Charging Cable Cooling Tube for Thermal Management
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Solution Overview
Problem
High power transfer levels in electric vehicle charging systems lead to increased temperatures, potentially damaging components and requiring reduced power transfer to prevent overheating, thereby increasing charging duration.
Innovation Solution
A charging system incorporating a power cable with a conductive core, insulating layer, and metallic shield layer, along with a cooling tube connected to a heat sink that engages the metallic shield layer to dissipate heat effectively, allowing for high power transfer over sustained periods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high power transfer levels are used to reduce charging duration, then charging speed is improved, but temperature of charging system components increases causing damage and requiring power reduction
Solution Approach 1:
A cooling tube is introduced as an intermediary component between the power cable and the environment. The cooling tube engages with the metallic shield layer of the power cable and transfers heat from the cable to the cooling tube, which then dissipates heat to the surrounding air, acting as a thermal mediator that protects the cable from overheating while allowing high current flow
Solution Approach 2:
The harmful thermal energy is extracted from the power cable system by the cooling tube. The cooling tube selectively removes excess heat from the metallic shield layer and conductive core, separating the thermal management function from the electrical conduction function, allowing the cable to operate at high power without accumulating damaging temperatures
2Loss of time
If high current is transferred to reduce charging time, then charging duration is reduced, but components may become deformed and damaged due to high temperatures
Solution Approach 1:
The cooling tube is positioned in advance along the power cable path to provide preemptive thermal protection. By engaging with the metallic shield layer before excessive heat accumulation occurs, the cooling tube prevents thermal deformation and damage to the conductive core and insulating layer, cushioning the system against thermal stress during high-current charging operations
3Productivity
If power transfer level is increased to shorten charging duration, then charging efficiency is improved, but controller may detect excessive temperature and decrease power transfer level
Solution Approach 1:
The cooling tube provides continuous passive feedback by actively transferring heat from the power cable to the environment throughout the charging process. This real-time thermal regulation prevents the controller from detecting excessive temperatures that would trigger power reduction, enabling sustained high power transfer by continuously balancing thermal accumulation with dissipation
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
Enables efficient thermal management, allowing for higher current power transfer without component damage, reducing charging duration and enabling the use of smaller, cheaper components.
Implementation Method 1
The cooling tube engages the metallic shield layer of the power cable to transfer heat from the power cable to the heat sink
Implementation Method 2
The cooling tube is connected to a heat sink and extends along a length of the power cable
Data Source
Figure 1
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AI summary
A charging system (100) includes a power cable (108) and a cooling tube (110). The power cable extends from a charging inlet (102) to a battery pack (104) to electrically connect the charging inlet to the battery pack. The charging inlet is configured to releasably couple to a mating connector (212) of an external power source. The power cable includes a conductive core (450), an insulating layer (452) surrounding the conductive core, and a metallic shield layer (330) surrounding the insulating layer. The cooling tube is connected to a heat sink (106) and extends along a length of the power cable. The cooling tube engages the metallic shield layer of the power cable to transfer heat from the power cable to the heat sink.