Liquid-Cooled Charging Cable for High-Current Fast Charging
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Solution Overview
Problem
Conventional air cooled charging cables become too large, heavy, and inflexible when charging currents exceed 200 A, limiting the ability to quickly charge high-current electric vehicles due to thermal resistance issues.
Innovation Solution
A liquid cooled charging cable system where a coolant is pumped directly around bare electrical conductors, reducing thermal resistance and allowing for higher currents (400 A to 1,000 A) while maintaining a compact, flexible design by using electrically non-conductive conduits and independent cooling devices for effective heat management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional air cooled charging cables are used to increase charging current, then charging power is improved, but cable size and weight increase significantly
Solution Approach 1:
The patent replaces air cooling with liquid cooling by circulating coolant through channels in the cable. This hydraulic cooling system allows the cable to dissipate heat more efficiently, enabling higher charging currents without requiring proportionally larger cable cross-sections, thus reducing cable weight while maintaining or increasing power capacity.
Solution Approach 2:
The patent changes the thermal management parameter from air cooling to liquid cooling. This parameter change fundamentally alters the heat dissipation capability of the cable, allowing it to sustain higher currents for longer durations without exceeding temperature limits, thereby increasing effective power delivery without proportional weight increase.
2Power
If conventional air cooled charging cables are used to increase charging current, then charging power is improved, but thermal resistance increases
Solution Approach 1:
The liquid cooling system uses forced circulation of coolant through channels in the cable conductors and insulation layers. This hydraulic flow continuously removes heat from the charging current path, maintaining lower operating temperatures and reducing thermal resistance even at high current levels, enabling sustained high power charging.
3Power
If conventional air cooled charging cables are used to increase charging current, then charging power is improved, but cable flexibility deteriorates
Solution Approach 1:
The liquid cooling channels are integrated into the cable structure in a way that does not compromise flexibility. The coolant channels are positioned and sized to provide adequate heat dissipation while allowing the cable to bend and flex during use. This enables the cable to maintain high current capacity without becoming rigid or unwieldy.
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 charging cable system enables faster charging of electric vehicles with higher currents, reducing charge time and maintaining flexibility and usability, while minimizing thermal resistance and electrical isolation risks.
Implementation Method 1
a coolant is pumped directly around bare electrical conductors, reducing thermal resistance
Implementation Method 2
The cooling device may pump a coolant around the supply conductor and the return conductor
Data Source
AI summary
A liquid cooled charging cable system may be provided. The liquid cooled charging cable system may comprise a source, a load, a liquid cooled charging cable, and a cooling device. The liquid cooled charging cable may connect the source to the load, and may supply electric energy from the source to the load. The liquid cooled charging cable may comprise a supply conductor and a return conductor. The cooling device may pump a coolant around the supply conductor and the return conductor where the supply conductor and the return conductor may be immersed in the coolant.