Braided Copper Mesh Cooling in EV Charging Cables
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Solution Overview
Problem
Charging devices, particularly those for electric vehicles, often overheat during the charging process, posing a safety risk due to overheating of the cable and its connection end.
Innovation Solution
A liquid cooled cable system comprising a braided copper mesh within insulating tubes, a filler, and a sheath, with a cooling module and liquid return channels in the charging station and gun connector, allowing for efficient heat dissipation through the flow of a coolant.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional charging cables are used without liquid cooling, then the charging device structure is simple and easy to manufacture, but the cable and connection end overheat during charging process
Solution Approach 1:
The patent combines the electrical conductor (braided copper mesh) with the cooling channel into a single integrated structure. The braided copper mesh serves dual functions: electrical conduction and forming the wall of the liquid cooling channel, eliminating the need for separate cooling tubes and reducing structural complexity despite the advanced cooling capability
Solution Approach 2:
The braided copper mesh is designed to perform multiple functions simultaneously: it acts as the electrical conductor for power transmission, provides structural support for the cable, and forms the cooling channel wall that contacts the coolant. This multi-functionality reduces the number of separate components needed
2Temperature
If the braided copper mesh is used as both conductor and cooling channel wall, then cooling efficiency is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent changes the physical state and arrangement of the copper material from solid rods to a braided mesh structure. This parameter change allows the formation of continuous cooling channels within the braid structure itself, achieving precise channel geometry through the braiding process rather than requiring separate tube installation
Solution Approach 2:
The patent uses a composite structure where the braided copper mesh is combined with insulating materials (such as PTFE or other electrical insulators) to create a multi-layered cable construction. The insulating layer is positioned between the copper braid and the coolant, preventing electrical short circuits while maintaining thermal contact for efficient cooling
3Loss of energy
If liquid cooling system is added to charging cable, then heat dissipation efficiency is improved, but device complexity and number of components increase
Solution Approach 1:
The patent merges the cooling channel with the conductor structure by using the braided copper mesh itself as the channel wall. This integration eliminates separate cooling tubes, seals, and mounting hardware, significantly reducing the number of components while maintaining effective liquid cooling
Solution Approach 2:
The patent employs liquid coolant flow through the braided copper mesh structure to achieve heat dissipation. The hydraulic system uses the natural flow of coolant through the channels formed by the braid, utilizing fluid dynamics to efficiently remove heat from the cable and connection ends without requiring complex pumping or pressure control systems
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Effectively mitigates overheating issues in charging devices by ensuring the braided copper mesh is fully contacted by the coolant, providing enhanced cooling and safety during the charging process.
Implementation Method 1
The second channel is located in the braided copper mesh... the first liquid return channel communicates to the first channel and the second channel... The liquid inlet is connected to the station end of the liquid cooled cable and communicates to the first channel
Implementation Method 2
A liquid cooled cable system comprising a braided copper mesh within insulating tubes, a filler, and a sheath, with a cooling module and liquid return channels in the charging station and gun connector, allowing for efficient heat dissipation through the flow of a coolant
Data Source
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AI summary
A charging device includes a liquid cooled cable (100), a charging gun (200), a charging station (300), a station connector (400) and a communicating pipe (500). The liquid cooled cable (100) has a gun end (110) and a station end (120). The liquid cooled cable (100) includes a first insulating tube (130), a second insulating tube (140), a tape, a filler and a sheath. The first insulating tube (130) has a first channel (130a). The second insulating tube (140) has a second channel (140a) and a braided copper mesh (141). The charging gun (200) is connected to the gun end (110) of the liquid cooled cable (100). The charging gun (200) includes a gun connector (210) and a first liquid return channel. The station connector (400) includes a second liquid return channel and a connection part (420). One end of the second liquid return channel communicates to the second channel (140a). The connection part (420) is connected to the station end (120) of the liquid cooled cable (100).