Liquid-Cooled EV Charging Port for Fast Charging Heat Control
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Solution Overview
Problem
Electric vehicles face challenges with slow recharging times due to poor energy storage and heat management, which limits their range and adoption, especially in applications like electric aircraft where high-speed charging is critical.
Innovation Solution
A connector system for electric vehicles that includes a housing with conductors for current, control signals, ground connections, and a coolant flow path to facilitate fast charging by preventing overheating, allowing for efficient energy transfer and monitoring of recharging processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If conventional charging methods are used, then simplicity of charging system is maintained, but recharging time is excessively long
Solution Approach 1:
The patent combines multiple functions into a single charging connector: electrical power transmission through conductors, thermal management through coolant flow paths, and control signaling through dedicated control signal conductors. This integrated approach enables fast charging while managing heat dissipation, resolving the contradiction between reducing recharging time and maintaining system simplicity.
Solution Approach 2:
The charging port housing acts as an intermediary structure that organizes and protects multiple functional components (conductors, coolant flow paths, control signal conductors) while enabling their coordinated operation. This mediator structure allows complex fast charging functionality to be delivered through a unified interface, reducing the perceived complexity for the user.
2Productivity
If fast charging is implemented, then recharging time is reduced, but heat management becomes critical
Solution Approach 1:
The charging system merges power transmission and cooling functions into a single integrated connector assembly. Electrical conductors transmit high-power current while adjacent coolant flow paths simultaneously remove generated heat, enabling fast charging without dangerous temperature increases.
Solution Approach 2:
The patent converts the harmful heat generated during fast charging into a manageable parameter by incorporating coolant flow paths that actively remove thermal energy. The heat that would otherwise be a detrimental byproduct of fast charging becomes a controlled aspect of the charging process, allowing high charging speeds to be sustained safely.
3Productivity
If multiple conductors and coolant flow paths are integrated, then charging efficiency is improved, but connection reliability must be ensured
Solution Approach 1:
The charging port housing serves multiple functions simultaneously: it provides structural support for all internal components, creates sealed environments for conductors and coolant paths, enables mechanical connection between charging equipment and vehicles, and facilitates thermal management. This multi-functional design achieves high charging efficiency while maintaining connection reliability through a unified, robust structure.
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
Enables high-speed charging of electric vehicles by managing heat and monitoring recharging processes, thereby overcoming the limitations of slow recharging times and improving the adoption of electric vehicles in various fields, including manned flight.
Implementation Method 1
at least a coolant flow path configured to contain a flow of a coolant
Implementation Method 2
at least a conductor configured to conduct a current
Implementation Method 3
at least a ground conductor configured to conduct to a ground
Data Source
AI summary
Aspects relate to an electric vehicle port and methods of use for charging an electric vehicle. An exemplary electric vehicle port includes a housing configured to mate with a connector for charging an electric vehicle, wherein the housing comprises a fastener for removable attachment with the connector; at least a conductor configured to conduct a current; at least a control signal conductor configured to conduct a control signal; at least a ground conductor configured to conduct to a ground; and at least a coolant flow path configured to contain a flow of a coolant, wherein, each of the at least a conductor, the at least a control signal conductor, the at least a ground conductor, and the at least a coolant flow path are configured to make a connection with a mating component on the connector for charging the electric vehicle when the housing is mated with the connector.