Coolant-Cooled Cable Assembly for High-Current Terminal Transitions
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Solution Overview
Problem
Conventional cable connections for electric vehicles face limitations in transmitting high currents due to heat generation and material costs, especially in vehicles with powerful drives, and the transition from cooled to uncooled areas leads to localized overheating.
Innovation Solution
A cable assembly with a continuous interstitial space for coolant and individually interconnected electrical conductors, using a terminal element with a larger cross-section to manage high currents, and spacers to prevent overheating, allowing for a well-defined transition from cooled to uncooled sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional copper conductors with large cross-section are used to transmit high currents, then the current transmission capability is improved, but the material cost and weight increase significantly
Solution Approach 1:
The cable is divided into multiple individual electrical conductors (at least two) that are spatially separated and individually connected to the terminal element. This segmentation allows the cooling medium to flow between the conductors, improving heat dissipation efficiency and enabling high current transmission with reduced conductor cross-section, thereby reducing weight and material cost.
Solution Approach 2:
A cooling medium (liquid coolant) is introduced into the cable structure to actively remove heat generated by high current transmission. The coolant flows through channels formed by the spaced conductors and cable conduit, enabling efficient thermal management and allowing the use of lighter conductor materials that would otherwise overheat.
2Weight of moving object
If cooled cables are used to transmit more than 1000 A, then the material cost and weight are reduced, but localized overheating occurs at the transition from uncooled to cooled area
Solution Approach 1:
The terminal element is designed with a larger cross-section specifically at the connection point where conductors transition to the terminal. This local geometric modification creates an extended cooling path and increases heat dissipation surface area at the critical transition zone, preventing localized overheating while maintaining the overall weight reduction benefits of the cooled cable design.
3Power
If electrical conductors are individually interconnected to terminal element, then the transition from cooled to uncooled section is well-defined and current transmission is improved, but the device complexity increases
Solution Approach 1:
The terminal element serves multiple functions simultaneously: it provides individual electrical connection points for each conductor, acts as a heat dissipation structure with larger cross-section, defines the transition zone between cooled and uncooled sections, and provides mechanical support for the conductor connections. This multi-functionality reduces the need for separate components and simplifies the overall structure despite the individual connection requirement.
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 cable assembly effectively transmits currents exceeding 1000 A with controlled temperature below 90°C, reducing material costs and weight while maintaining efficient cooling.
Implementation Method 1
The interstitial space is suitable for conducting a coolant... the local temperature of electrically conductive parts at any point of the cable assembly does not exceed 90° C... a flow rate of approx. 3 l/min of coolant is sufficient to cool the cable sufficiently
Implementation Method 2
the high heat generation in normal copper conductors due to their ohmic resistance
Data Source
AI summary
A cable assembly (1) comprises a cable conduit (2) which forms a interstitial space (3) passage along a longitudinal direction. Inside the interstitial space (3), a plurality of electrical conductors (4) extend along the longitudinal direction. The interstitial space (3) is suitable for conducting a coolant. The cable assembly (1) further comprises a first terminal element (5) to which the electrical conductors (4) are individually electrically interconnected at a first end (6) of the cable hose (2).