Wire Harness Cooling Unit for EV Power Storage
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Solution Overview
Problem
Conventional electric vehicle harness routing structures face challenges in maintaining proper mountability and cooling efficiency, especially with increased voltage and current demands during quick charging, which can lead to overheating and structural issues.
Innovation Solution
A wire harness unit incorporating a routing material that extends between a charging inlet and a power storage device, with a cooling unit that includes a cooling pipe for circulating a cooling medium, allowing for effective heat management and reduced cross-sectional area of the charging conduction path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the voltage and current are increased for high charging electric power output, then the charging speed is improved, but the heat generation in the harness increases causing overheating and reliability issues
Solution Approach 1:
A cooling medium is introduced as an intermediary substance that flows through the harness routing structure, absorbing heat from the routing material and conducting it away to a heat dissipation location, thereby mediating the thermal management between the high-power charging system and the surrounding environment
Solution Approach 2:
The patent employs a liquid cooling system where a cooling medium circulates through the harness routing structure via hydraulic flow, using the fluid's thermal capacity to transport heat away from the routing material during high-power charging operations
2Temperature
If a cooling system is added to the wire harness, then the temperature control is improved, but the device complexity increases
Solution Approach 1:
The cooling function is merged with the wire harness routing structure itself, where the harness routing material serves dual purposes as both electrical conductor and thermal management component, eliminating the need for separate cooling apparatus and reducing overall system complexity
Solution Approach 2:
The routing material is designed to perform multiple functions simultaneously: electrical power transmission and thermal heat conduction to the cooling medium, allowing a single component to serve both electrical and thermal management roles throughout the charging process
3Area of stationary object
If the cross-sectional area of the charging conduction path is reduced, then the mountability is improved, but the heat dissipation capability deteriorates
Solution Approach 1:
The patent replaces reliance on passive radiative heat dissipation from the harness surface with an active convective cooling system where a flowing cooling medium carries heat away, enabling effective thermal management from a compact cross-sectional area without depending on surface area for heat loss
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 cooling of the routing material, preventing overheating and ensuring proper mountability, even under high voltage and current conditions, while reducing the number of components and manufacturing costs.
Implementation Method 1
a cooling unit that cools the routing material... a cooling pipe at least a part of which is provided along the routing material and inside which a cooling medium is able to flow, and is capable of cooling the routing material by the cooling medium flowing inside the cooling pipe
Data Source
AI summary
A wire harness unit applied to a power storage device unit and a wire harness includes a routing material and a cooling unit that cools the routing material. The routing material constitutes a charging conduction path that extends between a charging inlet and a power storage device, and transmits electricity. The charging inlet is provided to a vehicle. The power storage device is provided to the vehicle and can store electric power. As a result, the wire harness unit, the power storage device unit, and the wire harness can reduce a cross-sectional area of the routing material to a relatively small area, thereby having an advantageous effect of capable of having proper mountability.