Dual-Hose Heavy-Current Charging Cable for Direct Coolant Heat Removal
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Solution Overview
Problem
Existing liquid cooled charging cables for electric vehicles face issues with safety, reliability, and performance, particularly at low temperatures, due to material compatibility problems and inefficient heat dissipation, leading to potential thermal runaway and limitations in current ratings.
Innovation Solution
A heavy-current charging cable design featuring a central wire as ground, surrounded by multiple power wires, with a cylindrical structure and a liquid coolant system that uses a non-insulating fluid, such as a water/glycol mixture, to maintain efficient cooling and mechanical robustness, allowing for higher current ratings like 500A and 1000V, while using aluminum conductors for reduced weight and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulating layers are added between conductors and coolant to prevent shorts, then electrical safety is improved, but thermal conductivity deteriorates
Solution Approach 1:
The patent applies local quality by providing power wire insulation only on specific sections of the conductors where electrical isolation is needed, while leaving other sections bare for direct thermal contact with the coolant. This selective insulation approach maintains electrical safety where required while maximizing thermal conductivity where heat transfer is needed.
Solution Approach 2:
The patent uses the coolant itself as an intermediary that serves dual functions: it provides thermal transfer from bare conductor sections and maintains electrical isolation through the cooling channels' geometric design. The cooling channels act as intermediaries that separate conductors electrically while allowing thermal coupling through the fluid medium.
2Temperature
If synthetic oil is used as coolant for direct cooling, then thermal conductivity is improved, but low temperature performance deteriorates
Solution Approach 1:
The patent changes the physical parameter of the coolant by using water/glycol mixtures instead of synthetic oils. This parameter change allows the system to maintain low viscosity and good flow characteristics at low temperatures, improving adaptability to various operating conditions while still achieving effective cooling through the optimized channel geometry and direct contact design.
3Power
If cable cross section is increased to handle higher currents, then current rating is improved, but cable weight and handling difficulty increase
Solution Approach 1:
The patent applies hydraulic cooling principles by using liquid coolant flowing through channels to actively remove heat from the conductors. This active thermal management allows the use of thinner conductor cross-sections for the same current rating compared to passive air cooling, thereby reducing cable weight and improving handling while maintaining the required current carrying capacity.
4Temperature
If insulating liquids are used for direct cooling, then thermal conductivity is improved, but environmental compatibility deteriorates
Solution Approach 1:
The patent changes the chemical composition parameter of the coolant from environmentally problematic synthetic oils to water-based glycol mixtures. This parameter change maintains adequate cooling efficiency through optimized channel design and direct contact geometry while dramatically improving environmental compatibility and safety.
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 provides improved thermal and mechanical performance, reduced conductor temperatures, and ease in manufacturing and assembly, enabling fast charging with enhanced safety and reliability, scalable for higher power ratings, and compatible with evolving standards.
Implementation Method 1
The coolant loop in the charging cable is generally designed to remove heat generated by Joule effect both in the charging cable and in the charging connector
Implementation Method 2
The liquid cooled charging cable is connected to a cooling unit, generally located inside a charge post, where the heat provided to the coolant by Joule effect is preferably dissipated to the surrounding ambient air
Implementation Method 3
the heat provided to the coolant by Joule effect is preferably dissipated to the surrounding ambient air
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a heavy-current charging cable (1) for charging an electric vehicle, comprising a central heavy-current wire (2) configured for serving as ground, the central heavy-current wire (2) comprising a central conductor (3) and extending in a longitudinal direction, a plurality of heavy-current power wires (5) configured for conducting positive and negative direct current, DC, each of said heavy-current power wires (5) comprising a power conductor (6) and a power wire insulation (7) surrounding said power conductor (6), the heavy-current power wires (5) extending parallel to the central wire, a liquid tight inner hose (8) extending in the longitudinal direction and surrounding the heavy-current central wire (2) and the heavy-current power wires (5) thereby defining a first hollow area (10) comprising liquid coolant to flow between the heavy-current central wire (2) and the heavy-current power wires (5) along the longitudinal direction, and a liquid tight outer hose (9) extending in the longitudinal direction and surrounding the inner hose (8) thereby defining a second hollow area (12) comprising liquid coolant to flow between the inner hose (8) and the outer hose (9) along the longitudinal direction.