High power, high frequency, liquid-cooled transmission cable and charging system

摘要

A charging system employing a liquid-cooled transmission cable for transferring power. The transmission cable has a central tube with an extruded member disposed therewithin for carrying coolant. A plurality of layers of coaxial tubular wire braid are disposed around the central tube that carry charging current and that are separated by a layers of dielectric material. An outer layer of wire braid is disposed around an outermost layer of dielectric material that is used for grounding and/or shielding. An outer jacket is disposed around the outer layer of wire braid for encasing the transmission cable. The extruded member may comprise a thermoplastic rubber extrusion, for example. The coolant path through the transmission cable is internally supported by means of the extruded member to assure uniform flexibility, maintain tangential magnetic flux, and eliminate kinking and collapse of the flow path. The transmission cable is designed for charging propulsion batteries of an electric vehicle at extremely high charge rates. The charging system includes an external power source and off-vehicle inverter for providing charging current to the propulsion batteries by way of a charge port and a rectification/filter circuit in the electric vehicle. The transmission cable is coupled between the charge port and the rectification/filter circuit. A cooling system is coupled to the transmission cable that has a radiator for cooling coolant, a manifold, a pump that pumps the coolant, and a reservoir for storing excess coolant. The coolant is pumped from the cooling system through the transmission cable to cool it. The transmission cable 20 is capable of transferring 120 kW @334 Amps RMS @75 KHz.