Liquid-Cooled Connector Assembly for High-Current EV Cable Heat
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing connector assemblies for new energy vehicles face issues with large wire diameters, high heat generation, and manual assembly, leading to labor and time costs, as well as safety risks due to high temperatures and potential short circuits.
Innovation Solution
A connector assembly with a liquid cooling function, featuring a hollow inner cavity for cooling liquid flow, a rigid electrical connection framework, and a shielding inner shell, allowing for automatic assembly and reduced heat generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a high-voltage cable with large diameter is used to meet high-power motor requirements, then the current transmission capability is improved, but the assembly process requires manual mounting which increases labor cost and time cost
Solution Approach 1:
The high-voltage cable is segmented into multiple parallel sub-cables, each with smaller diameter. This allows the cable bundle to be automatically assembled while maintaining the required current transmission capability through parallel conduction paths
Solution Approach 2:
The cable assembly uses composite structure combining multiple conductive materials or layered configurations, enabling both high current capacity and reduced individual cable diameter for automated handling
2Power
If a high-voltage cable with large diameter is used to transmit large current, then the power transmission capability is improved, but the cable generates excessive heat which causes high temperature and connection failures
Solution Approach 1:
Dividing the current path into multiple parallel sub-cables increases the surface area for heat dissipation, reducing the temperature rise per unit area and preventing overheating while maintaining total current capacity
Solution Approach 2:
Introducing liquid cooling channels through or around the cable assembly uses fluid circulation to actively remove heat, preventing excessive temperature rise during high-power operation
3Ease of manufacture
If manual mounting is adopted for high-voltage cables with large diameter, then the assembly can be completed, but labor cost and time cost are increased
Solution Approach 1:
Segmenting the cable into smaller sub-cables enables automated assembly equipment to handle and connect them efficiently, dramatically reducing both labor cost and assembly time while maintaining manufacturing feasibility
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 solution enables efficient heat dissipation, reduces wire diameter, facilitates automatic assembly, and enhances safety by preventing short circuits and electromagnetic interference, thus improving the service life and reliability of the connector assembly.
Implementation Method 1
the electrical connection framework is provided with at least one hollow inner cavity through which a cooling liquid flows
Data Source
AI summary
A connector assembly having a liquid cooling function and a vehicle. The connector assembly includes at least one electrical connection framework and a connector that includes a connection terminal. Two ends of the electrical connection framework are electrically connected to the connection terminal respectively, and the electrical connection framework is provided with at least one hollow inner cavity, through which a cooling liquid flows. The connector assembly adopts the liquid cooling technology to reduce the heat generation amount of the electrical connection framework, so that the electrical connection framework can conduct a large current with a small wire diameter to ensure the normal use of the high-voltage device.