High-Voltage Connector Cooling Channels for Cable Heat Control

Solution Overview

Problem

Existing high voltage power cables face challenges in efficiently cooling critical components due to limitations in passive cooling solutions, which can lead to increased weight and cost, and reduced flexibility, while active cooling systems often lack targeted cooling capabilities.

Innovation Solution

A high voltage power cable assembly with an integrated cooling system that includes an electrical connector with a conduit for circulating cooling fluid, providing direct cooling to critical points, and a connector design that allows for flexible placement and manufacturing of cooling pathways within the connector body.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

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

Engineering Contradiction:

Improvetemperature controlVSAvoidweight

Core Design Contradiction:

TemperatureVSWeight of moving object

Solution Approach 1:

The patent employs hydraulic cooling by circulating coolant through channels formed within the connector body itself. The connector includes integrated cooling channels that allow coolant flow directly through the high-voltage connector, enabling active thermal management without adding external cooling equipment or increasing overall system weight.

Inventive Principle:

Principle #29Pneumatics and hydraulics

Solution Approach 2:

The cooling function is merged with the connector structure by forming cooling channels directly within the connector body. This integration eliminates the need for separate cooling components and reduces overall system weight while maintaining effective temperature control of the high-voltage connector.

Inventive Principle:

Principle #5Merging (Combining)

2Temperature

If passive cooling solutions are used to reduce temperature, then temperature control is improved, but device complexity and cost increase

Engineering Contradiction:

Improvetemperature controlVSAvoiddevice complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The cooling function is merged with the connector structure by forming cooling channels directly within the connector body. This integration eliminates the need for separate cooling components and reduces overall system weight while maintaining effective temperature control of the high-voltage connector.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The connector serves multiple functions simultaneously: electrical connection and thermal management. The same connector body that provides electrical connectivity also contains integrated cooling channels, making it a multi-functional component that reduces overall system complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Temperature

If conductor dimensions are increased to reduce temperature, then temperature control is improved, but flexibility decreases

Engineering Contradiction:

Improvetemperature controlVSAvoidflexibility

Core Design Contradiction:

TemperatureVSAdaptability or versatility

Solution Approach 1:

The patent employs hydraulic cooling by circulating coolant through channels formed within the connector body itself. The connector includes integrated cooling channels that allow coolant flow directly through the high-voltage connector, enabling active thermal management without adding external cooling equipment or increasing overall system weight.

Inventive Principle:

Principle #29Pneumatics and hydraulics

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 enables targeted and efficient cooling of high voltage power cables, reducing operating temperatures and maintaining them below 50°C even at high current loads, thus improving the performance and reliability of the power distribution system.

Implementation Method 1

the connector comprises a heat transfer surface configured to be in contact with the cooling fluid circulating through the conduit for transferring heat from the connector to the cooling fluid

Methodology Applied

Scientific EffectHeat transfer: Heat Exchanger

Implementation Method 2

the conduit defining a path for the circulation of a cooling fluid through the connector

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentEP4287409A1Electrical connector for connecting high voltage power cable comprising electrical conductor to electrical terminal

Publication Date: 2023.12.06 APTIV TECHNOLOGIES AG

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AI summary

The specification provides an electrical connector (300) for connecting a high voltage power cable comprising an electrical conductor (200) to an electrical terminal (510). The electrical connector (300) comprises a terminal connection portion (313) and a conductor connection portion (314) comprising a conductor interface surface (335). The connector (300) further comprises a conduit (360) formed therein between an inlet opening (361) and an outlet opening (362), the conduit (360) defining a path for the circulation of a cooling fluid (450) through the connector, the conduit (360) being configured to receive the cooling fluid (450) from a cooling system pipe (440). The connector (300) comprises a heat transfer surface (346, 322) configured to be in contact with the cooling fluid (450) circulating through the conduit (360) for transferring heat from the connector (300) to the cooling fluid (450). The specification also provides a power cable assembly and a cooling system for coupling with a power cable assembly.