Cooling Sleeve for EV Charging Cables
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Solution Overview
Problem
Rapid charging systems for electric vehicles generate excessive heat due to high charging currents, leading to inefficiencies and potential interruptions, as existing cooling solutions are not feasible within the standardized and rigid charging cable constraints.
Innovation Solution
A cooling sleeve design featuring a grommet and housing with a cooling volume for fluid circulation, utilizing a fixing mechanism and thermally conductive materials to efficiently dissipate heat from power lines without increasing cable rigidity or cross-sectional size, leveraging existing fluid connections and potentially using windshield washer systems for cooling fluid.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If fluid channels are integrated into the charging cable, then cooling effectiveness is improved, but cable cross-section increases and rigidity worsens
Solution Approach 1:
The cooling system is segmented into a separate cooling sleeve that can be attached to the cable rather than integrating fluid channels directly into the cable structure. This allows the cable to remain flexible and standardized while providing targeted cooling where heat generation is highest.
Solution Approach 2:
A cooling sleeve acts as an intermediary component between the cable and the cooling fluid. The sleeve contains the fluid channels and thermally couples to the cable surface, enabling effective heat transfer without modifying the cable itself.
2Temperature
If cable cross-section is increased to accommodate cooling channels, then cooling capacity is improved, but cable flexibility and handling worsen
Solution Approach 1:
The cooling function is separated from the cable structure into an attachable sleeve, allowing the cable to maintain its original flexible design while still providing cooling capability when needed.
Solution Approach 2:
Instead of increasing cable cross-section (one dimension), the cooling channels are placed in a separate dimension - the cooling sleeve that wraps around the cable, providing cooling without affecting cable flexibility.
3Ease of operation
If standardized cable cross-sections are maintained, then handling ease is improved, but cooling effectiveness worsens
Solution Approach 1:
The cooling sleeve serves as an intermediary that provides thermal management functionality without requiring modification to the standardized cable design, thus maintaining handling ease while improving cooling effectiveness.
Solution Approach 2:
The cooling system transitions from a static integrated design to a dynamic attachable design, allowing the cooling sleeve to be added or removed based on operational requirements, thus maintaining cable flexibility while providing cooling when needed.
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 cooling sleeve effectively manages heat dissipation along power lines, ensuring continuous charging operations while maintaining standard cable dimensions and handling ease, without the need for additional coolant systems or increased cable stiffness.
Implementation Method 1
a cooling volume between the grommet and the housing designed to receive the cooling fluid
Implementation Method 2
the cooling fluid being able to flow around the spout at least in sections
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Cooling sleeve (1) for dissipating heat from at least one energy line (2) to a cooling fluid (3), comprising a nozzle (5) for at least partially passing through the at least one energy line, a housing (4) which is arranged to surround the nozzle (5) at least partially, wherein a cooling volume (24) for receiving the cooling fluid (3) is formed between the nozzle (5) and the housing (4), wherein the cooling volume (24) is preferably limited by the nozzle (5) and the housing (4), the cooling sleeve (1) further comprising at least one fixing means (7) by means of which the housing (4) is detachably fixed to the nozzle (5), wherein the housing (4) comprises a first fluid connection (8) for introducing the cooling fluid (3) and a second fluid connection (9) for discharging the cooling fluid (3), wherein the nozzle (5) is at least partially open to flow by the cooling fluid (3).