Coolable Charging Cable Line With Protected Internal Fluid Channels
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Solution Overview
Problem
Existing charging cables face inefficiencies in heat dissipation and flexibility, particularly when conducting high currents, and are prone to cooling fluid interruption under external pressure, compromising manageability and safety.
Innovation Solution
A single conductor design featuring an open support structure with channel conductors wrapped around it, allowing direct contact with a cooling fluid channel, enhancing heat dissipation and flexibility while maintaining structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If hoses or tubes are used inside the conductor assembly for cooling, then cooling fluid can be supplied to the conductors, but heat dissipation is delayed and less efficient due to the hose material barrier
Solution Approach 1:
The patent extracts the hose material barrier between the cooling fluid and conductor by using an open support structure with gaps. The cooling fluid flows directly through the support structure gaps to contact the conductors, eliminating the intermediate hose wall that impedes heat transfer. This is achieved by configuring the support structure with intentional openings that allow direct fluid-conductor contact while still providing mechanical support.
Solution Approach 2:
The support structure is designed with a porous or gap-filled configuration that allows cooling fluid to pass through and directly contact the conductors. The open structure acts as a porous medium that facilitates heat transfer while maintaining structural integrity, replacing the solid hose wall with a gap-based support system.
2Temperature
If cooling channels are placed on the outside of the conductor arrangement, then contact area is larger and heat dissipation is more efficient, but cooling can be easily interrupted by external pressure applied to the cable
Solution Approach 1:
The patent nests the cooling channels within the conductor assembly rather than placing them externally. The open support structure with cooling fluid passages is positioned inside the conductor arrangement, protecting the cooling channels from external pressure while maintaining efficient heat transfer to the conductors through direct contact.
Solution Approach 2:
The patent transitions from external cooling channels to internal cooling by utilizing the radial dimension within the conductor assembly. The cooling fluid flows through the support structure in the radial direction, contacting conductors from the inside, which protects the cooling path from external mechanical pressure while maintaining heat dissipation efficiency.
3Reliability
If the coolant channel is reinforced to prevent squeezing, then cooling continuity is maintained under external pressure, but the cable becomes thicker and loses manageability
Solution Approach 1:
The support structure serves multiple functions simultaneously: it provides mechanical support to protect the cooling channels from external pressure, enables cooling fluid flow through its open configuration, and maintains conductor positioning. This multi-functionality eliminates the need for separate reinforcement elements that would increase cable diameter.
Solution Approach 2:
The patent merges the support structure with the cooling channel formation into a single integrated component. The open support structure both supports the conductors and forms the cooling fluid passage, combining structural and cooling functions into one element rather than requiring separate reinforced channels.
4Volume of moving object
If the cable diameter is reduced for better manageability, then flexibility and ease of handling improve, but the ability to transmit high currents without excessive heating is compromised
Solution Approach 1:
The patent uses hydraulic cooling by forcing cooling fluid through the open support structure and directly over the conductors. This active fluid cooling system enables the cable to transmit high currents by continuously removing heat, allowing smaller cable diameters while maintaining thermal performance through efficient forced convection 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 efficiently dissipates heat generated by high currents, maintains flexibility, and protects the cooling channel from external pressure, ensuring safe and manageable operation.
Implementation Method 1
the cooling fluid can directly contact the channel conductor(s) through the open support structure, cooling is very efficient
Implementation Method 2
the heat generated in the channel conductor(s) owing to their ohmic resistance can be effectively dissipated
Implementation Method 3
The insulation is impermeable to the cooling fluid and is electrically insulating
Data Source
AI summary
A single line for a charging cable includes an open support structure (011, 012) having a longitudinal extent, at least one channel conductor (2) made of electrically conductive material, and an 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) wraps 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 is formed by the support structure (011, 012) and the channel conductor (2). The insulation (3) is impermeable to the cooling fluid (5) and is electrically insulating.