EV Charging Cable with Elastomeric Clip Bodies for Heat Transfer
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Solution Overview
Problem
Existing electric vehicle charging lines face challenges in maintaining optimal heat transfer between power and fluid line strands due to shifting and twisting, which can lead to overheating when using high charging currents, necessitating cooling but not always ensuring effective thermal management.
Innovation Solution
The charging line incorporates two elongated protective and supporting bodies made of elastomeric materials with continuous cavities and clip devices, allowing for modular assembly and precise strand alignment, along with different thermal conductivity materials for efficient cooling and protection, ensuring consistent heat transfer and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high charging currents are used to shorten charging times, then charging speed is improved, but electrical cables overheat
Solution Approach 1:
A cooling fluid is introduced as an intermediary substance that flows through channels in the charging cable. This fluid absorbs heat from the electrical conductors and transports it away, enabling high charging currents to be used without overheating the cable. The cooling fluid acts as a thermal mediator between the heat-generating conductors and the external environment.
2Temperature
If cooling fluid lines are added to charge cable heat, then heat transfer is improved, but the cable structure becomes complex and strands shift relative to one another
Solution Approach 1:
The electrical conductors and cooling fluid lines are merged into a single integrated charging cable assembly. Multiple conductors (power and signal) and cooling fluid lines are bundled together within a common protective jacket, creating a unified structure that maintains fixed relative positions between all strands. This integration prevents the complexity of separate cable management while ensuring optimal heat transfer contact.
Solution Approach 2:
The cable structure employs a nested arrangement where cooling fluid lines are positioned within or alongside electrical conductors. The cooling channels are nested within the cable structure, with fluid lines running through or adjacent to power conductors, maximizing heat transfer surface area while maintaining a compact, organized structure that prevents strand shifting.
3Ease of operation
If cable strands are allowed to move freely, then ease of installation is improved, but optimal heat transfer coupling is not maintained
Solution Approach 1:
The charging cable uses a flexible protective jacket made of elastomeric material that encloses all conductors and cooling fluid lines. This flexible shell maintains the structural integrity and fixed relative positioning of internal strands while allowing the entire cable to be bent and maneuvered during installation. The flexible jacket prevents strand shifting without restricting the cable's overall flexibility for installation purposes.
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 solution maintains optimal heat transfer and structural stability of the charging line, allowing for high charging currents without overheating, while enabling modular design and efficient cooling through thermally optimized materials, thus enhancing the reliability and efficiency of electric vehicle charging.
Implementation Method 1
For good heat transfer, it is necessary to optimally couple the electrical line strands to the fluid line strands
Implementation Method 2
each profile having continuous cavities in the longitudinal direction of the protective and supporting body
Data Source
Figure 1~2
AI summary
The invention relates to a charging cable (3) for an electric vehicle, wherein the charging cable (3) comprises a plurality of electrical and fluid conductor strands (4-10). The object of the invention was to create a charging cable (3) for an electric vehicle in which the comprised electrical and fluid conductor strands (4-10) remain in their position relative to each other, even when the charging cable (3) is moved.This problem is solved by the charging cable (3) having at least one first (1) and at least one second (2) protective and support body, each designed as an elongated profile made of at least one elastomeric material, wherein each profile has continuous cavities (4 - 10) in the longitudinal direction of the protective and support body (1, 2) and the protective and support bodies (1, 2) extend at least section by section over the length of the charging cable (3), wherein the first and the second protective and support body (1, 2) can be clipped together at least partially to form a composite protective and support body by means of a longitudinally extending clip device (11, 12).