Patent Application
20210347270
The present disclosure relates generally to vehicle charging systems. More specifically, the present disclosure relates to a transient heat storage connector assembly for a vehicle charging system.
At least one embodiment relates to a connector assembly for a vehicle charging system. The connector assembly includes a first housing defining a charge port of the vehicle charging system and a second housing coupled to the first housing. The second housing is configured to receive an electrical wire including a power terminal therein. The connector assembly further includes a flexible tube coupled to the second housing and a phase change material disposed therein. The phase change material is configured to surround at least a portion of the electrical wire. The phase change material is configured to store heat energy from at least one of the electrical wire or the power terminal. The connector assembly further includes a cover coupled to the second housing for facilitating the injection of the phase change material into the flexible tube.
The disclosure will become more fully understood from the following detailed description, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements, in which:
Before turning to the figures, which illustrate certain exemplary embodiments in detail, it should be understood that the present disclosure is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology used herein is for the purpose of description only and should not be regarded as limiting.
During charging of a fully or partially electrically-powered vehicle, a charger plug of an external power source is coupled to a charge port of a connector of the vehicle charging system, allowing current to flow between the external power source and a battery of the vehicle. During “fast-charging” situations, higher rates of power, current, and/or voltage that exceed the rated amounts for the wires/terminals of the connector may be used. These higher rates of current can, however, result in excessive heat being generated at the connector, which can decrease the efficiency of the charge.
The long time it takes to charge an electric vehicle is much greater than the time required to fill an equivalent vehicle with fuel. This increase in time is an inconvenience to end users. Generally speaking, charge inlets on electric vehicles use standard wire with insulation to conduct electric current. These wires depend on air movement to expel the heat generated by the current flow in the terminals and wire. In order to decrease the charge time, the electric current must be increased, such as during fast-charging situations. As electric current is passed through a conductive cable, heat is produced. The amount of electric current a wire can carry is limited by the temperature it is allowed to reach. Thus, there is a need for an improved way to store heat generated by electrical wires of a charge inlet for a vehicle during fast-charging situations.
Referring generally to the FIGURES, disclosed herein is a connector assembly for a vehicle charging system that includes a phase change material (PCM) disposed around electrical wires to absorb heat generated by the wires and temporarily store the heat at a relative constant temperature. The connector assembly further includes a first housing that defines one or more charge ports of the vehicle charging system and a second housing coupled to the first housing behind the charge ports. The second housing is configured to receive one or more electrical wires each including a power terminal therein for coupling to an external power source at the charge port of the first housing. The phase change material is disposed in flexible tubes that are coupled to the second housing and surrounds at least a portion of the electrical wires (e.g., wire insulation, conductor, etc.). The phase change material is configured to store heat energy from the electrical wires by direct physical contact between the phase change material and the electrical wires and part of the terminals.
In this manner, the disclosed connector assembly can, advantageously, help to increase efficiency within the connector assembly and reduce charging time for users of the vehicle charging system.
Referring to
The first housing 110 includes a mounting flange 110c disposed behind the first charge port 110a and the second charge port 110b. The mounting flange 110c is configured to couple the first housing 110 to a portion of the vehicle. The first housing 110 further includes a rear portion located opposite the front portion having the first and second charge ports 110a, 110b. The first housing 110 defines a first opening 110d and a second opening (not shown) each extending from the first charge port 110a and through the mounting flange 110c, to a second housing 120. The first and second housings 110, 120 may be made of a plastic non-conducting resin using standard injection mold and process.
The second housing 120 is coupled to the rear portion of the first housing 110. The second housing 120 defines a top portion 120a extending from the mounting flange 110c, opposite the first and second charge ports 110a, 110b. The top portion 120a defines two hollow circular channels, terminating with an opening 120b. Bottom portions 120c extend from the underside of the top portion 120a. Although, there are two bottom portions 120c in the embodiment described herein, it should be appreciated that more or fewer than two may be included in the connector assembly 100 according to other exemplary embodiments. Each bottom portion 120c correspond with a channel in the top portion 120a, thus creating a T-shaped passageway throughout the second housing 120. The bottom portions 120c each terminate with an opening 120d.
The connector assembly 100 further includes one or more flexible tubes 200. The flexible tubes may be made from an elastomer or any other flexible polymeric material or combinations of materials. The flexible tubes 200 are hollow tubes defining a cavity 200a therein. The flexible tubes 200 are configured to couple to the bottom portions 120c such that the flexible tubes 200 are disposed around the bottom portions 120c, the opening 120d corresponding with the cavity 200a. Further, the flexible tubes 200 couple to the second housing 120 in a sealed manner. For instance, a coupling mechanism 230 (e.g., a band clamp, interference fit, snap fit, shrink wrap, etc.) is disposed around the flexible tubes 200 when the flexible tubes are disposed around the bottom portions 120c to provide sealing to contain the PCM within the flexible tubes 200 and to keep moisture out. Although the orientation of the flexible tubes 200 as shown includes a bent segment, it should be appreciated that the configuration of the flexible tubes may vary. For instance, the flexible tubes could be substantially vertical or substantially horizontal. The orientation may depend on the vehicle and use with the PCM, as described herein.
The connector assembly 100 further includes power terminals 220 (i.e., inlet power terminal). The first housing 110 is configured to receive the power terminals 220 through the first opening 110d and the second opening, respectively, such that the power terminals 220 are positioned in the first charge port 110a (see, for example,
The electrical wires 210 are disposed through the flexible tubes 200 and into the second housing 120, such that the power terminals 220 for each electrical wire 210 are coupled to a terminal 210a (e.g., an inlet eyelet terminal) of the electrical wire 210 via the bolt 240. The terminal 210a and the power terminals 220 meet perpendicularly within the second housing 120. The terminal 210a includes a flat side 210b with surface area sufficient to interface with the surface area of the rear portion 220e. The terminal 210a may be attached to the electrical wires 210 by welding or crimping (see, for example,
In the exemplary embodiment of
Still referring to
The PCM 300 may be an organic material (e.g., from petroleum, plants, or animals) or a salt hydrate. The PCM 300 may be a hydrocarbon PCM to provide stability for repeated thermal cycles. The PCM 300 may have a high latent heat value and stable thermal cycling. For example, the PCM 300 may be C36H74. The PCM 300 is structured to absorb large amounts of heat energy while melting from a solid to a liquid. Thus, the PCM 300 will absorb the heat energy produced during the charging process when the electrical wires 210 heat up to approximately 50° C.-90 ° C. (e.g., 65° C.-75° C.), and melt the surrounding PCM. The energy is then released back when the PCM 300 begins to return to its solid state. By adding the PCM 300 to the flexible tubes 200, the rate of heat storage of the heat generated by the electrical wires 210 is increased. The PCM 300 will temporarily hold the heat produced by the electrical wires 210 and the power terminals 220 during a DC fast charge cycle. Further, because the PCM is retaining and releasing the heat energy, the electrical wires 210 are able to remain at a relatively constant temperature. In this manner, the connector assembly 100 can, advantageously, increase the efficiency of charging.
Referring still to
The third housing 400 further includes an opening 410d. The opening 410d is configured to receive only the electrical wires. As such, the flange 410 acts as the first barrier (i.e., seal) for the retaining the PCM, and therefore the heat energy generated by the electrical wires within the connector assembly 100. The third housing 400 includes a cable seal 410f. The cable seal 410f may be a compliant material between the second portions 410c and the electrical wires 210. The cable seal 410f is configured to substantially seal the volume of PCM 300 within the flexible tubes 200 as it is compressed by connectors 430 (e.g., holder, cap, seal, etc.) into the flange 410. The connectors 430 are disposed around the portion of the electrical wires 210 that extend beyond the second side portion of the flange 410 (i.e., the surface the second portions 410c extend from). The connectors 430 may act to substantially seal an end of the cavity 200a to contain the PCM material within the connector assembly 100 by compressing the cable seal 410f, as explained herein. The cable seal 410f may be coupled to an inner surface of the connectors 430 such that the cable seal 410f moves with the connectors 430. The connectors 430 may couple to the second portions 410c using snap features as illustrated. The connectors 430 may also couple via clamps, interference fit, etc., according to other exemplary embodiments. The connectors 430 may be detached from the second portions 410c while the PCM 300 is injected into the flexible tubes 200 to allow for the flexible tubes 200 to be filled and air bled. In the embodiment shown, two connectors 430 are shown, but it should be appreciated that more or less connectors 430 may be included.
The electrical wires 210 terminate at terminal 210c (e.g., battery eyelet terminal). The terminal 210c may be coupled to the electrical wires 210 by welding or crimping (see, for example,
Referring to
The disclosed connector assembly can, advantageously, help to increase efficiency within the connector assembly and reduce charging time for users of the vehicle charging system by surrounding the electrical wires with a phase change material that will absorb heat generated by the wires, and temporarily store the heat at a relative constant temperature.
As utilized herein, the terms “approximately,” “about,” “substantially,” and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the disclosure as recited in the appended claims.
It should be noted that the term “exemplary” and variations thereof, as used herein to describe various embodiments, are intended to indicate that such embodiments are possible examples, representations, or illustrations of possible embodiments (and such terms are not intended to connote that such embodiments are necessarily extraordinary or superlative examples).
The term “coupled” and variations thereof, as used herein, means the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent or fixed) or moveable (e.g., removable or releasable). Such joining may be achieved with the two members coupled directly to each other, with the two members coupled to each other using a separate intervening member and any additional intermediate members coupled with one another, or with the two members coupled to each other using an intervening member that is integrally formed as a single unitary body with one of the two members. If “coupled” or variations thereof are modified by an additional term (e.g., directly coupled), the generic definition of “coupled” provided above is modified by the plain language meaning of the additional term (e.g., “directly coupled” means the joining of two members without any separate intervening member), resulting in a narrower definition. than the generic definition of “coupled” provided above. Such coupling may be mechanical, electrical, or fluidic.
References herein to the positions of elements (e.g., “top,” “bottom,” “above,” “below”) are merely used to describe the orientation of various elements in the FIGURES. It should be noted that the orientation of various elements may differ according to other exemplary embodiments, and that such variations are intended to be encompassed by the present disclosure.
It is important to note that the construction and arrangement of the connector assembly as shown in the various exemplary embodiments is illustrative only. Additionally, any element disclosed in one embodiment may be incorporated or utilized with any other embodiment disclosed herein.
This application claims the benefit of and priority to U.S. Provisional Patent Application No. 63/053,982, filed Jul. 20, 2020, the contents of which are incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63053982 | Jul 2020 | US |
