Dual-Channel Liquid-Cooled Cable for High-Power Charging Heat
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
High-power charging of new energy vehicles results in excessive heat generation in cables, leading to accelerated aging and reduced service life, as increasing power increases heat, and larger cable diameters increase weight, complicating storage and management.
Innovation Solution
A liquid-cooled cable design with internal and external liquid cooling channels and fan-shaped cable cores, enhancing cooling efficiency, reducing weight, and prolonging service life by optimizing cable diameter and configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the cable diameter is increased to handle higher power, then the power transmission capacity is improved, but the cable weight increases
Solution Approach 1:
The cable structure is segmented into multiple functional layers: conductor, insulator, cooling channels, and protective layers. The cooling system is divided into internal and external channels that work independently but cooperatively to manage heat dissipation, allowing the cable to handle higher power without proportionally increasing weight.
Solution Approach 2:
A liquid cooling system is introduced with internal cooling channels surrounding the conductor and external cooling channels in the outer layer. Cooling medium flows through these channels to actively remove heat generated during high-power transmission, enabling the cable to maintain lower operating temperatures and handle higher power loads without excessive weight increase.
2Power
If the cable diameter is increased to handle higher power, then the power transmission capacity is improved, but the storage and management becomes complicated
Solution Approach 1:
The cable is designed with modular segmented structure where the cooling system is divided into internal and external channels. This segmentation allows for standardized manufacturing of cable sections that can be easily stored and deployed. The fan-shaped cable core arrangement also creates a compact configuration that simplifies storage compared to traditional circular arrangements.
Solution Approach 2:
The cable incorporates flexible protective layers including an outer sheath layer and insulation layers that maintain cable integrity while allowing for compact coiling and storage. The flexible design enables the cable to be wound into tight spaces for storage and management without damaging the internal cooling channels or conductor.
3Speed
If the power is increased to increase charging speed, then the charging speed is improved, but the heat generation increases
Solution Approach 1:
The cable incorporates a dual-channel liquid cooling system with internal cooling channels directly surrounding the conductor and external cooling channels in the outer layer. Cooling medium flows through these channels to actively remove heat generated during high-power transmission, enabling the cable to maintain lower operating temperatures while supporting higher power loads and faster charging speeds.
Solution Approach 2:
The cooling system utilizes phase change of the cooling medium (liquid to vapor and back) to efficiently absorb and remove heat. As the cooling medium flows through the internal and external channels, it absorbs heat from the conductor and cable structure, maintaining thermal management during high-power operation and enabling faster charging speeds without excessive heat accumulation.
4Speed
If the power is increased to increase charging speed, then the charging speed is improved, but the cable aging accelerates
Solution Approach 1:
The active liquid cooling system continuously removes heat from the cable during operation, maintaining lower operating temperatures that reduce thermal stress on the insulator, conductor, and protective layers. This thermal management significantly slows down the aging process of cable materials, extending service life even during frequent high-power charging operations.
Solution Approach 2:
The cable design changes the thermal parameter profile by introducing active cooling, which maintains the operating temperature within a narrower and lower range compared to conventional cables. This parameter control (temperature) directly impacts the degradation rate of cable materials, thereby extending the duration of action and service life under high-power charging conditions.
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 liquid-cooled cable design effectively manages heat, enhances carrying capacity, and prolongs service life while minimizing weight and improving production, storage, and management of cables.
Implementation Method 1
a cooling medium flows in the liquid cooling channel
Implementation Method 2
a cooling medium flows in the liquid cooling channel
Implementation Method 3
When transmitting current, the conductor generates heat due to its inherent resistance
Data Source
AI summary
The present disclosure provides a liquid-cooled cable, including a liquid cooling channel and at least one set of cable cores (1) with a cross section in a shape of fan. The liquid cooling channel includes an internal liquid cooling channel (2), an external liquid cooling channel (3), and at least one set of connecting channels (4). The external liquid cooling channel (3) communicates with the internal liquid cooling channel (2) via the connecting channels (4), and a cooling medium flows in the liquid cooling channel. The cable cores (1) are disposed at an outer periphery of the internal liquid cooling channel (2) and an inner periphery of the external liquid cooling channel (3), and the connecting channels (4) are disposed at a radial direction of the liquid-cooled cable and separate the cable cores (1). The present disclosure increases the liquid cooling channels inside and outside the cable cores, maximizing the cooling effect of the cable, thus enhancing the flow carrying capacity of the cable and prolonging the service life.