Integrated Cooling Tube Layout for Flexible Power Cable Assemblies
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Solution Overview
Problem
Existing high voltage power cable assemblies face limitations in cooling systems due to manufacturing and weight constraints, as passive cooling solutions are inefficient and increase the weight and cost of the cable while reducing flexibility.
Innovation Solution
A power cable assembly with a longitudinally extending cooling tube surrounded by an electrical conductor, where the thermally conductive wall of the cooling tube is in direct contact with the electrical conductor to transfer heat to a coolant medium, reducing manufacturing costs and weight by using a single central cooling tube.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If passive cooling solutions are applied to reduce temperature, then heat dissipation is improved, but weight and manufacturing cost increase while flexibility is reduced
Solution Approach 1:
The cooling tube is integrated directly into the cable core structure, merging the cooling function with the power transmission function. This eliminates the need for separate cooling components and reduces overall weight while maintaining effective heat dissipation through direct thermal contact between the conductor and cooling tube wall.
Solution Approach 2:
The cable assembly serves multiple functions simultaneously: the electrical conductor transmits power and generates heat, while the integrated cooling tube provides both structural support and heat dissipation. This multi-functionality reduces the need for additional components, lowering weight and cost.
2Temperature
If electrical conductor gauges are increased to reduce temperature, then heat dissipation is improved, but weight and cost increase while flexibility is reduced
Solution Approach 1:
The cooling tube acts as an intermediary thermal pathway between the electrical conductor and the external environment. Instead of relying solely on increasing conductor gauge for heat dissipation, the cooling tube provides a dedicated thermal conduction path that efficiently transfers heat away from the conductor, allowing the use of more flexible, lighter gauge conductors.
Solution Approach 2:
The solution replaces the mechanical approach of using thicker conductors for heat dissipation with a thermal management system. Instead of mechanically increasing conductor size to reduce temperature, a cooling tube with circulating coolant is used to actively manage heat transfer, preserving cable flexibility.
3Temperature
If multiple cooling tubes are used to improve heat dissipation, then cooling efficiency is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The cable core is segmented into functional layers: the electrical conductor, the insulating layer, and the cooling tube. This segmentation allows each component to perform its specific function efficiently. The single central cooling tube is strategically positioned to maximize thermal contact with the conductor while maintaining a simple overall structure.
Solution Approach 2:
Instead of adding multiple cooling tubes in parallel (increasing complexity), the solution utilizes the radial dimension by placing a single cooling tube at the center surrounded by the conductor. This dimensional arrangement maximizes the surface area for heat transfer from the conductor to the cooling tube wall, achieving efficient cooling with a single tube.
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 configuration enhances heat dissipation efficiency while maintaining the robustness and flexibility of the power cable assembly, addressing the limitations of existing cooling systems.
Implementation Method 1
the thermally conductive wall defining an interior channel for circulating, between a coolant inlet and a coolant outlet of the cooling tube, a coolant medium... at least a portion of an external surface of the thermally conductive wall is provided in direct contact with a corresponding portion of the electrical conductor over a heat exchange region so as to transfer heat from the electrical conductor to the coolant medium
Implementation Method 2
circulating, between a coolant inlet and a coolant outlet of the cooling tube, a coolant medium... transfer heat from the electrical conductor to the coolant medium circulating in the interior channel
Data Source
AI summary
A power cable assembly includes a power cable core. The power cable core has a longitudinally extending cooling tube comprising a thermally conductive wall defining an interior channel for circulating, between a coolant inlet and a coolant outlet of the cooling tube, a coolant medium; a longitudinally extending electrical conductor configured to be coupled via first and second connectors to respective electrical connections of a power distribution system; and a first insulating layer surrounding the power cable core. The electrical conductor is arranged to surround the cooling tube at least partially such that at least a portion of an external surface of the thermally conductive wall is provided in direct contact with a corresponding portion of the electrical conductor over a heat exchange region so as to transfer heat from the electrical conductor to the coolant medium circulating in the interior channel of the cooling tube.