Fluid-Cooled Cable Connection Element for High-Current Crimping
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Solution Overview
Problem
Charging electric vehicles requires longer times due to the need for high-current cables that are difficult and expensive to connect, prone to damage, and must withstand mechanical stress, while ensuring safe electrical and fluid connections.
Innovation Solution
A connection element with a conductive housing and counterpressure element forms a compression joint with a concentric conductor arrangement, allowing for a robust, fluid-permeable connection that dissipates heat and maintains a stable central cooling channel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high current (up to 700 A) is transmitted through the charging cable, then charging power is improved, but the cable temperature increases and requires active cooling
Solution Approach 1:
A cooling fluid is introduced as an intermediary substance that flows through a central cooling channel in the cable. This fluid absorbs heat from the conductor arrangement and transports it away, enabling high current transmission without excessive temperature rise. The cooling fluid acts as a thermal mediator between the heat-generating conductors and the environment.
Solution Approach 2:
The patent employs hydraulic cooling by circulating a liquid cooling fluid through the central channel of the cable. This hydraulic system efficiently removes heat from the high-current conductors, allowing the cable to transmit up to 700 A continuously without exceeding permissible temperature limits.
2Temperature
If the cable is actively cooled with a central cooling channel, then temperature control is improved, but the connection complexity and risk of damage during connection increases
Solution Approach 1:
The electrical connection and fluid connection are merged into a single integrated connection element. The compression sleeve simultaneously establishes both the electrical contact between conductors and the fluid-tight seal for the cooling channel, eliminating the need for separate connection steps and reducing overall complexity.
Solution Approach 2:
The connection element is designed as a multi-functional component that performs multiple tasks: it provides electrical connection between conductors, seals the cooling fluid channel, and maintains mechanical stability. This universal design simplifies the overall system by replacing what would otherwise require multiple specialized components.
3Strength
If a compression joint is used to connect the individual line, then mechanical robustness is improved, but the risk of damaging the central cooling channel increases
Solution Approach 1:
A fluid-tight film is introduced as an intermediary layer between the compression sleeve and the central cooling channel. This film absorbs the compression forces, preventing direct mechanical stress on the cooling channel while still allowing the compression joint to establish reliable electrical and fluid connections.
Solution Approach 2:
The patent uses a flexible, fluid-tight film that can deform under compression without compromising the integrity of the cooling channel. This thin film structure provides mechanical compliance, allowing the rigid compression sleeve to apply force without damaging the more fragile cooling channel components.
4Reliability
If the conductor arrangement is compressed to ensure electrical contact, then electrical conductivity is improved, but the central cooling channel may be closed off
Solution Approach 1:
The fluid-tight film serves as a mediator that decouples the compression action from the cooling channel. It allows the conductor arrangement to be compressed for optimal electrical contact while the film maintains the cooling channel's openness and fluid-tight seal, preventing compression-induced blockage.
Solution Approach 2:
The connection structure is segmented into distinct functional zones: the compression zone for electrical contact, the film layer for force absorption and sealing, and the cooling channel zone for fluid flow. This segmentation allows each zone to perform its function independently without interfering with the others.
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
Enables efficient, reliable, and cost-effective high-current transmission with reduced risk of damage, ensuring mechanical robustness and effective cooling of the charging cable.
Implementation Method 1
the heat produced in the conductor arrangement by the ohmic losses can be dissipated via the cooling fluid in the channel
Implementation Method 2
the compression joint and the compression sleeve can likewise be cooled via the internal cooling channel
Data Source
AI summary
The invention relates to a connection element for electrically connecting an individual line which has a concentric conductor arrangement (32) and a central passage (33) for a cooling fluid. The connection element comprises an electrically conductive housing (2) with a sleeve-shaped pressing portion which is suitable for producing a press connection to the concentric conductor arrangement (32). The electrically conductive housing (2) here has an internal cooling passage (10) with a connection opening (11) for an external cooling line, said cooling passage leading into a space surrounded by the sleeve-shaped pressing portion. In addition, the connection element comprises a counterpressure element (3) which can at least partially lie in the space surrounded by the sleeve-shaped pressing portion. The counterpressure element (3) is furthermore configured to support the concentric conductor arrangement (32) on the inner side thereof when the sleeve-shaped pressing portion is compressed during the production of a press connection. The invention furthermore relates to a fluid-coolable individual line unit and to a charging cable having a charging connector.