Coiled Cable Inductor for EV Power Control System Size Reduction

Solution Overview

Problem

Conventional electrified vehicles require a large and costly inductor in their power control systems, which is difficult to package and increases the overall size and cost of the system.

Innovation Solution

A cable with a coiled portion is used as an inductor, eliminating the need for a separate inductor within the power control system, and incorporating a silicon-carbide based switch for efficient power conversion, with the coiled portion being air-cooled and positioned within a rocker for efficient heat dissipation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a separate inductor is used in the power control system, then the required inductance is achieved, but the system size and cost increase

Engineering Contradiction:

Improveinductance requirementVSAvoidsystem size

Core Design Contradiction:

ReliabilityVSVolume of stationary object

Solution Approach 1:

The cable is designed with a coiled portion that serves dual functions: electrical connection and inductance provision. By merging the inductor function into the cable structure, the patent eliminates the need for a separate inductor component, thereby reducing system size while maintaining required inductance for power control operations

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The cable is transformed from a single-function electrical connector into a multi-functional component that simultaneously provides electrical connectivity and magnetic inductance. The coiled portion of the cable acts as both the conductor and the inductor, allowing one component to fulfill multiple system requirements

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If a separate inductor is used in the power control system, then the required inductance is achieved, but the system cost increases

Engineering Contradiction:

Improveinductance requirementVSAvoidsystem cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The cable is designed with a coiled portion that serves dual functions: electrical connection and inductance provision. By merging the inductor function into the cable structure, the patent eliminates the need for a separate inductor component, thereby reducing system size while maintaining required inductance for power control operations

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The cable is transformed from a single-function electrical connector into a multi-functional component that simultaneously provides electrical connectivity and magnetic inductance. The coiled portion of the cable acts as both the conductor and the inductor, allowing one component to fulfill multiple system requirements

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If a large inductor is packaged in the power control system, then the inductance requirement is met, but packaging difficulty increases

Engineering Contradiction:

Improveinductance requirementVSAvoidpackaging complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The cable is designed with a coiled portion that serves dual functions: electrical connection and inductance provision. By merging the inductor function into the cable structure, the patent eliminates the need for a separate inductor component, thereby reducing system size while maintaining required inductance for power control operations

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The cable is divided into functional segments, with a specific coiled portion dedicated to inductance while the rest of the cable maintains its conductor function. This segmentation allows the inductor function to be integrated into the cable assembly without requiring a separate packaged inductor component

Inventive Principle:

Principle #1Segmentation

4Productivity

If switching devices are used for power conversion, then efficient power conversion is achieved, but heat generation increases

Engineering Contradiction:

Improvepower conversion efficiencyVSAvoidswitching device temperature

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

The coiled cable portion acts as an intermediary thermal management element between the switching devices and the environment. By positioning the inductor in close proximity and using its coiled structure, it facilitates heat dissipation from the switching devices through thermal coupling, allowing efficient power conversion while managing the resulting heat generation

Inventive Principle:

Principle #24Intermediary (Mediator)

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 reduces the size and cost of the power control system, improves efficiency, and eliminates the need for a magnetic core, while maintaining the required inductance and current capability, and reduces the temperature of switching devices.

Implementation Method 1

A cable with a coiled portion is used as an inductor

Methodology Applied

Scientific EffectElectromagnetic Induction: Electromagnetic Induction

Implementation Method 2

the coiled portion being air-cooled

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS11476044B2Electrified vehicle cable having an inductor portion

Publication Date: 2022.10.18 FORD GLOBAL TECH LLC

AI summary

An exemplary electrified vehicle assembly includes a cable connected to an electrified vehicle battery. The cable has a coiled portion providing an inductor.