Connection Unit for Fluid-Cooled EV Cable
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing connection systems for fluid-cooled cables in electric vehicle charging are complex, time-consuming, and inefficient due to the parallel routing of cooling fluid lines, which is not space-saving and ineffective in rapidly cooling the high heat generated during rapid charging operations.
Innovation Solution
A compact connection unit for fluid-cooled electric cables with a central cooling fluid line surrounded by copper cores and buffer elements, allowing for efficient cooling fluid circulation between the charging plug-in connector and a cooling unit, enabling rapid heat dissipation and simultaneous electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling fluid lines are routed in parallel to the electric cable, then the cable can be cooled during charging operations, but the structure is not space-saving and the cooling effectiveness is reduced
Solution Approach 1:
The patent combines the cooling fluid line and electrical conductors into a single integrated cable structure. The cooling fluid line is positioned in the center, surrounded by electrical conductors, forming one unified component rather than separate parallel structures. This merging achieves both space efficiency and effective cooling by allowing the cooling fluid to directly contact the conductors through the cable wall.
Solution Approach 2:
The patent implements a nested structure where electrical conductors are arranged around the central cooling fluid line, with the cable sheath enclosing both. This nesting allows the cooling fluid line to be centrally positioned while conductors surround it, maximizing space utilization and enabling efficient heat transfer from conductors to cooling fluid through minimal thermal resistance.
2Ease of manufacture
If separate connections are made for electric cable and cooling fluid line, then both can be connected independently, but the connecting process becomes complex and time-consuming
Solution Approach 1:
The patent merges the electrical connection and cooling fluid connection into a single integrated connector. The connector simultaneously establishes both electrical contact between conductors and the charging station, and fluid connection for the cooling line, eliminating the need for separate connection operations and reducing overall connection time.
Solution Approach 2:
The connector is designed with multi-functionality, serving both electrical power transfer and cooling fluid connection purposes through a single component. This universal connector handles multiple functions (electrical connection, fluid connection, and potentially mechanical coupling) that would otherwise require separate components, simplifying the overall connection process.
3Productivity
If high currents are used for rapid charging, then charging speed increases, but heat generation in the plug-in connector increases significantly
Solution Approach 1:
The patent implements continuous cooling during the entire charging operation by maintaining a closed-loop cooling fluid circulation system. The cooling fluid continuously flows through the cable, absorbing heat generated during charging, ensuring that heat removal is an ongoing process that matches the continuous heat generation from high-current charging operations.
Solution Approach 2:
The patent converts the harmful heat generated by high-current charging into a beneficial cooling effect. The cooling fluid absorbs the excess heat from the conductors and plug-in connector, transforming the harmful thermal energy into a manageable heat transfer process that can be dissipated at the cooling unit, thereby enabling sustained high-current operation.
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 design significantly reduces the time required for connecting the cables and enhances cooling efficiency, allowing for faster charging of electric vehicles by enabling effective heat dissipation through a closed fluid circuit within a compact and space-efficient structure.
Implementation Method 1
the cooling fluid, heated by a charging plug-in connector, is cooled down again
Implementation Method 2
A cooling fluid flows, in a closed cooling circuit, through the fluid line
Implementation Method 3
in the cooling unit, the cooling fluid is conditioned, in that, after having been heated in the charging plug-in connector, it is cooled down again
Data Source
AI summary
A connection unit for a fluid-cooled electric cable is provided, the connection unit comprising a housing, which has a cable connecting opening, a fluid inlet opening and a fluid outlet opening.