Coolant-Cooled Covered Wire for Higher Current Capacity
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Solution Overview
Problem
Existing covered wires lack a cooling structure, leading to inefficient heat dissipation from the conductor, limiting the allowable current and making it difficult to increase the conductor's capacity.
Innovation Solution
Incorporating a tubular member through which a coolant flows, with the tubular member having higher resistance to the coolant than the covering member, allowing effective heat dissipation from the conductor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If natural cooling is used without a cooling structure, then the structure remains simple, but heat dissipation from the conductor is inefficient and allowable current is limited
Solution Approach 1:
The tubular member is nested within the conductor, forming a concentric structure where the tubular member is positioned at the center and the conductor surrounds it. This nested configuration allows the cooling function to be integrated within the existing conductor structure without adding external complexity, enabling efficient heat dissipation while maintaining a compact and simple overall design.
Solution Approach 2:
The tubular member acts as an intermediary element between the conductor and the cooling environment. It provides a dedicated pathway for coolant flow that mediates the heat transfer process, allowing heat from the conductor to be efficiently removed through the tubular member's inner surface where the coolant flows, thereby improving heat dissipation efficiency.
2Reliability
If the tubular member has high resistance to coolant, then durability is improved, but the covering member must have even higher resistance which complicates material selection
Solution Approach 1:
The patent applies different material properties to different components based on their specific functional requirements. The tubular member is designed with high resistance to the specific coolant it contacts, while the covering member is designed with high resistance to external environmental factors. This localized optimization of material properties allows each component to be manufactured with appropriate materials for its specific service conditions, simplifying the overall material selection process.
Solution Approach 2:
The patent employs composite material construction where the tubular member and covering member are made from different materials optimized for their respective functions. The tubular member uses materials resistant to coolant corrosion, while the covering member uses materials resistant to external environmental degradation. This composite approach allows simultaneous achievement of high durability for both components without requiring the covering member to have universally superior resistance to all factors.
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 covered wire effectively cools the conductor, enabling increased allowable current or reduced cross-sectional area, while maintaining flexibility and durability, suitable for automotive wiring applications.
Implementation Method 1
a tubular member (2) through which a coolant (5) flows
Implementation Method 2
allows effective heat dissipation from the conductor
Data Source
AI summary
Disclosed is a covered wire including: a tubular member through which a coolant flows; a conductor provided on an outer circumference of the tubular member; and a covering member covering an outer circumference of the conductor, wherein the tubular member and the covering member are insulating, and the tubular member has a higher resistance to the coolant than the covering member.