CN107039117B - Flexible cable for new energy automobile - Google Patents
Flexible cable for new energy automobile Download PDFInfo
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- CN107039117B CN107039117B CN201710390874.6A CN201710390874A CN107039117B CN 107039117 B CN107039117 B CN 107039117B CN 201710390874 A CN201710390874 A CN 201710390874A CN 107039117 B CN107039117 B CN 107039117B
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/42—Insulated conductors or cables characterised by their form with arrangements for heat dissipation or conduction
- H01B7/421—Insulated conductors or cables characterised by their form with arrangements for heat dissipation or conduction for heat dissipation
- H01B7/423—Insulated conductors or cables characterised by their form with arrangements for heat dissipation or conduction for heat dissipation using a cooling fluid
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
- H01B3/18—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
- H01B3/28—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances natural or synthetic rubbers
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
- H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
- H01B7/189—Radial force absorbing layers providing a cushioning effect
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
- H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
- H01B7/22—Metal wires or tapes, e.g. made of steel
- H01B7/221—Longitudinally placed metal wires or tapes
- H01B7/225—Longitudinally placed metal wires or tapes forming part of an outer sheath
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
- H01B7/28—Protection against damage caused by moisture, corrosion, chemical attack or weather
- H01B7/282—Preventing penetration of fluid, e.g. water or humidity, into conductor or cable
- H01B7/2825—Preventing penetration of fluid, e.g. water or humidity, into conductor or cable using a water impermeable sheath
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
- H01B7/29—Protection against damage caused by extremes of temperature or by flame
- H01B7/295—Protection against damage caused by extremes of temperature or by flame using material resistant to flame
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/60—Other road transportation technologies with climate change mitigation effect
- Y02T10/70—Energy storage systems for electromobility, e.g. batteries
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- Physics & Mathematics (AREA)
- Spectroscopy & Molecular Physics (AREA)
- Electric Propulsion And Braking For Vehicles (AREA)
- Insulated Conductors (AREA)
Abstract
The invention discloses a flexible cable for a new energy automobile, which is provided with a conductor and an insulating layer for coating the conductor, wherein the insulating layer is coated with a cooling layer, at least one cooling medium channel extending along the length direction of the insulating layer is arranged in the cooling layer, and the cooling medium channel is used for introducing cooling medium to cool and dissipate heat of the insulating layer. The invention can effectively, reliably and rapidly remove the heat radiated by the insulating layer by the cooling medium, and the heat radiated outside the cooling layer is reasonable, controllable and safe, so as to meet the special use requirements of the new energy automobile.
Description
Technical Field
The invention relates to a cable, in particular to a flexible cable for a new energy automobile, and particularly relates to a high-voltage flexible cable for a new energy automobile.
Background
The rechargeable automobile is taken as a new energy automobile, has an energy saving advantage which is incomparable with the traditional fuel automobile, and is a trend of automobile development in the future. In recent years, new energy charging automobiles are rapidly developed and have higher market popularity.
Although the new energy charging automobile has a plurality of advantages in the aspect of energy conservation, the main technical bottleneck limiting the popularization and development of the new energy charging automobile is how to ensure the reliability and stability of the running of the power source. The reliability and stability of the power source operation of the new energy charging automobile are improved, and the new energy charging automobile is required to have larger-capacity batteries, high-voltage electric motors, controllers and other electrical equipment, and the electric power supply between the electrical equipment needs to be connected with corresponding high-voltage cables, namely vehicle-mounted high-voltage flexible cables.
At present, a high-voltage flexible cable for a new energy charging automobile is a common high-voltage cable, which mainly comprises a single-core copper conductor, an insulating layer, a shielding layer and a sheath layer which are sequentially coated from inside to outside, and the sheath layer is usually molded by plastic. In the actual use process of the new energy charging automobile, the temperature designed on the conductor of the vehicle-mounted high-voltage flexible cable is usually higher than 120 ℃, and the high-voltage flexible cable is in a relatively closed environment in the automobile; therefore, the body of the vehicle-mounted high-voltage flexible cable is serious in heating and poor in heat dissipation environment, the temperature of the outer surface of the insulating layer is up to 100 ℃, and the temperature of the insulating layer which is finally acted on the sheath layer is up to 80-90 ℃, so that the local temperature of the cable or the environment in the vehicle is easily caused to be too high, and further fire disaster is caused, so that the existing high-voltage flexible cable applied to the new energy automobile has larger potential safety hazard.
The technical problems of insufficient heat dissipation and easy potential safety hazard initiation of the high-voltage flexible cable are difficult to solve by replacing a simple molding material (comprising a flame retardant material), and the best solution is to innovate and change the molding structure of the cable, realize excellent heat dissipation performance by forcedly cooling a cooling medium comprising air, and finally ensure the reliability and stability of the operation of a new energy charging automobile power source.
However, in the cable industry, no cable with forced heat dissipation and cooling functions, which can be applied to new energy automobiles, is known. In the published chinese patent literature, there are disclosed hollow self-cooling cable technologies applied to high-rise buildings, for example, technologies named "hollow self-cooling cable" (publication No. CN 101546626, publication No. 2009, 9, 30), and "self-cooling cable of high-rise building power distribution system" (publication No. CN 202796208, publication No. 2013, 3, 13); although the technology introduces cooling medium-air into the cable to realize the self-cooling of forced heat dissipation of the cable, namely, the technology arranges a hollow metal pipe in a hollow conductor, so that the hollow of the metal pipe forms a cooling medium channel to realize the cooling of heat dissipation of the conductor. However, the self-cooling cable has the technical problems of large molding section, large structural volume, large processing difficulty, more conductor consumables, high processing cost and the like, and is not suitable for new energy charging automobiles with compact accommodating spaces; moreover, they can only dissipate heat from the conductor through the hollow metal tube at the center of the conductor, and cannot directly, effectively and reliably dissipate the heat of the conductor directly radiating on the insulating layer, that is, the heat bearing capacity of the insulating layer coated outside the conductor is still higher, and the temperature of the insulating layer radiating on the protective layer (or the sheath layer) is still higher, so that the heat dissipation and self-cooling effects of the technologies are limited, and the reliability and practicality are relatively insufficient.
Disclosure of Invention
The technical purpose of the invention is that: aiming at the particularity of the new energy automobile and the defects of the prior cable technology, the soft cable for the new energy automobile is simple and compact in structure, small in molding difficulty, low in cost, excellent in heat dissipation effect, high in flame retardant property, reliable and safe.
The technical scheme adopted by the invention for realizing the technical purpose is as follows: the utility model provides a flexible cable for new energy automobile, the cable has the insulating layer of conductor and cladding conductor, the cladding has the cooling layer outside the insulating layer, have at least one cooling medium passageway that extends along insulating layer length direction in the cooling layer, cooling medium passageway is used for introducing cooling medium to cool off, dispel the heat to the insulating layer.
As one of the preferred embodiments, the cooling layer is formed by a high-strength flame-retardant material, and the cooling medium channels on the cooling layer are distributed on the periphery of the insulating layer in a circumferential segmented manner. Further, the molding material of the cooling layer is a high-strength, low-smoke and halogen-free polyolefin material, and the hardness of the polyolefin material is between 85 and 90A on the Shore scale. The cooling medium channels on the cooling layer are three or four, the cooling medium channels are distributed on the periphery of the insulating layer in a circumferential equidistant and uniform segmented mode, and the included angle between the radial central lines of the adjacent cooling medium channels is 120 degrees or 90 degrees.
As one of the preferred embodiments, the cooling medium channel on the cooling layer is mainly composed of an integral supporting bone and a periphery, the supporting bone is arranged at two ends of the periphery quilt, the inner wall of the supporting bone is abutted against the outer wall of the insulating layer, the periphery quilt is radially supported by the supporting bone, a clearance space is formed between the periphery quilt and the insulating layer, a cooling medium channel which is U-shaped in section and is used for introducing cooling medium is enclosed between the inner wall of the periphery quilt and the side walls of the supporting bones at two sides, and the radially inner opening of the cooling medium channel acts on the outer wall of the insulating layer. Further, the cross section of the cooling medium channel on the cooling layer is in a fan shape with a large outside and a small inside.
As one of the preferable embodiments, the cooling medium introduced into the cooling medium passage on the cooling layer is air.
As one of preferable schemes, the insulating layer is of a high-temperature resistant ceramic silicon rubber structure with the thickness of 0.80-2.8 mm.
As one of the preferable schemes, the cooling layer is covered with an armor layer. Furthermore, the armor layer is an interlocking metal armor layer made of an aluminum alloy material, the thickness of the interlocking metal armor layer is 0.2-0.5 mm, the bow height is 1-4 mm, and the pitch is 3-10 mm. Still further, the aluminum alloy material is a high strength 8030 aluminum alloy strip.
As one of the preferable schemes, a wrapping band layer is arranged between the cooling layer and the armor layer, and the wrapping band layer is wrapped on the outer surface of the cooling layer. Further, the wrapping band layer is of a semiconductive water-blocking band structure with the thickness of 0.3mm, and the overlapping rate of the wrapping band layer is 10-50%.
As one of preferable schemes, the conductor is a 6 th soft copper conductor or a 6 th tinned soft copper conductor, and the diameter of a copper wire formed by the soft copper conductor is 0.15-0.31 mm.
The beneficial technical effects of the invention are as follows:
1. the invention has the advantages that on the premise of not influencing the structural layout of conductors, the cooling layer with the cooling medium channel is coated outside the insulating layer, so that when in use, the cooling medium is introduced into the cooling medium channel of the cooling layer to directly, effectively, reliably and excellently forcedly cool and dissipate heat of the outer surface of the insulating layer, so that the heat radiated outwards by the insulating layer is effectively, reliably and rapidly and greatly eliminated by the cooling medium, the heat radiated outside the cooling layer is reasonable, controllable and safe, so as to meet the special use requirements of new energy automobiles, and the invention has the characteristics of simple structure, convenient molding, small molding difficulty, low molding cost, compact structure, good flexibility, excellent heat dissipation effect, high flame retardant property, high reliability, good safety, strong practicability and the like, and can reliably, safely and stably serve and operate in various severe environments;
2. the cooling layer structure can enable the cooling medium channel to reasonably, effectively and reliably surround the outer surface of the insulating layer, can reasonably, effectively and reliably increase the heat exchange area between the cooling medium and the outer surface of the insulating layer, can effectively enhance the overall structural strength and flexibility of the cable, and can further enhance the heat dissipation effect while reducing the molding difficulty;
3. the cooling medium adopted by the invention can realize good carrying and heat dissipation by natural (or forced) flow, has good heat exchange effect, strong operability and negligible cost, and is convenient, reliable and practical;
4. the insulating layer adopted by the invention is ceramic silicon rubber insulation with the temperature resistance of 180 ℃, the temperature resistance level is obviously higher than that of the conventional TPE insulation and irradiation crosslinking polyolefin insulation, the flexibility is higher than that of the conventional insulation, if the ceramic silicon rubber insulation can be quickly changed into a crust similar to ceramic in a flame environment, the conductor is ensured not to be short-circuited, and the invention has the advantages of high flame retardant property, high insulating property, safety and better reliability;
5. the armor layer has good flexibility, good extrusion resistance and excellent flame retardance, can effectively and reliably ensure that the cable does not self-ignite when meeting open fire, has flame retardance meeting the technical requirement of the ZA characteristic of the highest flame retardance grade, further ensures and improves the safety and reliability of the armor layer, and has extremely high flame retardance;
6. the wrapping tape layer can realize certain buffering and water blocking effects so as to improve the vibration resistance and water resistance of the wrapping tape, and further enhance the practicability of the wrapping tape.
Drawings
Fig. 1 is a schematic view of a structure of the present invention.
The meaning of the symbols in the figures: 1-a conductor; 2-an insulating layer; 3-a cooling layer; 31-supporting bone; 32-peripheral quilt; 33-cooling medium channels; 4-a tape layer; 5-armor layer.
Detailed Description
The invention relates to a flexible cable, in particular a high-voltage flexible cable, for a new energy vehicle, in particular a new energy charging vehicle, which is usually applied to the new energy vehicle in a vehicle-mounted manner. The technical content of the present invention will be described in detail with reference to the following embodiments, wherein embodiment 1 is described in detail with reference to the accompanying drawings, and other embodiments are not separately drawn, but the main technical points can be referred to the accompanying drawings of embodiment 1.
Example 1
Referring to fig. 1, the invention relates to a high-voltage flexible cable for a vehicle-mounted new energy charging automobile, which mainly comprises a conductor 1, and an insulating layer 2, a cooling layer 3, a wrapping layer 4 and an armor layer 5 which are sequentially coated from inside to outside, wherein the insulating layer 2, the cooling layer 3, the wrapping layer 4 and the armor layer 5 are radially layered and formed by taking the conductor 1 as a circle center.
Wherein the conductor 1 is a 6 th soft copper conductor. The diameter of the constituent copper wires of the soft copper conductor is about 0.20mm.
The insulating layer 2 is formed by extrusion molding of high-temperature resistant ceramic silicon rubber, namely, the insulating layer 2 is formed on the outer surface of the conductor 1 in an extrusion molding mode. The thickness of the insulating layer 2 is about 2.0mm.
The cooling layer 3 is extruded from a high-strength, low-smoke, halogen-free flame-retardant material, polyolefin, the hardness of which is approximately Shore 89A. The cooling layer 3 formed by extrusion is internally provided with four cooling medium channels 33 which extend along the length direction of the insulating layer 2 respectively, the four cooling medium channels 33 are distributed on the periphery of the insulating layer 2 in a mode of equally dividing the circumference equally, the four cooling medium channels 33 are mutually independent, and the included angle between the radial central lines of the adjacent cooling medium channels is about 90 degrees; each cooling medium channel 33 on the cooling layer 3 is used for introducing (natural or forced, typically forced) a cooling medium-air to cool and dissipate heat from the outer surface of the insulating layer 2. Specifically, the cooling medium channel 33 on the cooling layer 3 is mainly composed of an integral supporting rib 31 and a peripheral quilt 32, the supporting rib 31 is positioned at two ends of the peripheral quilt 32, the inner wall of the supporting rib 31 is abutted against the outer wall of the insulating layer 2, the peripheral quilt 32 is radially supported by the supporting rib 31, a clearance space is formed between the peripheral quilt 32 and the insulating layer 2, the cooling medium channel 33 which is U-shaped in section and is used for introducing cooling medium-air is enclosed between the inner wall of the peripheral quilt 32 and the side walls of the supporting ribs 31 at two sides, and the radial inner opening of the cooling medium channel 33 acts on the outer wall of the insulating layer 2, namely, each supporting rib 31 serves as a separation belt and a support rib of two adjacent cooling medium channels 33; the cooling medium passage 33 of the foregoing structure has a fan shape with a large outside and a small inside in cross section.
The wrapping tape layer 4 adopts a semi-conductive water-blocking tape structure, and the thickness of the wrapping tape layer 4 is about 0.3mm. The wrapping tape layer 4 is wrapped on the outer surface of the cooling layer 3, and the overlapping rate of the wrapping tape layer 4 on the outer surface of the cooling layer 3 is about 45%.
The armor layer 5 is an interlocking metal armor layer made of an aluminum alloy material-high-strength 8030 aluminum alloy belt, the armor layer 5 is coated on the outer surface of the wrapping belt layer 4, the thickness of the armor layer 5 is about 0.3mm, the bow height is about 2mm, and the pitch is about 7mm.
Example 2
The invention relates to a high-voltage flexible cable for a new energy charging automobile, which mainly comprises a conductor, and an insulating layer, a cooling layer, a wrapping tape layer and an armor layer which are sequentially coated from inside to outside, wherein the insulating layer, the cooling layer, the wrapping tape layer and the armor layer are radially layered and formed by taking the conductor as a circle center.
Wherein the conductor is a 6 th tinned soft copper conductor. The diameter of the constituent tin-plated copper wire of the soft copper conductor is about 0.25mm.
The insulating layer is formed by extrusion molding of high-temperature resistant ceramic silicon rubber, namely the insulating layer is formed on the outer surface of the conductor in an extrusion molding mode. The thickness of the insulating layer is about 2.0mm.
The cooling layer is extruded from a high strength, low smoke, halogen free flame retardant material, polyolefin, having a hardness of about shore 90A. The cooling layer formed by extrusion is internally provided with four cooling medium channels which extend along the length direction of the insulating layer respectively, the four cooling medium channels are distributed on the periphery of the insulating layer in a circumferential equidistant and uniform sectional mode, the four cooling medium channels are mutually independent, and the included angle between the radial central lines of the adjacent cooling medium channels is about 90 degrees; each cooling medium channel on the cooling layer is used for introducing (natural or forced, usually forced) cooling medium-air to cool and dissipate heat from the outer surface of the insulating layer. Specifically, the cooling medium channel on the cooling layer is mainly composed of an integrated supporting rib and a periphery, the supporting ribs are arranged at two ends of the periphery and the inner wall of the supporting rib is abutted against the outer wall of the insulating layer, the periphery is radially supported by the supporting ribs, a clearance space is formed between the periphery and the insulating layer, the cooling medium channel which is U-shaped in cross section and is used for introducing cooling medium-air is enclosed between the inner wall of the periphery and the side walls of the supporting ribs at two sides, and the radial inner opening of the cooling medium channel acts on the outer wall of the insulating layer, namely, each supporting rib serves as a separation belt and a supporting rib of two adjacent cooling medium channels; the cooling medium channel with the structure has a fan shape with a large outside and a small inside.
The wrapping band adopts a semi-conductive water-blocking band structure, and the thickness of the wrapping band is about 0.3mm. The wrapping tape layer is wrapped on the outer surface of the cooling layer, and the overlapping rate of the wrapping tape layer on the outer surface of the cooling layer is about 35%.
The armor is an interlocking metal armor made of aluminum alloy material-high-strength 8030 aluminum alloy belt, the armor is coated on the outer surface of the belt layer, the thickness of the armor is about 0.4mm, the bow height is about 3mm, and the pitch is about 6mm.
Example 3
The invention relates to a high-voltage flexible cable for a new energy charging automobile, which mainly comprises a conductor, and an insulating layer, a cooling layer, a wrapping tape layer and an armor layer which are sequentially coated from inside to outside, wherein the insulating layer, the cooling layer, the wrapping tape layer and the armor layer are radially layered and formed by taking the conductor as a circle center.
Wherein the conductor is a 6 th soft copper conductor. The diameter of the constituent copper wires of the soft copper conductor is about 0.15mm.
The insulating layer is formed by extrusion molding of high-temperature resistant ceramic silicon rubber, namely the insulating layer is formed on the outer surface of the conductor in an extrusion molding mode. The thickness of the insulating layer is about 0.80mm.
The cooling layer is extruded from a high strength, low smoke, halogen free flame retardant material, polyolefin, having a hardness of about shore 85A. Three cooling medium channels respectively extending along the length direction of the insulating layer are arranged in the extrusion-molded cooling layer, are distributed on the periphery of the insulating layer in a circumferential equidistant and uniform sectional mode, are mutually independent and have an included angle of about 120 degrees between radial central lines of adjacent cooling medium channels; each cooling medium channel on the cooling layer is used for introducing (natural or forced, usually forced) cooling medium-air to cool and dissipate heat from the outer surface of the insulating layer. Specifically, the cooling medium channel on the cooling layer is mainly composed of an integrated supporting rib and a periphery, the supporting ribs are arranged at two ends of the periphery and the inner wall of the supporting rib is abutted against the outer wall of the insulating layer, the periphery is radially supported by the supporting ribs, a clearance space is formed between the periphery and the insulating layer, the cooling medium channel which is U-shaped in cross section and is used for introducing cooling medium-air is enclosed between the inner wall of the periphery and the side walls of the supporting ribs at two sides, and the radial inner opening of the cooling medium channel acts on the outer wall of the insulating layer, namely, each supporting rib serves as a separation belt and a supporting rib of two adjacent cooling medium channels; the cooling medium channel with the structure has a fan shape with a large outside and a small inside.
The wrapping band adopts a semi-conductive water-blocking band structure, and the thickness of the wrapping band is about 0.3mm. The wrapping tape layer is wrapped on the outer surface of the cooling layer, and the overlapping rate of the wrapping tape layer on the outer surface of the cooling layer is about 20%.
The armor is an interlocking metal armor made of aluminum alloy material-high-strength 8030 aluminum alloy belt, the armor is coated on the outer surface of the belting layer, the thickness of the armor is about 0.2mm, the bow height is about 1mm, and the pitch is about 4mm.
Example 4
The invention relates to a high-voltage flexible cable for a new energy charging automobile, which mainly comprises a conductor, and an insulating layer, a cooling layer, a wrapping tape layer and an armor layer which are sequentially coated from inside to outside, wherein the insulating layer, the cooling layer, the wrapping tape layer and the armor layer are radially layered and formed by taking the conductor as a circle center.
Wherein the conductor is a 6 th soft copper conductor. The diameter of the constituent copper wires of the soft copper conductor is about 0.20mm.
The insulating layer is formed by extrusion molding of high-temperature resistant ceramic silicon rubber, namely the insulating layer is formed on the outer surface of the conductor in an extrusion molding mode. The thickness of the insulating layer is about 1.20mm.
The cooling layer is extruded from a high strength, low smoke, halogen free flame retardant material, polyolefin having a hardness of about shore 88A. Two cooling medium channels respectively extending along the length direction of the insulating layer are arranged in the extrusion-molded cooling layer, are distributed on the periphery of the insulating layer in a circumferential equidistant and uniform sectional mode, are mutually independent, and have an included angle of about 180 degrees between radial central lines of adjacent cooling medium channels; each cooling medium channel on the cooling layer is used for introducing (natural or forced, usually forced) cooling medium-air to cool and dissipate heat from the outer surface of the insulating layer. Specifically, the cooling medium channel on the cooling layer is mainly composed of an integrated supporting rib and a periphery, the supporting ribs are arranged at two ends of the periphery and the inner wall of the supporting rib is abutted against the outer wall of the insulating layer, the periphery is radially supported by the supporting ribs, a clearance space is formed between the periphery and the insulating layer, the cooling medium channel which is U-shaped in cross section and is used for introducing cooling medium-air is enclosed between the inner wall of the periphery and the side walls of the supporting ribs at two sides, and the radial inner opening of the cooling medium channel acts on the outer wall of the insulating layer, namely, each supporting rib serves as a separation belt and a supporting rib of two adjacent cooling medium channels; the cooling medium channel with the structure has a fan shape with a large outside and a small inside.
The wrapping band adopts a semi-conductive water-blocking band structure, and the thickness of the wrapping band is about 0.3mm. The wrapping tape layer is wrapped on the outer surface of the cooling layer, and the overlapping rate of the wrapping tape layer on the outer surface of the cooling layer is about 50%.
The armor is an interlocking metal armor made of aluminum alloy material-high-strength 8030 aluminum alloy belt, the armor is coated on the outer surface of the belting layer, the thickness of the armor is about 0.2mm, the bow height is about 1mm, and the pitch is about 3mm.
Example 5
The invention relates to a high-voltage flexible cable for a new energy charging automobile, which mainly comprises a conductor, and an insulating layer, a cooling layer, a wrapping tape layer and an armor layer which are sequentially coated from inside to outside, wherein the insulating layer, the cooling layer, the wrapping tape layer and the armor layer are radially layered and formed by taking the conductor as a circle center.
Wherein the conductor is a 6 th tinned soft copper conductor. The diameter of the constituent tin-plated copper wire of the soft copper conductor is about 0.25mm.
The insulating layer is formed by extrusion molding of high-temperature resistant ceramic silicon rubber, namely the insulating layer is formed on the outer surface of the conductor in an extrusion molding mode. The thickness of the insulating layer is about 2.5mm.
The cooling layer is extruded from a high strength, low smoke, halogen free flame retardant material, polyolefin, having a hardness of about shore 90A. The cooling layer formed by extrusion is internally provided with four cooling medium channels which extend along the length direction of the insulating layer respectively, the four cooling medium channels are distributed on the periphery of the insulating layer in a circumferential equidistant and uniform sectional mode, the four cooling medium channels are mutually independent, and the included angle between the radial central lines of the adjacent cooling medium channels is about 90 degrees; each cooling medium channel on the cooling layer is used for introducing (forcedly introducing) cooling medium-condensate to cool and dissipate heat of the outer surface of the insulating layer. Specifically, the cooling medium channel on the cooling layer is mainly composed of an integral inner peripheral quilt, supporting ribs and an outer peripheral quilt, the inner peripheral quilt is circumferentially coated on the outer surface of the insulating layer, the supporting ribs are arranged at two ends of the inner peripheral quilt and the outer wall of the outer peripheral quilt, the outer peripheral quilt is radially supported by the supporting ribs, a clearance space is formed between the outer peripheral quilt and the inner peripheral quilt, a cooling medium channel with a 'mouth' -shaped cross section and used for introducing cooling medium-condensate is formed between the outer wall of the inner peripheral quilt, the inner wall of the outer peripheral quilt and the side walls of the supporting ribs at two sides, and the inner periphery of the cooling medium channel is acted on the outer wall of the insulating layer, namely, each supporting rib serves as a separation belt and a support rib of two adjacent cooling medium channels; the cooling medium channel with the structure has a fan shape with a large outside and a small inside.
The wrapping band adopts a semi-conductive water-blocking band structure, and the thickness of the wrapping band is about 0.3mm. The wrapping tape layer is wrapped on the outer surface of the cooling layer, and the overlapping rate of the wrapping tape layer on the outer surface of the cooling layer is about 30%.
The armor is an interlocking metal armor made of aluminum alloy material-high-strength 8030 aluminum alloy belt, the armor is coated on the outer surface of the belt layer, the thickness of the armor is about 0.4mm, the bow height is about 3mm, and the pitch is about 8mm.
Example 6
The invention relates to a high-voltage flexible cable for a new energy charging automobile, which mainly comprises a conductor, and an insulating layer, a cooling layer, a wrapping tape layer and an armor layer which are sequentially coated from inside to outside, wherein the insulating layer, the cooling layer, the wrapping tape layer and the armor layer are radially layered and formed by taking the conductor as a circle center.
Wherein the conductor is a 6 th tinned soft copper conductor. The diameter of the constituent tin-plated copper wire of the soft copper conductor is about 0.31mm.
The insulating layer is formed by extrusion molding of high-temperature resistant ceramic silicon rubber, namely the insulating layer is formed on the outer surface of the conductor in an extrusion molding mode. The thickness of the insulating layer is about 2.8mm.
The cooling layer is extruded from a high strength, low smoke, halogen free flame retardant material, polyolefin, having a hardness of about shore 90A. Four cooling medium channels respectively extending along the length direction of the insulating layer are arranged in the extrusion-molded cooling layer, are distributed on the periphery of the insulating layer in a circumferential equidistant and uniform sectional mode, are communicated through drainage holes, and have an included angle of about 90 degrees between radial central lines; each cooling medium channel on the cooling layer is used for introducing (forcedly introducing) cooling medium-condensate to cool and dissipate heat of the outer surface of the insulating layer. Specifically, the cooling medium channel on the cooling layer is mainly composed of an integral inner peripheral quilt, supporting ribs and an outer peripheral quilt, the inner peripheral quilt is circumferentially coated on the outer surface of the insulating layer, the supporting ribs are arranged at two ends of the inner peripheral quilt and the outer wall of the outer peripheral quilt, the outer peripheral quilt is radially supported by the supporting ribs, a clearance space is formed between the outer peripheral quilt and the inner peripheral quilt, a cooling medium channel with a 'mouth' -shaped cross section and used for introducing cooling medium-condensate is formed between the outer wall of the inner peripheral quilt, the inner wall of the outer peripheral quilt and the side walls of the supporting ribs at two sides, and the inner periphery of the cooling medium channel is acted on the outer wall of the insulating layer, namely, each supporting rib serves as a separation belt and a support rib of two adjacent cooling medium channels; the cooling medium channel with the structure has a fan shape with a large outside and a small inside.
The wrapping band adopts a semi-conductive water-blocking band structure, and the thickness of the wrapping band is about 0.3mm. The wrapping tape layer is wrapped on the outer surface of the cooling layer, and the overlapping rate of the wrapping tape layer on the outer surface of the cooling layer is about 40%.
The armor is an interlocking metal armor made of aluminum alloy material-high-strength 8030 aluminum alloy belt, the armor is coated on the outer surface of the belt layer, the thickness of the armor is about 0.5mm, the bow height is about 4mm, and the pitch is about 10mm.
Example 7
The invention relates to a flexible cable for a new energy charging automobile, which mainly comprises a conductor, an insulating layer, a cooling layer and an armor layer which are sequentially coated from inside to outside, wherein the insulating layer, the cooling layer and the armor layer are radially layered and molded by taking the conductor as a circle center.
Wherein the conductor is a 6 th tinned soft copper conductor. The diameter of the constituent tin-plated copper wire of the soft copper conductor is about 0.28mm.
The insulating layer is formed by extrusion molding of high-temperature resistant ceramic silicon rubber, namely the insulating layer is formed on the outer surface of the conductor in an extrusion molding mode. The thickness of the insulating layer is about 2.2mm.
The cooling layer is extruded from a high strength, low smoke, halogen free flame retardant material, polyolefin having a hardness of about shore 86A. The cooling layer formed by extrusion is internally provided with four cooling medium channels which extend along the length direction of the insulating layer respectively, the four cooling medium channels are distributed on the periphery of the insulating layer in a circumferential equidistant and uniform sectional mode, the four cooling medium channels are mutually independent, and the included angle between the radial central lines of the adjacent cooling medium channels is about 90 degrees; each cooling medium channel on the cooling layer is used for introducing (natural or forced, usually forced) cooling medium-air to cool and dissipate heat from the outer surface of the insulating layer. Specifically, the cooling medium channel on the cooling layer is mainly composed of an integrated supporting rib and a periphery, the supporting ribs are arranged at two ends of the periphery and the inner wall of the supporting rib is abutted against the outer wall of the insulating layer, the periphery is radially supported by the supporting ribs, a clearance space is formed between the periphery and the insulating layer, the cooling medium channel which is U-shaped in cross section and is used for introducing cooling medium-air is enclosed between the inner wall of the periphery and the side walls of the supporting ribs at two sides, and the radial inner opening of the cooling medium channel acts on the outer wall of the insulating layer, namely, each supporting rib serves as a separation belt and a supporting rib of two adjacent cooling medium channels; the cooling medium channel with the structure has a fan shape with a large outside and a small inside.
The armor is an interlocking metal armor made of aluminum alloy material-high-strength 8030 aluminum alloy belt, the armor is coated on the outer surface of the belt layer, the thickness of the armor is about 0.3mm, the bow height is about 2mm, and the pitch is about 5mm.
Example 8
The invention relates to a flexible cable for a new energy charging automobile, which mainly comprises a conductor, an insulating layer and a cooling layer which are sequentially coated from inside to outside, wherein the insulating layer and the cooling layer are radially layered and molded by taking the conductor as a circle center.
Wherein the conductor is a 6 th soft copper conductor. The diameter of the constituent copper wires of the soft copper conductor is about 0.18mm.
The insulating layer is formed by extrusion molding of high-temperature resistant ceramic silicon rubber, namely the insulating layer is formed on the outer surface of the conductor in an extrusion molding mode. The thickness of the insulating layer is about 1.5mm.
The cooling layer is extruded from a high strength, low smoke, halogen free flame retardant material, polyolefin, having a hardness of about shore 87A. Three cooling medium channels respectively extending along the length direction of the insulating layer are arranged in the extrusion-molded cooling layer, are distributed on the periphery of the insulating layer in a circumferential equidistant and uniform sectional mode, are mutually independent and have an included angle of about 120 degrees between radial central lines of adjacent cooling medium channels; each cooling medium channel on the cooling layer is used for introducing (natural or forced, usually forced) cooling medium-air to cool and dissipate heat from the outer surface of the insulating layer. Specifically, the cooling medium channel on the cooling layer is mainly composed of an integrated supporting rib and a periphery, the supporting ribs are arranged at two ends of the periphery and the inner wall of the supporting rib is abutted against the outer wall of the insulating layer, the periphery is radially supported by the supporting ribs, a clearance space is formed between the periphery and the insulating layer, the cooling medium channel which is U-shaped in cross section and is used for introducing cooling medium-air is enclosed between the inner wall of the periphery and the side walls of the supporting ribs at two sides, and the radial inner opening of the cooling medium channel acts on the outer wall of the insulating layer, namely, each supporting rib serves as a separation belt and a supporting rib of two adjacent cooling medium channels; the cooling medium channel with the structure has a fan shape with a large outside and a small inside.
The above examples are only for illustrating the invention and are not to be construed as limiting the invention; although the invention has been described in detail with reference to the above embodiments, it will be understood by those of ordinary skill in the art that: the invention may be modified or substituted for some of the features of the embodiments described above without departing from the spirit and scope of the invention.
Claims (6)
1. A flexible cable for a new energy automobile, the cable having a conductor (1) and an insulating layer (2) covering the conductor (1);
the method is characterized in that:
the insulating layer (2) is of a high-temperature resistant ceramic silicon rubber structure with the thickness of 0.80-2.8 mm;
the insulation layer (2) is externally coated with a cooling layer (3) formed by extrusion of polyolefin materials with Shore hardness of 85-90A in a radial layered structure, a plurality of cooling medium channels (33) extending along the length direction of the insulation layer (2) are arranged in the cooling layer (3), the cross sections of the cooling medium channels (33) are U-shaped, the cooling medium channels (33) are circumferentially distributed on the periphery of the insulation layer (2) in a segmented mode in a circumferential mode in which radial inner openings act on the outer wall of the insulation layer (2), and the cooling medium channels (33) are used for introducing cooling medium to cool and dissipate heat of the insulation layer (2);
the cooling layer (3) is externally coated with an armor layer (5) in a radial layered structure, the armor layer (5) is an interlocking metal armor layer made of an aluminum alloy material, the thickness of the interlocking metal armor layer is 0.2-0.5 mm, the bow height is 1-4 mm, and the pitch is 3-10 mm.
2. The flexible cable for a new energy automobile according to claim 1, wherein: the cooling medium channel (33) on the cooling layer (3) mainly comprises an integrated supporting rib (31) and a peripheral quilt (32), the supporting rib (31) is arranged at two ends of the peripheral quilt (32), the inner wall of the supporting rib (31) is abutted against the outer wall of the insulating layer (2), the peripheral quilt (32) is radially supported by the supporting rib (31), a clearance space is formed between the peripheral quilt (32) and the insulating layer (2), the cooling medium channel (33) with a U-shaped cross section and used for introducing cooling medium is formed between the inner wall of the peripheral quilt (32) and the side walls of the supporting ribs (31) at two sides, and the radially inner opening of the cooling medium channel (33) acts on the outer wall of the insulating layer (2).
3. The flexible cable for a new energy automobile according to claim 2, wherein: the cross section of the cooling medium channel (33) on the cooling layer (3) is in a fan shape with large outside and small inside.
4. The flexible cable for a new energy automobile according to claim 1, wherein: the cooling medium introduced into the cooling medium channel (33) on the cooling layer (3) is air.
5. The flexible cable for a new energy automobile according to claim 1, wherein: a wrapping band layer (4) is arranged between the cooling layer (3) and the armor layer (5), and the wrapping band layer (4) is wrapped on the outer surface of the cooling layer (3).
6. The flexible cable for a new energy automobile according to claim 5, wherein: the wrapping band layer (4) is of a semiconductive water-blocking band structure with the thickness of 0.3mm, and the overlapping rate of the wrapping band layer (4) is 10-50%.
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| CN201710390874.6A CN107039117B (en) | 2017-05-27 | 2017-05-27 | Flexible cable for new energy automobile |
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| CN108682500A (en) * | 2018-04-27 | 2018-10-19 | 北海和思科技有限公司 | A kind of novel cable |
| CN109326372B (en) * | 2018-09-29 | 2019-12-31 | 深圳市宝道智能科技有限公司 | Novel cable and application |
| CN109994267A (en) * | 2019-04-12 | 2019-07-09 | 北京智充科技有限公司 | A kind of liquid cooling charge cable and its method of interface |
| CN111063485A (en) * | 2019-11-27 | 2020-04-24 | 安徽华通电缆集团有限公司 | High-power low-loss power transmission cable |
| US11147193B2 (en) * | 2020-02-25 | 2021-10-12 | GM Global Technology Operations LLC | Vascular cooling system for electrical conductors |
| CN114759412A (en) * | 2022-03-14 | 2022-07-15 | 长春捷翼汽车零部件有限公司 | Connector assembly with liquid cooling function and vehicle |
| CN114582548A (en) * | 2022-03-31 | 2022-06-03 | 远东电缆有限公司 | Welding gun cable |
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