Vascular Cooling in Electrical Conductors for High-Voltage Systems
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Solution Overview
Problem
High-voltage electrical systems in electric-drive vehicles face significant heat dissipation issues during power transfer, leading to unacceptable temperature profiles and increased costs, weight, and packaging space requirements due to traditional cooling methods.
Innovation Solution
The integration of internal vascular cooling systems within electrical conductor assemblies, which include a protective outer sheath with cooling channels parallel to the electrical cables, allowing for the transmission of both electrical power and coolant fluid, reducing the need for dedicated coolant piping and minimizing mass and size while maintaining power capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional dedicated cooling systems are used for high-voltage electrical systems, then heat dissipation is improved, but system cost, weight, and packaging space increase
Solution Approach 1:
The patent combines the electrical conductor and cooling channel into a single integrated assembly. The cooling channels are formed within the conductor structure itself, merging the electrical power transmission function with the thermal management function into one component, thereby eliminating separate cooling systems and reducing overall weight
Solution Approach 2:
The electrical conductor assembly serves multiple functions simultaneously: it transmits electrical power and provides thermal management through integrated cooling channels. This multi-functional design eliminates the need for separate dedicated cooling systems, reducing system complexity, weight, and packaging space
2Temperature
If traditional dedicated cooling systems are used for high-voltage electrical systems, then heat dissipation is improved, but system cost and packaging space increase
Solution Approach 1:
The patent combines the electrical conductor and cooling channel into a single integrated assembly. The cooling channels are formed within the conductor structure itself, merging the electrical power transmission function with the thermal management function into one component, thereby eliminating separate cooling systems and reducing overall weight
Solution Approach 2:
The electrical conductor assembly serves multiple functions simultaneously: it transmits electrical power and provides thermal management through integrated cooling channels. This multi-functional design eliminates the need for separate dedicated cooling systems, reducing system complexity, weight, and packaging space
3Power
If electrical conductor size is increased to handle higher power, then power capacity is improved, but mass and size increase
Solution Approach 1:
The patent employs fluid cooling through channels integrated within the conductor structure. This hydraulic cooling system efficiently removes heat from the conductor, allowing for reduced conductor cross-section while maintaining power capacity, thereby reducing mass without compromising thermal performance
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
This solution effectively reduces heat generation, decreases the mass and size of conductive materials, and lowers system costs, enhancing vehicle range and efficiency by integrating active cooling directly into the electrical conductor design.
Implementation Method 1
A coolant channel extends through the tubular sheath body, aligned parallel with and thermally connected to the cable body. The coolant channel passes therethrough a coolant fluid and thereby cools the electrical conductor.
Data Source
AI summary
Presented are electrical conductor assemblies with vascular cooling systems, methods for making/using such assemblies, and vehicles equipped with such assemblies for transmitting power and coolant between electric devices. An electrical conductor assembly includes an outer sheath, an electrical conductor extending through the sheath, a coolant channel defined through the sheath, and an optional cable jacket encasing the electrical conductor. The outer sheath has a tubular body formed from an electrically insulating material. The electrical conductor has a solid cable body located within a conductor duct extending through the sheath. The coolant channel, which is coaxial with and thermally connected to the cable body, passes therethrough coolant fluid that cools the electrical conductor. The cable jacket may be formed from an electrically insulating material having a thermal conductivity and melting point higher than that of the sheath. The conductor assembly may include multiple electrical conductors circumferentially spaced around the coolant channel.