General Motors Eyes Innovative Cooling for EV Charge Ports with New Patent Filing

General Motors explores innovative methods to manage heat in electric vehicle (EV) charge ports, much like microchip cooling techniques. Their latest patent suggests they're developing cooling systems for cables used in rapid DC charging.

The US Patent and Trademark Office made public a patent application on April 25, 2024, which General Motors initially submitted on October 18, 2022. This application focuses on the innovation of employing phase change material to cool electric vehicle charging ports.

A phase change material (PCM) functions by taking in and discharging thermal energy during its transition from one state to another, which is the origin of its designation. Utilizing PCM for thermal management in computer heat sinks has been a longstanding practice, and its use is growing more prevalent in outdoor equipment.

Image showcasing General Motors' patented cooling system for PCM charging ports.

In the proposed charging system, Phase Change Material (PCM) would be situated close to the charging port and would transition from a solid to a liquid as it takes in heat generated by the electrical current passing through the port, thereby delivering a cooling impact, according to GM's submission. Should temperatures continue to increase past a set limit, an integrated controller would then reduce the charging power, the car manufacturer further explains.

The application explores an option involving a heat spreader and metallic foam for the setup, however, it's doubtful that the cooling of the PCM charge port would necessitate any moving components. Additionally, this method is probably much simpler compared to a liquid cooling system.

Illustration of General Motors' patented cooling system for electric vehicle charge

To date, attempts to reduce the temperature of devices to accelerate the rate of charging have been directed elsewhere. Last year, a team from Ford and Purdue University demonstrated a technique that utilizes a phase-change in the cooling process to aid in the rapid charging of electric vehicles. This, however, took place within a cable through the transition of coolant from a liquid to a gas, rather than within the charging port. Additionally, in certain electric vehicles, the system that regulates the temperature inside the vehicle also assists in maintaining a cool battery while it charges, yet this system has not been adapted for use in the charging port itself.

The accumulation of heat is a significant factor in electric vehicle manufacturers moving towards greater voltage systems. That's the rationale behind Porsche's decision to opt for 800-volt charging over the 400-volt for their Taycan model.

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