Hollow High-Voltage Cable with Inner Tube Cooling and Insulation
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Solution Overview
Problem
High-voltage cables used in electric and hybrid electric vehicles require a balance between sufficient current capacity, weight reduction, and size minimization, while maintaining electrical insulation and cooling efficiency.
Innovation Solution
A high-voltage cable design featuring a hollow conductor with an inner metal tube and a first electrically insulating layer in direct contact with both the inner and outer surfaces, allowing for internal cooling and a second insulating layer on the exterior, along with a shield layer, made from lightweight aluminum alloys to reduce weight and size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the size of high-voltage cables is increased to provide sufficient current capacity for higher voltage applications, then the current capacity is improved, but the weight and size of the cable increase
Solution Approach 1:
The patent introduces a hollow conductor design that allows cooling fluid to flow through the interior space, effectively using hydraulic cooling to remove heat from the cable. This enables the cable to sustain higher current densities without overheating, thereby improving current capacity without proportionally increasing the cable size and weight
Solution Approach 2:
The patent transitions from solid conductor to hollow conductor, adding a third dimension (the internal cooling channel) to the traditional cable structure. This dimensional change allows simultaneous achievement of high current capacity and reduced weight by enabling efficient heat removal that permits smaller conductor cross-sections
2Power
If the size of high-voltage cables is increased to provide sufficient current capacity, then the current capacity is improved, but the cable cross-sectional area increases
Solution Approach 1:
The hollow conductor with internal fluid cooling enables higher current density by actively removing heat. This hydraulic cooling system allows the cable to achieve the same power transmission capability with a smaller cross-sectional area compared to conventional air-cooled or uninsulated cables
Solution Approach 2:
The patent employs composite material structure combining conductive material for the hollow conductor with electrically insulating material coatings. This composite approach allows optimized cross-sectional design where each layer serves specific functions, enabling reduced overall cable area while maintaining electrical performance and thermal management
3Temperature
If an inner metal tube is added inside the hollow conductor for cooling, then cooling efficiency is improved, but the device complexity increases
Solution Approach 1:
The cable is segmented into distinct functional layers: the hollow conductor for current carrying and cooling fluid flow, the inner electrically insulating material layer, and the outer electrically insulating material layer. This segmentation allows each component to be optimized independently while maintaining overall system simplicity through modular construction
Solution Approach 2:
The hollow conductor serves multiple functions simultaneously: it carries the high-voltage current, provides the cooling channel for fluid flow, and maintains structural integrity. This multi-functionality reduces the need for additional separate components, thereby limiting the increase in device complexity despite improved cooling efficiency
4Reliability
If electrically insulating material is applied between the inner tube and hollow conductor, then electrical insulation is improved, but the manufacturing complexity increases
Solution Approach 1:
The electrically insulating material is applied to the inner tube before insertion into the hollow conductor. This preliminary action ensures proper insulation positioning and prevents manufacturing defects, simplifying the overall assembly process while guaranteeing reliable electrical insulation between the cooling channel and conductor
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 design enables a smaller cross-sectional area for the same voltage application, reducing weight and size while maintaining sufficient electrical insulation and cooling efficiency, suitable for electric vehicles and charging infrastructure.
Implementation Method 1
a first electrically insulating layer is arranged between the inner metal tube and the hollow conductor, wherein the first electrically insulating layer is in direct contact with the entire outer surface of the inner tube and the entire inner surface of the hollow conductor tube
Implementation Method 2
the cable can be cooled by means of cooling fluid flowing through the interior of the inner tube
Implementation Method 3
due to the inward electrical insulation in the hollow conductor the cable can be cooled by means of cooling fluid flowing through the interior of the inner tube
Data Source
AI summary
A high-voltage cable (1) comprising a hollow conductor (2), characterized in that an inner tube (3) is arranged inside the hollow conductor (2), and a first electrically insulating layer (4) is arranged between the innertube (3) and the hollow conductor (2), wherein said first electrically insulating layer (4) is in direct contact with the entire outer surface of the inner tube (3) and the entire inner surface of the hollow conductor tube (2), and a method (100) of manufacture of the cable.