Liquid-Cooled Cable Structure With Spiral Copper Heat Dissipation
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Solution Overview
Problem
Existing liquid-cooling high-power cables for charging stations suffer from poor thermal conductivity, leading to high temperatures and safety hazards due to inefficient heat dissipation, which limits charging efficiency and safety.
Innovation Solution
A liquid cooling heat dissipation cable design featuring spiral metal pipes, copper cable layers, and insulating layers, with an oil supply system to rapidly transfer heat away from copper cables using liquid cooling oil.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a nylon plastic pipe is used for liquid cooling in the cable, then the cable structure is simple and easy to manufacture, but the thermal conductivity is very low resulting in poor heat dissipation effect
Solution Approach 1:
The patent applies composite materials by combining copper (high thermal conductivity) with plastic (insulating properties). The copper braid is wrapped around the plastic cooling pipe to form a composite structure that leverages copper's superior thermal conductivity for heat dissipation while maintaining the plastic pipe's flexibility and ease of manufacture. This resolves the contradiction by integrating materials with complementary properties.
Solution Approach 2:
The patent implements nesting by placing the plastic cooling pipe inside the copper braid layer. The copper braid envelops the plastic pipe, creating a nested configuration where the inner plastic component provides structural flexibility and the outer copper layer provides thermal conduction pathways. This nested arrangement allows both materials to function simultaneously without interfering with each other's primary characteristics.
2Reliability
If liquid cooling flows in the nylon pipe, then the cable structure is complete, but the poor thermal conductivity results in high temperature inside and on the cable surface
Solution Approach 1:
The copper braid wrapped around the plastic cooling pipe creates a composite heat dissipation system. The copper's high thermal conductivity provides efficient heat transfer pathways from the cable core to the cooling liquid, while the plastic pipe maintains structural integrity and flexibility. This composite approach ensures both structural completeness and effective temperature control.
3Reliability
If the cable is heavily insulated and protected, then the cable durability and safety are improved, but the heat dissipation efficiency is reduced
Solution Approach 1:
The patent uses nested arrangement where the copper braid is positioned between the insulating layers, creating a thermal pathway through the insulated structure. The cooling pipe is nested within the copper braid, forming multiple concentric layers that simultaneously provide insulation, mechanical protection, and thermal conduction. This nested configuration allows heat dissipation functionality to be integrated within the protective insulation structure rather than compromising it.
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 achieves effective heat dissipation, enhances safety, extends service life, and maintains high transmission efficiency while ensuring flexibility and structural support.
Implementation Method 1
rapid flow of the liquid cooling oil, so that the purposes of cooling and heat dissipation are achieved
Implementation Method 2
the heat generated by the copper cable layer is transferred from the spiral metal pipe to the liquid cooling oil
Data Source
Figure 1
Figure 2~4
AI summary
The present invention discloses a liquid cooling heat dissipation cable which comprises an insulating sheath, a plurality of signal transmission lines, a plurality of power lines, a PE cable, an oil supply pipe and at least two liquid cooling heat dissipation spiral metal transmission copper cable structures. The plurality of signal transmission lines, the plurality of power lines, the PE cable, the oil supply pipe and the at least two liquid cooling heat dissipation spiral metal transmission copper cable structures are all arranged in the insulating sheath, and the at least two liquid cooling heat dissipation spiral metal transmission copper cable structures are arranged in the insulating sheath and used for signal transmission and heat dissipation, and the oil supply pipe is used for supplying liquid cooling oil to the liquid cooling heat dissipation spiral metal transmission copper cable structures. The present invention has the advantages of being good in heat dissipation effect, capable of reducing heating, longer in overall service life, higher in safety and the like.