High Voltage Cable With Internal Dielectric Cooling

Solution Overview

Problem

Existing high voltage power cables face limitations in cooling due to manufacturing and weight constraints, as passive cooling solutions are inadequate for efficiently dissipating heat generated during high current flow, particularly in battery charging applications.

Innovation Solution

A high voltage power cable assembly with an integrated cooling system, featuring an electrical conductor with an internal surface acting as an electrically conductive heat transfer surface, allowing direct contact with a dielectric coolant that circulates through an interior channel, enhancing heat exchange and conductivity while maintaining a reduced conductor cross-section.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If passive cooling solutions are applied to reduce temperature, then heat dissipation is improved, but weight and cost increase while flexibility decreases

Engineering Contradiction:

Improveheat dissipationVSAvoidweight

Core Design Contradiction:

TemperatureVSWeight of moving object

Solution Approach 1:

The cooling function is merged with the electrical conductor itself by creating an internal channel within the conductor structure. The conductor serves dual purposes: electrical conduction and coolant transport, eliminating the need for separate cooling components that would add weight and reduce flexibility.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The coolant channel is nested within the electrical conductor, with the internal channel formed inside the conductor body. This nested structure allows the cooling system to be integrated within the existing conductor geometry without adding external bulk or weight.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Temperature

If electrical conductor dimensions are increased to reduce temperature, then heat dissipation is improved, but weight and cost increase while flexibility decreases

Engineering Contradiction:

Improvetemperature reductionVSAvoidflexibility

Core Design Contradiction:

TemperatureVSEase of operation

Solution Approach 1:

The cooling function is merged with the electrical conductor itself by creating an internal channel within the conductor structure. The conductor serves dual purposes: electrical conduction and coolant transport, eliminating the need for separate cooling components that would add weight and reduce flexibility.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

A liquid coolant is introduced to transfer heat from the conductor internally. This hydraulic cooling method provides efficient heat removal without requiring increased conductor dimensions, thereby maintaining flexibility while reducing temperature.

Inventive Principle:

Principle #29Pneumatics and hydraulics

3Temperature

If active cooling systems with direct coolant contact are implemented, then heat transfer efficiency is improved, but system complexity increases

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidsystem complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The cooling function is merged with the electrical conductor itself by creating an internal channel within the conductor structure. The conductor serves dual purposes: electrical conduction and coolant transport, eliminating the need for separate cooling components that would add weight and reduce flexibility.

Inventive Principle:

Principle #5Merging (Combining)

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 configuration provides improved heat transfer and conductivity, allowing for efficient cooling of high voltage systems, maintaining operating temperatures within safe levels, and enabling flexibility in current load handling without increasing weight or cost.

Implementation Method 1

the internal surface is an electrically conductive heat transfer surface arranged to be in direct contact with the dielectric coolant for transferring heat from the conducting body to the dielectric coolant

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentEP4125099A1A power cable assembly for a power distribution system having an integrated cooling system

Publication Date: 2023.02.01 APTIV TECHNOLOGIES AG

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AI summary

According to arrangements of the specification, there is provided a high voltage power cable assembly comprising an electrically conductive and thermally conductive conductor. The electrical conductor extends longitudinally between first and second end contact surfaces configured for coupling via first and second connectors to electrical connections. The electrical conductor comprises an internal surface and an external surface, wherein the internal surface defines an interior channel configured for receiving a dielectric coolant from a cooling system arranged in communication with the electrical conductor; and wherein the internal surface is an electrically conductive heat transfer surface arranged to be in direct contact with the dielectric coolant for transferring heat from the conducting body to the dielectric coolant.