EV Charging Cable Cooling With Sub-Ambient Refrigeration
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Solution Overview
Problem
Charging cables for electric vehicles generate excessive heat due to high currents, necessitating effective cooling solutions to manage thermal management and enable high current rates without exceeding temperature limits.
Innovation Solution
An electric vehicle charging system utilizing a vapor-compression refrigeration system to cool the charging cable and connector, with separate cooling loops for the cable and electrical contacts, and an interconnecting heat exchanger to optimize coolant and refrigerant efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high currents are used for charging, then charging speed is improved, but heat generation increases causing temperature to rise
Solution Approach 1:
The patent converts the harmful heat generated by high current charging into a manageable thermal management problem by implementing a cooling circuit that circulates coolant through the charging cable and connector. The coolant absorbs the excess heat, transforming the harmful thermal effect into a controllable cooling process that enables sustained high current operation.
Solution Approach 2:
The patent introduces a coolant as an intermediary substance that mediates heat transfer between the charging cable/connector and the environment. The coolant circulates through dedicated cooling channels, absorbing heat from the high-current components and transporting it to a heat exchanger, thereby enabling high current charging while maintaining safe operating temperatures.
2Temperature
If cooling arrangements with pumps are added, then temperature control is improved, but device complexity increases
Solution Approach 1:
The patent implements a self-service cooling system where the coolant circulation is driven by thermal convection and pressure differentials rather than external pumps. The cooling circuit is integrated into the charging cable and connector structures themselves, with coolant channels formed within the cable jacket and connector housing, eliminating the need for separate pumping devices and reducing overall system complexity.
Solution Approach 2:
The patent merges the cooling function with the structural components of the charging system. The cooling channels are integrated into the cable jacket and connector housing, combining the mechanical support structure with the thermal management function. This integration eliminates separate cooling components and reduces device complexity while maintaining effective temperature control.
3Temperature
If coolant guiding devices are added to cables, then cooling efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The patent uses a flexible cable jacket with integrated cooling channels that can be manufactured using extrusion or molding processes. The coolant guiding structure is formed as a thin-walled channel within the cable jacket, allowing the cable to remain flexible while providing effective cooling. This approach maintains ease of manufacture through standard cable fabrication processes while improving cooling efficiency.
Solution Approach 2:
The patent designs the charging cable and connector to serve multiple functions: electrical power transmission and thermal management. The same structural components (cable jacket, connector housing) that provide mechanical support also serve as coolant guiding channels. This multi-functionality reduces manufacturing complexity by eliminating the need for separate cooling device fabrication and assembly.
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
Enables high current charging rates while maintaining component temperatures within safe limits, improving usability in high ambient temperatures and reducing energy consumption and component complexity.
Implementation Method 1
The thermal management unit comprises a vapor-compression refrigeration system (VCRS) for cooling the coolant below ambient temperature
Implementation Method 2
The heat may be actively conducted away from the heat sources using liquids. In this way current rates over 500 A are achieved.
Implementation Method 3
The heat may be actively conducted away from the heat sources using liquids
Implementation Method 4
an interconnecting heat exchanger to optimize coolant and refrigerant efficiency
Data Source
AI summary
An electric vehicle charging system includes a charging connector configured to receive a charging cable. The charging cable and/or the charging connector provide structures for guiding a coolant, cooling the charging cable and/or the charging connector. The electric vehicle charging system further comprises a thermal management unit for cooling the coolant. The thermal management unit comprises a vapor-compression refrigeration system for cooling the coolant below ambient temperature.