Oil cooled high power inductive coupler

A high power fluid cooled inductive charging coupler for use with inductive charging apparatus comprising a power source and a charge port disposed in an electric vehicle that is coupled to propulsion batteries thereof, and wherein the coupler is insertable into the charge port to couple power from the power source to charge the batteries of the electric vehicle, said coupler comprising:

• a coaxial cable coupled between the power source and the coupler that comprises power conductors for coupling power to the coupler, and inlet and outlet cooling channels for coupling high dielectric strength cooling fluid to and from the coupler;
• a housing;
• a flood box disposed within the housing and having an open interior that forms a conductor termination area, and wherein the inlet cooling channel is coupled to the flood box to deliver fluid thereto, and wherein the power conductors of the coaxial cable are terminated in the termination area and are exposed to cooling fluid that is pumped therethrough;
• a heat exchanger having a fluid inlet channel coupled to the flood box to receive cooling fluid therefrom, and an outlet channel coupled to the outlet cooling channel of said coaxial cable to return cooling fluid to said power source;
• a primary winding electrically coupled to the power conductors in the termination area of said flood box, and thermally coupled to the heat exchanger;
• and
• a magnetic puck disposed in an opening in the heat exchanger;
• and wherein the cooling fluid is pumped through the inlet and outlet channels of the coaxial cable, the flood box and the inlet and outlet channels of the heat exchanger to cool the primary winding, the puck, the power conductor terminations, and the power conductors to permit high power levels to be transferred between the power source and the propulsion batteries of the electric vehicle.