EV Charge Port Cooling Infrastructure for Thermal Management
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Solution Overview
Problem
Conductive charging of electric vehicles generates heat in the charge port and surrounding environment, which can lead to temperature rises and potentially affect charging efficiency and safety.
Innovation Solution
A cooling system is integrated with the charge port to monitor and manage temperature, using either a liquid cooling system with a cold plate and heat exchanger or an air cooling system with forced or natural air convection, to dissipate heat effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conduction of charging current is increased to improve charging speed, then productivity is improved, but temperature of charge port increases causing harmful thermal effects
Solution Approach 1:
A cooling system is introduced as an intermediary between the charge port and the surrounding environment. The cooling system includes a coolant flow path that circulates cooling fluid through channels in the charge port housing, acting as a thermal mediator to transfer heat away from the charge port during high-current charging operations.
Solution Approach 2:
The cooling system utilizes hydraulic principles by circulating liquid coolant through the charge port housing. The coolant absorbs heat from the charge port through thermal conduction and is then pumped back through the housing to continuously remove heat, enabling sustained high-current charging without excessive temperature rise.
2Temperature
If cooling system is added to manage temperature, then temperature control is improved, but device complexity increases
Solution Approach 1:
The cooling channels are integrated directly into the charge port housing structure, merging the cooling function with the existing mechanical housing. This eliminates the need for separate cooling components and reduces overall system complexity while still providing effective temperature management.
Solution Approach 2:
The charge port housing serves multiple functions: it provides structural support, electrical insulation, and now also acts as a heat sink through integrated cooling channels. This multi-functionality reduces the need for additional dedicated cooling components, simplifying the overall system.
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 cooling system effectively manages temperature, ensuring efficient and safe charging by maintaining the charge port within a safe operating range, thereby enhancing charging performance and prolonging the lifespan of charging components.
Implementation Method 1
a cold plate having a coolant chamber with a coolant ingress port and a coolant egress port, the cold plate being attached to the charge port
Implementation Method 2
a heat exchanger configured to cool heated coolant
Implementation Method 3
The air cooling system may be a forced air cooling system configured to provide a forced flow of air toward the charge port to dissipate heat from the charge port into an environment of the charge port
Implementation Method 4
The air cooling system may be a natural air convection system
Data Source
AI summary
A vehicle conductive charge port is configured to conductively transfer charging current from an external source to the vehicle for charging a traction battery of the vehicle. A cooling system is configured to cool the charge port depending on a temperature of the charge port. The cooling system may use coolant and/or air to cool the charge port.