CN115376738A - Intelligent monitoring high-power charging cable for new energy automobile and production process thereof - Google Patents

Abstract

The invention relates to the technical field of wires and cables, in particular to an intelligent monitoring high-power charging cable for new energy vehicles and a production process thereof. The cable specifically includes a cabled bus core. The cabled bus core includes a power core, an auxiliary core, a grounding core, and a signal core group. The outer edge gap of the cabled bus core is filled with heat conductors, and the cabled bus core The outer wrapping has a reinforced tape, and the reinforced tape is extruded with an outer sheath. The cable does not need to add a liquid heat pipe in the structure. The overall outer diameter of the cable is small, light in weight, resistant to bending, twisting, and dragging. The power core itself has excellent heat conduction effect, which can greatly improve charging efficiency and prolong battery life cable life.

Description

Intelligent monitoring high-power charging cable for new energy vehicles and its production process

technical field

The invention relates to the technical field of wires and cables, in particular to an intelligent monitoring high-power charging cable for new energy vehicles and a production process thereof.

Background technique

Compared with traditional vehicles, new energy vehicles have excellent characteristics such as strong power, low cost, energy saving and environmental protection, but the development of new energy vehicles is limited due to low charging efficiency. In order to solve the problem of charging time for new energy vehicles, most of the high-power charging cables currently designed and developed are liquid-cooled, and liquid cooling tubes need to be added to the cables, resulting in larger outer diameters of cables, increased weight, and poor flexibility, which in turn affects users. Use experience.

Contents of the invention

The object of the present invention is to provide a high-power charging cable with good heat dissipation effect, small outer diameter, light weight, high flexibility and intelligent monitoring function and its production process.

In order to achieve the above object, on the one hand, the present invention adopts the following technical solutions:

An intelligent monitoring high-power charging cable for new energy vehicles, which includes a cabled bus core, the cabled bus core includes a power core, an auxiliary core, a grounding core and a signal core group, and the two power cores are tangentially twisted together, the grounding core is tangent to one side of the two power cores at the same time, and the two auxiliary cores are distributed on both sides of the grounding core and are respectively tangent to the grounding core and the power core. The signal core group includes the first A signal core, a second signal core and a third signal core, the first signal core is tangent to the other side of the two power cores at the same time, the second signal core and the third signal core are distributed on the third The two sides of a signal core are respectively tangent to the first signal core and the power core, the outer edge gap of the cabled bus core is filled with a heat conductor, and the cabled bus core is wrapped with a reinforcing tape to strengthen The strap is extruded and covered with an outer sheath.

In particular, the power core includes several twisted power core conductors, and the power core conductors are wrapped with an insulating layer. The insulating layer includes two power core insulating layers of high thermal conductivity insulating silicon rubber material, and two power core conductors. A braided layer of aramid fiber is arranged between the insulating layers of the wire cores.

In particular, the grounding core includes several twisted grounding core conductors, and a grounding core insulating layer of high thermal conductivity insulating silicon rubber material is arranged outside the grounding core conductors.

In particular, the high thermal conductivity insulating silicone rubber material includes A component, B component and spherical boron nitride nanosheets, wherein the weight ratio of A component: B component: spherical boron nitride nanosheets is 10:8:3.5, Component A is in parts by mass: 100 parts of methyl vinyl silicone rubber, 10 parts of reinforcing agent fumed silica, 6 parts of coupling agent, and 2 parts of hydroxyl silicone oil; component B is in parts by mass: A 100 parts of vinyl silicone rubber, 20 parts of flame retardant, 3 parts of flame retardant synergist, and 4 parts of catalyst.

In particular, the auxiliary core includes several twisted auxiliary core conductors, and the auxiliary core conductor is provided with an auxiliary core insulating layer wrapped with a high thermal conductivity insulating tape.

In particular, the first signal core includes several twisted first signal core conductors, the first signal core conductors are provided with a first signal core insulation layer, and the six first signal cores are cut and twisted in pairs. The first non-woven fabric layer is combined and wrapped around, and an optical fiber unit is passed through the twisted center, and the optical fiber unit is wrapped with a polyamide braided layer; the second signal core includes several twisted second signal core conductors, The second signal core conductor is provided with a second signal core insulation layer, the two second signal cores are tangentially stranded, and wrapped with an aluminum-plastic composite tape, and a copper wire braided layer is provided outside the aluminum-plastic composite tape ; The third signal core includes several twisted third signal core conductors, the third signal core conductor is provided with a third signal core insulation layer, the two third signal cores are tangentially twisted, and the outer Wrapped with a second non-woven layer.

In particular, the first signal core insulating layer, the second signal core insulating layer, and the third signal core insulating layer are all wrapped with high thermal conductivity insulating tape.

In particular, the outer diameter of the first signal core is the same as that of the grounding core, the outer diameters of the second signal core and the third signal core are the same as those of the two auxiliary cores, so that the overall structure of the cable is symmetrical .

In particular, the outer sheath is extruded from a thermoplastic polyurethane elastomer rubber material.

On the other hand, the present invention adopts the following technical solutions:

A production process based on the above-mentioned intelligent monitoring high-power charging cable for new energy vehicles, which comprises the following steps:

S100: preparing conductors for power cores, grounding cores, auxiliary cores and signal core groups;

S200: Prepare the insulation layer of the power core, the ground core, the auxiliary core and the signal core group;

S300: making the first signal core, the second signal core, and the third signal core;

S400: Twisting the power core, auxiliary core, grounding core, and signal core group into a cabled bus core, and filling the outer edge gap of the cabled bus core with a heat conductor, and then winding outside the cabled bus core Reinforced straps;

S500: The outer sheath is extruded outside the reinforced tape.

To sum up, the beneficial effect of the present invention is that, compared with the prior art, the intelligent monitoring high-power charging cable for new energy vehicles and its production process have the following advantages:

(1) The insulating layer of the power core and the grounding core is made of high thermal conductivity insulating silicone rubber material. Spherical boron nitride nanosheets are added to the formula of the conventional insulating silicone rubber material. The insulating material has small thermal resistance, high temperature resistance, high Thermal conductivity and high flexibility characteristics increase the current carrying capacity of the cable, prolong the service life of the cable and improve the charging efficiency;

(2) The insulation layer of the power core adopts the structure of high thermal conductivity silicone rubber insulation layer-aramid braided layer-high thermal conductivity silicone rubber insulation layer. Re-vulcanization, bonding the inner and outer silicone rubber insulation layers and the aramid wire braided layer together, can greatly improve the tensile performance and winding bending performance of the insulation layer, and effectively prolong the service life of the cable;

(3) The outer edge gap of the cabled bus core is filled with high thermal conductivity material, which can effectively reduce the external temperature of the insulation layer of the power core, ground core, auxiliary core and signal core group, and enhance the heat dissipation performance of the power core. Extended cable life;

(4) An optical fiber unit is installed at the center of the signal core, which can monitor the integrity of the signal core after bending and moving during use at any time, and quickly locate the fault point of the signal core, and the optical fiber unit adopts multi-mode or single-mode Reinforced with rayon braid, it has excellent bending resistance and tensile properties, ensuring the stability of the optical fiber unit;

(5) The insulation layer of the auxiliary core and the signal core group is wrapped with high thermal conductivity insulating tape. The outer diameter of the insulation is small and the flexibility is high, which effectively improves the cable flexibility and production efficiency, reduces the cable cost The weight of the cable and the outer diameter of the cable are specified;

(6) The outer diameters of the second signal core and the third signal core are set to be the same as the outer diameters of the two auxiliary cores, and the outer diameters of the first signal core and the grounding core are the same, so that the overall structure of the cable is symmetrical, Effectively improve the stability of the cable;

(7) The cable does not need to add a liquid heat pipe in the structure. The overall outer diameter of the cable is small, light in weight, resistant to bending, twisting, and dragging. The power core itself has excellent heat conduction effect, which can greatly improve charging efficiency. , extending the service life of the cable.

Description of drawings

Fig. 1 is a schematic structural diagram of an intelligent monitoring high-power charging cable for a new energy vehicle provided by an embodiment of the present invention.

In the picture:

1-power core; 11-power core conductor; 12-power core insulation layer; 13-aramid braiding layer;

2-auxiliary core; 21-auxiliary core conductor; 22-auxiliary core insulation layer;

3-grounding core; 31-grounding core conductor; 32-grounding core insulation layer;

4-first signal core; 41-first signal core conductor; 42-first signal core insulation layer; 43-first non-woven fabric layer; 44-optical fiber unit; 45-polyamide braiding layer;

5-second signal core; 51-second signal core conductor; 52-second signal core insulation layer; 53-aluminum-plastic composite tape; 54-copper wire braiding layer;

6-the third signal core; 61-the third signal core conductor; 62-the third signal core insulation layer; 63-the second non-woven fabric layer;

7- heat conductor;

8-Strengthen the strap;

9 - Outer sheath.

Detailed ways

Embodiments of the present invention will be described in detail below, and examples of the embodiments are shown in the drawings, wherein the same or similar reference numerals denote the same or similar components or components having the same or similar functions throughout. The embodiments described below by referring to the figures are exemplary and are intended to explain the present invention and should not be construed as limiting the present invention.

In the description of the present invention, unless otherwise clearly stipulated and limited, the terms "connected", "connected" and "fixed" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or a mechanical connection. A connection can also be an electrical connection, or an indirect connection through an intermediary, or an internal communication between two elements or an interaction relationship between two elements. Those of ordinary skill in the art can understand the specific meanings of the above terms in the present invention according to specific situations.

In the description of the present invention, unless otherwise clearly specified and limited, a first feature being "on" or "under" a second feature may include direct contact between the first feature and the second feature, or include the first feature Not in direct contact with the second feature but through another feature therebetween. Moreover, "above", "above" and "above" the first feature on the second feature include that the first feature is directly above and obliquely above the second feature, or simply means that the first feature is horizontally higher than the second feature. "Below", "beneath" and "under" the first feature to the second feature include that the first feature is directly below and obliquely below the second feature, or simply means that the first feature has a lower level than the second feature. The technical solutions of the present invention will be further described below in conjunction with the accompanying drawings and through specific implementation methods.

Please refer to Fig. 1, this preferred embodiment provides a kind of intelligent monitoring high-power charging cable for new energy vehicles, which includes a cabled bus core, and the cabled bus core includes a power core 1, an auxiliary core 2, and a grounding core. 3 and the signal wire core group, the outer edge gap of the cabled bus core is filled with a heat conductor 7, and the cabled bus core is wrapped with a reinforcing tape 8, and the reinforced tape 8 is extruded and wrapped with an outer sheath 9.

In this embodiment, preferably, the two power cores 1 are tangentially twisted, the grounding core 3 is tangent to one side of the two power cores 1 at the same time, and the two auxiliary cores 2 are distributed on the sides of the grounding core 3. The two sides are respectively tangent to the ground core 3 and the power core 1. The signal core group includes the first signal core 4, the second signal core 5 and the third signal core 6. The first signal core 4 is simultaneously Tangent to the other side of the two power cores 1, the second signal core 5 and the third signal core 6 are distributed on both sides of the first signal core 4 and connected to the first signal core 4 and the power line respectively. Core 1 is tangent.

Further, the outer diameter of the first signal core 4 is the same as that of the grounding core 3, the outer diameters of the second signal core 5 and the third signal core 6 are the same as those of the two auxiliary cores 2, Make the overall structure of the cable symmetrical.

Wherein, the power core 1 includes several stranded power core conductors 11, and the power core conductors 11 are wrapped with an insulation isolation layer, and the insulation isolation layer includes two power core insulation layers 12 of high thermal conductivity insulating silicon rubber material, An aramid fiber braided layer 13 is arranged between the two power core insulation layers 12 .

The grounding core 3 includes several twisted grounding core conductors 31, and the grounding core conductor 31 is provided with a grounding core insulating layer 32 of high thermal conductivity insulating silicon rubber material.

It is worth mentioning that the high thermal conductivity insulating silicon rubber material here includes A component, B component and spherical boron nitride nanosheets, wherein A component: B component: the weight ratio of spherical boron nitride nanosheets is 10:8:3.5, component A is based on mass parts: 100 parts of methyl vinyl silicone rubber, 10 parts of reinforcing agent fumed silica, 6 parts of coupling agent, 2 parts of hydroxyl silicone oil; component B is In parts by mass: 100 parts of methyl vinyl silicone rubber, 20 parts of flame retardant, 3 parts of flame retardant synergist, and 4 parts of catalyst.

Therefore, spherical boron nitride nanosheets are added to the high thermal conductivity insulating silicone rubber material component, and component A, B component, and spherical boron nitride nanosheets are made into raw rubber in proportion, and the concentration is 1.2% to 1.3% % DCP vulcanizing agent, the vulcanization temperature is 180°C, and the production speed is 15-20m/s. The insulating material obtained has the characteristics of small thermal resistance, high temperature resistance, high thermal conductivity, and high flexibility, which can effectively increase the current carrying capacity of the cable. Extend the service life of the cable and improve charging efficiency.

The auxiliary core 2 includes several twisted auxiliary core conductors 21, and the auxiliary core conductor 21 is provided with an auxiliary core insulating layer 22 wrapped with a high thermal conductivity insulating tape.

The first signal core 4 includes several stranded first signal core conductors 41, the first signal core conductors 41 are provided with a first signal core insulation layer 42, and the six first signal cores 4 are two-phase The first non-woven fabric layer 43 is cut, twisted and wrapped around, and the fiber unit 44 is pierced through the twisted center, and the fiber unit 44 is wrapped with a polyamide braided layer 45 .

The second signal core 5 includes several stranded second signal core conductors 51, the second signal core conductor 51 is provided with a second signal core insulation layer 52, and the two second signal cores 5 are tangentially twisted. and the aluminum-plastic composite tape 53 is wrapped around the outside, and the aluminum-plastic composite tape 53 is provided with a braided layer of copper wire 54.

The third signal core 6 includes several stranded third signal core conductors 61, the third signal core conductor 61 is provided with a third signal core insulation layer 62, two third signal cores 6 are tangentially twisted Closed, and the second non-woven fabric layer 63 is wrapped around the outside.

Wherein, the first signal core insulating layer 42 , the second signal core insulating layer 52 , and the third signal core insulating layer 62 are all wrapped with high thermal conductivity insulating tape.

The thermal conductor 7 can be high thermal conductivity carbon fiber, high thermal conductivity glass fiber tape, etc.

The reinforcement strap 8 is preferably reinforced non-woven fabric.

The outer sheath 9 is extruded by thermoplastic polyurethane elastomer rubber material.

In addition, this embodiment also provides a production process based on the above-mentioned intelligent monitoring high-power charging cable for new energy vehicles, which includes the following steps:

S100: Prepare the conductors of the power core 1, the ground core 3, the auxiliary core 2 and the signal core group.

Specifically, the preparation method of the power core conductor 11 is as follows: firstly, copper conductor strands are made, and the copper monofilament strands are twisted into copper conductor strands by a Nihoff stranding machine. The pitch is 12 to 14 times the outer diameter of the strands; then the copper conductor strands are twisted to form the power core conductor 11, and the twisting pitch is 13 to 15 times the outer diameter of the power core conductor 11; after the twisting is completed, the wrapping is strengthened Type non-woven fabric layer, covering rate of 20% to 30%.

The preparation method of grounding core 3, auxiliary core 2 and signal core conductors is as follows: the copper monofilament bundles are twisted into copper conductor bundles by a Nihoff beam machine, and the diameter of the monofilaments is 0.140mm to 0.145mm. The distance is 12 to 14 times the outer diameter of the strand.

S200: Prepare the insulation layers of the power core 1, the ground core 3, the auxiliary core 2 and the signal core group.

Specifically, the preparation method of the power core insulation layer 12 is as follows: firstly, the power core conductor 11 is extruded with a high thermal conductivity silicone rubber inner insulation layer, and the insulation layer is kept in a semi-vulcanized state, and then braided with aramid yarn with a weaving density of ≥85. %, and finally extrude the outer insulation layer of high thermal conductivity silicone rubber.

The preparation method of the insulating layer 32 of the grounding core is: extruding and wrapping the insulating layer of high thermal conductivity silicon rubber on the grounding core conductor 31 .

The manufacturing method of the insulating layer of the auxiliary core 2 and the signal core group is as follows: wrap a thermally conductive insulating tape on the outside of the conductor, the wrapping direction is right, and the covering rate of the insulating tape layer is ≥ 50%.

S300: Manufacturing the first signal core 4, the second signal core 5, and the third signal core 6.

Specifically, the preparation method of the first signal core 4 is as follows: twist six signal insulated cores and one optical fiber unit 44 in the form of 1+6, the optical fiber unit 44 is located in the center, and is wrapped with non-woven fabric, and the wrapping is lapped. Coverage rate ≥ 25%.

The preparation method of the second signal wire core 5 is as follows: two signal insulated wire cores are twisted in pairs, and the twisting pitch is 12 to 16 times the outer diameter of the twisting, and the aluminum-plastic composite tape 53 is wrapped, and the wrapping direction is right, and the wrapping direction is right. The covering rate is 25% to 30%, and the copper wire is braided outside the tape. The diameter of the single copper wire is 0.12mm, and the weaving density is ≥80%.

The preparation method of the third signal core 6 is as follows: two signal insulated cores are twisted to each other with a twist pitch of 12 to 16 times the twisted outer diameter, wrapped with non-woven fabric, and the covering rate of the wrap is ≥ 25%.

S400: Twisting the power core 1, auxiliary core 2, grounding core 3, and signal core group into a cabled bus core, and filling the outer edge gap of the cabled bus core with heat conductor 7, and then The outside of the bus core is wrapped with reinforcing tape 8, and the covering rate of the wrapping is 25% to 30%.

S500: The outer sheath 9 is extruded on the reinforced tape 8, and the outer sheath 9 is made of high softness and wear-resistant thermoplastic polyurethane elastomer rubber material, with a thickness of 2.5mm to 3.0mm, produced by extrusion.

The above embodiments have only set forth the basic principles and characteristics of the present invention, the present invention is not limited by the above-mentioned examples, and on the premise of not departing from the spirit and scope of the present invention, the present invention also has various changes and changes, and these changes and changes all fall within the scope of the claimed invention. The protection scope of the present invention is defined by the appended claims and their equivalents.

Claims (10)

1. The utility model provides a high-power charging cable of intelligent monitoring for new energy automobile, its characterized in that, includes the stranding bus core, the stranding bus core includes power sinle silk, supplementary sinle silk, earth core and signal sinle silk group, two the tangent transposition of power sinle silk, earth core is tangent with one side of two power sinle silks simultaneously, two supplementary sinle silk distribute in earth core's both sides and respectively with earth core and power sinle silk tangent, signal sinle silk group includes first signal sinle silk, second signal sinle silk and third signal sinle silk, first signal sinle silk is tangent with the opposite side of two power sinle silks simultaneously, second signal sinle silk third signal sinle silk distribute in the both sides of first signal sinle silk and respectively with first signal sinle silk and power sinle silk tangent, it has the heat conductor to fill in the outer fringe clearance of stranding bus sinle silk, and the stranding bus sinle silk has the enhancement band outward, it has the oversheath to strengthen crowded package outward.

2. The intelligent monitoring high-power charging cable for the new energy automobile according to claim 1, characterized in that: the power cable core comprises a plurality of twisted power cable core conductors, an insulating isolation layer is wrapped outside each power cable core conductor, each insulating isolation layer comprises two power cable core insulating layers made of high-heat-conductivity insulating silicon rubber materials, and an aramid yarn weaving layer is arranged between each two power cable core insulating layers.

3. The intelligent monitoring high-power charging cable for the new energy automobile according to claim 1, characterized in that: the ground wire core comprises a plurality of stranded ground wire core conductors, and a ground wire core insulating layer made of high-thermal-conductivity insulating silicon rubber materials is arranged outside the ground wire core conductors.

4. The intelligent monitoring high-power charging cable for the new energy automobile according to claim 2 or 3, characterized in that: the high-thermal-conductivity insulating silicon rubber material comprises a component A, a component B and spherical boron nitride nanosheets, wherein the weight ratio of the component A to the component B to the spherical boron nitride nanosheets is 10.5, and the component A comprises the following components in parts by mass: 100 parts of methyl vinyl silicone rubber, 10 parts of reinforcing agent fumed silica, 6 parts of coupling agent and 2 parts of hydroxyl silicone oil; the component B comprises the following components in parts by mass: 100 parts of methyl vinyl silicone rubber, 20 parts of flame retardant, 3 parts of flame retardant synergist and 4 parts of catalyst.

5. The intelligent monitoring high-power charging cable for the new energy automobile according to claim 1, characterized in that: the auxiliary wire core comprises a plurality of twisted auxiliary wire core conductors, and auxiliary wire core insulating layers formed by wrapping high-heat-conductivity insulating tapes are arranged outside the auxiliary wire core conductors.

6. The intelligent monitoring high-power charging cable for the new energy automobile according to claim 1, characterized in that: the first signal wire core comprises a plurality of twisted first signal wire core conductors, a first signal wire core insulating layer is arranged outside each first signal wire core conductor, every two of the six first signal wire cores are twisted in a tangent mode and wrapped with a first non-woven fabric layer, an optical fiber unit penetrates through the twisting center, and a polyamide braided layer wraps the optical fiber unit;

the second signal wire core comprises a plurality of twisted second signal wire core conductors, a second signal wire core insulating layer is arranged outside each second signal wire core conductor, two second signal wire cores are twisted in a tangent mode and wrapped with an aluminum-plastic composite belt in an outer winding mode, and a copper wire weaving layer is arranged outside the aluminum-plastic composite belt;

the third signal core comprises a plurality of twisted third signal core conductors, third signal core insulating layers are arranged outside the third signal core conductors, and the third signal core conductors are twisted in a tangent mode and wrapped with a second non-woven fabric layer.

7. The intelligent monitoring high-power charging cable for the new energy automobile according to claim 6, characterized in that: the first signal wire core insulating layer, the second signal wire core insulating layer and the third signal wire core insulating layer are all formed by wrapping high-heat-conductivity insulating adhesive tapes.

8. The intelligent monitoring high-power charging cable for the new energy automobile according to claim 1, characterized in that: the outer diameter of the first signal wire core is the same as that of the grounding wire core, and the outer diameters of the second signal wire core and the third signal wire core are the same as those of the two auxiliary wire cores, so that the whole cable structure is symmetrical.

9. The intelligent monitoring high-power charging cable for the new energy automobile according to claim 1, characterized in that: the outer sheath is extruded by adopting a thermoplastic polyurethane elastomer rubber material in an extrusion mode.

10. The production process of the intelligent monitoring high-power charging cable for the new energy automobile based on any one of claims 1 to 9 is characterized by comprising the following steps

S100: preparing conductors of the power wire core, the grounding wire core, the auxiliary wire core and the signal wire core group;

s200: preparing insulating layers of the power wire core, the grounding wire core, the auxiliary wire core and the signal wire core group;

s300: manufacturing a first signal wire core, a second signal wire core and a third signal wire core;

s400: the power wire core, the auxiliary wire core, the grounding wire core and the signal wire core are combined and twisted into a cabling main wire core, a heat conductor is filled in a gap at the outer edge of the cabling main wire core, and a reinforcing wrapping tape is wrapped outside the cabling main wire core;

s500: an outer sheath is extruded outside the reinforcing wrapping tape.

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