Motor Vehicle Charging Cable With Localized Conductor Clamping

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Solution Overview

Problem

Motor vehicle charging cables face challenges with heat dissipation and handling due to increasing electrical charging powers, resulting in stiffness and large bending radii, making them difficult to manage effectively.

Innovation Solution

A cooling-fluid-cooled motor vehicle charging cable design featuring shaped elements and clamping elements that restrict relative movement between conductors and the cable sheath only at fixed positions, eliminating the need for filling materials and allowing for flexible handling while maintaining effective heat dissipation through dual cooling fluid channels.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If filling material is used to restrict relative movement between conductors and cable sheath, then conductor stability is improved, but cable flexibility and ease of handling deteriorate

Engineering Contradiction:

Improveconductor stabilityVSAvoidcable flexibility

Core Design Contradiction:

Stability of the object's compositionVSEase of operation

Solution Approach 1:

The cable is divided into multiple sections: flexible sections without shaped elements that allow bending and movement, and fixed sections with shaped elements that provide conductor stability. This segmentation allows different parts of the cable to have different mechanical properties, resolving the contradiction between overall flexibility and local stability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Shaped elements are applied locally only at fixed positions (mounting points) rather than throughout the entire cable. This local application provides conductor restriction only where needed for stability, while leaving the rest of the cable flexible and easy to handle.

Inventive Principle:

Principle #3Local quality

2Temperature

If cable diameter is increased to improve heat dissipation capacity, then heat dissipation efficiency is improved, but handling ease deteriorates due to increased stiffness and bending radius

Engineering Contradiction:

Improveheat dissipation efficiencyVSAvoidhandling ease

Core Design Contradiction:

TemperatureVSEase of operation

Solution Approach 1:

A cooling fluid channel is introduced into the cable structure, allowing coolant to flow through and carry heat away from the conductors. This hydraulic cooling system enables effective heat dissipation without requiring an excessively large cable diameter, thereby maintaining flexibility and ease of handling.

Inventive Principle:

Principle #29Pneumatics and hydraulics

3Stability of the object's composition

If shaped elements are added to restrict conductor movement, then conductor positioning stability is improved, but device complexity increases

Engineering Contradiction:

Improveconductor positioning stabilityVSAvoidcable structure complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

Shaped elements are implemented only at specific fixed positions (mounting points) rather than throughout the entire cable length. This localized approach provides necessary conductor positioning stability at critical points while minimizing the overall structural complexity of the cable.

Inventive Principle:

Principle #3Local quality

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 design enhances flexibility and ease of handling while ensuring efficient heat dissipation from the electrical conductors, addressing the stiffness and handling issues associated with high-power charging cables.

Implementation Method 1

a cooling fluid channel is formed between the insulation layer and the conductor cores of the respective electrical conductor, and a cooling fluid for cooling the respective electrical conductor can be guided in the cooling fluid channel

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS11220188B2Motor vehicle charging cable

Publication Date: 2022.01.11 DR ING H C F PORSCHE AG

AI summary

A motor vehicle charging cable for DC voltage charging of an electrical energy store of a motor vehicle has a cable sheath that encloses conductors, such as first and second cooling-fluid-cooled electrical conductor for first and second DC voltage phases, a ground conductor or equipotential bonding conductor and/or at least one control conductor. Shaped elements are arranged between the cable sheath and the conductors at positions of the motor vehicle charging cable that are fixed in mounts. The shaped elements guide, clamp and restrict a relative movement between the conductors. The cable sheath restricts a relative movement between the conductors between those positions at which the motor vehicle charging cable is fixed in mounts.