Liquid-Cooled Charging Cable Structure for EV Overheating Control
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Solution Overview
Problem
Charging devices, particularly those for electric vehicles, often overheat during the charging process, posing a safety risk due to overheating of the cable and its connection end.
Innovation Solution
A liquid cooled cable system comprising a braided copper mesh within insulating tubes, with a cooling module and liquid return channels, effectively dissipates heat by allowing liquid coolant to flow through the cable, reducing overheating risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional charging cables are used, then the charging process can be completed, but the cable and connection end overheat causing safety risks
Solution Approach 1:
The cable is divided into multiple segments with independent cooling channels running through different sections. Each segment has its own cooling path, allowing localized heat dissipation throughout the cable length rather than relying on a single cooling point.
Solution Approach 2:
A cooling liquid is introduced as an intermediary substance that absorbs heat from the cable conductors and connection ends. The liquid flows through cooling channels and carries thermal energy away from critical areas, preventing overheating without directly contacting the electrical components.
2Productivity
If charging power is increased to improve charging speed, then productivity increases, but heat generation increases causing overheating
Solution Approach 1:
The cooling liquid flows continuously through the cooling channels during the entire charging process, providing constant heat removal. This continuous cooling action allows the system to sustain higher power levels without temperature accumulation, enabling faster charging speeds.
Solution Approach 2:
A hydraulic cooling system is implemented where pressurized cooling liquid is pumped through the cable. The hydraulic flow provides efficient heat transfer and can be adjusted to match varying power demands, allowing the system to handle high-power charging while maintaining safe temperatures.
3Temperature
If liquid cooling channels are added to the cable, then heat dissipation improves, but device complexity increases
Solution Approach 1:
The cooling channels are merged with the cable structure itself, integrating the cooling function into the existing cable design. The cooling channels are formed within the cable insulation layers, combining the electrical conductor, insulation, and cooling pathways into a single unified structure rather than adding separate external cooling components.
Solution Approach 2:
The cable structure is designed to serve multiple functions simultaneously: electrical power transmission through the conductors, thermal insulation through the insulation layers, and heat dissipation through the integrated cooling channels. This multi-functionality reduces the need for separate dedicated cooling components.
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 system significantly reduces overheating issues during charging, enhancing safety and efficiency by ensuring effective heat dissipation across the braided copper mesh.
Implementation Method 1
The liquid cooled cable includes a first insulating tube with a first channel and a second insulating tube with a second channel... The first liquid return channel communicates to the first channel and the second channel... The liquid inlet is connected to the station end of the liquid cooled cable and communicates to the first channel... Two ends of the communicating pipe are respectively connected to the other end of the second liquid return channel and the liquid outlet of the cooling module
Implementation Method 2
the cable and its connection end are particularly prone to overheating during the charging process... The second insulating tube has a second channel and a braided copper mesh... The second channel is located in the braided copper mesh
Data Source
AI summary
A charging device includes a liquid cooled cable, a charging gun, a charging station, a station connector and a communicating pipe. The liquid cooled cable has a gun end and a station end. The liquid cooled cable includes a first insulating tube, a second insulating tube, a tape, a filler and a sheath. The first insulating tube has a first channel. The second insulating tube has a second channel and a braided copper mesh. The charging gun is connected to the gun end of the liquid cooled cable. The charging gun includes a gun connector and a first liquid return channel. The station connector includes a second liquid return channel and a connection part. One end of the second liquid return channel communicates to the second channel. The connection part is connected to the station end of the liquid cooled cable.