Flat EV Charging Cable Layout for Tight Bending and Protection
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Solution Overview
Problem
The existing charging cables for electric vehicle chargers have a limited curvature radius due to their circular cross-section, making them inflexible, difficult to handle, and exposed to environmental degradation, which affects their usability and aesthetic appearance.
Innovation Solution
A charging cable with a flat cross-section, partitioned into internal regions for positive and negative power cables, a communication/sensor cable, a coolant flow channel, and a ground, allowing for a reduced curvature radius and accommodation within the charger, minimizing external exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the charging cable has a circular cross-section with multiple wires, then the cable structure is stable and easy to manufacture, but the curvature radius is high (300-310 mm) and flexibility is poor
Solution Approach 1:
The patent changes the cable cross-section from a symmetric circular shape to an asymmetric flat shape with width and height dimensions. This asymmetric geometry allows the cable to bend with a smaller radius while maintaining structural integrity, directly resolving the contradiction between shape stability and operational flexibility.
2Ease of manufacture
If the charging cable has a circular cross-section, then the manufacturing process is simple, but the curvature radius is limited to approximately 300-310 mm
Solution Approach 1:
The patent transitions from a circular cross-section (one-dimensional symmetry) to a flat cross-section with distinct width and height dimensions. This dimensional change allows the cable to achieve a smaller curvature radius while maintaining manufacturing simplicity through standardized flat cable production techniques.
3Ease of operation
If the charging cable is fully exposed to the environment, then the cable is easily accessible for connection, but the cable is susceptible to degradation and contamination from external environmental elements
Solution Approach 1:
The patent employs the flat cable structure that can be routed and positioned more effectively within the charging station housing, allowing portions of the cable to be protected or shielded from environmental elements while maintaining operational accessibility through designed cable exits and connection points.
4Stability of the object's composition
If the charging cable has a large curvature radius, then the cable structure is stable, but the cable is difficult to handle and store
Solution Approach 1:
The flat asymmetric cross-section geometry enables the cable to achieve stable structural composition while allowing tighter bending radii, making the cable easier to handle, route, and store compared to traditional circular cables with fixed large curvature radii.
Data Source
AI summary
A charging cable for an electric vehicle includes a cable main body having a flat cross-section in a width direction thereof and partitioned into a plurality of internal regions. The charging cable includes terminal portions through which positive and negative power cables, a communication/sensor cable, a coolant flow channel, and a ground pass into the plurality of internal regions, respectively. The terminal portions are arranged in a row in the width direction of the cable main body.