valve (V) and the insulating part (340). As a result, the refrigerant discharged from the cooling system (300) expands to a low temperature and low pressure state during the delivery process, thereby improving cooling efficiency. In the drawings, the nozzle (350a) is shown as being provided on the refrigerant pipe (360) on the discharge side of the valve (V), but the mounting location of the nozzle (350a) is not limited thereto, and it can be provided anywhere on the flow path through which the refrigerant discharged from the cooling system (300) is supplied to the connector (100).

[0077] Meanwhile, as illustrated in FIGS. 6a to 6c, the refrigerant pipe (360) and the conductive part (370), and the refrigerant pipe (360) and the valve (V) are connected in a watertight state by a hose nipple (362), a tube compression ring (363), and a flare nut (364), but can be configured to be optionally detachable. At this time, as shown in FIG. 6c, the nozzle (350a) can be inserted into the hose nipple (362).

[0078] Meanwhile, another embodiment of FIG. 7 illustrates a system diagram in which an expansion means is selectively placed at the location of at least one (C) of a separate refrigerant pipe or a refrigerant pipe with a ground line embedded therein.

[0079] Referring to FIGS. 7, 8a, and 8b, the refrigerant passing through the condenser (330) flows into the connector (100) through the third refrigerant pipe (310c), then branches out into the positive refrigerant pipe (310a) and the negative refrigerant pipe (310b) inside the connector (100), flows back into the compressor (320). As shown in FIG. 10, the refrigerant flowing into the third refrigerant pipe (310c) passes through an expansion means (350b, which may be a nozzle) placed inside the connector, is cooled to a low temperature and low pressure state, then branches out into the positive refrigerant pipe (310a) and the negative refrigerant pipe (310b). By making the refrigerant reach the lowest temperature at the connector side where the heat generation is most severe, the cooling efficiency can be increased.

[0080] Meanwhile, the third refrigerant tube (310c) in FIGS. 8a and 8b is shown in a state joined to the connector (100) side in the form of a hollow tube with an empty interior, and FIG. 9 is shown in a state where a ground wire (210c) is embedded inside the third refrigerant tube (310c). That is, FIG. 9 presents a structure in which a ground wire (210c) is placed together inside the third refrigerant tube (310c), and this improves the electrical stability and temperature balance of the entire system through cooling of the ground wire (210c) in addition to the positive / negative wires (210a, 210b).

[0081] Referring to FIGS. 8 and 10, a pressure regulating nozzle or orifice is inserted into the connector (100) during the process in which the refrigerant flows into and out of the connector (100). This nozzle (350b) stabilizes the refrigerant flow and optimizes cooling efficiency by ensuring that contact with the power lines (210a, 210b) occurs immediately after the refrigerant expands. Consequently, the system has technical features that integrate the power lines and the cooling path, minimize the heat exchange path through a vapor compression refrigerant loop and selective expansion positions, suppress vortices, simplify the structure, and precisely control cooling. This is a system that simultaneously satisfies cooling performance, structural integrity, and reliability even under high-current charging conditions.

[0082] Additionally, with reference to FIG. 10, the connector (100) is provided with a flow path structure or cover (110) to prevent the formation of vortices that may occur due to a sudden change in flow velocity in the section where the refrigerant flows into the connector side, and to uniformly disperse the flow of the refrigerant. The cover (110) may include a guide ridge or a tube shape formed along the internal inflow path and performs the function of mitigating collisions and uneven branching phenomena of the refrigerant within the internal space of the connector (100). In particular, by solving the problem of high-speed vortices or pressure instability that may occur when the refrigerant flows in immediately after expansion through a nozzle or orifice, it contributes to stabilizing the flow of the refrigerant branching into each refrigerant pipe (310a, 310b).

[0083] These circulation covers (110) or vortex-preventing flow path structures not only increase the heat exchange efficiency of the section where the power lines (210a, 210b) and the refrigerant come into contact, but also play an important role in ensuring structural stability inside the connector and uniformity of refrigerant distribution. Therefore, the present invention can simultaneously improve the consistency of cooling performance and the reliability of the system during high-power charging.

Claims

1. A connector for charging an electric vehicle; a power supply unit including a power line for supplying electricity to the connector; and a cooling system including a cooling unit through which a refrigerant for cooling the power line flows; wherein The above power line is configured in the form of an uninsulated bare wire. The above cooling unit is formed with a structure in which the above-mentioned wire is directly inserted into the refrigerant pipe through which the refrigerant flows. The above cooling system is a high-power charging system characterized by forming a vapor compression refrigeration cycle including a compressor and a condenser.

2. In Paragraph 1, The above cooling system forms a closed-loop structure connecting a compressor, a condenser, an expansion valve, and a cooling section through which refrigerant flows to cool the power line. The refrigerant in the above refrigerant pipe is supplied in a low-temperature, low-pressure liquid state after passing through the expansion valve and comes into direct contact with the above bare wire, and during charging, at least a portion of the refrigerant undergoes a phase change from liquid to gas through heat exchange to absorb latent heat and directly cool the above bare wire, and A high-power charging system characterized by the above-mentioned refrigerant pipe extending to the connector.

3. In Paragraph 2, A high-power charging system characterized in that the above cooling system includes an insulating part at least at either before or after the refrigerant flows into the cooling part.

4. In Paragraph 2, The above power line includes a positive line and a negative line. The above cooling unit includes an anode ray coolant pipe for cooling the anode ray; and a cathode ray for cooling the cathode ray. A refrigerant pipe; and a connecting pipe connecting the positive refrigerant pipe and the negative refrigerant pipe. The above positive ray refrigerant pipe and the negative ray refrigerant pipe are the refrigerant in the entire cooling system A high-power charging system characterized by being an insulating and thermal insulation material with lower thermal conductivity than a flowing refrigerant pipe.

5. In Paragraph 4, A high-power charging system characterized by the above-mentioned connecting tube including an insulating part.

6. In Paragraph 2, A high-power charging system characterized in that the power line includes a positive electrode and a negative electrode, and the cooling system separates and cools the positive electrode or the negative electrode in multiple ways.

7. In Paragraph 2, A high-power charging system characterized in that the connector includes a power supply terminal for connecting to a charging terminal of an electric vehicle, and the cooling unit includes a sub-refrigerant pipe for cooling the power supply terminal by bypassing the flow of some refrigerant.

8. In Paragraph 2, A high-power charging system characterized in that the above-mentioned refrigerant is selected from one of R134a, R404A, R507, 1234yf, and 1234ze as a cryogenic cooling refrigerant, and undergoes a liquid evaporation phase change through heat exchange in the cooling section.

9. In Paragraph 1, A high-power charging system characterized in that the above vapor compression refrigeration cycle further includes an expansion means for depressurizing the refrigerant, wherein the expansion means is an orifice or a nozzle instead of an expansion valve.

10. In Paragraph 1, A high-power charging system characterized in that the above orifice or nozzle is installed in at least one of the installation location of the expansion valve, inside the connector, or an insulating part provided before the power line is inserted into the cooling part.

11. In Paragraph 1, A high-power charging system characterized by the above-described cooling unit including a positive ray refrigerant pipe for cooling a positive ray, a negative ray refrigerant pipe for cooling a negative ray, and a third refrigerant pipe through which the refrigerant flows.

12. In Paragraph 11, A high-output charging system characterized by having a ground wire inserted inside the third refrigerant pipe.

13. In Paragraph 13, A high-power charging system characterized in that the above refrigerant flows into the connector side through the third refrigerant pipe, and then the refrigerant, whose temperature has been lowered through the expansion means, branches out to the positive refrigerant pipe and the negative refrigerant pipe.

14. In Paragraph 1, A high-power charging system characterized by further including a cover in the connector to prevent vortices that may occur due to an instantaneous increase in flow rate in the section where the refrigerant flows into the connector and to uniformly control the refrigerant flow.

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