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: An electrical connector for connecting a high voltage power cable including an electrical conductor to an electrical terminal. The electrical connector includes a terminal connection portion and a conductor connection portion including a conductor interface surface. The connector further includes a conduit formed therein between an inlet opening and an outlet opening, the conduit defining a path for the circulation of a coolant through the connector, the conduit being configured to receive the coolant from a cooling system pipe. The connector includes a heat transfer surface configured to be in contact with the coolant circulating through the conduit for transferring heat from the connector to the coolant. The specification also provides a power cable assembly and a cooling system for coupling with a power cable assembly.

Abstract: The electrical connector comprises at least one contact terminal, a printed circuit board on which at least one thermal sensor is mounted to monitor the temperature of the at least one contact terminal, at least one thermal conductive pad that includes at least one first thermal contact surface in direct engagement with the at least one contact terminal, and a second thermal contact surface in direct engagement with the at least one thermal sensor, to transfer heat from the at least one contact terminal to the at least one thermal sensor, and a support device for the at least one thermal conductive pad. The at least one thermal conductive pad is compressed between the support device and the printed circuit board by a force of compression causing the at least one first thermal contact surface to press against the at least one contact terminal and the second thermal contact surface to deform on the thermal sensor covering the thermal sensor.

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 power cable assembly and a power distribution system incorporate an integrated cooling system. The power cable assembly comprises a power cable core comprising an electrical conductor an electrical conductor extending longitudinally, a plurality of longitudinally extending cooling pipes, and a thermal interface material (TIM) surrounding the cooling pipes and electrical conductor. The TIM is configured to thermally couple an external surface of the thermally conductive wall of each cooling pipe with an external surface of the insulating material of the electrical conductor such that the heat generated at the electrical conductor is transferred, via the external surface of the cooling pipes over a heat transfer region, to the coolant medium circulating in the interior channel.

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.