Abstract: A high voltage power cable assembly for a power distribution system of a vehicle incorporating an integrated cooling system is presented. The power cable assembly comprises first and second electrical conductors spaced apart from one another and extending longitudinally. The power cable assembly further comprises a longitudinally extending cooling tube arranged between the first and second electrical conductors such that opposing portions of an external surface of the cooling tube are provided in direct contact with corresponding portions of the insulating material of the electrical conductors over a heat exchange region so as to transfer heat from the electrically conductive core of the electrical conductors to a coolant medium circulating in an internal channel of the cooling tube.

Abstract: A power cable assembly includes a power cable core. The power cable core has a longitudinally extending cooling tube comprising a thermally conductive wall defining an interior channel for circulating, between a coolant inlet and a coolant outlet of the cooling tube, a coolant medium; a longitudinally extending electrical conductor configured to be coupled via first and second connectors to respective electrical connections of a power distribution system; and a first insulating layer surrounding the power cable core. The electrical conductor is arranged to surround the cooling tube at least partially such that at least a portion of an external surface of the thermally conductive wall is provided in direct contact with a corresponding portion of the electrical conductor over a heat exchange region so as to transfer heat from the electrical conductor to the coolant medium circulating in the interior channel of the cooling tube.

Abstract: A high voltage power cable including an insulating body comprising a polymer and defining an interior channel configured to receive a coolant, and an electrical conductor buried in the insulating body.

Abstract: A power cable assembly includes a power cable core. The power cable core has a longitudinally extending cooling tube comprising a thermally conductive wall defining an interior channel for circulating, between a coolant inlet and a coolant outlet of the cooling tube, a coolant medium; a longitudinally extending electrical conductor configured to be coupled via first and second connectors to respective electrical connections of a power distribution system; and a first insulating layer surrounding the power cable core. The electrical conductor is arranged to surround the cooling tube at least partially such that at least a portion of an external surface of the thermally conductive wall is provided in direct contact with a corresponding portion of the electrical conductor over a heat exchange region so as to transfer heat from the electrical conductor to the coolant medium circulating in the interior channel of the cooling tube.

Abstract: A high voltage power cable assembly includes an electrically conductive and thermally conductive conductor. The electrical conductor extends longitudinally between first and second end contact surfaces configured for coupling via first and second connectors to electrical connections. The electrical conductor comprises an internal surface and an external surface, wherein the internal surface defines an interior channel configured for receiving a dielectric coolant from a cooling system arranged in communication with the electrical conductor; and wherein the internal surface is an electrically conductive heat transfer surface arranged to be in direct contact with the dielectric coolant for transferring heat from the conducting body to the dielectric coolant.

Abstract: A high voltage power cable assembly for a power distribution system of a vehicle incorporating an integrated cooling system is presented. The power cable assembly comprises first and second electrical conductors spaced apart from one another and extending longitudinally. The power cable assembly further comprises a longitudinally extending cooling tube arranged between the first and second electrical conductors such that opposing portions of an external surface of the cooling tube are provided in direct contact with corresponding portions of the insulating material of the electrical conductors over a heat exchange region so as to transfer heat from the electrically conductive core of the electrical conductors to a coolant medium circulating in an internal channel of the cooling tube.

Abstract: A cable termination includes a cable end of a cable having a protective outer jacket and an overmolded sealant. The cable termination is manufactured using a method having the steps of providing a cable end of a cable having a protective outer jacket, preparing the protective outer jacket of the cable end such as to promote adhesion with a sealant, and overmolding the cable end with a sealant.

Abstract: A cable termination includes a cable end of a cable having a protective outer jacket and an overmolded sealant. The cable termination is manufactured using a method having the steps of providing a cable end of a cable having a protective outer jacket, preparing the protective outer jacket of the cable end such as to promote adhesion with a sealant, and overmolding the cable end with a sealant.

Abstract: A method used to predict a strength of an ultrasonic weld-joint of a wire-cable comprising the steps of providing a wire-cable, determining a combined-weight, removing a contaminant, determining a weight, determining a percentage by weight of the contaminant, and determining whether the percentage by weight of contaminant is less than a threshold. Determining the percentage by weight of the contaminant removed from the wire-cable is based on a formula [(Mb?Ma)/Mb]*100, where Mb is the combined-weight of the wire-cable and the contaminant and Ma is the weight of the wire-cable. The threshold of the percentage by weight of the contaminant correlates to the strength of the ultrasonic weld-joint.

Abstract: A method used to predict a strength of an ultrasonic weld-joint of a wire-cable comprising the steps of providing a wire-cable, determining a combined-weight, removing a contaminant, removing a solvent, determining a weight, determining a percentage by weight of the contaminant, and determining whether the percentage by weight of contaminant is less than a threshold. Determining the percentage by weight of the contaminant removed from the wire-cable is based on a formula [(Mb?Ma)/Mb]*100, where Mb is the combined-weight of the wire-cable and the contaminant and Ma is the weight of the wire-cable. The threshold of the percentage by weight of the contaminant correlates to the strength of the ultrasonic weld-joint.

Abstract: A method used to predict a strength of an ultrasonic weld-joint of a wire-cable comprising the steps of providing a wire-cable, determining a combined-weight, removing a contaminant, removing a solvent, determining a weight, determining a percentage by weight of the contaminant, and determining whether the percentage by weight of contaminant is less than a threshold. Determining the percentage by weight of the contaminant removed from the wire-cable is based on a formula [(Mb?Ma)/Mb]*100, where Mb is the combined-weight of the wire-cable and the contaminant and Ma is the weight of the wire-cable. The threshold of the percentage by weight of the contaminant correlates to the strength of the ultrasonic weld-joint.

Abstract: A method used to predict a strength of an ultrasonic weld-joint of a wire-cable comprising the steps of providing a wire-cable, determining a combined-weight, removing a contaminant, determining a weight, determining a percentage by weight of the contaminant, and determining whether the percentage by weight of contaminant is less than a threshold. Determining the percentage by weight of the contaminant removed from the wire-cable is based on a formula [(Mb?Ma)/Mb]*100, where Mb is the combined-weight of the wire-cable and the contaminant and Ma is the weight of the wire-cable. The threshold of the percentage by weight of the contaminant correlates to the strength of the ultrasonic weld-joint.