Heat Pipe Power Cable for High-Current EV Charging Cooling
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Solution Overview
Problem
Existing power supply cables face challenges in efficiently managing heat dissipation when high currents are transmitted, leading to potential temperature rises and increased cable weight, which can result in material deterioration and reduced product lifespan.
Innovation Solution
Incorporating a heat pipe with a corrugated container and insulating layer into the power supply cable design, allowing for efficient heat transfer without the need for an auxiliary power source, and enabling the cable to be safely cooled over its entire length, even with longer cables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a large current of 400 A or more flows through the power supply cable, then the cable can enable quick charging of electric vehicles, but the temperature of the cable rises and material deterioration occurs
Solution Approach 1:
The patent converts the harmful heat generated by large current flow into a beneficial cooling mechanism by using the heat pipe to transfer and dissipate the heat efficiently. The heat generated during quick charging is no longer a detrimental factor but is instead managed constructively through phase change heat transfer, allowing sustained high current operation without temperature-related deterioration.
Solution Approach 2:
The heat pipe acts as an intermediary thermal management component between the power lines and the external environment. It mediates the heat transfer process by absorbing heat from the power lines through its evaporation section and dissipating it through the condensation section, preventing direct thermal damage to the cable materials while enabling quick charging.
2Temperature
If the cable diameter is increased to manage heat dissipation without a cooling method, then heat management improves, but the cable weight increases
Solution Approach 1:
The patent replaces the conventional mechanical approach of increasing cable diameter for heat dissipation with a thermal management system based on heat pipe technology. Instead of relying on increased surface area through larger dimensions, the system uses phase change heat transfer mechanisms to achieve efficient heat dissipation with a compact cable structure, significantly reducing cable weight while maintaining effective thermal management.
Solution Approach 2:
The patent changes the thermal management approach from passive conduction through large-diameter cables to active phase change heat transfer. By utilizing the latent heat of vaporization and condensation in the heat pipe, the system achieves superior heat dissipation efficiency with smaller dimensions, thereby reducing cable weight while maintaining effective temperature control during high current operation.
3Temperature
If an auxiliary power source is used for cooling, then cooling capability improves, but the risk of electrical short circuit increases
Solution Approach 1:
The heat pipe cooling system is self-service in that it passively manages heat without requiring external power input. The phase change process occurs automatically based on temperature gradients, with the working fluid evaporating at the hot section and condensing at the cool section, creating a self-sustaining thermal management system that eliminates the need for auxiliary power sources and associated electrical safety risks.
Solution Approach 2:
The patent replaces the electrical cooling system (which would require auxiliary power sources and control electronics) with a thermal-mechanical heat pipe system. This substitution eliminates the need for additional electrical components that could cause short circuits, providing inherent electrical safety while maintaining effective cooling capability through passive phase change heat transfer.
4Length of stationary object
If the cable length is increased to meet charging requirements, then adaptability improves, but heat accumulation over the entire length increases
Solution Approach 1:
The patent segments the thermal management function along the cable length by distributing heat pipe units at intervals along the power supply cable. Each heat pipe segment independently manages heat from its local section, preventing heat accumulation over the entire cable length. This segmented approach allows the cable to be extended to meet various charging requirements while maintaining effective temperature control throughout its length.
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 solution effectively reduces cable diameter and weight, prevents material deterioration, and enables quick charging of electric vehicles by maintaining efficient cooling, thus prolonging product life and ensuring safe operation.
Implementation Method 1
a heat pipe including a container and an insulating layer formed on an outer periphery of the container
Implementation Method 2
a condensation portion in which a working fluid is condensed in the heat pipe may be located at a higher position in a vertical direction than an evaporation portion in which a working fluid is evaporated in the heat pipe
Implementation Method 3
an evaporation portion in which a working fluid is evaporated in the heat pipe
Implementation Method 4
a condensation portion in which a working fluid is condensed in the heat pipe
Implementation Method 5
an insulating layer formed on an outer periphery of the container
Data Source
AI summary
A power supply cable includes a heat pipe including a container and an insulating layer formed on an outer periphery of the container, and a plurality of power lines disposed radially outside the heat pipe and including conductive wires.