Multi-layer coaxial cable for EV power routing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
High-voltage electrical power cables used in hybrid and electric vehicles are thick and difficult to route due to their side-by-side arrangement, restricting bending direction and increasing the size of protective members, which complicates installation and reduces workability.
Innovation Solution
A multilayer coaxial cable design where high-voltage and low-voltage circuits are coaxially integrated with a conductive shield and coating, allowing for a narrower profile and improved flexibility, reducing the size of protective members and enhancing workability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two high-voltage electrical power cables are arrayed side by side, then each cable can be individually protected and installed, but the width dimension becomes great and the size of protective member increases
Solution Approach 1:
The patent combines two separate high-voltage cables into a single integrated cable structure where both conductors share common protective layers including a single outer protective member. This merging eliminates the need for two separate protective members while maintaining individual cable protection through internal insulation layers.
Solution Approach 2:
The patent employs a nested structure where one cable is positioned inside or adjacent to another cable within a shared protective member. The conductors are arranged concentrically or in close proximity with shared insulation and protective layers, reducing the overall width dimension while maintaining individual cable integrity.
2Ease of operation
If two high-voltage electrical power cables are arrayed side by side, then installation flexibility is maintained, but the bending capability is restricted and routing freedom is reduced
Solution Approach 1:
By merging two cables into a single integrated structure with shared protective layers, the overall flexibility is improved compared to two separate rigid cables. The unified structure allows for easier routing and bending while maintaining the electrical independence of both conductors through internal insulation.
3Ease of manufacture
If two high-voltage electrical power cables are arrayed side by side, then each cable can be independently routed, but the degree of freedom in routing is influenced and workability is poor
Solution Approach 1:
The integrated cable structure combines routing operations into a single unit, improving productivity by reducing the number of separate routing operations. Both conductors are routed together as one component while maintaining electrical independence, significantly reducing installation time and complexity.
Solution Approach 2:
While merged into a single structure, the cable maintains internal segmentation with distinct conductors and insulation layers, allowing for independent electrical routing while simplifying mechanical installation as a unified component.
4Reliability
If multiple high-voltage and low-voltage cables are housed separately, then each cable type can be individually protected, but the number of insertion operations increases and workability deteriorates
Solution Approach 1:
The patent merges high-voltage and low-voltage circuits into a single integrated cable assembly with shared protective members. This consolidation reduces the number of separate insertion operations required during installation while maintaining appropriate protection for both voltage levels through layered insulation design.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A multilayer coaxial cable (15) includes high-voltage circuits (16, 17) that are coaxially disposed with each other. The high-voltage circuits (16, 17) include high-voltage conductors (21, 23) and high-voltage insulators (22, 24) that are disposed on the outside of the high-voltage conductors. In addition, the multilayer coaxial cable includes a conductive shield member (18) that is coaxially disposed on the outside of the high-voltage circuits, and an insulating coating member (19) that is coaxially disposed on the outside of the shield member.