Helical Cable Cooling Structure for High-Current Heat Dissipation
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Solution Overview
Problem
Existing cable cooling solutions for high-current charging in electric vehicles fail to maintain the temperature below 40°C, which is a safety requirement in many regions, while achieving efficient heat dissipation.
Innovation Solution
A heat dissipation structure comprising a cable jacket with a fluid channel and a deformable, temperature-adaptive helical component that generates a two-phase flow and vortex within the working fluid to enhance cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high current charging is implemented to improve charging rate, then charging speed is improved, but cable temperature increases beyond safe limits
Solution Approach 1:
The patent utilizes phase transition of working fluid from liquid to vapor within the deformable component to absorb heat from the cable. The phase change process absorbs large amounts of latent heat, effectively cooling the cable while maintaining safe temperature limits during high-current charging operations.
Solution Approach 2:
The deformable component dynamically adjusts its structure based on temperature conditions. When the cable temperature rises, the deformable component deforms to increase the liquid-vapor interface area, enhancing heat dissipation efficiency. This dynamic adaptation allows the system to maintain effective cooling throughout the charging process.
2Temperature
If conventional cooling methods are used to reduce cable temperature, then temperature control is improved, but cooling uniformity is insufficient
Solution Approach 1:
The phase transition from liquid to vapor occurs throughout the deformable component, creating distributed heat absorption zones. This ensures uniform heat removal along the cable length, preventing localized hot spots and achieving consistent temperature distribution during charging.
Solution Approach 2:
The helical or curved structure of the deformable component promotes uniform heat distribution by ensuring consistent contact with the cable surface along its entire length. The curved geometry allows the working fluid to access heat sources uniformly, improving overall temperature distribution.
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 structure effectively maintains the cable temperature below 40°C by generating a two-phase flow and vortex, ensuring uniform cooling performance and dynamic efficiency as temperature varies.
Implementation Method 1
The deformable component allows a two-phase flow and a vortex to be generated in a working fluid in the fluid channel
Implementation Method 2
The deformable component allows a two-phase flow and a vortex to be generated in the working fluid in the fluid channel
Data Source
AI summary
A heat dissipation structure configured to cool a cable, includes a cable jacket, an electric conductor, and a deformable component which is temperature-adaptive and in a helical shape. The cable jacket has a fluid channel extending along an axial direction of the cable jacket. The electric conductor is disposed in the cable jacket. The deformable component is disposed in the fluid channel. The deformable component allows a two-phase flow and a vortex to be generated in a working fluid in the fluid channel.