Liquid-Cooled Charging Port Layout for High-Current EV Fast Charging

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Solution Overview

Problem

Electric vehicles face challenges with level three chargers due to increased temperatures from large electric currents, which constrain charging capacity and require separate AC/DC and DC/DC power converters, leading to electromagnetic compatibility issues.

Innovation Solution

Directly coupling a vehicle traction battery charging port to a liquid cooled cold plate to reduce connector heat, allowing higher current flow and integrating AC/DC and DC/DC converters for efficient cooling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If larger amounts of electric current are used for fast charging, then charging speed is improved, but temperature of conductors and connectors increases

Engineering Contradiction:

Improvecharging speedVSAvoidconnector temperature

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

The patent applies active cooling to the charging port and connectors, converting the harmful heat generated by high-current fast charging into a manageable condition. By integrating cooling channels directly into the charging port structure, the system actively removes heat during high-power charging operations, enabling sustained high charging speeds without thermal damage to components.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent introduces a cooling medium (liquid coolant flowing through channels) as an intermediary between the charging port/connectors and the external environment. This cooling medium acts as a heat transfer intermediary, absorbing heat from the high-current components and carrying it away, thereby enabling high current flow without excessive temperature rise.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If AC/DC and DC/DC power converters are located at different ends of the vehicle, then packaging constraints are satisfied, but electromagnetic compatibility is degraded

Engineering Contradiction:

Improvepackaging flexibilityVSAvoidelectromagnetic interference

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent merges the AC/DC power converter and DC/DC power converter into a single integrated power conversion system located at one end of the vehicle. This consolidation reduces the physical separation between converters, minimizing electromagnetic interference through shorter internal connections and shared grounding, while still satisfying packaging requirements through compact design.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated power conversion system performs multiple functions (AC/DC conversion and DC/DC conversion) within a single unified structure. This multi-functional design eliminates the need for separate converter locations, reducing electromagnetic compatibility issues while maintaining packaging flexibility through the compact, consolidated architecture.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of manufacture

If long power lines are used to connect power converters at different vehicle ends, then packaging constraints are satisfied, but electromagnetic compatibility and signal integrity are degraded

Engineering Contradiction:

Improvepackaging flexibilityVSAvoidelectromagnetic interference

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

By consolidating power converters at one location, the patent eliminates the need for long power lines connecting distributed converters. The merged architecture uses short internal connections within the integrated system, dramatically reducing electromagnetic interference and signal integrity issues while maintaining packaging flexibility through the compact converter design.

Inventive Principle:

Principle #5Merging (Combining)

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

This approach enhances charging efficiency, simplifies design, and improves electromagnetic compatibility by reducing cable lengths and cooling connections.

Implementation Method 1

directly coupled to a liquid cooled cold plate

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

liquid cooled cold plate

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 3

larger amounts of electric current flowing through conductors and connectors within the vehicle may tend to increase temperatures of the conductors and connectors

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS12581624B2Vehicle charging system and method, with power converters directly coupled to liquid cooled cold plate

Publication Date: 2026.03.17 FORD GLOBAL TECH LLC

AI summary

Methods and systems are provided for controlling a temperature of a vehicle power input port that is configured to receive power for a traction battery. In one example, a liquid cooled cold plate is configured to extract heat from the vehicle power input port so that there may be a reduced possibility of limiting electric power flow to the vehicle during charging of a traction battery.