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1. WO2019180622 - LIQUID-COOLED CHARGING CONNECTOR

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CLAIMS

WHAT IS CLAIMED IS:

1. A charging connector comprising:

a first electrical socket and a second electrical socket;

a first sleeve that is concentrically coupled to the first electrical socket and a second sleeve that is concentrically coupled to the second electrical socket;

a manifold assembly enclosing the first and second electrical sockets and the first and second sleeves, such that the first and second sleeves and the manifold assembly create a hollow interior space there between; and

an inlet conduit and an outlet conduit within the manifold assembly such that the inlet conduit, the hollow interior space, and the outlet conduit together create a fluid flow path.

2. The charging connector of claim 1, wherein a cooling fluid flows through the fluid flow path for cooling the charging connector.

3. The charging connector of claim 2, wherein the cooling fluid bifurcates into a first fluid stream which flows around the first sleeve, and a second fluid stream which flows around the second sleeve.

4. The charging connector of claim 3, wherein the first fluid stream and the second fluid stream combine together upstream of a fluid outlet.

5. The charging connector of claim 1, wherein the first sleeve partially encloses the first electrical socket, and the second sleeve partially encloses the second electrical socket.

6. The charging connector of claim 1, wherein the first and second sleeves comprise a thermally conducting plastic material.

7. The charging connector of claim 1, wherein the first and second sleeves are coupled to the first and second electrical sockets by one or more of an overmolding process, or a press-fit assembly.

8. The charging connector of claim 1, further comprising a two part Printed Circuit Board Assembly (PCBA) coupled to the charging connector.

9. The charging connector of claim 1, further comprising a first pair of O-rings provided between the first sleeve and the manifold assembly, and a second pair of O-rings provided between the second sleeve and the manifold assembly.

10. A charging system for an electric vehicle, the charging system comprising:

a power supply;

a charging cable having a first end and a second end, wherein the first end of the charging cable is coupled to the power supply;

a charging connector coupled to the charging cable at the second end, wherein the charging connector has a form factor corresponding to a charging inlet of the electric vehicle, the charging connector including:

a first electrical socket and a second electrical socket;

a first sleeve and a second sleeve, such that the first sleeve is concentrically coupled to the first electrical socket and the second sleeve is concentrically coupled to the second electrical socket;

a manifold assembly adapted to enclose the first and second electrical sockets and the first and second sleeves, such that the first and second sleeves and the manifold assembly create a hollow interior space there between; and

an inlet conduit and an outlet conduit defined within the manifold assembly such that the inlet conduit, the hollow interior space, and the outlet conduit together create a fluid flow path.

11. The charging system of claim 10, wherein a cooling fluid flows through the fluid flow path for cooling the charging connector.

12. The charging system of claim 11, wherein the cooling fluid bifurcates in a first fluid stream which flows around the first sleeve, and a second fluid stream which flows around the second sleeve.

13. The charging system of claim 12, wherein the first fluid stream and the second fluid stream combine together upstream of a fluid outlet.

14. The charging system of claim 10, wherein the first sleeve partially encloses the first electrical socket, and the second sleeve partially encloses the second electrical socket.

15. The charging system of claim 10, wherein the first and second sleeves comprises a thermally conducting plastic material.

16. The charging system of claim 10, wherein the first and second sleeves are coupled to the first and second electrical sockets by one or more of an overmolding process, or a press-fit assembly.

17. The charging system of claim 10, further comprising a two part Printed Circuit Board Assembly (PCBA) coupled to the charging connector.

18. The charging system of claim 10, further comprising a first pair of O-rings provided between the first sleeve and the manifold assembly, and a second pair of O-rings provided between the second sleeve and the manifold assembly.

19. A handle assembly for a charging connector of an electric vehicle, the handle assembly comprising:

a charging cable having a first end and a second end, wherein the first end of the charging cable is coupled to a power supply;

a charging connector coupled to the charging cable at the second end, wherein the charging connector has a form factor corresponding to a charging inlet of the electric vehicle, the charging connector including:

a first electrical socket and a second electrical socket;

a first sleeve and a second sleeve, such that the first sleeve is concentrically coupled to the first electrical socket and the second sleeve is concentrically coupled to the second electrical socket;

a manifold assembly that encloses the first and second electrical sockets and the first and second sleeves, such that the first and second sleeves and the manifold assembly create a hollow interior space there between; and

an inlet conduit and an outlet conduit defined within the manifold assembly such that the inlet conduit, the hollow interior space, and the outlet conduit together create a fluid flow path; and

a handle housing partially enclosing the charging connector, and at least partially enclosing the charging cable such that the charging cable extends outwards from one end of the handle housing, and the first and second electrical sockets extends outwards from another end of the handle housing.

20. The handle assembly of claim 19, wherein the first and second sleeves comprise a thermally conducting plastic material.