CN115985562A - Liquid-cooled high-power cable for charging new energy automobile and production process - Google Patents
Liquid-cooled high-power cable for charging new energy automobile and production process Download PDFInfo
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- CN115985562A CN115985562A CN202310089912.XA CN202310089912A CN115985562A CN 115985562 A CN115985562 A CN 115985562A CN 202310089912 A CN202310089912 A CN 202310089912A CN 115985562 A CN115985562 A CN 115985562A
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 18
- 238000001816 cooling Methods 0.000 claims abstract description 45
- 239000007788 liquid Substances 0.000 claims abstract description 8
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- 239000004020 conductor Substances 0.000 claims description 51
- 239000000463 material Substances 0.000 claims description 19
- 238000009413 insulation Methods 0.000 claims description 18
- 229920000098 polyolefin Polymers 0.000 claims description 9
- 238000005253 cladding Methods 0.000 claims description 3
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- 230000002035 prolonged effect Effects 0.000 abstract description 4
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 8
- 229910052802 copper Inorganic materials 0.000 description 8
- 239000010949 copper Substances 0.000 description 8
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- 238000002360 preparation method Methods 0.000 description 3
- 238000013461 design Methods 0.000 description 2
- 238000011161 development Methods 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 239000004745 nonwoven fabric Substances 0.000 description 2
- 239000004033 plastic Substances 0.000 description 2
- 230000005855 radiation Effects 0.000 description 2
- 241001391944 Commicarpus scandens Species 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
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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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- 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
- Y02T10/7072—Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
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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
- Y02T90/00—Enabling technologies or technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02T90/10—Technologies relating to charging of electric vehicles
- Y02T90/14—Plug-in electric vehicles
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Abstract
The invention relates to the technical field of electric wires and cables, in particular to a liquid-cooled high-power cable for charging a new energy automobile and a production process thereof. Wherein the high-power cable of liquid cooling includes the bus core cable core, the bus core cable core is wrapped around outward and has total cable core band, total cable core outband crowded package has the oversheath, bus core cable core includes the control cable core that sets up between two parties, the control cable core includes the control cable core and the earth connection core that a plurality of transposition was cabled, and the periphery of control cable core is crisscross to be provided with two power core and two signal core groups, the both sides of every power core are provided with a cooling tube and a back flow respectively, the control cable core respectively with two power core, two cooling tubes and two back flows are tangent, every signal core group is tangent with the back flow and the cooling tube of both sides. According to the liquid-cooling high-power cable and the production process, the structure of each wire core is optimally designed, the core breaking rate of the wire core is reduced, the contact area of the cooling pipe and each wire core is increased, the current-carrying capacity of the cable is effectively improved, and the service life of the cable is prolonged.
Description
Technical Field
The invention relates to the technical field of electric wires and cables, in particular to a liquid-cooled high-power cable for charging a new energy automobile and a production process thereof.
Background
Compared with the traditional automobile, the new energy automobile has the excellent characteristics of strong power, low cost, energy conservation, environmental protection and the like, but the new energy automobile is limited in development due to lower charging efficiency. For long problem when solving new energy automobile and charging, the high-power cable of liquid cooling for new energy automobile charges of design development, increases the liquid cooling pipe in cable structure, nevertheless because liquid cooling pipe external diameter is little, and is little with sinle silk area of contact, and the cooling effect is not good, and this cable is for synthesizing the cable structure, and wherein control sinle silk and signal sinle silk are because of the uneven disconnected core condition that easily takes place of atress, and life is low.
Disclosure of Invention
The invention aims to provide a liquid-cooled high-power cable for charging a new energy automobile, which optimizes the layout of each wire core, ensures that each wire core is uniformly stressed, reduces the core breaking rate of a control wire core and a signal wire core, increases the contact area of a cooling pipe and each wire core, effectively improves the current-carrying capacity of the cable, and prolongs the service life of the cable
The invention further aims to provide a production process of the liquid-cooled high-power cable for charging the new energy automobile.
In order to achieve the purpose, the invention adopts the following technical scheme:
the utility model provides a high-power cable of liquid cooling for new energy automobile charges, it includes the total core cable core, the total core cable core is wrapped around outward and is had total cable core band, total core cable core outband crowded package has the oversheath, the control cable core of total core cable core including setting between two parties, the control cable core includes the control core and the earth connection core that a plurality of transposition was cabled, and the periphery of control cable core is crisscross to be provided with two power core and two signal core groups, the both sides of every power core are provided with a cooling tube and a back flow respectively, the control cable core respectively with two power core, two cooling tubes and two back flows are tangent, every signal core group is tangent with the back flow and the cooling tube of both sides.
Particularly, the control cable core is formed by regularly twisting ten control wire cores around a grounding wire core, and a control cable core wrapping belt is integrally wrapped outside the ten control wire cores.
Particularly, the control wire core comprises a plurality of stranded control wire core conductors, and the control wire core conductors are wrapped with control wire core insulation of an irradiated polyolefin material.
In particular, the ground wire core comprises a plurality of stranded ground wire core conductors, and the ground wire core conductors are wrapped with TPE material to form ground wire core insulation.
Particularly, the power wire core comprises a plurality of twisted power wire core conductors, and the power wire core conductors are wrapped with TPE materials to form power wire core insulation.
Especially, signal core group includes the signal sinle silk of two pair twists, and signal sinle silk includes the signal sinle silk conductor of a plurality of transposition, and signal sinle silk conductor is provided with polyolefin material's signal sinle silk insulating outward, winds package signal sinle silk band behind two signal sinle silk pair twists, and signal sinle silk band is provided with the metallic braid outward.
In particular, the cooling pipe and the return pipe are made of radiation cross-linked polyolefin materials, and the outer diameters of the cooling pipe and the return pipe are the same as the outer diameter of the power line core.
In particular, the outer sheath is made of TPU material.
On the other hand, the invention adopts the following technical scheme:
a production process of a liquid-cooled high-power cable for charging a new energy automobile comprises the following steps:
s100: respectively preparing conductors of the power wire core, the signal wire core, the grounding wire core and the control wire core;
s200: respectively preparing the insulation of the power wire core, the signal wire core, the grounding wire core and the control wire core;
s300: manufacturing a signal wire core group and a control wire core;
s400: manufacturing a cooling pipe and a return pipe;
s500: the power cable core, the signal cable core group, the cooling pipe, the return pipe and the control cable core are twisted into a main cable core, and a main cable core wrapping belt is wrapped outside the main cable core;
s600: and extruding the outer sheath outside the total cable core cladding.
In summary, compared with the prior art, the liquid-cooled high-power cable for charging the new energy automobile and the production process thereof have the following advantages:
(1) All the control wire cores are uniformly arranged on the outer ring of the grounding wire core by taking the grounding wire core as the center and twisted into a control cable core by a 1+ N structure, and the control wire core is positioned at the center of the cable in the cable assembly structure, so that the control wire core is uniformly stressed, the problem that the control wire core is easy to break is solved, and the service life of the cable is prolonged;
(2) The outer diameters of the power wire core, the cooling pipe and the return pipe are the same, the control cable core is taken as the center in the main wire core cable core, the signal wire core group, the power wire core, the cooling pipe and the return pipe are symmetrically distributed, the whole cable core is uniformly stressed, the structure is stable, and the problem of wire core displacement cable deformation after the cable is frequently bent and twisted for use is solved;
(3) The cooling pipe, the return pipe and the power line core are arranged at intervals and are in contact with the control line core and the signal line core group, so that the cooling effect of the line core is greatly improved, the charging efficiency is improved, and the service life of the cable is effectively prolonged.
Drawings
Fig. 1 is a schematic structural diagram of a liquid-cooled high-power cable for charging a new energy vehicle according to an embodiment of the present invention.
In the figure:
1-controlling the cable core; 11-control wire core; 111-control line core conductor; 112-control wire core insulation; 12-ground core; 121-ground wire core conductor; 122-ground wire core insulation; 13-controlling the cable core wrapping belt;
2-a power wire core; 21-a power core conductor; 22-power wire core insulation;
3-signal wire core group; 31-a signal core; 311-signal core conductors; 312-signal wire core insulation; 32-signal wire core wrapping tape; 33-a metal braid;
4-a cooling pipe;
5-a return pipe;
6-total cable core belting;
7-outer sheath.
Detailed Description
Reference will now be made in detail to the embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like or similar reference numerals refer to the same or similar parts throughout or parts having the same or similar functions. The embodiments described below with reference to the drawings are illustrative and intended to be illustrative of the invention and are not to be construed as limiting the invention.
In the description of the present invention, unless otherwise explicitly stated or limited, the terms "connected," "connected," and "fixed" are to be construed broadly and may include, for example, fixed or detachable connections, mechanical or electrical connections, indirect connections through intervening media, communications between two elements, or the interaction of two elements. The specific meanings of the above terms in the present invention can be understood by those skilled in the art according to specific situations.
In the description of the present invention, unless otherwise expressly specified or limited, the first feature "on" or "under" the second feature may include the first feature and the second feature being in direct contact, or may include the first feature and the second feature being in contact not directly but with another feature therebetween. Also, the first feature being "on," "above" and "over" the second feature includes the first feature being directly on and obliquely above the second feature, or merely indicating that the first feature is at a higher level than the second feature. A first feature being "under," "below," and "beneath" a second feature includes the first feature being directly under and obliquely below the second feature, or simply meaning that the first feature is at a lesser elevation than the second feature. The technical scheme of the invention is further explained by the specific implementation mode in combination with the attached drawings.
Please refer to fig. 1, this preferred embodiment provides a liquid-cooled high-power cable for charging of a new energy vehicle, which includes a bus core cable, a bus core cable wrapping belt 6 is wrapped around the bus core cable, an outer sheath 7 is extruded outside the bus core wrapping belt 6, the bus core cable includes a control cable core 1 disposed in the middle, two power cores 2 and two signal core groups 3 are staggered on the periphery of the control cable core 1, two sides of each power core 2 are respectively provided with a cooling pipe 4 and a return pipe 5, the control cable core 1 is respectively tangent to the two power cores 2, the two cooling pipes 4 and the two return pipes 5, and each signal core group 3 is tangent to the return pipes 5 and the cooling pipes 4 on the two sides.
Particularly, the power wire cores 2 are the same as the outer diameters of the cooling pipe 4 and the return pipe 5, so that a stable structure with the wire cores symmetrically distributed is formed, and the power wire cores 2 are separated from the return pipe 5 by the cooling pipe 4, so that the wire core cooling effect is improved.
In this embodiment, the control cable core 1 is preferably formed by regularly twisting ten control cable cores 11 around one grounding cable core 12, and a control cable core wrapping tape 13 is integrally wrapped outside the ten control cable cores 11.
The control wire core 11 comprises a plurality of twisted control wire core conductors 111, and the control wire core conductors 111 are wrapped with high-strength smooth type irradiated polyolefin material control wire core insulation 112.
The ground wire core 12 includes a plurality of twisted ground wire core conductors 121, and the ground wire core conductors 121 are wrapped with high-strength and high-flexibility TPE material ground wire core insulation 122.
The power wire core 2 comprises a plurality of power wire core conductors 21 which are twisted, and the power wire core conductors 21 are wrapped with power wire core insulators 22 made of high-strength and high-flexibility TPE materials.
The signal core group 3 includes the signal sinle silk 31 of two pair twists, and signal sinle silk 31 includes the signal sinle silk conductor 311 of a plurality of transposition, and signal sinle silk conductor 311 is provided with the signal sinle silk of high strength, smooth type polyolefin material outward and is insulating 312, and two signal sinle silks 31 pair twists the back around signal sinle silk band 32 of wrapping plastic-aluminum composite tape or other similar materials, and signal sinle silk band 32 is provided with metallic braid 33 outward.
The cooling pipe 4 and the return pipe 5 are made of radiation cross-linked polyolefin material.
The outer sheath 7 is made of high-strength and high-wear-resistance TPU material.
In addition, this embodiment still provides a production technology based on foretell new energy automobile charges with liquid cooling high-power cable, and it includes following step:
s100: the conductors of the power wire core 2, the signal wire core 31, the grounding wire core 12 and the control wire core 11 are respectively prepared.
Specifically, the power wire core conductor 21 and the ground wire core conductor 121 are prepared by the following steps: firstly, manufacturing copper conductor plied yarns, stranding copper single-yarn bundles into copper conductor bunches by a Nichhoff bundle yarn machine, wherein the diameter of each single-yarn is 0.190-0.195 mm, and the stranding pitch is 11-13 times of the outer diameter of each plied yarn; and stranding the copper conductor compound wires to form corresponding wire core conductors, wherein the stranding pitch is 13-15 times of the outer diameter of each wire core conductor.
The preparation method of the control wire core conductor 111 and the signal wire core conductor 311 comprises the following steps: copper single-strand bundles are stranded into copper conductor bundles by a Nichhoff bundle silk machine, the diameter of the single-strand silk is 0.120 mm-0.125 mm, and the stranding pitch is 11-13 times of the outer diameter of the strand.
S200: the insulation of the power wire core 2, the signal wire core 31, the grounding wire core 12 and the control wire core 11 is respectively prepared.
Specifically, the conductor of each wire core is externally extruded with an insulating material with high strength and high flexibility, the thickness of the power wire core insulation 22 and the grounding wire core insulation 122 is 0.8 mm-1.0 mm, and the thickness of the control wire core insulation 112 is 0.3 mm-0.5 mm.
S300: and manufacturing the signal wire core group 3 and the control cable core 1.
The preparation method of the signal wire core group 3 comprises the following steps: the two signal wire cores 31 are twisted in pairs and then wrapped with an aluminum-plastic composite belt, the aluminum-plastic composite belt is woven with copper wires, the twist pitch is controlled to be 10-11 times of the outer diameter of the pair, the diameter of the woven copper wires is 0.10-0.12 mm, and the weaving density is more than or equal to 80%.
The preparation method of the control cable core 1 comprises the following steps: 1 grounding wire core 12 and N control wire cores 11 are twisted into a cable in a 1+ N structure, the grounding wire core 12 is placed at the center position, the twisting pitch is 12-14 times of the outer diameter of the control wire core 11, white non-woven fabric is wrapped outside, and the wrapping overlapping rate is 25% -30%.
S400: a cooling pipe 4 and a return pipe 5 were fabricated, both having an inner diameter of 4mm and an outer diameter of 6mm.
S500: the power wire core 2, the signal wire core group 3, the cooling pipe 4, the backflow pipe 5 and the control cable core 1 are twisted into a main wire core cable core, a main cable core tape 6 made of non-woven fabrics is wrapped outside the main wire core cable core, and the wrapping and covering rate is more than or equal to 30%.
S600: an outer sheath 7 is extruded outside the total cable core cladding belt 6, the outer sheath 7 is made of high-flexibility wear-resistant thermoplastic TPU material, the thickness is 1.8-2.0 mm, and extrusion production is carried out.
To sum up, above-mentioned liquid cooling high-power cable and production technology for new energy automobile charges will be grounded core and control core stranded into the control cable core, and establish the control cable core into the cable center, power sinle silk and cooling tube, the back flow is alternative, symmetrical arrangement, make each sinle silk atress even, control sinle silk and signal sinle silk disconnected core rate have been reduced, cooling tube and each sinle silk area of contact have been increased, effectively improved the cable current-carrying capacity, the cable life has been prolonged, this structural design is compact simultaneously, can effectively reduce the cable external diameter, promote the cable portability.
The foregoing embodiments are merely illustrative of the principles and features of this invention, which is not limited to the above-described embodiments, but rather is susceptible to various changes and modifications without departing from the spirit and scope of the invention, which changes and modifications are within the scope of the invention as claimed. The scope of the invention is defined by the appended claims and equivalents thereof.
Claims (9)
1. The utility model provides a high-power cable of liquid cooling for new energy automobile charges, a serial communication port, including the total core cable core, the total core cable core has total cable core band around the package outward, total cable core outband crowded package has the oversheath, the total core cable core is including the control cable core that sets up between two parties, the control cable core includes the control core and the earth connection core of a plurality of transposition stranding, and the periphery of control cable core is crisscross to be provided with two power core and two signal core groups, and the both sides of every power core are provided with a cooling tube and a back flow respectively, the control cable core is tangent with two power core, two cooling tubes and two back flows respectively, and every signal core group is tangent with the back flow and the cooling tube of both sides.
2. The liquid-cooled high-power cable for charging the new energy automobile as claimed in claim 1, wherein: the control cable core is formed by ten control wire cores which surround one grounding wire core in a regular stranding mode, and a control cable core wrapping belt is integrally wrapped outside the ten control wire cores.
3. The liquid-cooled high-power cable for charging the new energy automobile as claimed in claim 2, wherein: the control wire core comprises a plurality of twisted control wire core conductors, and the control wire core conductors are wrapped with control wire core insulation of an irradiation polyolefin material.
4. The liquid-cooled high-power cable for charging the new energy automobile as claimed in claim 2, wherein: the grounding wire core comprises a plurality of stranded grounding wire core conductors, and the grounding wire core conductors are wrapped with TPE materials to form the grounding wire core insulation.
5. The liquid-cooled high-power cable for charging the new energy automobile as claimed in claim 1, wherein: the power cable core comprises a plurality of twisted power cable core conductors, and the power cable core conductors are wrapped with TPE materials to form power cable core insulation.
6. The liquid-cooled high-power cable for charging the new energy automobile as claimed in claim 1, wherein: the signal conductor core group comprises two twisted signal conductor cores, each signal conductor core comprises a plurality of twisted signal conductor core conductors, the signal conductor core conductors are externally provided with polyolefin signal conductor core insulators, the two signal conductor cores are twisted in pairs and then wrapped with signal conductor core wrapping belts, and metal braided layers are arranged outside the signal conductor wrapping belts.
7. The liquid-cooled high-power cable for charging the new energy automobile as claimed in claim 1, wherein: the cooling pipe and the backflow pipe are made of irradiation cross-linked polyolefin materials, and the outer diameters of the cooling pipe and the backflow pipe are the same as those of the power line core.
8. The liquid-cooled high-power cable for charging the new energy automobile as claimed in claim 1, wherein: the outer sheath is made of TPU materials.
9. The production process of the liquid-cooled high-power cable for charging the new energy automobile is characterized by comprising the following steps of:
s100: respectively preparing conductors of the power wire core, the signal wire core, the grounding wire core and the control wire core;
s200: respectively preparing the insulation of the power wire core, the signal wire core, the grounding wire core and the control wire core;
s300: manufacturing a signal wire core group and a control wire core;
s400: manufacturing a cooling pipe and a return pipe;
s500: the power cable core, the signal cable core group, the cooling pipe, the return pipe and the control cable core are twisted into a main cable core, and a main cable core wrapping belt is wrapped outside the main cable core;
s600: and extruding the outer sheath outside the total cable core cladding.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202310089912.XA CN115985562A (en) | 2023-01-18 | 2023-01-18 | Liquid-cooled high-power cable for charging new energy automobile and production process |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202310089912.XA CN115985562A (en) | 2023-01-18 | 2023-01-18 | Liquid-cooled high-power cable for charging new energy automobile and production process |
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| Publication Number | Publication Date |
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| CN115985562A true CN115985562A (en) | 2023-04-18 |
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| CN202310089912.XA Pending CN115985562A (en) | 2023-01-18 | 2023-01-18 | Liquid-cooled high-power cable for charging new energy automobile and production process |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN120824072A (en) * | 2025-09-16 | 2025-10-21 | 双登电缆股份有限公司 | Liquid-cooled charging cable for electric vehicles and production device thereof |
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2023
- 2023-01-18 CN CN202310089912.XA patent/CN115985562A/en active Pending
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN120824072A (en) * | 2025-09-16 | 2025-10-21 | 双登电缆股份有限公司 | Liquid-cooled charging cable for electric vehicles and production device thereof |
| CN120824072B (en) * | 2025-09-16 | 2025-12-02 | 双登电缆股份有限公司 | A liquid-cooled charging cable for electric vehicles and its manufacturing apparatus |
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