Liquid-Cooled Tangle-Resistant Cable Asymmetric Hose
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Solution Overview
Problem
Modern liquid-cooled charging cables tend to tangle and overheat due to inadequate resistance to bending and crimping, which can inhibit liquid cooling functionality and pose safety hazards, and they do not effectively utilize the cooling surface area or have failsafe mechanisms to terminate charging when overheating occurs.
Innovation Solution
The design of liquid-cooled tangle-resistant (LCTR) charging cables features a non-circular sheath with asymmetrical flexibility, a hose with a flat side that abuts a conductor or insulation jacket for enhanced cooling, and a thermistor to reduce or terminate current flow when temperatures exceed a threshold, along with an armor layer for added protection and bending stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a liquid-cooled charging cable uses a traditional circular hose design, then the cable becomes flexible and easy to handle, but the cable becomes prone to tangling and the liquid cooling efficiency is reduced
Solution Approach 1:
The patent applies asymmetry by changing the hose cross-section from a traditional circular shape to an asymmetric design with at least one flat side. This asymmetric geometry serves dual purposes: the flat side maximizes contact area with the conductor for improved cooling efficiency, while the non-circular shape provides inherent resistance to tangling and bending during cable use.
Solution Approach 2:
The patent applies local quality by concentrating the cooling function at specific locations where the flat side of the hose abuts against the conductor or insulation jacket. This localized contact arrangement optimizes heat transfer at the critical interface between the cooling liquid and the heat-generating conductor, rather than distributing cooling uniformly throughout the cable.
2Volume of moving object
If the cable is made smaller and sleeker to meet design requirements, then the cable is more compact and aesthetically pleasing, but the cooling surface area relative to conductor size is reduced and overheating risk increases
Solution Approach 1:
The asymmetric hose cross-section with flat sides allows the cable to maintain a compact overall size while maximizing the cooling surface area at critical contact points. The non-circular geometry enables more efficient use of the available space within the cable cross-section, providing enhanced cooling capability without increasing the cable's external dimensions.
3Device complexity
If the cable lacks a failsafe mechanism, then the cable structure is simpler and manufacturing is easier, but safety hazards increase when overheating occurs
Solution Approach 1:
The patent incorporates a thermistor that provides feedback on the cable's temperature condition. When the temperature exceeds a predetermined threshold, the thermistor triggers a failsafe mechanism that terminates current flow, preventing dangerous overheating. This feedback-based safety system adds minimal complexity while significantly reducing safety hazards.
4Temperature
If the hose abuts extensively against the conductor, then cooling efficiency is maximized, but the cable becomes stiffer and more prone to damage
Solution Approach 1:
The patent applies local quality by concentrating the abutment contact between the hose and conductor at specific localized regions rather than along the entire length. This localized contact arrangement provides sufficient cooling efficiency while maintaining cable flexibility and resistance to bending stresses in other areas.
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 LCTR charging cables effectively prevent tangling, maintain efficient cooling, and ensure user safety by terminating current flow when overheating is detected, thereby preventing damage to internal components and reducing safety hazards.
Implementation Method 1
a hose disposed in the cavity and configured to carry a liquid... configured to cool the conductor
Implementation Method 2
a thermistor to reduce or terminate current flow when temperatures exceed a threshold
Data Source
AI summary
A liquid-cooled tangle-resistant charging cable may include a sheath defining a cavity, the sheath having a width dimension, a height dimension, a thickness dimension and a length dimension; wherein the width dimension is larger than the height dimension, and the length dimension is larger than both the height dimension and the width dimension; a first conductor disposed in the cavity, the first conductor having at least one substantially flat side; a hose disposed in the cavity and configured to carry a cooling liquid, the cross-sectional profile of the hose being non-circular and having at least one flat side. In some embodiments, the sheath's cross-sectional height dimension may be between 2% and 95% of the sheath's cross sectional width dimension.