US-12617305-B2 - Charge port cooling system for an electric vehicle

Abstract

A cooling system for an electric vehicle charge port includes a member having a base wall including an opening and a perimetrical wall extending from the base wall. The base wall and the perimetrical wall defining a volume. A heat spreader arranged in the volume. A terminal extends from the heat spreader through the opening in the base wall. An amount of phase change material (PCM) arranged in the volume, the amount of PCM is in contact with the terminal.

Inventors

• Peter Paul ANDRUSKIEWICZ, IV
• Chih-Hung Yen
• Satish P. Ketkar
• SeungHwan Keum
• Taeyoung Han
• Vicente Domenech Llopis
• Orlando Saenz Fuentes

Assignees

• GM Global Technology Operations LLC

Dates

Publication Date

20260505

Application Date

20221019

Claims (20)

1. 1 . A cooling system for an electric vehicle charge port comprising: a member having a base wall including an opening and a perimetrical wall extending from the base wall, the base wall and the perimetrical wall defining a volume; a heat spreader arranged in the volume; a terminal extending from the heat spreader through the opening in the base wall; and an amount of phase change material (PCM) arranged in the volume, the amount of PCM being in contact with the terminal, wherein the member is manufactured from an electrically-insulative heat-shrink material that contracts, when heated, to press its inner surface against the heat spreader and seal the PCM volume.
2. 2 . The cooling system for the electric vehicle charge port according to claim 1 , wherein the heat spreader extends from the terminal to the perimetrical wall.
3. 3 . The cooling system for the electric vehicle charge port according to claim 1 , wherein the heat spreader comprises a metallic foam.
4. 4 . The cooling system for the electric vehicle charge port according to claim 3 , wherein the metallic foam is an open cell metallic foam.
5. 5 . The cooling system for the electric vehicle charge port according to claim 1 , wherein the heat spreader includes a plurality of fins that project radially outwardly from the terminal.
6. 6 . The cooling system for the electric vehicle charge port according to claim 5 , wherein the heat spreader includes a central support including a bore receptive of the terminal, the plurality of fins being formed with the central support.
7. 7 . The cooling system for the electric vehicle charge port according to claim 1 , wherein the perimetrical wall is annular.
8. 8 . The cooling system for the electric vehicle charge port according to claim 1 , wherein the base wall includes a first opening and a second opening, the member including a divider that extends between the first opening and the second opening dividing the volume into a first portion and a second portion.
9. 9 . The cooling system for the electric vehicle charge port according to claim 8 , wherein the terminal includes a first terminal extending into the first portion of the volume through the first opening in the base wall and a second terminal extending into the second portion of the volume through the second opening in the base wall.
10. 10 . The cooling system for the electric vehicle charge port according to claim 1 , wherein the member further comprises a cover formed from an electrically-insulative heat-shrink material, the cover being configured to seal against and/or around the member to prevent leakage of the phase change material (PCM).
11. 11 . The cooling system for the electric vehicle charge port according to claim 1 , wherein the heat spreader comprises a central support having a bore receptive of the terminal, and a plurality of fins projecting radially outwardly from the central support, the inner surface of the member contacting each of the plurality of fins when contracted.
12. 12 . An electric vehicle comprising: a body; an electric motor arranged in the body; a battery pack electrically connected to the electric motor; and a charge port supported by the body and electrically connected to the battery pack, the charge port comprising: a member having a base wall including an opening and a perimetrical wall extending from the base wall, the base wall and the perimetrical wall defining a volume; a heat spreader arranged in the volume; a terminal extending from the heat spreader through the opening in the base wall; and an amount of phase change material (PCM) arranged in the volume, the amount of PCM being in contact with the terminal, wherein the member is manufactured from an electrically-insulative heat-shrink material that contracts, when heated, to press its inner surface against the heat spreader and seal the PCM volume.
13. 13 . The electric vehicle according to claim 12 , wherein the heat spreader extends from the terminal to the perimetrical wall.
14. 14 . The electric vehicle according to claim 12 , wherein the heat spreader comprises a metallic foam.
15. 15 . The electric vehicle according to claim 14 , wherein the metallic foam is an open cell metallic foam.
16. 16 . The electric vehicle according to claim 12 , wherein the heat spreader includes a plurality of fins that project radially outwardly from the terminal.
17. 17 . The electric vehicle according to claim 16 , wherein the heat spreader includes a central support including a bore receptive of the terminal, the plurality of fins being formed with the central support.
18. 18 . The electric vehicle according to claim 12 , wherein the perimetrical wall is annular.
19. 19 . The electric vehicle according to claim 12 , wherein the base wall includes a first opening and a second opening, the member including a divider that extends between the first opening and the second opening dividing the volume into a first portion and a second portion.
20. 20 . The electric vehicle according to claim 19 , wherein the terminal includes a first terminal extending into the first portion of the volume through the first opening in the base wall and a second terminal extending into the second portion of the volume through the second opening in the base wall.

Description

INTRODUCTION The subject disclosure relates to the art of electric vehicles and, more particularly, to a charge port cooling system for an electric vehicle. Electric vehicles include a charge port that may serve as an electrical interface with a charging station. The charging station provides electricity to charge an on-board vehicle battery. Often times, the charge port includes a sensor and an onboard control module. The sensor may communicate with the onboard control module, and the onboard control module may communicate with the charging station. For example, the sensor may take the form of a temperature sensor that detects charge port temperatures. When charge port temperatures exceed a predetermined threshold, the onboard control module or the charging station may derate charging. That is, charging may continue at a reduced rate or may be paused to allow charge port temperatures to drop. The charge rate may be increased and/or charging may be restarted once temperatures fall below the predetermined threshold. Inhibiting a charging rate due to high charging temperatures may be inconvenient to a user. Accordingly, the industry would welcome a charge port cooling system that is not dependent on liquid cooling techniques. SUMMARY A cooling system for an electric vehicle charge port, in accordance with a non-limiting example, includes a member having a base wall including an opening and a perimetrical wall extending from the base wall. The base wall and the perimetrical wall define a volume. A heat spreader is arranged in the volume. A terminal extends from the heat spreader through the opening in the base wall. An amount of phase change material (PCM) is arranged in the volume. In addition to one or more of the features described herein the heat spreader extends from the terminal to the perimetrical wall. In addition to one or more of the features described herein the heat spreader comprises a metallic foam. In addition to one or more of the features described herein the metallic foam is an open cell metallic foam. In addition to one or more of the features described herein the heat spreader includes a plurality of fins that project radially outwardly from the terminal. In addition to one or more of the features described herein the heat spreader includes a central support including a bore receptive of the terminal, the plurality of fins being formed with the central support. In addition to one or more of the features described herein the perimetrical wall is annular. In addition to one or more of the features described herein the member is formed from a heat-shrink rubber material. In addition to one or more of the features described herein the base wall includes a first opening and a second opening, the member including a divider that extends between the first opening and the second opening dividing the volume into a first portion and a second portion. In addition to one or more of the features described herein the terminal includes a first terminal extending into the first portion of the volume through the first opening in the base wall and a second terminal extending into the second portion of the volume through the second opening in the base wall. A vehicle, in accordance with a non-limiting example, includes a body, an electric motor arranged in the body, a battery pack electrically connected to the electric motor, and a charge port supported by the body and electrically connected to the battery pack. The charge port includes a member having a base wall including an opening and a perimetrical wall extending from the base wall. The base wall and the perimetrical wall define a volume. A heat spreader is arranged in the volume. A terminal extends from the heat spreader through the opening in the base wall. An amount of phase change material (PCM) is arranged in the volume. In addition to one or more of the features described herein In addition to one or more of the features described herein the heat spreader extends from the terminal to the perimetrical wall. In addition to one or more of the features described herein the heat spreader comprises a metallic foam. In addition to one or more of the features described herein the metallic foam is an open cell metallic foam. In addition to one or more of the features described herein the heat spreader includes a plurality of fins that project radially outwardly from the terminal. In addition to one or more of the features described herein the heat spreader includes a central support including a bore receptive of the terminal, the plurality of fins being formed with the central support. In addition to one or more of the features described herein the perimetrical wall is annular. In addition to one or more of the features described herein the member is formed from a heat-shrink rubber material. In addition to one or more of the features described herein the base wall includes a first opening and a second opening, the member including a divider that extends bet