EV Charging Cable Cooling Heat Exchanger
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Solution Overview
Problem
The inefficiency of onboard charging cables in electric vehicles due to increased electrical resistance during high current charging, leading to reduced charging efficiency and bulkier, more expensive cables.
Innovation Solution
A refrigerant circuit with a cable cooling heat exchanger that includes an inner tube for the charging cable and an outer tube, where a refrigerant flows through a flow path between them to dissipate heat, enhancing the cable's operational efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the current flow supplied to the battery assembly is increased to increase the charging rate, then the charging speed is improved, but the electrical resistance of the onboard charging cables increases causing reduced efficiency and requiring increased wire gauge
Solution Approach 1:
The patent changes the temperature parameter of the charging cable by introducing a cooling system. By actively cooling the cable during high-current charging, the electrical resistance is reduced, allowing high charging rates without the energy losses that would normally require thicker cables. This parameter change (temperature control) resolves the contradiction between charging speed and energy efficiency.
Solution Approach 2:
The patent replaces the mechanical solution of using thicker cables (increased wire gauge) with a thermal management system. Instead of mechanically increasing cable size to reduce resistance, the system uses refrigerant circulation through heat exchangers to thermally manage the cable temperature, achieving low resistance without increased cable dimensions.
2Loss of energy
If the wire gauge of onboard charging cables is increased to reduce electrical resistance, then the charging efficiency is improved, but the cables become bulkier, more expensive, and difficult to package
Solution Approach 1:
The patent changes the temperature parameter to reduce electrical resistance instead of changing the physical dimensions (wire gauge) of the cable. By maintaining the cable at a lower temperature through active cooling, the electrical resistance decreases, allowing thin cables to achieve the same efficiency as thick cables would provide at room temperature.
Solution Approach 2:
The patent substitutes the mechanical approach of increasing cable thickness with a thermal management approach. The cooling system uses refrigerant circulation and heat exchangers to thermally control the cable, replacing the need for mechanically larger cable cross-sections.
3Loss of energy
If the wire gauge of onboard charging cables is increased to reduce electrical resistance, then the charging efficiency is improved, but the cables become more expensive and difficult to package
Solution Approach 1:
The patent changes the temperature parameter to control electrical resistance, allowing the use of thinner, more flexible cables that are easier to package and handle. The active cooling system compensates for the smaller cable size by maintaining optimal temperature, thereby reducing resistance without requiring increased wire gauge.
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 allows for increased current flow through the charging cable, reducing charging time while maintaining efficiency and minimizing cable thickness, making it more pliable and easier to route within the vehicle.
Implementation Method 1
A fluid configured to cool the onboard charging cable flows through a flow path formed between the inner tube and the outer tube
Implementation Method 2
a refrigerant circulated through the refrigerant circuit flows through a flow path formed between the inner tube and the outer tube
Implementation Method 3
a refrigerant circulated through the refrigerant circuit flows through a flow path formed between the inner tube and the outer tube
Data Source
AI summary
A heat exchanger for use in a vehicle powered by a battery comprises an inner tube having an onboard charging cable associated with a charging of the battery disposed therein and an outer tube surrounding the inner tube. A refrigerant configured to cool the onboard charging cable flows through a flow path formed between the inner tube and the outer tube. A first connector is coupled to a first end of the outer tube. The first connector is in fluid communication with the flow path formed between the inner tube and the outer tube and further includes an opening for receiving a portion of the inner tube. The inner tube is securely coupled to the first connector at a joint therebetween to establish a position of the inner tube relative to the outer tube.