Coolable Charging Cable Structure With Direct Conductor Cooling
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Solution Overview
Problem
Existing vehicle charging cables face inefficiencies in heat dissipation due to internal cooling systems, which can be disrupted by external pressures, and are often bulky and difficult to handle, especially when transmitting high currents.
Innovation Solution
A charging cable design featuring a single line with an open support structure and conductor braid that forms an internal cooling duct, allowing direct contact between the cooling fluid and the conductor, enhancing heat dissipation efficiency while maintaining flexibility and robustness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If hoses or pipes are used inside the conductor arrangement for cooling, then the cable can transmit high currents, but the cooling efficiency is reduced due to heat conduction delays through the hose material
Solution Approach 1:
The invention extracts the separating layer (hose material) between the cooling fluid and the conductor arrangement. Instead of having the cooling fluid flow inside enclosed hoses, the duct is formed directly by the support structure and conductor braid, allowing the cooling fluid to contact the conductors directly and eliminate thermal conduction delays through hose walls
Solution Approach 2:
The conductor braid itself serves as the intermediary structure that forms the cooling duct. The braided conductors create an open structure that allows cooling fluid to flow through while maintaining electrical conductivity and mechanical strength, eliminating the need for separate hose materials
2Loss of energy
If the cooling duct is placed on the outside of the conductor arrangement to improve heat dissipation, then the cooling efficiency increases, but the cooling can be easily interrupted by external pressure loads
Solution Approach 1:
The cooling duct is nested within the conductor arrangement itself. The support structure and conductor braid form an internal duct that is protected by the surrounding cable structure, including the insulation element and outer jacket, preventing external pressure from collapsing the duct while maintaining efficient heat dissipation
Solution Approach 2:
The cable design incorporates the cooling duct within the robust conductor arrangement and surrounding insulation layers before external pressure can affect it. This pre-protective structure cushions the cooling duct against external pressure loads that might otherwise collapse an external duct
3Ease of operation
If the cable diameter is reduced to improve handleability, then the cable becomes more flexible and easier to grasp, but the ability to transmit high currents and dissipate heat is compromised
Solution Approach 1:
The invention uses a flexible braided conductor structure that provides both mechanical strength and thermal conductivity in a compact form. The conductor braid creates an open duct structure without requiring thick rigid walls, allowing the cable to maintain a small diameter while still supporting high current transmission and efficient cooling
Solution Approach 2:
The cable combines multiple materials with complementary properties: the support structure provides mechanical strength, the conductor braid provides electrical conductivity and forms the cooling duct, and the insulation element provides electrical isolation. This composite structure enables high power transmission in a compact, handleable cable
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 manages heat dissipation without the need for additional separating layers, maintains flexibility and robustness, and allows for the transmission of high currents without excessive heating, making the cable easier to handle and more resistant to external pressures.
Implementation Method 1
the cooling fluid can enter directly into contact with the conductor arrangement through the open support structure, the cooling is very efficient
Implementation Method 2
the heat does not have to be conducted through a hose or some other type of separating layer
Data Source
AI summary
A single line (6) for a charging cable comprises an open support structure (011, 012) with a longitudinal extent, a conductor braid (2) composed of conductors and an insulating element (3). The conductor braid (2) directly covers the open support structure (011, 012) along its longitudinal extent. The insulation element (3) covers the open support structure (011, 012) and the conductor braid (2). There is at least one duct (4) for a cooling fluid (5) in the single line (6). This duct (4) is formed by the support structure (011, 012) and the conductor braid (2). The insulation element (3) cannot be penetrated by the cooling fluid (5) and is electrically insulating.