Dual-Flow Charging Cable Cooling for High-Power Heat Dissipation
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Solution Overview
Problem
Existing vehicle charging systems face challenges in effectively dissipating heat generated by cables, which can lead to inefficiencies and potential damage due to increased conductor size for higher current handling.
Innovation Solution
A vehicle charging system that employs a dual cooling flow path through inner and outer jackets, utilizing porous materials to maintain cable spacing and enhance heat exchange with a cooling fluid, which is cooled and circulated by a cooler unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If higher current is transmitted through the cable, then charging power is improved, but heat generation increases and conductor size must be enlarged
Solution Approach 1:
The patent converts the harmful heat generated by high-current cable conduction into a beneficial cooling process by introducing a cooling fluid flow path that circulates through the cable structure, absorbing heat and maintaining lower operating temperatures during high-power charging
Solution Approach 2:
The patent introduces a cooling fluid as an intermediary substance that mediates heat transfer from the cable conductors to the external environment, allowing high current transmission without direct thermal damage to the cable components
2Power
If conductor size is increased to accommodate higher current, then power transmission capability is improved, but cable volume and weight increase
Solution Approach 1:
The patent makes the cable structure multi-functional by integrating both electrical conduction and thermal management functions into a single unified structure, where the cable jacket serves as both mechanical protection and a cooling fluid passage, eliminating the need for separate cooling components
Solution Approach 2:
The patent embeds the cooling fluid flow path within the cable structure itself, nesting the thermal management system inside the electrical conductor assembly, allowing heat dissipation without increasing external cable dimensions
3Area of stationary object
If multiple cables are bundled together, then space utilization is improved, but heat dissipation becomes more difficult
Solution Approach 1:
The patent merges multiple cable cooling flow paths into a single integrated cooling system, where cooling fluid flows through all cables in sequence or parallel, efficiently removing heat from multiple conductors simultaneously while maintaining compact bundling
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
This solution effectively dissipates heat from the cables by utilizing a dual cooling flow path and porous materials to maintain optimal cable spacing, thereby improving the efficiency and reliability of the charging system.
Implementation Method 1
heat generated from a cable is transferred to a cooling fluid passing through a dual cooling flow path
Implementation Method 2
cooling fluid passing through one of the inner flow path and the outer flow path and then pass through the other of the inner flow path and the outer flow path, thereby effectively dissipating the heat
Implementation Method 3
a porous material disposed in at least one of the inner flow path or the outer flow path... effectively dissipating the heat of the cables through the cooling fluid
Data Source
AI summary
An embodiment may comprise: a plurality of cables; an inner jacket in which an inner flow path is formed, wherein the plurality of cables pass through the inner flow path; an outer jacket in which an outer flow path is formed and which surrounds the outer circumference of the inner jacket; a porous material disposed in at least one of the inner flow path or the outer flow path; and a cooler which cools a cooling fluid that has passed through one of the inner flow path or the outer flow path, and then supplies the cooling fluid to the other of the inner flow path or the outer flow path.