Refrigerant-Cooled EV Cable Connector for Heat Without Bulk
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Solution Overview
Problem
The increase in heat generation due to higher voltage and current in electric vehicle cables leads to a need for larger diameters, which in turn increases weight and mounting space requirements, and existing cooling methods for terminals do not effectively address this issue for cables.
Innovation Solution
A vehicle cooling system with refrigerant flow passages integrated into the cable and connectors that allow refrigerant to circulate between these passages, forming a U-turn connection flow path to efficiently cool the electric wires, thereby preventing an increase in cable diameter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the diameter of the cable is increased to withstand higher voltage and current, then the heat generation problem is solved, but the weight and mounting space increase
Solution Approach 1:
A refrigerant circulation system is introduced as an intermediary cooling mechanism between the cable and the environment. The refrigerant flows through passages in the connector and cable, absorbing heat from the cable conductors and carrying it away, thereby enabling effective heat dissipation without requiring increased cable diameter
Solution Approach 2:
The invention utilizes fluid (refrigerant) flow through hydraulic/pneumatic passages integrated into the connector and cable structure. The refrigerant circulates through these passages to provide active cooling, allowing the cable to dissipate heat efficiently while maintaining a compact diameter and reduced weight
2Loss of energy
If the diameter of the cable is increased to withstand higher voltage and current, then the heat generation problem is solved, but the mounting space increases
Solution Approach 1:
The refrigerant circulation system acts as an intermediary cooling mechanism that enables effective heat dissipation without requiring increased cable diameter, thereby reducing the mounting space required for the cable while still solving the heat generation problem
Solution Approach 2:
The cooling function is merged with the electrical connection function by integrating refrigerant passages into the connector structure. This combination allows the connector to serve dual purposes: electrical connection and active cooling, eliminating the need for separate cooling components that would occupy additional mounting space
3Loss of energy
If the diameter of the cable is increased to withstand higher voltage and current, then the heat generation problem is solved, but both weight and mounting space increase
Solution Approach 1:
The refrigerant circulation system serves as an intermediary cooling mechanism that enables effective heat dissipation without requiring increased cable volume, thereby solving the heat generation problem while maintaining compact cable dimensions
Solution Approach 2:
Fluid flow cooling through integrated refrigerant passages provides efficient heat removal from the cable conductors, allowing the cable to operate at higher currents without increasing volume, as the active cooling system manages the thermal load
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 system effectively cools electric vehicle cables, minimizing diameter and weight increases while reducing space requirements, facilitating efficient refrigerant circulation and easy assembly.
Implementation Method 1
two refrigerant flow passages that extend along the electric wire and that are for cooling the electric wire by a refrigerant flowing through an inside of the two refrigerant flow passages
Data Source
AI summary
A vehicle cooling system includes a cable including an electric wire and two refrigerant flow passages that extend along the electric wire and that are for cooling the electric wire by a refrigerant flowing through an inside of the two refrigerant flow passages, and a female connector that is attached to an end portion of the cable and that is fitted and connected to a counterpart male connector mounted on a vehicle. The female connector is provided with a U-turn connection flow path that causes, by causing the two refrigerant flow passages of the cable to communicate with each other, the refrigerant flowing through one of the two refrigerant flow passages to flow into the other.