Liquid-cooled charging connector

Patent metadata

Field	Value
Publication number	US-12469999-B2
Application number	US-202117305554-A
Country	US
Kind code	B2
Filing date	Jul 9, 2021
Priority date	Mar 22, 2018
Publication date	Nov 11, 2025
Grant date	Nov 11, 2025

Abstract

A charging connector includes a first electrical socket and a second electrical socket. A first sleeve and a second sleeve are provided, such that the first sleeve is concentrically coupled to the first electrical socket and the second sleeve is concentrically coupled to the second electrical socket. A manifold assembly is adapted to enclose the first and second electrical sockets and the first and second sleeves, such that the first and second sleeves and the manifold assembly create a hollow interior space there between. An inlet conduit and an outlet conduit within the manifold assembly such that inlet conduit, the interior space, and the outlet conduit together create a fluid flow path.

First claim

What is claimed is:

1 . A charging connector comprising:
a manifold assembly enclosing a plurality of connector portions coupled to respective sleeves, wherein the manifold assembly defines a hollow interior space there between; and an inlet conduit and an outlet conduit through which a cooling fluid flows for cooling the charging connector, wherein the manifold assembly is configured to cause the cooling fluid to flow in through the inlet conduit and bifurcate into two or more streams which flow around the sleeves and which subsequently combine together upstream to flow out of the outlet conduit.

2 . The charging connector of claim 1 , wherein the cooling fluid is recirculated back to the inlet conduit.

3 . The charging connector of claim 1 , wherein a first sleeve partially encloses a first electrical connector portion and a second sleeve partially encloses a second connector portion.

4 . The charging connector of claim 1 , wherein the sleeves comprise a thermally conducting plastic material.

5 . The charging connector of claim 1 , wherein the sleeves are coupled to corresponding connector portions by one or more of an overmolding process, or a press-fit assembly.

6 . The charging connector of claim 1 , wherein the charging connector is configured for connection to a two part Printed Circuit Board Assembly (PCBA).

7 . The charging connector of claim 1 , further comprising a pair of O-rings provided between a first sleeve and the manifold assembly.

8 . The charging connector of claim 1 , further comprising a temperature sensor coupled to at least one of the connector portions.

9 . A charging system for an electric vehicle, the charging system comprising:
a power supply; a charging cable having a first end and a second end, wherein the first end of the charging cable is coupled to the power supply; a charging connector coupled to the charging cable at the second end, wherein the charging connector has a form factor corresponding to a charging inlet of the electric vehicle, the charging connector including:
a manifold assembly enclosing a plurality of connector portions coupled to respective sleeves, wherein the manifold assembly defines a hollow interior space there between; and
an inlet conduit and an outlet conduit through which a cooling fluid flows for cooling the charging connector,
wherein the manifold assembly is configured to cause the cooling fluid to flow in through the inlet conduit and bifurcate into two or more streams which flow around the sleeves and which subsequently combine together upstream to flow out of the outlet conduit.

10 . The charging system of claim 9 , wherein the cooling fluid is recirculated back to the inlet conduit.

11 . The charging system of claim 9 , wherein a first sleeve partially encloses a first electrical connector portion and a second sleeve partially encloses a second connector portion.

12 . The charging system of claim 9 , wherein the sleeves comprise a thermally conducting plastic material.

13 . The charging system of claim 9 , wherein the sleeves are coupled to corresponding connector portions by one or more of an overmolding process, or a press-fit assembly.

14 . The charging system of claim 9 , further comprising a two part Printed Circuit Board Assembly (PCBA) configured for connection to the charging connector.

15 . The charging system of claim 14 , wherein the two part PCBA includes a first part which is positioned on top of the connector portions.

16 . The charging system of claim 15 , wherein the two part PCBA includes a second part which is connected to the first part via a rigid-flex PCB construction.

17 . The charging system of claim 9 , wherein the charging connector further comprises a temperature sensor coupled to at least one of the connector portions.

18 . A handle assembly for a charging connector of an electric vehicle, the handle assembly comprising:
a charging cable having a first end and a second end, wherein the first end of the charging cable is coupled to a power supply; a charging connector coupled to the charging cable at the second end, wherein the charging connector has a form factor corresponding to a charging inlet of the electric vehicle, the charging connector including:
a manifold assembly enclosing a plurality of connector portions coupled to respective sleeves, wherein the manifold assembly defines a hollow interior space there between; and
an inlet conduit and an outlet conduit through which a cooling fluid flows for cooling the charging connector,
wherein the manifold assembly is configured to cause the cooling fluid to flow in through the inlet conduit and bifurcate into two or more streams which flow around the sleeves and which subsequently combine together upstream to flow out of the outlet conduit; and
a handle housing partially enclosing the charging connector, and at least partially enclosing the charging cable such that the charging cable extends outwards from one end of the handle housing, and first and second electrical connector portions of the plurality of connector portions extend outwards from another end of the handle housing.

19 . The handle assembly of claim 18 , wherein the cooling fluid is recirculated back to the inlet conduit.

20 . The handle assembly of claim 18 , wherein the charging connector further comprises a temperature sensor coupled to at least one of the connector portions.

Assignees

• Tesla Inc

Inventors

• Chou Chuen
• Fortin Pascal-Andre

Classifications

• H02J7/70

  characterised by the mechanical construction · CPC title

• B60L53/18

  Cables specially adapted for charging electric vehicles · CPC title

• B60L53/302

  Cooling of charging equipment · CPC title

• B60L53/16 Primary

  Connectors, e.g. plugs or sockets, specially adapted for charging electric vehicles · CPC title

• H01R13/5202

  Sealing means between parts of housing or between housing part and a wall, e.g. sealing rings · CPC title