Cryogenic Charging Cable for Electric Vehicles
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Solution Overview
Problem
The existing charging station arrangements for electric vehicles are cumbersome due to the weight and handling difficulties of the electric lines connected to the vehicle, which require substantial electrically conductive material for high current transmission.
Innovation Solution
A thermally insulated and flexible metal tube surrounds the electrical conductors, evacuated and corrugated for improved flexibility, with a refrigerated medium at -160°C reducing conductor resistance to 10% of normal levels, and a pump for slow medium flow, allowing for reduced conductor size and weight, along with a return tube for efficient cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional electric lines with substantial electrically conductive material are used for high current transmission, then high current transmission capability is achieved, but the weight and handling difficulty increase significantly
Solution Approach 1:
The patent changes the temperature parameter of the electrical conductors by introducing a refrigerated medium that cools them to -160°C. This parameter change reduces the electrical resistance to 10% of normal levels, allowing the use of conductors with much smaller cross-sections while maintaining the same current transmission capability, thereby reducing weight by 80%
Solution Approach 2:
The patent introduces a refrigerated medium as an intermediary substance that mediates between the power source and the electrical conductors. This medium cools the conductors to achieve superconductivity, enabling high current transmission through lightweight conductors. The refrigerated medium acts as a thermal bridge that facilitates the temperature reduction necessary for low-resistance conduction
2Weight of moving object
If the electric line is cooled to -160°C to reduce resistance, then conductor size and weight are reduced, but thermal insulation requirements increase
Solution Approach 1:
The patent implements a nested structure where the electrical conductors are placed inside an inner tube, which is surrounded by thermal insulation material, which in turn is enclosed by an outer tube. This nested arrangement integrates multiple functions (conduction, insulation, protection) into a compact structure, managing thermal requirements without excessive complexity
Solution Approach 2:
The patent uses composite construction combining different materials with complementary properties: electrically conductive materials for the conductors, thermally insulating materials for the insulation layer, and structurally sound materials for the tubes. This composite approach optimizes both thermal performance and mechanical properties while controlling overall complexity
3Loss of energy
If a rigid thermally insulated tube is used to cool the conductors, then thermal insulation is improved, but flexibility and handling ease deteriorate
Solution Approach 1:
The patent replaces rigid tubes with flexible tubes that can bend and conform to different positions. These flexible tubes maintain their thermal insulation properties while providing the necessary flexibility for easy handling and connection during charging operations, directly resolving the contradiction between insulation rigidity and operational flexibility
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 solution significantly reduces the weight of the charging line to 20% of conventional lines, making it easier to handle and maintain, while maintaining high current transmission efficiency with improved thermal insulation and flexibility.
Implementation Method 1
a flowable medium refrigerated to a temperature of at least −160° C. is contained in the space enclosed by the tube
Implementation Method 2
The value of the electrical resistance of the electrical conductor at a temperature of −160° C. is only about 10% of the value at normal ambient temperature
Implementation Method 3
the space between the tube and outer tube is evacuated
Implementation Method 4
the tube is a thermally insulated and flexible tube made of metal
Data Source
AI summary
Specified is an arrangement for supplying power to a motor vehicle which is equipped with an electric motor and in which there is arranged at least one rechargeable electric battery to which the electric motor is connected. The arrangement includes a stationary charging station which is equipped with an electric power source and to which an electric line having at least two mutually insulated electrical conductors is connected, a part of an electrical coupling for connecting to a complementary coupling part present on or in the motor vehicle being attached to the free ends of said electrical conductors, said coupling part being connected to the battery in an electrically conductive manner. The electric line is surrounded along its entire axial length by a thermally insulated and flexible tube made of metal which is closed all around and which, in addition to the line, encloses a cavity along its entire axial length. A flowable medium refrigerated to a temperature of at least −160° C. is contained in the space enclosed by the tube, and a thermally insulated storage tank containing a store of the refrigerated medium is arranged in the charging station, the tube being connected to said storage tank.