Charging Cable Heat Transfer Layer for Fast Charging Thermal Management
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing charging cable assemblies for electric vehicles require high cooling efforts to manage excessive heating of current conductor cables during fast charging, which is inefficient and costly.
Innovation Solution
Incorporating a heat transfer layer made of materials like silver, copper, and aluminum, formed as a gauze or mesh, that contacts the current conductor outer sheathing and coolant lines for efficient heat distribution and exchange, with a configuration that allows for flexible adaptation and increased contact surfaces for enhanced heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling devices are added to the charging cable assembly to cool the current conductor cables, then the heating problem is addressed, but the device complexity and manufacturing cost increase
Solution Approach 1:
The heat transfer layer integrates the cooling function directly into the cable structure by combining the current conductor cable and coolant line into a single integrated assembly. The heat transfer layer is applied to both the current conductor outer sheathing and the coolant line, creating a unified thermal management system that eliminates the need for separate cooling devices and reduces overall system complexity.
Solution Approach 2:
The heat transfer layer acts as an intermediary thermal management component between the current conductor cable and the coolant line. It facilitates heat transfer from the heated current conductor cable to the coolant, enabling efficient cooling while maintaining a simple and compact cable assembly structure without requiring complex cooling mechanisms.
2Volume of moving object
If the charging cable assembly is designed with compact arrangement of current conductor cables and coolant lines, then the cable cross section is reduced, but the heat transfer efficiency may be compromised
Solution Approach 1:
The charging cable assembly employs a nested arrangement where the coolant line is positioned within or alongside the current conductor cable structure. The heat transfer layer is applied to both components, creating a compact nested configuration that maximizes heat transfer surface area within a minimal cable cross section, thereby maintaining high heat transfer efficiency while minimizing cable volume.
3Temperature
If high cooling effort is applied to limit excessive heating of current conductor cables, then the temperature control is improved, but the energy consumption and operational cost increase
Solution Approach 1:
The charging cable assembly implements self-cooling through the integrated heat transfer layer and coolant line configuration. The system utilizes its own internal structure to dissipate heat generated during operation, with the coolant circulating through the embedded coolant line to actively remove heat from the current conductor cable. This self-service cooling mechanism reduces reliance on external high-power cooling systems and lowers overall energy consumption.
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 ensures a homogeneous temperature distribution and efficient heat flux density, reducing the need for high cooling efforts and enhancing the compactness of the charging cable assembly while providing effective heat management.
Implementation Method 1
The current conductor outer sheathing gives off heat to the heat transfer layer, which in turn is in heat exchange with the coolant lines
Implementation Method 2
The current conductor outer sheathing gives off heat to the heat transfer layer, which in turn is in heat exchange with the coolant lines
Data Source
AI summary
A charging cable assembly for transmitting electrical energy between a power supply station and an electrically drivable vehicle with a charging cable outer sheathing, in which at least one current conductor cable with a current conductor outer sheathing and at least one coolant line with a heat transfer surface are arranged, there being provided at least one heat transfer layer, which lies at least partially against the heat transfer surface and the current conductor outer sheathing.