Coolable Charging Cable Conductor With Open Support Cooling Channels
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Charging cables for vehicles face inefficiencies in heat dissipation due to the need for cooling fluids to travel through hoses or pipes, leading to delayed and less effective cooling, and are prone to cooling interruption under external pressure, making them uncomfortable to handle and vulnerable to damage.
Innovation Solution
A charging cable design featuring an open support structure with channel conductors that wrap around and contact the support structure, allowing direct contact between the cooling fluid and conductors for efficient heat dissipation, while maintaining a compact and flexible form.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If hoses or pipes are used inside the conductor arrangement for cooling, then the cooling fluid can be transported away, but the heat dissipation is delayed and less efficient due to the need to conduct heat through the tubing material
Solution Approach 1:
The invention extracts the cooling fluid transport function from enclosed hoses and implements it through an open support structure. The support structure's openings allow cooling fluid to directly contact and flow around the conductor arrangement, eliminating the intermediate heat conduction step through hose walls and enabling immediate heat dissipation from the conductors to the cooling fluid.
2Temperature
If the cooling fluid flows past the outside of the conductor arrangement, then the contact area is larger and heat dissipation is more efficient, but the cable is prone to cooling interruption under external pressure
Solution Approach 1:
The invention provides beforehand cushioning by positioning the conductor arrangement within the open support structure, which acts as a protective framework. This structure pre-shields the conductor-cooling fluid interface from external pressures that could otherwise displace the conductors and interrupt cooling, ensuring continuous heat dissipation even under mechanical stress.
3Temperature
If additional layers are added to enable cooling, then heat dissipation efficiency improves, but the cable diameter increases and manageability decreases
Solution Approach 1:
The open support structure serves multiple functions simultaneously: it provides mechanical support for the conductor arrangement, defines the cooling fluid flow path, enables direct heat dissipation through its openings, and maintains cable flexibility. This multi-functionality eliminates the need for separate cooling hoses and additional insulating layers, keeping the cable compact and manageable while achieving efficient cooling.
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 design effectively dissipates heat without the need for additional layers, enhances cooling efficiency, and maintains manageability and robustness, allowing for the transmission of high currents without excessive heating or damage from external pressure.
Implementation Method 1
allowing direct contact between the cooling fluid and conductors for efficient heat dissipation
Data Source
Figure 1a~1c
Figure 2a~2c
Figure 3a~4b
AI summary
A single conductor for a charging cable comprises an open support structure (011, 012) with a longitudinal extension, at least one channel conductor (2) made of electrically conductive material, and insulation (3). The at least one channel conductor (2) wraps around and contacts the open support structure (011, 012) along its longitudinal extension. The insulation (3) encases the open support structure (011, 012) and the at least one channel conductor (2). At least one channel (4) for a cooling fluid (5) is provided, and this channel (4) is formed by the support structure (011, 012) and the channel conductor (2). The insulation (3) is impermeable to the cooling fluid (5) and electrically insulating.