A Novel Method for Management of Thermal Loads in the EV Cable Based on Improved Thermal Conductivity of Insulation and Sheathing Materials

For the purpose of shortening charging time and promoting the acceptance of EVs, high power charging system becomes imperative which makes the EV cable have to carry high current varying from tens to hundreds. Under such large current, heat generating is a serious issue. In this paper, a novel method was proposed to manage the thermal loads of EV cable, where high thermal conductivity insulation and sheathing materials were employed to make up the cable. In order to ensure the feasibility of the modified materials applying in cable, electrical and thermal properties of various specimens with different materials were investigated. Obtained results showed that both the modified EPDM insulating and CSM sheathing materials had excellent electrical and improved thermal properties. In order to investigate the effects of high thermal conductivity insulation and sheathing materials on temperature behavior, two EPDM-insulated, CSM-sheathed, and single-core cables for EVs were extruded and shaped, and temperature rise experiments were carried out. Obtained results showed that the temperature distribution of cable was improved and the heat dissipation capability was enhanced.