Liquid-cooled tangle resistant charge cable

Patent metadata

Field	Value
Publication number	US-10867723-B2
Application number	US-201715720181-A
Country	US
Kind code	B2
Filing date	Sep 29, 2017
Priority date	Sep 30, 2016
Publication date	Dec 15, 2020
Grant date	Dec 15, 2020

Abstract

A liquid-cooled tangle-resistant charging cable may include a sheath defining a cavity, the sheath having a width dimension, a height dimension, a thickness dimension and a length dimension; wherein the width dimension is larger than the height dimension, and the length dimension is larger than both the height dimension and the width dimension; a first conductor disposed in the cavity, the first conductor having at least one substantially flat side; a hose disposed in the cavity and configured to carry a cooling liquid, the cross-sectional profile of the hose being non-circular and having at least one flat side. In some embodiments, the sheath's cross-sectional height dimension may be between 2% and 95% of the sheath's cross sectional width dimension.

First claim

The invention claimed is:

1. A liquid-cooled tangle-resistant charging cable comprising:
a sheath defining a cavity, the sheath having a width dimension, a height dimension, a thickness dimension and a length dimension; wherein the width dimension is larger than the height dimension, and the length dimension is larger than both the height dimension and the width dimension;
a first conductor disposed in the cavity, the cross-sectional profile of the first conductor being non-circular and having at least one substantially flat side;
second conductor disposed in the cavity;
a third conductor disposed in the cavity;
a hose disposed in the cavity and configured to carry a cooling liquid, the cross-sectional profile of the hose being non-circular and having at least one flat side; and
a first insulation jacket disposed in the cavity and configured to cover at least a portion of the first conductor; a second insulation jacket disposed in the cavity and configured to cover at least a portion of the second conductor; and a third insulation jacket disposed in the cavity and configured to cover at least a portion of the third conductor;
wherein the at least one substantially flat side of the first conductor is adjacent to the at least one substantially flat side of the hose.

2. The liquid-cooled tangle-resistant charging cable of claim 1 , further comprising a ground conductor disposed within the cavity.

3. The liquid-cooled tangle-resistant charging cable of claim 1 , wherein the substantially flat side of the hose abuts between 15% and 100% of the substantially flat side of the first conductor by surface area.

4. The liquid-cooled tangle-resistant charging cable of claim 3 , wherein the substantially flat side of the hose abuts between 15% and 100% of the substantially flat side of the second conductor by surface area.

5. The liquid-cooled tangle-resistant charging cable of claim 4 , wherein the substantially flat side of the hose abuts between 15% and 100% of the substantially flat side of the third conductor by surface area.

6. The liquid-cooled tangle-resistant charging cable of claim 1 , wherein the substantially flat side of the hose abuts between 15% and 100% of the substantially flat side of the first insulation jacket by surface area.

7. The liquid-cooled tangle-resistant charging cable of claim 6 , wherein the substantially flat side of the hose abuts between 15% and 100% of the substantially flat side of the second insulation jacket by surface area.

8. The liquid-cooled tangle-resistant charging cable of claim 7 , wherein the substantially flat side of the hose abuts between 15% and 100% of the substantially flat side of the third insulation jacket by surface area.

9. The liquid-cooled tangle-resistant charging cable of claim 1 , wherein the first conductor comprises multiple metallic wires bundled together such that the outer cross-sectional profile of the bundled metallic wires is substantially rectangular.

10. The liquid-cooled tangle-resistant charging cable of claim 1 , wherein the sheath is made of a material that changes pigment based on changes in temperature.

11. A liquid-cooled tangle-resistant charging cable comprising:
a sheath defining a cavity, the sheath having a width dimension, a height dimension, a thickness dimension and a length dimension; wherein the width dimension is larger than the height dimension, and the length dimension is larger than both the height dimension and the width dimension;
a first conductor disposed in the cavity, the cross-sectional profile of the first conductor being non-circular and having at least one substantially flat side;
a hose disposed in the cavity and configured to carry a cooling liquid, the cross-sectional profile of the hose being non-circular and having at least one flat side; and
a thermistor coupled to the first conductor, wherein current flow is reduced responsive to the thermistor signaling that the temperature of the first conductor is above a predefined level;
wherein the at least one substantially flat side of the first conductor is adjacent to the at least one substantially flat side of the hose.

12. The liquid-cooled tangle-resistant charging cable of claim 1 , further comprising a thermistor coupled to the first conductor, wherein current flow is terminated responsive to the thermistor signaling that the temperature of the first conductor is above a predefined level.

13. A liquid-cooled tangle-resistant charging cable comprising:
a sheath defining a cavity, the sheath having a width dimension, a height dimension, a thickness dimension and a length dimension; wherein the width dimension is larger than the height dimension, and the length dimension is larger than both the height dimension and the width dimension;
a first conductor disposed in the cavity, the cross-sectional profile of the first conductor being non-circular and having at least one substantially flat side;
a hose disposed in the cavity and configured to carry a cooling liquid, the cross-sectional profile of the hose being non-circular and having at least one flat side;
wherein the at least one substantially flat side of the first conductor is adjacent to the at least one substantially flat side of the hose; and
wherein the sheath is configured to display a bending stiffness in a first direction (or about a first axis) that is greater than the bending stiffness in a second direction (or about a second axis).

14. The liquid-cooled tangle-resistant charging cable of claim 13 , wherein the first axis and the second axis are orthogonal.

15. The liquid-cooled tangle-resistant charging cable of claim 1 , further comprising an armor layer disposed between the sheath and the first insulation jacket, wherein the armor layer is configured with a bending stiffness in a first direction (or about a first axis) that is greater than the bending stiffness in a second direction (or about a second axis).

Assignees

• Faraday&Future Inc
• Faraday & Future Inc

Inventors

• Cao Chi Hung
• de Jung Mike

Classifications

• Y02T10/70

  Energy storage systems for electromobility, e.g. batteries · CPC title

• H01B9/006

  Constructional features relating to the conductors · CPC title

• H02H5/042

  using temperature dependent resistors · CPC title

• H01B7/425 Primary

  the construction being bendable · CPC title

• Y02T10/7072

  Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors · CPC title