Charging Harness With Integrated Cooling Channels
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Solution Overview
Problem
Existing charging systems for electric vehicles are limited by the maximum receiving capacity of electrical energy due to heat buildup during high-power transmission, which restricts charging speed and efficiency.
Innovation Solution
A charging harness unit with integrated cooling channels and a cooling fluid system that actively manages heat, using a cooling fluid such as a water-glycol mixture to maintain a high transmission capacity by dissipating heat effectively, and includes features like deflections to create a closed cooling circuit and central cooling hoses for efficient heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If electrical energy is transmitted at high power through the charging harness, then the charging output and receiving capacity are improved, but the temperature increase in the charging harness worsens, limiting the maximum transmission capacity
Solution Approach 1:
A cooling fluid (water-glycol mixture) is introduced as an intermediary substance to transfer heat away from the charging harness. The cooling fluid flows through channels in the charging harness, absorbing heat from the high-power electrical transmission and carrying it away to a cooling device, thereby enabling sustained high power transmission without excessive temperature increase.
Solution Approach 2:
The invention employs a hydraulic cooling system where a liquid cooling fluid circulates through the charging harness via pumped flow. The cooling fluid is pressurized and circulated through channels formed in or around the charging harness conductors, using hydraulic principles to efficiently remove heat and maintain transmission capacity.
2Power
If active cooling is implemented in the charging harness, then the electrical energy transmission capacity is improved, but the device complexity increases due to additional cooling components
Solution Approach 1:
The cooling channels are integrated directly into the structure of the charging harness itself, merging the electrical transmission function and thermal management function into a single unified component. The cooling fluid channels are formed within or around the conductors, eliminating the need for separate external cooling apparatus and reducing overall system complexity.
Solution Approach 2:
The charging harness is designed to perform multiple functions simultaneously: electrical energy transmission and thermal management. The same structural elements that conduct electricity also serve as or contain the cooling channels, making the charging harness a multi-functional component that handles both power transmission and heat 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
The solution enables a significantly higher electrical energy transmission capacity, allowing for faster and more efficient charging by maintaining lower temperatures within the charging harness, thus overcoming the limitations of non-cooled systems.
Implementation Method 1
the at least one lead has the cooling channel through which a cooling fluid can flow
Implementation Method 2
the cooling channel can be supplied with the cooling fluid via a cooling device arranged on the vehicle side
Data Source
AI summary
A charging harness unit for a battery of a motor vehicle includes a charging harness which has at least one lead and respective ends, one end being on the battery side and the other end being for connecting to a vehicle-external charging station. A cooling channel through which a coolant can flow is arranged in the charging harness. The cooling channel can be supplied with the coolant via a cooling device arranged on the vehicle side.