Liquid-Cooled Connector Assembly for EV Cable Heat and EMI
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Solution Overview
Problem
Existing connector assemblies for new energy automobiles face issues with high wire diameters, high heat generation, labor-intensive manual assembly, electromagnetic interference, and lack of automated production capabilities, leading to safety hazards and inefficiencies.
Innovation Solution
A liquid cooling connector assembly with a rigid electrical connection skeleton, a protective shell, and a shielding inner shell, incorporating a cooling liquid flow to reduce heat and shield electromagnetic interference, allowing for automated assembly and improved safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high-voltage cables are used to drive high-power motors, then power transmission capability is improved, but wire diameter increases and manual assembly is required
Solution Approach 1:
The high-voltage cable is segmented into multiple parallel sub-cables, each carrying a portion of the total current. This segmentation allows the use of thinner individual cables that can be handled and assembled automatically, while collectively maintaining the required power transmission capability for high-power motors.
Solution Approach 2:
The patent introduces a liquid cooling system with cooling channels that flow through the cable assembly. The coolant circulation mechanism enables automated installation of the cable system while the liquid cooling allows for reduced cable diameter by efficiently dissipating heat, preventing overheating in high-current applications.
2Power
If high current flows through high-voltage cable, then power transmission is improved, but heat generation increases causing safety hazards
Solution Approach 1:
A liquid cooling system with circulating coolant flows through channels in the cable assembly, actively removing heat generated by high-current operation. This hydraulic cooling mechanism enables sustained high power transmission without excessive temperature rise that would create safety hazards.
Solution Approach 2:
The patent changes the thermal management parameters by introducing active liquid cooling, which fundamentally alters the temperature profile of the cable system. The coolant flow rate and temperature are controlled parameters that enable the cable to sustain higher current densities without exceeding safe operating temperatures.
3Object-affected harmful factors
If shielding net is used to reduce electromagnetic interference, then electromagnetic shielding is improved, but equipment complexity and cost increase
Solution Approach 1:
The shielding function is merged with the cable structure itself by incorporating conductive shielding layers directly into the cable assembly. This integration combines the cable's mechanical function with electromagnetic shielding, eliminating the need for separate shielding nets and reducing overall system complexity.
Solution Approach 2:
The cable assembly is designed to perform multiple functions simultaneously: power transmission, thermal management through integrated cooling channels, and electromagnetic shielding through conductive layers. This multi-functionality eliminates the need for separate dedicated shielding components, reducing device complexity.
4Power
If high-voltage cable connection position is subjected to high temperature, then power transmission capability is maintained, but connection reliability decreases due to short circuit or open circuit
Solution Approach 1:
Liquid cooling channels are integrated into the connection positions and cable assembly, actively removing heat at the most critical thermal zones. This hydraulic cooling ensures that connection terminals and contact points remain within safe temperature ranges, maintaining reliable electrical connections even during high-power transmission.
Solution Approach 2:
The patent implements preventive thermal management by cooling the cable assembly before excessive heat accumulation occurs. The continuous coolant circulation acts as a cushioning mechanism that prevents temperature from reaching levels that would compromise connection reliability, avoiding short circuits and open circuits before they can occur.
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 effectively reduces heat generation, enables automated assembly, enhances safety by preventing short circuits and electromagnetic interference, and extends the service life of the connector assembly.
Implementation Method 1
a cavity is formed between the periphery of the electrical connection skeleton and an inner wall of the protective shell with a shielding effectiveness, and the cavity has cooling liquid flowing through it
Implementation Method 2
protective shell with a shielding effectiveness is sleeved on an outer periphery of the electrical connection skeleton
Data Source
AI summary
A liquid cooling connector assembly and a vehicle. The liquid cooling connector assembly comprises at least one electrical connection skeleton and connectors. In which each of the connectors including a connection terminal, in which two ends of the electrical connection skeleton are respectively electrically connected to connection terminals, a protective shell is sleeved on an outer periphery of the electrical connection skeleton, a cavity is formed between the periphery of the electrical connection skeleton and an inner wall of the protective shell, and the cavity has cooling liquid flowing through it. The disclosure can reduce high temperature failure, reduce the diameter of the electrical connection skeleton, prolong the service life, improve the safety of the whole vehicle and shield the electromagnetic interference.