HEAT EXCHANGER FOR A CHARGING INLET ASSEMBLY
A DC charging module for a charging inlet assembly includes a module housing extending between a front and a rear. The module housing has an inner chamber between the front and the rear. The DC charging module includes a terminal having a mating pin at a front of the terminal and a cable connector at a rear of the terminal. The cable connector is located in the inner chamber of the module housing. The mating pin extends forward of the module housing into the charging inlet assembly for mating with a charging connector coupled to the charging inlet assembly. The DC charging module includes a power cable extending into the inner chamber of the module housing to electrically connect to the cable connector of the terminal. The DC charging module includes a heat exchanger received in the inner chamber of the module housing. The heat exchanger is thermally coupled to the cable connector of the terminal. The heat exchanger includes a coolant channel for coolant flow through the heat exchanger for actively cooling the terminal.
1 . A DC charging module for a charging inlet assembly, the DC charging module comprising:
a module housing extending between a front and a rear, the module housing having an inner chamber between the front and the rear;
a terminal including a mating pin at a front of the terminal and a cable connector at a rear of the terminal, the cable connector being located in the inner chamber of the module housing, the mating pin extending forward of the module housing into the charging inlet assembly for mating with a charging connector coupled to the charging inlet assembly;
a power cable extending into the inner chamber of the module housing to electrically connect to the cable connector of the terminal; and
a heat exchanger received in the inner chamber of the module housing, the heat exchanger being thermally coupled to an end of the power cable in the inner chamber, the heat exchanger being thermally coupled to the cable connector of the terminal, the heat exchanger including a coolant channel for coolant flow through the heat exchanger for actively cooling the terminal and the power cable.
2 . The DC charging module of claim 1 , wherein the module housing includes a separable mating interface at the front of the module housing, the separable mating interface configured to be removably coupled to the charging inlet assembly.
3 . The DC charging module of claim 1 , wherein the heat exchanger includes a thermal interface thermally coupled to the cable connector to dissipate heat from the terminal.
4 . The DC charging module of claim 1 , wherein the heat exchanger includes a heat exchanger body and a thermally conductive separator between the heat exchanger body and the cable connector, the thermally conductive separator electrically isolating exchanger body from the cable connector.
5 . The DC charging module of claim 1 , wherein the heat exchanger includes a heat exchanger body defining the coolant channel, the heat exchanger including a supply port coupled to a coolant supply line and a return port coupled to a coolant return line.
6 . The DC charging module of claim 1 , wherein the heat exchanger includes a heat exchanger seal sealingly coupled to the module housing.
7 . The DC charging module of claim 1 , wherein the heat exchanger extends between a supply side and a return side, the coolant channel being in flow communication with the supply side and the return side.
8 . The DC charging module of claim 1 , wherein the heat exchanger includes a divider wall extending into the coolant channel, the coolant flowing along the divider wall between a supply port and a return port.
9 . The DC charging module of claim 1 , wherein heat exchanger is generally box shaped defined by a planar sides, the heat exchanger including a thermal interface thermally coupled to the cable connector at the side having the largest surface area.
10 . The DC charging module of claim 1 , wherein the power cable includes a weld pad, the weld pad being coupled to the cable connector, the heat exchanger being thermally coupled to the weld pad.
11 . The DC charging module of claim 1 , further comprising a second terminal including a second mating pin and a second cable connector terminated to a second power cable the heat exchanger being thermally coupled to the second cable connector of the second terminal.
12 . The DC charging module of claim 1 , further comprising fasteners coupled to the module housing, the fasteners configured to be removably coupled to the charging inlet assembly.
13 . The DC charging module of claim 1 , wherein the terminal is removable from the charging inlet assembly with the module housing.
14 . The DC charging module of claim 1 , wherein the power cable includes a cable seal, the cable seal being sealingly coupled to the module housing.
15 . A DC charging module for a charging inlet assembly, the DC charging module comprising:
a module housing extending between a front and a rear, the module housing having an inner chamber between the front and the rear;
a terminal including a mating pin at a front of the terminal and a cable connector at a rear of the terminal, the cable connector being located in the inner chamber of the module housing, the mating pin extending forward of the module housing into the charging inlet assembly for mating with a charging connector coupled to the charging inlet assembly;
a power cable extending into the inner chamber of the module housing to electrically connect to the cable connector of the terminal;
a heat exchanger received in the inner chamber of the module housing, the heat exchanger being thermally coupled to the cable connector of the terminal, the heat exchanger including a coolant channel for coolant flow through the heat exchanger for actively cooling the terminal;
a housing seal sealed between the heat exchanger and the module housing; and
a cable seal sealed between the heat exchanger and the power cable.
16 . The DC charging module of claim 15 , wherein the heat exchanger is thermally coupled to the power cable.
17 . The DC charging module of claim 15 , wherein the power cable includes a weld pad, the weld pad being coupled to the cable connector, the heat exchanger being thermally coupled to the weld pad.
18 . The DC charging module of claim 15 , wherein the module housing includes a separable mating interface at the front of the module housing, the separable mating interface configured to be removably coupled to the charging inlet assembly.
19 . The DC charging module of claim 15 , wherein the heat exchanger includes a thermal interface thermally coupled to the cable connector to dissipate heat from the terminal.
20 . The DC charging module of claim 15 , wherein the heat exchanger includes a heat exchanger body and a thermally conductive separator between the heat exchanger body and the cable connector, the thermally conductive separator electrically isolating exchanger body from the cable connector.