Charging Cable Insulation Spacing for Direct Cooling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electric charging cables for motor vehicles face overheating issues due to inefficient heat dissipation, as the cooling ducts are costly and hinder heat transfer between the electric leads and the cooling medium.
Innovation Solution
The insulation layer is spaced apart from the electric lead, allowing the cooling fluid to flow directly around the lead, eliminating the need for separate insulation and enhancing heat transfer through direct convection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a separate cooling duct is arranged in the electric leads, then cooling capability is improved, but manufacturing cost increases and heat transmission efficiency decreases
Solution Approach 1:
The insulation layer is integrated with the cooling duct function by spacing it apart from the lead, creating a cavity that serves as the cooling channel. This merging of the insulation layer's electrical isolation function with the cooling duct's thermal management function eliminates the need for separate cooling duct structures, reducing manufacturing cost and structural complexity while maintaining effective cooling capability.
Solution Approach 2:
The insulation layer performs multiple functions: it provides electrical insulation between the lead and surrounding components, and simultaneously forms the cooling duct cavity when spaced apart from the lead. This multi-functionality reduces the number of separate components needed, simplifying the overall structure and reducing manufacturing costs.
2Reliability
If additional insulation is added to the cooling duct and electric leads, then electrical isolation is improved, but heat transmission between the electric leads and cooling medium decreases
Solution Approach 1:
The insulation is applied selectively only where electrical isolation is required, rather than uniformly covering all surfaces. By spacing the insulation layer apart from the lead to form a cavity, the design maintains electrical isolation properties while creating a direct thermal pathway for heat transmission from the lead to the cooling medium, optimizing both electrical safety and thermal efficiency.
Solution Approach 2:
The spaced insulation layer acts as an intermediary structure that simultaneously provides electrical insulation and creates the cooling duct cavity. This intermediary arrangement allows heat to be transmitted efficiently from the lead through the cavity to the cooling medium, while the insulation layer itself maintains the necessary electrical isolation, resolving the conflict between insulation and heat transmission.
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 configuration improves heat dissipation with reduced technical expenditure, allowing for effective cooling of the electric leads without insulation barriers, thus preventing overheating during high-power charging.
Implementation Method 1
the cooling fluid in the coolant duct can directly flow around the electric lead or electric conductors of the electric lead or can directly contact the current-conducting conductors of the electric lead, with the result that a direct transmission of heat from the electric lead to the cooling fluid is possible
Implementation Method 2
a direct conventional transfer of heat between the electric conductor and the cooling fluid is ensured
Data Source
AI summary
An electric line arrangement, in particular a charging cable for a motor vehicle, having at least one electrically conductive lead which can be placed in electrical contact at its ends in order to transmit electrical energy, an insulation layer which surrounds the lead circumferentially, and a coolant duct in which a cooling fluid for cooling the lead is conducted, wherein the insulation layer is spaced apart from the lead, and the coolant duct is formed between the insulation layer and the lead in such a way that the cooling fluid flows directly around the lead.