EV Charging Cable Cooling via Integrated AC Heat Exchange
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Solution Overview
Problem
Existing charging cables for electric vehicles lack specific cooling features, limiting their current carrying capacity and increasing battery charging time, and current cooling solutions are cumbersome and costly.
Innovation Solution
A cable cooling system incorporating a heat exchanger within the air conditioner coolant fluid circuit, using a phase-changing expansion refrigerant to efficiently cool the charging cable by circulating a non-dielectric cooling liquid through insulated compartments in the cable, which is then discharged into the air conditioner coolant fluid circuit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If no specific cooling features are integrated into the charging cable, then the cable structure remains simple and cost-effective, but the current carrying capacity is significantly limited and battery charging time increases
Solution Approach 1:
The patent merges the cable cooling function with the vehicle's existing air conditioning system by integrating a heat exchanger into the AC coolant circuit. This allows the charging cable to be cooled using the vehicle's refrigerant system, eliminating the need for a separate cooling system and reducing overall complexity while enabling high-current charging capability
Solution Approach 2:
The air conditioning coolant circuit is given a dual function: it continues to cool the vehicle cabin while simultaneously cooling the charging cable through the integrated heat exchanger. This multi-functionality approach allows one system to serve multiple purposes, improving charging speed without adding dedicated cooling infrastructure
2Reliability
If dedicated cooling systems are added to the charging cable, then current carrying capacity improves, but cost and system complexity increase
Solution Approach 1:
The system utilizes the vehicle's existing air conditioning system to provide cooling for the charging cable. The AC system's refrigerant circuit serves the dual purpose of cabin cooling and cable cooling, allowing the vehicle's own systems to support the charging function without requiring external or dedicated cooling infrastructure
Solution Approach 2:
The cable cooling heat exchanger is nested within the existing air conditioning coolant circuit. The AC system's refrigerant lines are routed through or alongside the charging cable, allowing heat transfer from the cable to the refrigerant flow without requiring a completely separate cooling loop
3Loss of time
If the cable is cooled efficiently to increase current carrying capacity, then charging time is reduced, but the system requires additional components and integration complexity
Solution Approach 1:
The cooling system is segmented into modular components: a heat exchanger unit integrated into the AC circuit, separate coolant flow paths for cable cooling, and distinct thermal management zones. This segmentation allows for easier manufacturing and assembly while maintaining efficient cooling performance
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
The system reduces complexity and cost while enhancing performance and reliability, allowing for efficient heat absorption and discharge, thus reducing charging time and improving cable efficiency.
Implementation Method 1
an air conditioning system operated with a coolant fluid circuit that is configured for absorbing heat by phase changing expansion
Implementation Method 2
a cable cooling liquid that is circulated in a closed circuit of the cable cooling heat exchanger for absorbing heat from the charging cable and discharging the heat to the air conditioner coolant fluid
Data Source
AI summary
The disclosure concerns a cable cooling system for cooling an embedded part of a battery charging cable of a battery-operated vehicle, the vehicle comprising an air conditioning system operated with a coolant fluid circuit that is configured for absorbing heat by phase changing expansion, such as a compressor operated air conditioning system. According to the disclosure, the cable cooling system comprises a cable cooling liquid that is circulated in a closed circuit for absorbing heat from the charging cable and discharging the heat toward the air conditioner coolant fluid, through a cable cooling heat exchanger that is incorporated within the air conditioner coolant fluid circuit so as to be cooled by the air conditioner coolant fluid circuit. Preferably, the cable cooling liquid is a non-dielectric liquid such as an ethylene-glycol solution, which enables a very efficient cooling with simple and standard components.