Cu-Graphene Coated EV Cable for Higher Power Density
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Solution Overview
Problem
Current conductive cables for battery electric vehicles face challenges in increasing electric power density and reducing energy consumption.
Innovation Solution
The conductive cables incorporate a copper-graphene multilayer composite coating on conductive wires to enhance conductivity through the skin effect, utilizing a plurality of first and second Cu-Gr multilayer composites on metal substrates, and a non-conductive layer to form a cable bundle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional conductive cables are used in battery electric vehicles, then the vehicle can operate with standard conductivity, but electric power density is limited and energy consumption is higher
Solution Approach 1:
The patent applies composite materials by coating conductive wires with copper-graphene multilayer composites. The graphene layers are deposited on copper substrates to form a composite structure that combines the high electrical conductivity of copper with the superior electron transport properties of graphene, thereby increasing electric power density and reducing energy consumption in battery electric vehicles.
Solution Approach 2:
The patent changes the physical and chemical parameters of the conductive wire surface by applying thin-film copper-graphene coatings. The graphene layers are controlled to have specific thicknesses (0.1-0.5 micron per layer) and copper content (0.002%-0.2% volume fraction), which optimizes electron transport parameters and reduces electrical resistance, thereby improving power density and energy efficiency.
2Reliability
If copper-graphene multilayer composites are applied to conductive wires, then conductivity is enhanced through the skin effect, but manufacturing complexity increases
Solution Approach 1:
The patent uses thin-film technology to deposit graphene layers on copper substrates, creating flexible multilayer coatings that conform to the wire surface. The thin-film approach (0.1-0.5 micron per layer) allows for enhanced conductivity through the skin effect while maintaining manufacturing feasibility through established thin-film deposition techniques.
Solution Approach 2:
The patent transitions from bulk material properties to surface-dimensional properties by applying nanoscale graphene coatings on micrometer-scale copper layers. This dimensional approach exploits the skin effect where current flows primarily on the surface, making the multilayer composite structure effective for high-frequency applications while controlling manufacturing complexity through precise thickness control.
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 enhances conductivity and reduces energy consumption by leveraging the skin effect of electron transport, improving the efficiency of high-frequency applications in battery electric vehicles.
Implementation Method 1
enhance conductivity through the skin effect, utilizing a plurality of first and second Cu-Gr multilayer composites on metal substrates
Data Source
AI summary
A conductive cable for a battery electric vehicle is provided. The conductive cable comprises a plurality of first members in alignment to define a longitudinal axis of the conductive cable. Each first member comprises a first conductive wire about which a first outer layer is disposed for electric current to flow therethrough relative to the longitudinal axis. The first outer layer comprises a first metal substrate having a first side and an opposite second side. The first outer layer comprises a first copper-graphene (Cu-Gr) multilayer composite disposed on the first side and a second Cu-Gr multilayer composite disposed on the second side of the first metal substrate. Each first conductive wire comprises a first metallic material. The plurality of first members is disposed together along the longitudinal axis to define a cable bundle. The conductive cable further comprises a non-conductive layer disposed about the cable bundle.