EV Charging Cable with Internal Coolant Channels
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Solution Overview
Problem
Existing charging cables for electric vehicles become too heavy and difficult to handle when scaled up to support higher charging currents, such as those required for electric long-distance trucks, due to increased thickness needed for higher battery capacities, and current actively cooled cables are cumbersome for users.
Innovation Solution
A flexible charging cable design featuring a coolant supply tube, earth wire, and multiple power wires with spacers between conductors and insulation, allowing for individual cooling and deformation, enabling easy handling while supporting currents up to 3000 A, using an ultrapure water/glycol coolant and materials like aluminum and copper for power conductors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the charging cable is made thicker to support higher charging currents, then the charging current capacity is improved, but the cable weight increases and becomes difficult to handle
Solution Approach 1:
The cable is divided into multiple independent power conductors (e.g., six 50mm² conductors) instead of using fewer thicker conductors. This segmentation allows the cable to achieve high current capacity (3000A) while maintaining flexibility and manageable weight through the distributed structure of multiple smaller conductors.
Solution Approach 2:
The patent implements a nested structure where power conductors are arranged around a central coolant supply tube, with each conductor having its own insulation layer. The conductors are further nested within an outer protective mantle. This nested arrangement optimizes space utilization and allows the cable to maintain high current capacity without excessive outer diameter or weight.
2Power
If the charging cable is made thicker to support higher charging currents, then the charging current capacity is improved, but the cable flexibility deteriorates
Solution Approach 1:
By segmenting the cable into multiple independent conductors rather than using fewer thick conductors, the cable achieves high current capacity while maintaining flexibility. The multiple smaller conductors can bend and deform more easily than a single thick conductor, enabling the cable to be maneuvered during plugging operations.
Solution Approach 2:
The patent incorporates a flexible coolant supply tube at the center of the cable and arranges power conductors dynamically around it. This dynamic structure allows the cable to bend and twist as needed during operation while maintaining electrical connectivity and cooling functionality, improving ease of handling despite high current capacity requirements.
3Weight of moving object
If actively cooled charging cables are used to reduce cable thickness, then the cable weight is reduced, but the device complexity increases
Solution Approach 1:
The cooling function is merged with the cable structure itself by integrating a coolant supply tube running through the center of the cable and coolant channels within the insulation layers. This integration allows the cable to be actively cooled without adding separate external cooling equipment, reducing overall system complexity while maintaining reduced cable thickness and weight.
Solution Approach 2:
The cooling system is nested within the cable structure, with the coolant supply tube positioned at the center and coolant channels embedded within the insulation layers surrounding each conductor. This nested arrangement allows the cooling function to be incorporated without increasing the cable's outer dimensions or adding external complexity, achieving weight reduction while maintaining manageable complexity.
4Ease of operation
If multiple power wires are used to improve cable flexibility, then the ease of operation is improved, but the device complexity increases
Solution Approach 1:
Each power conductor in the multiple-wire configuration serves dual functions: it conducts electrical current and simultaneously acts as a structural element that contributes to cable flexibility. The conductors are arranged symmetrically around the central coolant tube, creating a balanced structure that provides both electrical functionality and mechanical flexibility without requiring additional specialized components.
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 flexible design allows for efficient cooling and manageable handling of high-current charging cables, maintaining flexibility and ease of use while effectively cooling the power conductors, even at high charging currents, thus facilitating faster and safer charging of electric vehicles.
Implementation Method 1
a coolant supply tube extending in a longitudinal direction and configured for transporting a coolant through the charging cable
Implementation Method 2
multiple spacers are provided between the power conductor and the power wire insulation such that a coolant channel is defined between the power conductor and the power wire insulation
Implementation Method 3
By cooling the charging cables during charging, the thickness of the charging cable may be limited
Data Source
AI summary
The disclosure relates to a charging cable for charging an electric vehicle, wherein the charging cable includes a coolant supply tube extending in a longitudinal direction and configured for transporting a coolant through the charging cable, an earth extending in a longitudinal direction substantially parallel to the coolant supply tube and configured for serving as ground, a plurality of power wires extending in the longitudinal direction and configured for conducting positive and/or negative direct current, and an outer layer extending in the longitudinal direction and surrounding the coolant supply tube, the earth and the plurality of power wires, wherein each of the plurality of power wires includes a power conductor and a power wire insulation surrounding the power conductor, wherein multiple spacers are provided between the power conductor and the power wire insulation such that a coolant channel is defined between the power conductor and the power wire insulation.