Internally Cooled EV Charging Cable for High-Current Fast Charging
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Solution Overview
Problem
Standardized charging cable connectors limit charging current to prevent overheating, restricting rapid charging of electric vehicles, as existing cooling solutions only address plug temperatures and not the entire cable.
Innovation Solution
A charging cable system with internal cooling channels and valve means that circulate a cooling medium around the individual lines, allowing high charging currents without increasing connector dimensions, and optionally directing cooling to the vehicle's energy storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If higher charging currents are used for rapid charging, then charging speed is improved, but the charging cable and connector overheat
Solution Approach 1:
A cooling medium (liquid or gas) is introduced as an intermediary substance to absorb heat from the charging cable and connector. The cooling medium flows through cooling channels in the cable sheath and around contact pins in the connector, transferring thermal energy away from critical components, thereby enabling high charging currents without overheating.
Solution Approach 2:
The patent employs hydraulic cooling by circulating a liquid cooling medium through channels in the cable sheath and connector. This hydraulic system efficiently removes heat generated during high-current charging operations, allowing rapid charging while maintaining safe operating temperatures.
2Temperature
If cooling channels are added to the charging cable, then temperature control is improved, but the cable structure becomes more complex
Solution Approach 1:
The cooling channels are merged into the cable sheath structure itself, combining the protective insulation function with the thermal management function. This integration allows the cooling system to be implemented without adding separate external cooling components, thereby reducing overall structural complexity while maintaining effective temperature control.
Solution Approach 2:
The cable sheath serves multiple functions: electrical insulation, mechanical protection, and thermal management through integrated cooling channels. This multi-functionality reduces the need for separate components, simplifying the overall cable structure while achieving effective temperature control during high-power charging.
3Temperature
If the connector geometry is increased to accommodate cooling, then temperature control is improved, but the standardized connector dimensions are exceeded
Solution Approach 1:
Cooling channels are implemented locally at critical heat-generating points such as around the contact pins within the connector, rather than requiring overall connector enlargement. This localized cooling approach maintains standardized connector external dimensions while providing effective temperature control where it is most needed.
Solution Approach 2:
The cooling channels are nested within the existing connector structure, with cooling passages arranged around the contact pins in a compact configuration. This nesting allows the cooling system to be embedded within the standardized connector geometry without exceeding external dimension limits, maintaining compatibility with existing charging infrastructure.
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
Enables fast charging without overheating the cable or connector, maintaining standard dimensions, and allows for selective cooling of the vehicle's energy storage during charging.
Implementation Method 1
at least one cooling channel (40) runs within the charging cable (10), through which a cooling medium is guided to the cable connector (20)... the cooling medium at least partially flows around the individual lines (11, 12)
Implementation Method 2
a cooling channel thus serves as a supply line for the cooling medium... a closed circuit for the cooling medium is created, which can thus cool the charging cable and cable connector
Data Source
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AI summary
The invention relates to a charging cable system, having a charging cable (10) with a plurality of individual conductors (11; 12) running within the charging cable (10) to transfer a charging current and with a cable connection part (20) for connecting the charging cable (10) to the stored energy source (50) of an electrically driven vehicle. According to the invention, at least one cooling channel (40) runs within the charging cable (10), in which cooling channel a cooling medium is guided to the cable connection part (20), and in the cable connection part (20) valve means (21) are provided for returning the cooling medium to the charging cable (10). The charging cable (20) is designed such that after this return, the cooling medium flows at least partially around the individual conductors (11; 12).