Cooled Charging Cable Layout for High-Current Heat Dissipation
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Solution Overview
Problem
Existing charging cables for electric vehicles face challenges in efficiently transferring high charging power without overheating, particularly due to small conductor cross sections which can lead to excessive heating and damage, and existing cooling solutions are not optimal in terms of cooling power and complexity.
Innovation Solution
A single line for a charging cable is designed with a cooling hose and multiple uninsulated electrical conductors arranged around the cooling hose in a circumferential direction, allowing for efficient heat dissipation through direct contact with the cooling medium without insulation barriers, thereby reducing conductor cross sections while maintaining high power transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If small conductor cross sections are used in charging cables, then cable flexibility and ease of handling are improved, but the cable overheats and maximum permissible conductor temperature is exceeded
Solution Approach 1:
The conductor is segmented into multiple fine strands (conductor braid) rather than a single solid conductor. This segmentation allows the cable to be flexible while maintaining adequate current carrying capacity, resolving the contradiction between flexibility and overheating
Solution Approach 2:
A cooling fluid is introduced as an intermediary substance that flows through channels in the support structure, actively removing heat from the conductor. This mediator enables the use of smaller conductor cross-sections without exceeding temperature limits
2Temperature
If conventional cooling hoses are integrated into the cable construction, then heat dissipation is improved, but the cable cross section increases and complexity increases
Solution Approach 1:
The cooling function is merged with the mechanical support structure. The open support structure serves dual purposes: providing mechanical strength and forming cooling fluid channels. This eliminates the need for separate cooling hoses, reducing complexity while maintaining heat dissipation capability
Solution Approach 2:
The support structure performs multiple functions simultaneously: it provides mechanical support, defines the cable geometry, and serves as the cooling fluid conduit. This multi-functionality reduces the number of separate components needed in the cable construction
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 enables the efficient transfer of high charging power up to several hundred amperes without appreciable heating, even with smaller conductor cross sections, thus preventing overheating and damage, while also simplifying the cooling system and reducing the risk of user injury.
Implementation Method 1
The at least one uninsulated electrical conductor is in heat-conducting connection with the cooling hose in such a manner that the at least one uninsulated electrical conductor can be cooled by the cooling medium
Data Source
AI summary
A single line for a charging cable, for example for electric vehicles, and a charging cable having single lines of this kind are provided. The single line (10) includes a cooling hose (12) in which a coolant (14) can be conveyed, and at least one uninsulated electrical conductor (16). The at least one uninsulated electrical conductor (16) is connected in a thermally conductive manner to the cooling hose (12) in such a way that the at least one uninsulated electrical conductor (16) can be cooled by the coolant (14).