Modular Charge Inlet Interface Plate for Megawatt Cooling
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Solution Overview
Problem
Existing electric vehicle charging systems face challenges in effectively cooling charge inlets due to increased manufacturing complexity and limited cooling capacity, particularly in megawatt charging systems, which can lead to heat generation and reduced component lifespan.
Innovation Solution
A modular interface plate with integrated cooling channels and busbars is installed between the charge inlet and power distribution hardware, utilizing a thermal interface material for electrical isolation and thermal coupling, allowing for efficient heat dissipation through a vehicle's cooling system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling modules are integrated within the charge inlet, then cooling capacity is improved, but manufacturing complexity increases
Solution Approach 1:
The cooling system is segmented into two independent parts: the charge inlet and the interface plate with cooling channels. This allows the cooling functionality to be provided through a separate component that can be easily manufactured and installed without modifying the charge inlet structure, thereby resolving the contradiction between cooling capacity and manufacturing complexity.
Solution Approach 2:
The interface plate acts as an intermediary component between the charge inlet and the vehicle cooling system. It provides the cooling channels and thermal management functionality without being part of the charge inlet itself, enabling effective cooling while keeping the charge inlet manufacturing simple and unchanged.
2Temperature
If liquid cooling is implemented in the charge inlet, then heat dissipation is improved, but manufacturing complexity increases
Solution Approach 1:
The liquid cooling functionality is extracted from the charge inlet and placed in a separate interface plate. This extraction allows the charge inlet to remain simple and easy to manufacture, while the cooling function is provided by the interface plate that can be independently manufactured and installed.
Solution Approach 2:
The interface plate serves as an intermediary that introduces liquid cooling between the charge inlet and the vehicle cooling system, enabling effective heat dissipation without modifying the charge inlet structure or increasing its manufacturing complexity.
3Temperature
If cooling modules are integrated into the charge inlet, then cooling capacity is improved, but adaptability to different charge inlet designs decreases
Solution Approach 1:
The interface plate is designed as a universal component that can be installed with various charge inlet designs from different manufacturers. It provides cooling functionality without being specific to any particular charge inlet configuration, thereby improving adaptability while maintaining cooling capacity.
Solution Approach 2:
By separating the cooling functionality into an independent interface plate, the system becomes adaptable to different charge inlet designs. The interface plate can be manufactured to fit various charge inlet configurations without requiring modifications to the charge inlets themselves, resolving the contradiction between cooling capacity and adaptability.
4Adaptability or versatility
If third-party charge inlets are installed, then configuration flexibility is improved, but cooling capacity may be insufficient
Solution Approach 1:
The interface plate acts as an intermediary that adds cooling functionality to third-party charge inlets that may not have sufficient built-in cooling. It bridges the gap between the charge inlet and the vehicle cooling system, ensuring adequate cooling capacity is achieved regardless of the charge inlet manufacturer or design.
Solution Approach 2:
The interface plate modifies the thermal parameters of the charging system by introducing dedicated cooling channels and thermal management features. This allows third-party charge inlets with insufficient cooling to achieve adequate heat dissipation performance without changing the charge inlet itself, maintaining configuration flexibility while improving cooling capacity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The interface plate provides effective cooling for charge inlets, extending their usable lifespan by managing heat generated during high-current charging, while maintaining compatibility with various charge inlet designs and simplifying manufacturing.
Implementation Method 1
a cooling channel integrated within the interface plate
Implementation Method 2
efficient heat dissipation through a vehicle's cooling system
Data Source
AI summary
Systems for cooling a charge inlet of an electric vehicle are provided. In one example, interface plate for cooling a charge inlet of an electric vehicle may include a front face configured to be positioned in face-sharing contact with the charge inlet, a back face opposite the front face, a charge inlet aperture, an inlet recess surrounding the charge inlet aperture and including a recessed surface that is recessed relative to the front face, wherein the charge inlet aperture is defined by an inner surface comprised of a plurality of aperture segments that extend from the recessed surface to the back face, and a cooling channel integrated within the interface plate.