Heat exchanger for a power connector

A cooling system for a power connector of a charging inlet assembly includes a cooling adapter coupled to a housing of the charging inlet assembly including an adapter body forming a cavity. The cooling adapter includes supply and return ports adjacent a cable exit. The cooling system includes a heat exchanger positioned in the cavity of the cooling adapter including a heat exchanger body configured to receive the power cable and/or the terminal. The heat exchanger body is thermally coupled to the power cable or the terminal to dissipate heat therefrom.

BACKGROUND OF THE INVENTION

The subject matter herein relates generally to heat exchangers for power connectors.

Electrical connectors, such as power connectors, generate heat when current flows through the terminals and cables of the power connectors. For example, a power connector of a charging inlet assembly for a battery system of an electric vehicle (EV) or hybrid electric vehicle (HEV) may generate heat through the terminals and the cables of the charging inlet assembly during a charging process. A charging connector is configured to be mated with the terminals of the charging inlet assembly to charge the battery system of the vehicle. It is desirable to increase the current transmitted through the terminals for charging the battery. However, at higher currents, the terminals and the power cables experience an increase in temperature, which may damage the components of the charging inlet assembly.

A need remains for a cooling system for cooling a power connector, such as for a charging inlet assembly.

BRIEF DESCRIPTION OF THE INVENTION

In embodiments herein a cooling system for a power connector of a charging inlet assembly is provided. The cooling system includes a cooling adapter configured to be coupled to a housing of the charging inlet assembly. The cooling adapter includes an adapter body forming a cavity. The adapter body has a cable exit for a power cable of the charging inlet assembly. The cooling adapter includes a supply port adjacent the cable exit and a return port adjacent the cable exit. The cooling system includes a heat exchanger positioned in the cavity of the cooling adapter. The heat exchanger includes a heat exchanger body configured to receive at least one of the power cable or a terminal extending from the power cable. The heat exchanger body is thermally coupled to the at least one of the power cable or the terminal to dissipate heat therefrom.

In another embodiment, a power connector is provided. The power connector includes a housing extending between a front and a rear. The housing has a chamber at the rear. The housing has a terminal channel between the front and the rear. The power connector includes a terminal coupled to the housing. The terminal has a mating end for mating with a charging connector. The power connector includes a power cable terminated to the terminal. The power cable includes a conductor. The power connector includes a heat exchanger positioned in the chamber. The heat exchanger includes a heat exchanger body receiving at least one of the power cable or the cable connector of the terminal. The heat exchanger body is thermally coupled to the at least one of the power cable or the terminal to dissipate heat therefrom. The heat exchanger includes a coolant tube extending from the heat exchanger body. The coolant tube is thermally coupled to the heat exchanger body. The coolant tube has a coolant channel for coolant flow through the coolant tube. The heat exchanger includes a thermally conductive separator electrically isolating the heat exchanger body from the at least one of the power cable or the terminal.

In a further embodiment, a charging inlet assembly for an electric vehicle is provided. The charging inlet assembly includes a housing extending between a front and a rear. The housing has a chamber at the rear. The housing has a power connector at the front for receiving a charging connector. The power connector includes a first terminal channel and a second terminal channel between the front and the rear. The charging inlet assembly includes a first terminal coupled to the housing. The first terminal is positioned in the first terminal channel for mating with the charging connector and is terminated to a first power cable. The charging inlet assembly includes a second terminal coupled to the housing. The second terminal is positioned in the second terminal channel for mating with the charging connector and is terminated to a second power cable. The charging inlet assembly includes a heat exchanger positioned in the chamber. The heat exchanger includes a heat exchanger body having a first thermal interface being thermally coupled to at least one of the first terminal or the first power cable and having a second thermal interface being thermally coupled to at least one of the second terminal or the second power cable. The heat exchanger includes a coolant tube extending from the heat exchanger body. The coolant tube is thermally coupled to the heat exchanger body. The coolant tube has a coolant channel for coolant flow through the coolant tube. The coolant tube includes a supply tube at a supply side of the heat exchanger and a return tube at a return side of the heat exchanger.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1is a front perspective view of a power connector102of a charging inlet assembly100having a cooling system130for cooling components of the power connector102.FIG. 2is a rear perspective view of the charging inlet assembly100and cooling system130in accordance with an exemplary embodiment. While the power connector102may be described herein as part of the charging inlet assembly100, it is realized that the power connector102may be another type of electrical connector, such as a stand-alone power connector or a power connector used in another device or system.

The charging inlet assembly100is used as a charging inlet for a vehicle, such as an electric vehicle (EV) or hybrid electric vehicle (HEV). The charging inlet assembly100includes a power connector102configured for mating reception with a charging connector (not shown). In an exemplary embodiment, the power connector102is configured for mating with a DC fast charging connector, such as the SAE combo CCS charging connector, in addition to AC charging connectors, such as the SAE J1772 charging connector.

The charging inlet assembly100includes a housing110holding terminals114forming part of the power connector102. The terminals114may include DC charging terminals, AC charging terminals or other types of terminals. The terminals114are electrically connected to corresponding power cables118. The terminals114are configured to be mated to the charging connector. The terminals114are received in terminal channels116of the housing110. The terminals114may be coupled to the housing110in the terminal channels116. In an exemplary embodiment, the charging inlet assembly100includes the cooling system130for actively cooling the terminals114, such as by directly cooling the terminals and/or by cooling the power cables118to cool the terminals114. Coolant may be pumped through lines or channels of the cooling system130and flow in thermal communication with the terminals114and/or the power cables118to dissipate heat from the terminals114.

The charging inlet assembly100includes a mounting flange120extending from the housing110. The mounting flange120is used to couple the charging inlet assembly100to the vehicle. The mounting flange120includes mounting tabs122having openings124that receive fasteners (not shown) used to secure the charging inlet assembly100to the vehicle. Other types of mounting features may be used to secure the charging inlet assembly100to the vehicle. The mounting flange120may include a seal to seal the charging inlet assembly100to the vehicle.

The charging inlet assembly100includes a terminal cover126(FIG. 1) hingedly coupled to the mounting flange120and/or the housing110. The terminal cover126is used to cover corresponding terminals114. The housing110includes a rear cover128(FIG. 2) at a rear of the housing110that closes access to the rear of the housing110. The rear cover128may be clipped onto the main part of the housing110, such as using clips or latches. Other types of securing features, such as fasteners may be used in alternative embodiments. The cooling system130may be integrated into the housing110, such as passing through and/or coupled to the rear cover128.

In an exemplary embodiment, the cooling system130includes a cooling adapter131(FIG. 2) at the rear of the housing110. The cooling adapter131may be coupled to the rear cover128or may be defined, at least in part, by the rear cover128. A seal may be provided at the interface between the cooling adapter131and the main body of the housing110and/or between pieces of the cooling adapter131. For example, the cooling adapter131may be a multi-piece adapter. The cooling adapter131includes an adapter body133forming a cavity. The adapter body133forms part of the housing110to enclose the rear chamber of the housing110. The cavity is open to the rear chamber of the housing110. The cooling components of the cooling system130are thermally coupled to the terminals114and/or the power cables118in the cavity and/or the rear chamber of the housing110. The adapter body133includes cable exits137for the power cables118. The cooling adapter131includes a supply port138adjacent the cable exits137and a return port139adjacent the cable exits137.

A coolant supply line132is coupled to the supply port138and extends from the adapter body133generally parallel to the power cables118such that the coolant supply line132may be bundled with the power cables118for controlled routing of the coolant supply line132and the power cables118from the charging inlet assembly100, such as to the battery of the electric vehicle. A coolant return line134is coupled to the return port139and extends from the adapter body133generally parallel to the power cables118such that the coolant return line134may be bundled with the power cables118for controlled routing of the coolant return line134and the power cables118from the charging inlet assembly100, such as to the battery of the electric vehicle. The cooling adapter131may include one or more interface seals (not shown) for interfacing with the coolant supply and return lines132,134.

In the illustrated embodiment, the supply port138and the return port139are arranged at the rear of the adapter body133, such as adjacent the cable exits137, such that the coolant supply line132and the coolant return line134extend from the rear (for example, parallel to the power cables118). However, the ports138,139may be at other locations. In an alternative embodiment, the supply port138and/or the return port139may be located on opposite sides of the adapter body133.

FIG. 3is a side view of the terminal114in accordance with an exemplary embodiment. The terminal114includes a mating pin200at a front210of the terminal114and a cable connector202at a rear212of the terminal114. The terminal114extends along a longitudinal axis204. The mating pin200is configured to be mated to the charging connector. The cable connector202is configured to be electrically connected to the power cable118(shown inFIG. 2). In an exemplary embodiment, the mating pin200and/or the cable connector202are configured to be cooled by the cooling system130(shown inFIG. 2).

In various embodiments, the cable connector202is separate and discrete from the mating pin200and configured to be mechanically and electrically coupled to the mating pin200. For example, the cable connector202may be press fit onto the mating pin200. However, the cable connector202may be secured to the mating pin200by other processes in alternative embodiments, such as welding, riveting, a bolted joint, and the like. In other various embodiments, the cable connector202is integral with the mating pin200, such as formed with the mating pin200. In various embodiments, the cable connector202is configured to be terminated to the power cable118by welding the power cable118to the cable connector202. For example, the cable connector202may include a weld tab. In other various embodiments, the cable connector202is terminated to the power cable118by other processes, such as being crimped, soldered, and the like. For example, the cable connector202may include a crimp barrel configured to be terminated to the power cable118.

The mating pin200is electrically conductive. For example, the mating pin200may be manufactured from a metal material, such as a copper material. In an exemplary embodiment, the mating pin200is screw machined. The mating pin200may be manufactured from a metal alloy (for example, copper alloy) having additives to increase machinability. In an exemplary embodiment, the mating pin200is cylindrical. In an exemplary embodiment, a seal228is coupled to the mating pin200near a rear end of the mating pin200for interface sealing against an interior surface of the terminal channel116(shown inFIG. 1).

The cable connector202extends from and/or is coupled to the rear end of the mating pin200. The cable connector202may be press-fit on the mating pin200. The cable connector202includes a cable terminating end240at the rear212of the terminal114. The power cable118is configured to be terminated to the cable terminating end240. In the illustrated embodiment, the cable connector202includes a pad242extending from a base244of the cable connector202. The pad242is provided at the rear212. The pad242may be rectangular or have other shapes in alternative embodiments. The pad242may include planar, parallel surfaces for attaching the power cable118to the pad242. In various embodiments, the pad242may be a weld pad and the power cable118may be a welded to the weld pad. The cable terminating end240may include a crimp barrel (not shown) rather than the pad242in alternative embodiments. The base244may be cylindrical and hollow to receive the rear end of the mating pin200. The base244is mechanically and electrically coupled to the rear end of the mating pin200. The base244may be press-fit onto the rear end of the mating pin200.

FIG. 4is a cross-sectional view of the charging inlet assembly100in accordance with an exemplary embodiment.FIG. 4illustrates one of the terminals114coupled to the housing110. The housing110has a chamber140at the rear of the housing110. The rear cover128is rearward of and closes the chamber140. The power cables118and the coolant supply and return lines exit the chamber140through the rear cover128(for example, through openings or ports in the rear cover128).

The terminal114extends into the chamber140and the power cable118is terminated to the terminal114in the chamber140. The cooling system130interfaces with the power cable118in the chamber140to provide active cooling for the terminal114. For example, the cooling system130includes a heat exchanger300positioned in the chamber140to interface with the terminal114. The heat exchanger300is thermally coupled to the terminal114. The cooling system130lowers the operating temperature of the terminal114to improve performance of the charging inlet assembly100and/or to allow higher current through the terminal114and/or to reduce risk of damage to the terminal114.

The terminal114is received in the corresponding terminal channel116. The mating pin200is located in the terminal channel116for interfacing with a charging connector plugged into the housing110. The housing110includes a primary latch162extending into the terminal channel116to engage and axially retain the terminal114in the terminal channel116. The primary latch162may be a deflectable latch. The primary latch162may be integral with the housing110, such as co-molded with the housing110. The primary latch162resists rearward pull out of the terminal114from the terminal channel116. In an exemplary embodiment, the seal228is sealed to a surface of the housing110defining the terminal channel116.

In an exemplary embodiment, the terminal114is located in the terminal channel116such that the cable connector202is located immediately rearward of the terminal channel116. The cable connector202extends into the chamber140for electrical connection with the power cable118. The power cable118is coupled to the pad242within the chamber140. In an exemplary embodiment, the power cable118may be ultrasonically welded to the pad242, creating a low resistance interface between the terminal114and the power cable118. In other various embodiments, the power cable118may be crimped or otherwise mechanically and electrically terminated to the terminal114. The cooling system130is thermally coupled to the terminal114, such as immediately rearward of the terminal channel116, to define a low-profile connection between the cooling system130and the terminal114. In various embodiments, the heat exchanger300may be directly thermally coupled to the base244and/or the pad242. Optionally, a thermal interface material, a thermal grease or another thermal bridge may be provided between the terminal114and the heat exchanger300. In other various embodiments, the heat exchanger300may be indirectly thermally coupled to the terminal114, such as through the power cable118. For example, by dissipating heat from the power cable118, the temperature of the terminal114may be reduced. The power cable118functions as a thermal bridge between the heat exchanger300and the terminal114.

FIG. 5is a side view of the supply side of a portion of the charging inlet assembly100in accordance with an exemplary embodiment showing the heat exchanger300thermally coupled to the terminal114.FIG. 6is a top view of a portion of the charging inlet assembly100in accordance with an exemplary embodiment showing the heat exchanger300thermally coupled to the terminal114.FIG. 7is a side view of the return side of a portion of the charging inlet assembly100in accordance with an exemplary embodiment showing the heat exchanger300thermally coupled to the terminal114.FIG. 8is a top view of a portion of the charging inlet assembly100in accordance with an exemplary embodiment showing the heat exchanger300thermally coupled to the terminal114.FIGS. 5 and 6illustrate the heat exchanger300coupled to the coolant supply line132and the coolant return line134.FIGS. 7 and 8illustrate the heat exchanger300with the coolant supply and return lines132,134removed to illustrate supply and return ends of the heat exchanger300.

The heat exchanger300includes a coolant channel302through the heat exchanger300. Coolant flows through the coolant channel302to transfer heat from the heat exchanger300. The heat exchanger300is configured to be thermally coupled to the terminals114(for example, directly coupled to the pads242or through the power cables118). The heat exchanger300may be pressed against the terminals114and/or the power cables118. For example, the heat exchanger300may be secured by fasteners, clips, latches or other securing features.

The heat exchanger300includes a heat exchanger body304defining the coolant channel302. The heat exchanger300includes a coolant tube305extending from the heat exchanger body304. The coolant tube305may be separate and discrete from the heat exchanger body304and coupled to the heat exchanger body304. For example, the coolant tube305may be brazed, welded or soldered to the heat exchanger body304. In an exemplary embodiment, the coolant tube305is a U-shaped tube. The coolant tube305may have other shapes in alternative embodiments. In an exemplary embodiment, the coolant tube305includes a supply tube306, a return tube308and a transition tube307between the supply tube306and the return tube308. The transition tube307is coupled to the heat exchanger body304. The supply tube306extends from one side of the heat exchanger body304and the return tube308extends from the opposite side of the heat exchanger body304. The supply tube306extends to the supply port138of the cooling adapter131(both shown inFIG. 2). The return tube308extends to the return port139of the cooling adapter131(both shown inFIG. 2). In an exemplary embodiment, the coolant tube305is continuous from the transition tube307to the supply tube306and the return tube308.

The heat exchanger300extends between a supply side310and a return side312. The supply tube306is provided at the supply side310and the return tube308is provided at the return side312. The heat exchanger body304includes a front314and a rear316. The front314faces the terminals114. The rear316faces the power cables118. The heat exchanger body304includes an end wall318extending between the front314and the rear316. The end wall318extends along and is configured to be thermally coupled to the terminals114and/or the power cables118. In an exemplary embodiment, the end wall318includes a saddle322for supporting the terminals114and/or the power cables118. The saddle322receives the terminals114and/or the power cables118. In an exemplary embodiment, the saddle322(also shown inFIG. 11) includes pockets324that receive the terminals114and/or the power cables118. The pockets324are sized and shaped to receive the terminals114and/or the power cables118. In the illustrated embodiment, the pockets324are sized and shaped to receive the power cables118. The pockets324have a complementary shape as the power cables118to securely receive the power cables118such that the heat exchanger body304is in thermal contact with the power cables118. For example, the pockets324may have a hemicylindrical shape. Other shapes are possible in alternative embodiments, such as a complementary shape as the pads242of the terminals114.

In an exemplary embodiment, the heat exchanger300includes a heat exchanger lid320coupled to the heat exchanger body304. The terminals114and/or the power cables118may be captured between the end wall318and the heat exchanger lid320. The heat exchanger lid320may be clipped onto the heat exchanger body304, such as at the sides310,312. The heat exchanger lid320may be secured to the heat exchanger body304using fasteners, such as at the front314and/or the rear316. When the heat exchanger lid320is coupled to the heat exchanger body304, the power cables118are compressed against the heat exchanger body304to ensure efficient thermal transfer between the power cables118and the heat exchanger body304.

The heat exchanger body304and the heat exchanger lid320may be manufactured from thermally conductive materials, such as metal materials. Optionally, both the heat exchanger body304and the heat exchanger lid320are manufactured form the same material. In various embodiments, the heat exchanger body304and/or the heat exchanger lid320are manufactured from aluminum or an aluminum alloy. The heat exchanger body304and the heat exchanger lid320may be stamped and formed. However, the heat exchanger body304and the heat exchanger lid320may be manufactured by other processes in alternative embodiments, such as being molded, machined, and the like.

The coolant channel302is configured for flow communication through the supply tube306, the transition tube307, and the return tube308. The coolant channel302is in flow communication with the supply and return lines132,134. The coolant is routed through the coolant channel302to dissipate heat from the heat exchanger body304of the heat exchanger300for cooling the terminal114. In the illustrated embodiment, the coolant tube305is U-shaped forming a U-shaped coolant channel302. The coolant channel302may extend along other non-linear paths, such as a curved or serpentine path in alternative embodiments. The coolant channel302extends between an inlet332at the supply side310and an outlet334at the return side312. The supply tube306defines the inlet332and the return tube308defines the outlet334. In an exemplary embodiment, the coolant tube305includes a first bend336between the supply tube306and the transition tube307and a second bend338between the transition tube307and the return tube308. The coolant flow directions through the supply tube306and the return tube308are parallel to the power cables118and straight into/out of the supply and return lines132,134. The coolant flow direction through the inlet332and/or the outlet334are parallel to the power cables118(for example, straight flow path to/from the coolant supply line132and the coolant return line134). The coolant flow direction through the transition tube307is generally perpendicular to the flow through the supply and return tubes306,308.

In an exemplary embodiment, the heat exchanger300includes a supply fitting340coupled to an end342of the supply tube306. The supply fitting340may be separate and discrete from the supply tube306and coupled thereto. For example, the supply fitting340may be threadably coupled to the supply tube306. In various embodiments, the end342of the supply tube306may be formed, such as being hydroformed, to include threads (for example, internal threads) for receiving the supply fitting340. The supply fitting340may be coupled by other processes in alternative embodiments, such as being welded or brazed to the end of the supply tube306. A fluid seal (not shown) may be provided at the interface between the supply tube306and the supply fitting340. In an exemplary embodiment, the heat exchanger300includes a supply tube seal344proximate to the end342of the supply tube306. The supply tube seal344may be positioned between locating features346of the supply tube306. The locating features346may be formed, such as by the hydroforming process. The supply tube seal344is configured to be sealed against the adapter body133of the cooling adapter131.

In an exemplary embodiment, the supply fitting340includes a securing feature348for securing the coolant supply line132to the supply fitting340. For example, the securing feature348may include a latch or flange forming a circumferential groove around the supply fitting340. The groove is configured to receive a securing feature of the coolant supply line132to secure the coolant supply line132to the supply fitting340. In an exemplary embodiment, the coolant supply line132includes a supply line fitting350coupled to the supply fitting340. The supply line fitting350may be snappably coupled to the supply fitting340. For example. the supply line fitting350may include a securing feature352configured to be coupled to the securing feature348of the supply fitting340. The securing feature352may include one or more latches configured to be received in the circumferential groove around the supply fitting340. Other types of securing features may be provided in alternative embodiments. For example, the fittings340,350may be quick couplers. The fittings340,350may be threadably coupled in alternative embodiments.

In an exemplary embodiment, the heat exchanger300includes a return fitting360coupled to an end362of the return tube308. The return fitting360may be separate and discrete from the return tube308and coupled thereto. For example, the return fitting360may be threadably coupled to the return tube308. In various embodiments, the end362of the return tube308may be formed, such as being hydroformed, to include threads (for example, internal threads) for receiving the return fitting360. The return fitting360may be coupled by other processes in alternative embodiments, such as being welded or brazed to the end of the return tube308. A fluid seal (not shown) may be provided at the interface between the return tube308and the return fitting360. In an exemplary embodiment, the heat exchanger300includes a return tube seal364proximate to the end362of the return tube308. The return tube seal364may be positioned between locating features366of the return tube308. The locating features366may be formed, such as by the hydroforming process. The return tube seal364is configured to be sealed against the adapter body133of the cooling adapter131.

In an exemplary embodiment, the return fitting360includes a securing feature368for securing the coolant return line134to the return fitting360. For example, the securing feature368may include a latch or flange forming a circumferential groove around the return fitting360. The groove is configured to receive a securing feature of the coolant return line134to secure the coolant return line134to the return fitting360. In an exemplary embodiment, the coolant return line134includes a return line fitting370coupled to the return fitting360. The return line fitting370may be snappably coupled to the return fitting360. For example. the return line fitting370may include a securing feature372configured to be coupled to the securing feature368of the return fitting360. The securing feature372may include one or more latches configured to be received in the circumferential groove around the return fitting360. Other types of securing features may be provided in alternative embodiments. For example, the fittings360,370may be quick couplers. The fittings360,370may be threadably coupled in alternative embodiments.

FIG. 9is a partial sectional view of a portion of the cooling system130in accordance with an exemplary embodiment showing the supply fitting340coupled to the end342of the supply tube306. In the illustrated embodiment, the supply tube306is hydroformed to include threads354at the end342. A fluid seal356is provided at the end342. The supply fitting340engages the fluid seal356and the supply tube306to seal the interface between the supply fitting340and the supply tube306. In an exemplary embodiment, the supply tube seal344is positioned between the locating features346of the supply tube306and sealed against the adapter body133of the cooling adapter131.

FIG. 10is a partial sectional view of a portion of the cooling system130in accordance with an exemplary embodiment showing the supply fitting340coupled to the end342of the supply tube306. In an exemplary embodiment, the supply tube306includes a ferrule358at the end342. The ferrule358may be a machined part having the threads354along the interior of the ferrule358. The supply fitting340is configured to be threadably coupled to the ferrule358at the end342of the supply tube306. The ferrule358may be coupled to the main portion of the supply tube, such as being welded or brazed at a joint.

FIG. 11is a rear perspective view of a portion of the charging inlet assembly100in accordance with an exemplary embodiment.FIG. 12is another rear perspective view of a portion of the charging inlet assembly100in accordance with an exemplary embodiment.FIGS. 11 and 12illustrate the pair of power cables118terminated to the pair of terminals114.FIGS. 11 and 12illustrate a portion of the cooling system130showing the heat exchanger300thermally coupled to the terminals114.

The heat exchanger300is coupled to the coolant supply line132and the coolant return line134(both shown inFIG. 11). The heat exchanger body304is thermally coupled to the terminals114(such as through the power cables118) and the coolant tube305extends from the heat exchanger body304to the coolant supply and return lines132,134. For example, the transition tube307extends transversely across both power cables118and the supply and return tubes306,308are bent (for example, right angle bends) such that the supply and return tubes306,308extend parallel to the power cables118. The coolant supply and return lines132,134are coupled to the supply and return tubes306,308and continue to extend parallel to the power cables118. The power cables118may be bundled with the coolant supply and return lines132,134and routed together to another location in the vehicle, such as to the battery assembly. With additional reference toFIG. 2, in an exemplary embodiment, the supply tube306passes through the supply port138such that the supply fitting340is provided exterior of the adapter body133. The supply line fitting350is coupled to the supply fitting340from outside of the adapter body133. In an exemplary embodiment, the return tube308passes through the return port139such that the return fitting360is provided exterior of the adapter body133. The return line fitting370is coupled to the return fitting360from outside of the adapter body133.

FIG. 13is a cross sectional view of the cooling system130in accordance with an exemplary embodiment showing the heat exchanger300thermally coupled to the terminal114. The power cable118passes through the cable exit137. In an exemplary embodiment, an environmental seal141is provided at the cable exit137to seal the power cable118. The environmental seal141is sealed against the adapter body133.

The heat exchanger300is used to lower the temperature of the terminal114by dissipating heat from the terminal114, such as through the power cable118. For example, the heat exchanger300is thermally coupled to the power cable118, which is in turn thermally coupled to the terminal114. As such, dissipating heat from the power cable118reduces the operating temperature of the terminal114during charging. In alternative embodiments, the heat exchanger300may be directly thermally coupled to the terminal114to reduce the operating temperature of the terminal114.

In an exemplary embodiment, the pocket324receives the power cable118such that the heat exchanger body304is thermally coupled to the power cable118. The heat exchanger lid320holds the power cable118tightly in the pocket324and presses the power cable118against the heat exchanger body304. The coolant tube305passes liquid coolant through the heat exchanger300to dissipate heat away from the heat exchanger body304, and thus reduce the temperature of the power cable118and the terminal114.

In an exemplary embodiment, the heat exchanger300includes a thermally conductive separator390between the heat exchanger body304and the power cable118. In various embodiments, the thermally conductive separator390may be applied to the surface of the pocket324and/or the heat exchanger lid320. In various embodiments, the thermally conductive separator390may additionally or alternatively be applied to the power cable118or the terminal114. The thermally conductive separator390may be a thermal gasket. The thermally conductive separator390may be a silicone tape or film coupled to the terminal114. In various embodiments, the thermally conductive separator390may be an overmolded thin layer on the outer surface382. The thermally conductive separator390may be manufactured from a material that is electrically insulative and highly thermally conductive. The thermally conductive separator390may be a thermally conductive epoxy, a thermoplastic material or a thermoset material. The thermally conductive separator390may be manufactured from beryllium oxide, aluminum oxide, aluminum nitride, boron nitride, silicone, ceramic, Kapton, nylon, polyester, and the like. The thermally conductive separator390may be a pre-formed structure, such as a film, a pad, a sheet, a tube, an injection molded piece, and the like. In other various embodiments, the thermally conductive separator390may be applied in situ, such as an overmolded body, a grease or a paste applied to the heat exchanger body304or the power cable118or the terminal114. In various embodiments, the thermally conductive separator390may be a heat shrink tube applied to the terminal114. The thermally conductive separator390may be manufactured from a doped polymer material, such as a plastic material having thermally conductive materials added to the plastic material to increase the thermal conductivity. Other types of thermally conductive, electrically isolating material may be used in alternative embodiments. In various embodiments, the thermally conductive separator390extends for a length of the power cable118beyond the heat exchanger body304to provide increased creep distance between the power cable118and the heat exchanger body304. The thermally conductive separator390may provide double electrical isolation layers between the power cable118and the heat exchanger body304.