EV Charging Cable Liquid Coolant Deionization
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Solution Overview
Problem
High current electric vehicle charging systems face challenges with heat management in cables and connectors, leading to weight issues and increased risk of short circuits due to ionizable coolants, which existing designs fail to address effectively at currents above 200 A.
Innovation Solution
An electric vehicle charging system utilizing a flow path for a liquid coolant within the charging cable and connector, combined with a thermal management unit and a deionizing unit to reduce coolant conductivity, ensuring efficient cooling and minimizing the risk of short circuits, allowing operation at higher currents with improved safety and reduced maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a circulating cooling liquid is used to cool the cable and connector, then the temperature is kept at an acceptable level, but the risk of short circuits increases due to ionizable coolant
Solution Approach 1:
The patent changes the chemical composition parameters of the coolant by adding ion-suppressing additives that prevent ionization. This modifies the coolant's electrical properties to maintain low conductivity even at elevated temperatures, thus preventing short circuits while preserving the cooling function.
Solution Approach 2:
The patent introduces ion-suppressing additives as intermediary substances that act between the coolant and the electrical components. These additives serve as a mediator that prevents the coolant from ionizing and causing short circuits, while allowing the coolant to continue performing its heat dissipation function.
2Productivity
If high current rates are used for charging, then charging speed increases, but heat generation in the cable and connector increases
Solution Approach 1:
The patent extracts heat from the cable and connector system by implementing a dedicated cooling circuit with coolant flow paths integrated into the cable structure and connector housing. This separates the heat dissipation function from the electrical conduction function, allowing high current flow without excessive temperature rise.
Solution Approach 2:
The patent employs a hydraulic cooling system where liquid coolant circulates through channels in the cable and connector to remove heat. This hydraulic approach to thermal management enables sustained high current operation by continuously extracting heat generated during fast charging.
3Device complexity
If passive cooling solutions are used for currents up to 200 A, then the design is simple, but the cable becomes too heavy to handle comfortably above 200 A
Solution Approach 1:
The patent merges the electrical conduction function and thermal management function into a single integrated cable structure. The coolant channels are embedded within the cable insulation layers, and the connector housing serves dual purposes as both electrical connector and heat dissipation component. This integration eliminates the need for separate active cooling devices and heavy external cooling systems.
Solution Approach 2:
The patent implements multi-functional components where the cable insulation serves both electrical isolation and coolant flow channel functions, and the connector housing provides both electrical connection and heat dissipation. This universality reduces the number of separate components needed, thereby reducing overall system weight while maintaining effective cooling capability.
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 manages heat and reduces the risk of short circuits, enabling higher current charging while maintaining safety and reducing maintenance needs, thus operating more economically and efficiently.
Implementation Method 1
cooling the charging cable and/or the charging connector
Implementation Method 2
circulating a cooling liquid to keep the temperature of the cable and the connector
Implementation Method 3
a thermal management unit for cooling the liquid coolant
Implementation Method 4
a deionizing unit is provided and fluidly connected to the flow path for deionizing the liquid coolant, to decrease the conductivity of the coolant
Data Source
AI summary
An electric vehicle charging system includes a charging connector configured to receive a charging cable provided with electrical charging wires. The charging cable and/or the charging connector provide a flow path for guiding a liquid coolant, cooling the charging cable and/or the charging connector, and a thermal management unit for cooling the liquid coolant, the thermal management unit being fluidly connected to the flow path. The liquid coolant is an ionizable coolant, wherein a deionizing unit is provided and fluidly connected to the flow path for deionizing the liquid coolant to decrease its conductivity.