Charging Cable Cooling Channels for Stable Flow and Even Heat Removal
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Solution Overview
Problem
Conventional charging cable cooling systems experience flow instability, pressure drop, and uneven cooling due to the pumping of a constant volume of cooling fluid, leading to inefficiencies in temperature management, especially during different charging modes.
Innovation Solution
A charging cable cooling system utilizing channels, a fluid annulus, and spiral pathways to direct cooling fluid, combined with a pump, valve, and controller to manage fluid flow and temperature, ensuring even distribution and reduced pressure drop.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a constant volume of cooling fluid is pumped through the charging cable, then cooling is provided, but flow instability occurs due to vapor creation
Solution Approach 1:
The charging cable is divided into multiple cooling channels (first cooling channel, second cooling channel, third cooling channel) that segment the cooling fluid flow path. This segmentation allows vapor to be directed to specific channels while maintaining stable flow in others, resolving the contradiction between providing cooling and maintaining flow stability.
Solution Approach 2:
A vapor venting channel is introduced as an intermediary pathway that collects and redirects vapor away from the main cooling channels. This mediator prevents vapor from disrupting the cooling fluid flow, maintaining both cooling effectiveness and flow stability simultaneously.
2Temperature
If cooling fluid is pumped along the conductor core, then cooling is achieved, but pressure drop increases along the cable length
Solution Approach 1:
The cooling system transitions from a single linear cooling path to a multi-dimensional network of cooling channels arranged in different orientations and positions around the conductor core. This dimensional expansion creates multiple parallel flow paths, reducing the pressure drop along any single path while maintaining overall cooling effectiveness.
3Temperature
If cooling fluid is pumped through the charging cable, then cooling is provided, but uneven cooling occurs along the cable surface
Solution Approach 1:
Different cooling channels are positioned at different locations around the conductor core with optimized geometries tailored to local heat generation patterns. The first, second, and third cooling channels are strategically arranged to provide targeted cooling to specific regions, ensuring uniform temperature distribution across the entire cable surface.
Solution Approach 2:
The cooling system is segmented into multiple independent channels that can be optimized for different regions of the cable. This segmentation allows each channel to be designed with specific characteristics (dimensions, orientation, positioning) that address local cooling requirements, achieving uniform overall temperature distribution.
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 achieves more stable fluid flow, reduced pressure drop, and uniform temperature distribution along the cable, enhancing efficiency in both slow and fast charging modes.
Implementation Method 1
a wick, and an outer cover. Channels or spiral pathways may be coupled to the wick which surrounds the conductor core
Implementation Method 2
Cooling fluid may be pumped by a pump through the channels, spiral pathways, and/or space
Implementation Method 3
The cooling fluid may be cooled by a heat exchanger
Data Source
AI summary
The present disclosure is directed to systems and methods for cooling an electric charging cable. The system includes a conductor core, a wick placed around an exterior of the conductor core, an outer cover surrounding the wick, wherein the outer cover comprises an inner surface, and wherein a space is formed between the wick and the inner surface of the outer cover, and one or more channels disposed within the space between the wick and the inner surface of the outer cover and coupled to the wick, wherein the one or more channels includes an outer surface and wherein the outer surface of the one or more channels is placed a distance from the inner surface of the outer cover.