EV Charge Port PCM Cooling for Continuous Fast Charging
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Solution Overview
Problem
Existing charge port cooling systems in electric vehicles often rely on liquid cooling techniques, which can be inconvenient due to the need to derate or pause charging when temperatures exceed a threshold, and there is a need for an alternative cooling method that does not depend on liquids.
Innovation Solution
A charge port cooling system utilizing a heat spreader and phase change material (PCM) to absorb heat and maintain terminal temperatures within a selected range, using a metallic foam with radial fins and a heat-shrink material to facilitate heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If liquid cooling techniques are used for charge port cooling, then cooling effectiveness is improved, but system complexity and inconvenience increase due to derating or pausing charging
Solution Approach 1:
The patent utilizes phase change material (PCM) that transitions from solid to liquid state to absorb heat from the charge port. The PCM is contained in a cooling system with a heat spreader and fins that directly contact the charge port terminals. As the PCM melts, it absorbs latent heat, maintaining the charge port temperature below threshold levels without requiring charging to be paused or derated, thus resolving the contradiction between effective cooling and charging convenience.
2Temperature
If liquid cooling techniques are used for charge port cooling, then cooling effectiveness is improved, but device complexity increases
Solution Approach 1:
The patent extracts the cooling function from a complex liquid cooling system and implements it using a simpler PCM-based passive cooling system. The liquid cooling system requires pumps, reservoirs, and active circulation mechanisms, whereas the PCM system uses the phase change property of material to provide cooling through a straightforward heat spreader and containment structure, significantly reducing device complexity while maintaining cooling effectiveness.
Solution Approach 2:
The PCM cooling system operates autonomously without requiring external control systems, pumps, or active management. The phase change material automatically absorbs heat when the charge port temperature rises and releases heat when temperature drops, providing self-regulating cooling that eliminates the complexity of active liquid cooling control systems.
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 system effectively maintains charge port temperatures within a selected range, allowing continuous charging without derating, by using phase change material to absorb heat and release it to ambient, thus ensuring efficient and uninterrupted charging.
Implementation Method 1
An amount of phase change material (PCM) arranged in the volume, the amount of PCM is in contact with the terminal
Implementation Method 2
allowing the PCM to change phase and dissipate heat without significant temperature increase
Implementation Method 3
A heat spreader arranged in the volume... the heat spreader extends from the terminal to the perimetrical wall
Implementation Method 4
the heat spreader comprises a metallic foam... the metallic foam is an open cell metallic foam
Implementation Method 5
the heat spreader includes a plurality of fins that project radially outwardly from the terminal
Data Source
AI summary
A cooling system for an electric vehicle charge port includes a member having a base wall including an opening and a perimetrical wall extending from the base wall. The base wall and the perimetrical wall defining a volume. A heat spreader arranged in the volume. A terminal extends from the heat spreader through the opening in the base wall. An amount of phase change material (PCM) arranged in the volume, the amount of PCM is in contact with the terminal.