Liquid cooled metallic inductive probe for high power charging

Abstract

An inductive charging coupler for use in inductive charging apparatus for charging a battery. The charging coupler is insertable into a charge port that is coupled to the battery. The charge port comprises a housing, an opening into which the charging coupler is inserted, and a secondary core surrounded by secondary windings. The charging coupler comprises a housing, a primary core, a primary winding having an even number of primary turns disposed around the core, and a hollow coolant conducting heat exchanger symmetrically disposed between the primary turns of the primary winding. The heat exchanger is typically them tally bonded to the primary turns of the primary winding by means of heat conducting adhesive or epoxy. The coolant flow passages of the heat exchanger may be configured in several ways. One approach is to construct thin, flat, self-contained flexible bladders made of metal, such as copper. Adjacent turns of the primary winding are bonded directly to the heat exchanger in order to provide good thermal contact, a large heat transfer area, and a very thin profile. Inlet and outlet coolant passages transition from a very thin rectangular cross sectional shape under the turns to a round tube shape, for attachment to a coolant lines within a flexible hose. The metallic heat exchanger is located at the center of a magnetic field created by the windings, which produces no extra loss in the heat exchanger due to induced eddy currents. The present invention is specifically designed for rapid, high rate charging of electric vehicle batteries.