Interleaved DC Charging Cable with Magnetic Shielding
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Solution Overview
Problem
Existing DC charging cables face challenges in managing high current ratings without exceeding electromagnetic field limits, particularly static magnetic fields, which are critical for health and compatibility with sensitive devices.
Innovation Solution
A hybrid solution combining interleaved conductors of different polarities with a magnetic shielding, where the conductors are arranged circumferentially and the magnetic shielding surrounds the interleaved arrangement, providing a synergistic suppression of magnetic fields.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the current rating of charging cables is increased to meet fast-growing demands of e-mobility business, then the power transmission capability is improved, but the magnetic field strength around the cable increases and may exceed safety limits
Solution Approach 1:
The patent applies magnetic shielding material around the conductors to convert the harmful magnetic field effect into a contained field within the shielding. The shielding material absorbs and redirects magnetic field lines, transforming the harmful radiating field into a contained field that does not exceed external exposure limits while maintaining high current transmission capability
Solution Approach 2:
The patent uses composite cable construction combining conductors of different polarities with magnetic shielding material in an interleaved arrangement. This composite structure integrates both high-power transmission capability and magnetic field containment, allowing the cable to simultaneously achieve high current ratings and comply with electromagnetic exposure limits
2Object-affected harmful factors
If magnetic shielding is added to reduce magnetic field strength, then the safety compliance is improved, but the cable weight and complexity increase
Solution Approach 1:
The patent applies magnetic shielding selectively around specific conductors carrying high current, rather than uniformly shielding the entire cable. The shielding is concentrated in regions where magnetic field generation is most significant, reducing overall material usage and cable weight while maintaining effectiveness in critical areas
Solution Approach 2:
The patent optimizes the thickness and material properties of the magnetic shielding layer to achieve the minimum effective shielding that complies with safety limits. By carefully controlling shielding parameters such as material permeability and layer thickness, the design achieves adequate field containment with minimal added weight
3Object-affected harmful factors
If conductors of different polarities are arranged in an interleaved configuration, then the magnetic field cancellation is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent divides the cable conductors into distinct segments of different polarities arranged in an interleaved pattern. This segmentation allows for modular assembly where conductor bundles are pre-arranged and then assembled together, simplifying the manufacturing process compared to attempting to interleave individual conductors
Solution Approach 2:
The patent combines multiple conductors of the same polarity into bundled groups that are then interleaved with bundles of opposite polarity. This merging approach simplifies manufacturing by treating conductor bundles as single units rather than manipulating individual conductors, reducing assembly complexity while maintaining the magnetic field cancellation benefits of interleaved arrangement
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 hybrid solution effectively suppresses magnetic fields, allowing for high current ratings up to 3 kA while maintaining compliance with electromagnetic field limits, resulting in a lighter, more flexible, and efficient charging cable design.
Implementation Method 1
The magnetic shielding radially surrounds the interleaved arrangement of the first-polarity conductors and the second-polarity conductors
Implementation Method 2
the first-polarity conductors and the second-polarity conductors are arranged circumferentially in an interleaved arrangement
Data Source
Figure 1
Figure 2
Figure 3A~3C
AI summary
A DC charging cable assembly for charging an electrical vehicle is provided. The charging cable assembly includes a cable, including a plurality of first-polarity conductors, a plurality of second-polarity conductors, and a magnetic shielding. In a cross-section of the cable, the first-polarity conductors and the second-polarity conductors are arranged circumferentially in an interleaved arrangement. The magnetic shielding radially surrounds the interleaved arrangement of the first-polarity conductors and the second-polarity conductors. The charging cable assembly includes a first connector at a first end of the cable configured to connect the cable to a power source, the connector being configured for connecting the first-polarity conductors to a first-polarity voltage and connecting the second-polarity conductors to a second-polarity voltage.