Fluid-Cooled Cable Assembly for High-Current Flexibility
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Solution Overview
Problem
Existing cable assemblies face challenges in efficiently regulating temperature while maintaining flexibility and handling high electrical currents, often requiring complex mechanical heat transfer members or fillers that increase costs and reduce flexibility.
Innovation Solution
A cable assembly design featuring a cable hose with a first interstitial space between the conductor and the hose, allowing a cooling fluid to circulate for efficient heat transfer without additional contact elements, enabling flexible and lightweight cables with effective temperature regulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional conductors are used with increased diameter to reduce electrical resistance, then electrical current transmission capability is improved, but cable weight and volume increase
Solution Approach 1:
The patent changes the temperature parameter of the conductor by introducing active cooling systems. By maintaining the conductor at lower temperatures, electrical resistance decreases, allowing high current transmission without increasing conductor diameter or weight. This directly resolves the contradiction by altering the thermal state rather than the dimensional parameters.
Solution Approach 2:
The patent introduces cooling media (such as liquid nitrogen or helium) as intermediaries to transfer heat away from the conductor. These cooling agents act as mediators between the conductor and the environment, enabling efficient heat removal without requiring the conductor itself to be larger or heavier.
2Temperature
If cooling pipes are pressed against cable parts to ensure thermal contact, then heat transfer efficiency is improved, but cable flexibility deteriorates
Solution Approach 1:
The patent employs flexible thermal interface materials or flexible cooling pipe structures that can bend and deform with the cable. These flexible components maintain thermal contact between the conductor and cooling system while allowing the cable to bend and move freely, thus preserving flexibility while ensuring effective heat transfer.
Solution Approach 2:
The patent designs the cooling system with dynamic characteristics, allowing the cooling pipes or thermal interface materials to adapt their shape and position in response to cable deformation. This dynamic design ensures continuous thermal contact during cable movement without compromising flexibility.
3Temperature
If filler materials are used to ensure thermal contact between conductors and cooling pipes, then heat transfer is improved, but cable flexibility and handling are reduced
Solution Approach 1:
The patent replaces rigid filler materials with flexible thermal interface materials that can conform to the conductor surface and maintain thermal contact during cable bending. These flexible materials provide effective heat transfer while allowing the cable to be handled and positioned easily without the rigidity imposed by traditional fillers.
4Temperature
If complex mechanical heat transfer members are used to regulate temperature, then temperature control is improved, but manufacturing costs increase
Solution Approach 1:
The patent employs fluid-based cooling systems (liquid or gas) that can be more easily manufactured and installed compared to complex mechanical heat transfer members. The cooling fluid circulates through simple conduits or channels, providing effective temperature control without requiring complex mechanical components, thereby reducing manufacturing costs.
Solution Approach 2:
The patent designs cooling systems that utilize the natural properties of cooling media (such as phase change or natural convection) to provide passive cooling without requiring complex active mechanical components. This self-service approach reduces manufacturing complexity and cost while maintaining effective temperature control.
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
The solution provides a cable assembly with enhanced flexibility, efficient temperature regulation, and reduced manufacturing costs by eliminating the need for complex mechanical heat transfer members, while maintaining high electrical current transmission capabilities.
Implementation Method 1
allowing a cooling fluid to circulate for efficient heat transfer
Implementation Method 2
cooling fluid to circulate for efficient heat transfer
Data Source
AI summary
The invention is directed to a cable assembly (10, 10a-b), comprising a cable (10, 10a-b) with a cable hose (11, 11a-b) and at least one conductor (12, 12a-f) arranged therein. The cable hose (11, 11a-b) is spaced a distance apart from the conductor (12) forming a first interstitial space (15, a-b) between the at least conductor (12) and the cable hose (11, 11a-b). At least one tube (20, 20a-b) for conveying of a cooling fluid (21), and a connector (30) comprising at least one contact member (31) interconnected to the at least one conductor (12) and a chamber (32). Said chamber (32) comprises a first port (33) which is interconnected to the first interstitial space between the at least one conductor (12, 12a-f) and the cable hose (11, 11a-b) and a second port (34a, 34a-b) which is interconnected to the at least one tube (20, 20a-b).