Fluid-Cooled Stranded Power Conductor for Flexible EV Charging
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Solution Overview
Problem
Current temperature-controlled power line devices for electric vehicle charging face challenges in cooling performance and cost-effectiveness, particularly due to complex manufacturing processes and material limitations, which hinder mass production and flexibility.
Innovation Solution
A temperature-controlled power line device featuring a tubular fluid line element with stranded wires, where the free space around the wires allows for improved cooling performance, and a method for production that includes forming a tubular fluid line element from conductive material, introducing stranded wires, and applying them in connection areas, enabling efficient and cost-effective series production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the conductor cross-section is increased to reduce thermal stress, then the cooling performance improves, but the flexibility and handling of the charging cable deteriorate
Solution Approach 1:
The conductor is segmented into multiple individual wires bundled together as a stranded wire structure. This allows the cable to maintain adequate total cross-sectional area for heat dissipation while the stranded configuration provides flexibility and ease of handling, resolving the contradiction between thermal management requirements and mechanical flexibility.
Solution Approach 2:
The stranded wire is nested within the tubular fluid conduction element, with the free space between the wire and tube wall utilized for fluid flow. This nested arrangement allows the conductor to be surrounded by cooling fluid, enhancing heat dissipation without increasing the overall cable diameter, thereby maintaining flexibility while improving thermal management.
2Temperature
If water cooling is implemented to improve cooling performance, then thermal stress is reduced, but the device complexity and manufacturing complexity increase
Solution Approach 1:
The fluid conduction element is merged with the electrical conductor by integrating the stranded wire directly into the tubular structure. The tube serves dual functions as both a structural/cooling component and an electrical conductor, eliminating the need for separate cooling channels and reducing manufacturing complexity while maintaining effective water cooling.
Solution Approach 2:
The tubular fluid conduction element performs multiple functions simultaneously: it provides structural support, conducts cooling fluid, and serves as an electrical conductor. This multi-functionality reduces the number of separate components needed, simplifying the overall device structure and manufacturing process while achieving effective thermal management.
3Manufacturing precision
If traditional manufacturing methods are used to ensure quality, then manufacturing precision is maintained, but the productivity and cost-effectiveness for mass production decrease
Solution Approach 1:
The stranded wire is prepared and pre-assembled before being integrated into the tubular fluid conduction element. This preliminary preparation allows for standardized components to be manufactured separately with controlled quality, then quickly assembled in high-volume production, maintaining manufacturing precision while significantly improving productivity and cost-effectiveness for mass production.
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 enhances cooling performance while simplifying production, making the devices more cost-effective and suitable for mass production, with improved flexibility and reduced thermal stress on materials.
Implementation Method 1
a free space within the fluid conduction element, which free space creates a fluid-conducting connection between the two openings
Implementation Method 2
The temperature control fluid can be introduced through one opening and discharged through the other opening, thereby cooling the power conduction device
Implementation Method 3
a tubular fluid conduction element made of an electrically conductive material, in particular metal, preferably copper or aluminum including corresponding alloys
Data Source
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AI summary
A temperature-controlled electrical conduction device (1) is described, comprising: a tubular fluid conduction element (2) made of an electrically conductive material, in particular metal, preferably copper or aluminum including corresponding alloys; at least two openings (2a) of the fluid conduction element (2), which openings (2a) are preferably arranged at different ends of the fluid conduction element (2); and a free space (3) within the fluid conduction element (2), which free space (3) creates a fluid-conducting connection between the two openings (2a); which electrical conduction device (1) is characterized in that a strand (4) with several stranded wires, preferably made of copper, is guided in the fluid conduction element (2); the free space (3) extends around the strand (4) at least in regions along the fluid conduction element (2);and the stranded wire (4) or stranded wires are applied to the fluid-conducting element (2) in at least one connection area, pressed against it, or vice versa. Furthermore, a method for manufacturing a temperature-controlled power line device (1) and a method for temperature-controlling a power line are described.