Liquid-Cooled Cable Offset Pipes for Fast-Charging Heat Dissipation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional liquid-cooled cables are rigid and exhibit inadequate heat dissipation, limiting their charging efficiency, especially in high-load and fast-charging applications.

Innovation Solution

The cable design includes offset segments in the pipes to increase coolant contact with power conducting members, enhancing heat dissipation efficiency by allowing coolant to absorb more heat along its flow path, and maintaining operating temperature within desired limits.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If conventional liquid-cooled cables are used, then the cable structure is simple, but the heat dissipation efficiency is inadequate and the cable is rigid

Engineering Contradiction:

Improveheat dissipation efficiencyVSAvoidcable structure complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The patent introduces offset segments with curved or spiral configurations in the cooling pipes, replacing straight rigid pipe structures. This curvature increases the surface area contact between coolant and power conducting members, enhancing heat dissipation efficiency while the flexible curved design allows the cable to bend and adapt to complex installation scenarios

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Power

If the cable supports high-load and fast charging applications, then the current-carrying capacity increases, but the operating temperature rises and charging efficiency is limited

Engineering Contradiction:

Improvecurrent-carrying capacityVSAvoidoperating temperature

Core Design Contradiction:

PowerVSTemperature

Solution Approach 1:

The patent utilizes liquid coolant flowing through offset segments to actively cool the power conducting members during high-current operation. The hydraulic flow of coolant absorbs heat generated by high power transmission, enabling the cable to maintain safe operating temperatures even under fast charging conditions with currents of 500A to 800A

Inventive Principle:

Principle #29Pneumatics and hydraulics

Solution Approach 2:

The curved offset segments increase the heat exchange surface area between coolant and conductors, improving thermal management efficiency during high-power operation, which enables safer high-current fast charging

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Adaptability or versatility

If the cable accommodates complex installations, then the flexibility increases, but conventional rigid pipe structures prevent bending

Engineering Contradiction:

Improveinstallation flexibilityVSAvoidpipe structure rigidity

Core Design Contradiction:

Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

The offset segments are designed with curved or spiral geometries that inherently provide flexibility, allowing the cooling pipes to bend without breaking. This curved structure replaces rigid straight pipes, enabling the cable to accommodate complex installation routes while maintaining structural integrity

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The cooling pipes are designed with flexible offset segments that can bend and deform elastically, allowing the cable to be routed through complex installation paths. The flexible pipe design maintains coolant flow capability while adapting to various installation configurations

Inventive Principle:

Principle #30Flexible shells and thin films

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 design improves heat dissipation efficiency, enabling the cable to accommodate complex installations and support high-load and fast charging applications while maintaining operating temperature within safe limits.

Implementation Method 1

The coolant absorbs this heat and carries it to a reservoir

Methodology Applied

Scientific EffectHeat absorption: Absorption (physical)

Implementation Method 2

passes through a radiator where the heat is dissipated

Methodology Applied

Scientific EffectHeat dissipation: Heat Exchanger

Implementation Method 3

each of the plurality of pipes comprising an offset segment having portions spaced from the respective power conducting member by varying distances

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Data Source

PatentEP4635784A1Liquid-cooled cable and system thereof

Publication Date: 2025.10.22 AMPHENOL PCD SHENZHEN

Figure 1A
Figure 1B
Figure 1C

AI summary

Liquid-cooled cable and system thereof. A cable includes first pipes, second pipes fluidly connected to the first pipes, and power conducting members disposed in the first pipes. In some embodiments, each first pipe with a power conducting member disposed therein comprises an offset segment. The offset segment has portions spaced from the power conducting member disposed therein by varying distances. In some embodiments, each first pipe with a power conducting member disposed therein includes multiple offset segments, and straight segments connecting adjacent offset segments. In some embodiments, the cable may include straight segments at opposite ends for connecting to a charging gun and a cooling unit, respectively. In some embodiments, the first pipes are outlet pipes, and the second pipes are inlet pipes. Techniques described herein enables flexible cables that can provide enhanced heat dissipation and therefore improved charging efficiency.