Hughes Electronics Corporation

Delco Electronics Corporation

Juventino Rosas

George R Woody

Sergio Ramos

Victor O Asbury

Eddie Yeow

Clint Conrady

An oil cooled inductive coupler for use with an inductive charging system that charges propulsion batteries of an electric vehicle. The coupler is connected to a power source by way of a coaxial cable that has power conductors for coupling power to the coupler, and cooling channels for coupling high dielectric strength cooling fluid to and from the coupler. The coupler has a housing with a flood box formed therein having an open interior that forms a conductor termination area. The cooling channels are coupled to the flood box, and the power conductors are terminated in the termination area and are exposed to the cooling fluid that is pumped therethrough to cool them. A heat exchanger having a fluid flow path therethrough is coupled to the flood box and permits the cooling fluid to circulate therethrough. A primary winding is secured or bonded to the heat exchanger, a magnetic puck is disposed in an opening in the heat exchanger, and upper and lower primary winding covers enclose the heat exchanger. The cooling fluid is pumped through the coaxial cable, the flood box and the heat exchanger to cool the primary winding, the magnetic puck, and the power conductors, to permit high power levels to be transferred between the power source and the propulsion batteries of the electric vehicle.

Oil cooled high power inductive coupler

A charging system employing a liquid-cooled transmission cable for transferring power. The transmission cable has a central tube with an extruded member disposed therewithin for carrying coolant. A plurality of layers of coaxial tubular wire braid are disposed around the central tube that carry charging current and that are separated by a layers of dielectric material. An outer layer of wire braid is disposed around an outermost layer of dielectric material that is used for grounding and/or shielding. An outer jacket is disposed around the outer layer of wire braid for encasing the transmission cable. The extruded member may comprise a thermoplastic rubber extrusion, for example. The coolant path through the transmission cable is internally supported by means of the extruded member to assure uniform flexibility, maintain tangential magnetic flux, and eliminate kinking and collapse of the flow path. The transmission cable is designed for charging propulsion batteries of an electric vehicle at extremely high charge rates. The charging system includes an external power source and off-vehicle inverter for providing charging current to the propulsion batteries by way of a charge port and a rectification/filter circuit in the electric vehicle. The transmission cable is coupled between the charge port and the rectification/filter circuit. A cooling system is coupled to the transmission cable that has a radiator for cooling coolant, a manifold, a pump that pumps the coolant, and a reservoir for storing excess coolant. The coolant is pumped from the cooling system through the transmission cable to cool it. The transmission cable 20 is capable of transferring 120 kW @334 Amps RMS @75 KHz.

High power, high frequency, liquid-cooled transmission cable and

Growing community of inventors

Los Angeles, CA, United States of America

Juventino Rosas