Liquid-Cooled Cable Structure with External Inflow Hose
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Solution Overview
Problem
Existing liquid-cooled cable structures for high current applications, such as electric vehicle charging, face challenges with heat buildup due to large cable cross-sections and handling difficulties caused by integrated coolant flow lines.
Innovation Solution
A liquid-cooled cable structure where the cooling liquid hose is arranged inside the outer casing, outside the cables, with separate inflow and return flow lines, reducing the cable's overall diameter and improving handling by eliminating the need for coolant lines within the cables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If both inflow and return flow of cooling liquid are integrated within a cable, then cooling function is provided, but cable cross-section becomes large and handling becomes difficult
Solution Approach 1:
The cooling system is segmented into two separate functional parts: the return flow path is integrated within the cable (cooling liquid line surrounded by electrical conductors), while the inflow path is provided separately via a cooling liquid hose arranged outside the cables but inside the outer casing. This segmentation allows the cable to remain compact and easy to handle while still providing complete cooling functionality through the combined system.
2Temperature
If both inflow and return flow of cooling liquid are integrated within a cable, then cooling function is provided, but overall diameter of cable structure increases
Solution Approach 1:
The inflow cooling liquid hose is positioned in the radial dimension outside the cables but within the outer casing, rather than requiring axial integration within the cable structure. This dimensional repositioning allows the overall diameter of the cable structure to be determined primarily by the cable diameters themselves, while the hose utilizes the available space in the annular region between the cables and outer casing.
3Temperature
If large flow cross sections for cooling liquid are provided, then cooling efficiency is improved, but cable cross-section becomes large
Solution Approach 1:
The cooling system merges the cable-internal return flow path with the cable-external inflow hose to create a complete cooling circuit. This combination allows large flow cross-sections to be achieved in the overall system (improving cooling efficiency) while the cable itself maintains a compact cross-section since it only needs to accommodate the return flow path, not the entire cooling circuit.
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 design enhances cooling efficiency while simplifying handling and reducing the overall diameter of the cable structure, making it more compact and flexible for high current applications like electric vehicle charging.
Implementation Method 1
each of which comprises a coolant line, a plurality of electrical conductors arranged around the respective coolant line
Implementation Method 2
cooling liquid is routed in the outer liquid line to the electrical contact element and routed back in the central liquid line
Data Source
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AI summary
The invention relates to a liquid-cooled cable assembly with at least two cables (2), each comprising a coolant line (3), several electrical conductors (4) arranged around the respective coolant line (3), and a cable sheath (5). An outer sheath (50) surrounds the at least two cables (2). At least one coolant hose (10) is arranged inside the outer sheath (50) and outside the cables (2). Furthermore, a corresponding method for cooling a cable assembly is described.