Fast-Charging Cable Sheath for EV Heat Dissipation
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Solution Overview
Problem
Existing charging technologies for electric vehicles result in excessive heating due to increased current during fast charging, leading to long charging times and undesirable increases in cost and weight when conductor sections are modified to address this issue.
Innovation Solution
The use of sheaths, applied via extrusion or co-extrusion, to surround the assembly of electrical conductors and insulating layers in charging cables, eliminating air gaps and promoting heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the electric current is increased to reduce charging duration, then the charging speed is improved, but excessive heating occurs due to the Joule effect
Solution Approach 1:
The patent converts the harmful heat generated by the Joule effect into a beneficial thermal management solution. The sheath material is specifically designed to conduct heat away from the connector and cables, transforming the waste heat into a controlled thermal flow that prevents overheating while maintaining fast charging capabilities
Solution Approach 2:
The patent changes the thermal parameters of the charging system by introducing a sheath with specific thermal conductivity properties. This parameter change allows the system to dissipate heat more effectively, enabling higher currents to be used without exceeding temperature limits, thus resolving the contradiction between charging speed and temperature control
2Temperature
If the sections of electrical conductors are increased to reduce heating, then the temperature control is improved, but the cost and weight of the charging device increase
Solution Approach 1:
The patent introduces a sheath as an intermediary thermal management component between the electrical conductor and the environment. This sheath acts as a heat sink and thermal conduit, allowing the system to maintain temperature control with the original conductor dimensions, thus avoiding the need to increase conductor sections and the associated weight and cost penalties
3Temperature
If the sections of electrical conductors are increased to reduce heating, then the temperature control is improved, but the cost of the charging device increases
Solution Approach 1:
The sheath serves as a cost-effective intermediary solution that addresses temperature control without requiring expensive increases in conductor sections. The sheath can be manufactured using standard extrusion processes and integrated into existing cable designs, providing thermal management at a lower cost than redesigning the entire conductor system
Solution Approach 2:
The patent changes the thermal parameters of the system by adding a sheath with appropriate thermal conductivity, allowing the original conductor design to be maintained. This avoids the cost increases associated with larger conductor sections while achieving the desired temperature control for fast charging applications
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
This approach reduces temperature rise and enables faster charging times while maintaining cost and weight efficiency, eliminating the need for conductor section modifications.
Implementation Method 1
an excessive heating of the system by the Joule effect (W=R.I2) is observed... Promoting heat dissipation
Implementation Method 2
an excessive heating of the system by the Joule effect (W=R.I2) is observed
Data Source
AI summary
The invention concerns a charging device for a hybrid or electric vehicle intended to be connected to an electricity distribution network (2) on the one hand, and to the terminals of the battery (10) of a hybrid or electric vehicle on the other hand, the device comprising two charging cables (61, 62) suitable for running, independently of each other, inside the vehicle, each being intended to be connected to a terminal of the battery, each charging cable (61, 62) comprising an electrical conductor (8) and at least one insulating layer (9) surrounding the electrical conductor (8), each charging cable further comprising a protective device (G) consisting of at least once sheath (G1, G2) disposed around the insulating layer and matching the assembly formed by the electrical conductor (8) and the actuating layer (9).