Integrated Cooling Tube Layout for High-Voltage Power Cables
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Solution Overview
Problem
Existing high voltage power cable assemblies face limitations in cooling systems due to manufacturing and weight constraints, as passive cooling solutions are inadequate for efficient heat dissipation, particularly in high current applications like battery charging, where increased conductor gauges would increase weight and cost while reducing flexibility.
Innovation Solution
An integrated cooling system is introduced, featuring a thermally conductive cooling tube with a U-shape or equivalent configuration, positioned between electrical conductors, utilizing a coolant medium for improved heat dissipation, and a thermal interface material to enhance heat transfer, while maintaining flexibility and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If passive cooling solutions are used to reduce temperature, then heat dissipation is improved, but weight and cost increase while flexibility decreases
Solution Approach 1:
The cooling tube is merged with the power cable core structure, positioning it between the electrical conductors so that it serves dual purposes: structural support and heat dissipation. This integration eliminates the need for separate cooling components, reducing overall weight while maintaining effective heat dissipation through direct thermal contact with the conductors.
2Temperature
If conductor gauges are increased to reduce temperature, then heat dissipation is improved, but weight and cost increase while flexibility decreases
Solution Approach 1:
The cooling tube acts as an intermediary thermal pathway between the electrical conductors and the external environment. Instead of increasing conductor size to improve heat dissipation, the cooling tube provides a dedicated thermal conduction path that efficiently transfers heat away from the conductors, maintaining simple conductor design while achieving effective temperature control.
3Temperature
If multiple cooling tubes are used to improve heat dissipation, then cooling efficiency is improved, but manufacturing cost and weight increase
Solution Approach 1:
The cooling tube is segmented into multiple sections along its length, with each section positioned to contact different portions of the electrical conductors. This segmentation allows efficient heat dissipation from multiple heat generation zones along the conductors while using a single integrated cooling tube structure, avoiding the need for multiple separate cooling tubes and reducing manufacturing complexity.
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 effectively reduces the number of cooling tubes required, lowering the weight and cost of the power cable assembly while improving heat dissipation efficiency, ensuring safe and efficient high voltage power transmission.
Implementation Method 1
opposing portions of an external surface of the thermally conductive wall are provided in direct contact with corresponding portions of the insulating material of the electrical conductors over a heat exchange region so as to transfer heat from the electrically conductive core of the electrical conductors to the coolant medium circulating in the interior channel of the cooling tube
Data Source
AI summary
A high voltage power cable assembly for a power distribution system of a vehicle incorporating an integrated cooling system is presented. The power cable assembly comprises first and second electrical conductors spaced apart from one another and extending longitudinally. The power cable assembly further comprises a longitudinally extending cooling tube arranged between the first and second electrical conductors such that opposing portions of an external surface of the cooling tube are provided in direct contact with corresponding portions of the insulating material of the electrical conductors over a heat exchange region so as to transfer heat from the electrically conductive core of the electrical conductors to a coolant medium circulating in an internal channel of the cooling tube.