Flat Cable With Integrated Cooling Channel for Battery Thermal Gradients
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Solution Overview
Problem
In the field of electromobility, flat electrical cables connecting battery cells often create significant thermal gradients due to uneven heat dissipation, as they typically run along the upper side of cells without integrated cooling, leading to inefficient heat management.
Innovation Solution
A flat electrical cable design featuring a conductive core and an integrated cooling channel, mutually parallel and connected by a web, which can be made from the same or different materials, to facilitate heat dissipation without increasing installation space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If flat electrical cables are installed along the upper side of battery cells without integrated cooling, then the installation space is kept compact, but significant thermal gradients develop in the battery cells
Solution Approach 1:
The patent combines the electrical cable function with the cooling function into a single integrated component. The cable includes both conductive cores for electrical connection and integrated cooling channels for heat dissipation, eliminating the need for separate cooling systems and reducing thermal gradients while maintaining compact installation space.
Solution Approach 2:
The flat electrical cable serves multiple functions simultaneously: it provides electrical connection between battery cells and acts as a cooling channel for heat dissipation. This multi-functionality allows the cable to address both electrical and thermal management requirements without increasing installation space or device complexity.
2Temperature
If cooling channels are integrated into the flat electrical cable, then thermal gradients are reduced, but the cable structure becomes more complex
Solution Approach 1:
The cooling channels are merged with the cable structure during manufacturing, creating an integrated component rather than adding separate cooling equipment. The channels are formed within the cable body itself, allowing heat dissipation functionality to be incorporated without significantly increasing overall structural complexity.
3Temperature
If cooling channels are added to the cable, then heat dissipation improves, but the installation space requirements may increase
Solution Approach 1:
The cable serves dual purposes as both an electrical conductor and a cooling channel, eliminating the need for separate cooling infrastructure. This multi-functionality allows effective heat dissipation to be achieved within the existing cable installation space without requiring additional area for separate cooling systems.
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 design effectively reduces thermal gradients in battery cells by allowing for efficient heat dissipation through the cooling channel, maintaining compactness and flexibility, suitable for use in electromobility applications.
Implementation Method 1
a cooling channel having a cooling channel sheath... integrally joined to one another by a web extending along the core and the cooling channel
Implementation Method 2
efficient heat dissipation through the cooling channel
Data Source
AI summary
A flat electrical cable comprises a conductive core having a core sheath and a cooling channel having a cooling channel sheath. The cooling channel and the core extend mutually parallel to one another along a length of the cable and are integrally joined to one another by a web extending along the core and the cooling channel.