CN115997258A - High-power charging cable for new energy vehicles and its production process - Google Patents

Abstract

The application provides a high-power charging cable for a new energy automobile and a production process thereof. The liquid cooling high-power charging cable comprises a bus core cable core, a liquid cooling pipe, a filling layer, a bus core wrapping tape and an outer sheath, wherein the bus core cable core comprises an anode power wire core, a cathode power wire core, a grounding wire core and a control wire core, the grounding wire core is positioned in the center of the bus core cable core, and the two anode power wire cores and the two cathode power wire cores are distributed on two sides of the grounding wire core and tangent to the grounding wire core; each of the two liquid cooling pipes is tangent to the positive power wire core and the negative power wire core which are oppositely arranged on the same side respectively and is tangent to the ground wire core at the same time, a filling layer which enables the cable to be round is arranged outside the bus core cable core, a total cable core wrapping belt is wrapped outside the filling layer, and an outer sheath is extruded outside the total cable core wrapping belt.

Description

High-power charging cable for new energy vehicles and its production process

technical field

This application relates to the field of electric wire and cable technology, for example, it relates to a high-power charging cable for new energy vehicles and its production process.

Background technique

Compared with traditional vehicles, new energy vehicles have the advantages of strong power, low cost, energy saving and environmental protection, but the development of new energy vehicles is limited due to their low charging efficiency. In order to solve the charging time problem of new energy vehicles, it is necessary to design and develop high-power charging cables. Most high-power charging cables are liquid-cooled, that is, a liquid-cooled tube is added to the cable structure. However, due to the small outer diameter of the liquid-cooled tube, it is not compatible with the power line The core contact area is small and the cooling effect is not good. At the same time, the liquid cooling tube is soft and has low strength. During use, it will be squeezed and deformed by the cable power core, resulting in problems such as poor cooling liquid circulation and heat dissipation failure, which will affect the cable. actual use.

Contents of the invention

The application provides a high-power charging cable for new energy vehicles and its production process, which increases the contact area between the liquid-cooled tube and the power core, increases the ampacity of the cable, reduces the rate of broken cores, and prolongs the service life of the cable.

This application provides a high-power charging cable for new energy vehicles, including a bus core cable core, a liquid cooling tube, a filling layer, a total cable core wrapping tape, and an outer sheath, wherein,

The bus core cable includes a positive power core, a negative power core, a ground core and a control core. Both sides of the core and tangent to the grounding core;

Each of the two liquid-cooled tubes is respectively tangent to the positive power core and the negative power core on the same side and is tangent to the grounding core at the same time; the control core is arranged on the positive power core and the negative power core. In the gap with the outer edge of the liquid cooling tube;

The filling layer is formed outside the bus core cable core and arranged to make the cable round. The filling layer is wrapped with a total cable core tape, and the total cable core tape is extruded with an outer sheath.

The present application also provides a production process applied to the above-mentioned high-power charging cable for new energy vehicles, including:

Prepare a power core and a ground core, and split the power core into a positive power core and a negative power core;

Prepare the control wire core and make the control cable core;

Make liquid cooling tubes;

Strand the positive power core, negative power core, grounding core, liquid cooling tube, control core and control cable core into a bus core cable, and set a full circle of filling layer outside the bus core cable core;

Wrap the total cable core tape outside the filling layer;

Extrude the outer sheath outside the total cable core tape.

Description of drawings

Fig. 1 is a schematic structural diagram of a high-power charging cable for a new energy vehicle provided in an embodiment of the present application.

In the picture:

1-positive power core; 1'-negative power core; 11-power core conductor; 12-power core insulation layer;

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

3-control wire core; 31-control wire core conductor; 32-control wire core insulation layer; 33-control cable core tape;

4- liquid cooling tube;

5 - filling layer;

6- total cable core tape;

7 - Outer sheath.

Detailed ways

Embodiments of the present application are described 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 application, and should not be construed as limiting the present application.

In the description of this application, unless otherwise specified 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. It may 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. The meanings of the above terms in this application can be understood according to the actual situation.

In the description of the present application, unless otherwise 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, and may also include the first feature and the second feature. Two features are not in direct contact but through another feature between them. 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 solution of the present application will be described below in conjunction with the accompanying drawings and through embodiments.

Please refer to Figure 1, this embodiment provides a high-power charging cable for new energy vehicles, including a bus core cable core, the bus core cable core includes a positive power core 1, a negative power core 1', and a ground core 2 , control wire core 3 and liquid cooling tube 4, the bus core cable core is provided with a filling layer 5 to make the cable round, the filling layer 5 is wrapped with a total cable core tape 6, and the total cable core tape 6 is extruded Outer sheath 7 is arranged.

High-power charging cable for new energy vehicles, including bus core cable core, liquid cooling tube 4, filling layer 5, total cable core tape 6 and outer sheath 7, wherein the bus core cable core includes positive power core 1, negative pole Power core 1', grounding core 2 and control core 3, grounding core 2 is located in the center of the bus core, two positive power cores 1 and two negative power cores 1' are distributed in grounding core 2 Each of the two liquid-cooled tubes 4 is respectively tangent to the positive power core 1 and the negative power core 1' set on the same side, and is also tangent to the ground core 2 at the same time. tangent; the control wire core 3 is arranged in the outer edge gap between the positive power wire core 1, the negative power wire core 1' and the liquid cooling tube 4; the filling layer 5 is formed outside the bus core cable core and is set to make the cable round, The filling layer 5 is wrapped with a total cable core tape, and the total cable core tape is extruded with an outer sheath 7 .

In this embodiment, the grounding core 2 is located at the center of the bus core cable, and two positive power cores 1 and two negative power cores 1' are distributed on both sides of the grounding core 2 and are tangent to the grounding core 2. , there is a liquid cooling tube 4 between the positive power core 1 and the negative power core 1' on both sides, and the liquid cooling tube 4 is connected to the grounding core 2, positive power core 1, and negative power core 1' at the same time. cut. Therefore, splitting the positive and negative poles of the power core can greatly increase the contact area between the power core and the liquid cooling tube 4 , the cooling effect is better, and the current carrying capacity of the cable is effectively increased.

The outer diameters of the positive power core 1, the negative power core 1', and the liquid cooling tube 4 are set to be the same, so that the overall structure is symmetrically distributed around the ground core 2, and the force is uniform and the structure is stable.

Both the positive power core 1 and the negative power core 1' include a plurality of twisted power core conductors 11, and the power core conductors 11 are wrapped with a power core insulation layer of thermoplastic elastomer (Thermoplastic Elastomer, TPE) material. 12.

The grounding core 2 includes a plurality of twisted grounding core conductors 21, and the grounding core conductors 21 are wrapped with a grounding core insulating layer 22 made of TPE material.

The liquid cooling tube 4 is made of irradiated cross-linked polyolefin material, and the cooling liquid in the two liquid cooling tubes 4 flows in the opposite direction, which can improve the heat dissipation effect of the power core, provide the current carrying capacity of the cable, and prolong the service life of the cable.

The control core 3 is arranged in the space between the positive power core 1, the negative power core 1' and the outer edge of the liquid cooling tube 4, which can effectively reduce the outer diameter of the cable and improve the portability of the cable. The control core 3 includes a plurality of stranded control core conductors 31 , and the control core conductors 31 are wrapped with a control core insulating layer 32 of TPE material.

Considering that the space between the two positive power cores 1 and the two negative power cores 1' are respectively arranged at intervals, a control cable core is arranged in the gap between them, and the control cable core is composed of two control cores. 3 pairs are twisted and wrapped with a control cable core tape 33 .

A control cable core 3 tangent to the two positive power cores 1 is arranged in the gap between the two positive power cores 1, and a control cable core 3 tangent to the two positive power cores 1' is arranged in the gap between the two negative power cores 1'. The negative power core 1 ′ is tangent to the control cable core 3 , and each control cable core 3 is twisted from two control cores 3 and wrapped with a control cable core tape 33 .

The filling layer 5 is made of highly soft and highly thermally conductive foaming material, with high-density polyethylene as the base material, which is light in weight and has good heat resistance, and is modified by adding graphite and carbon fiber to increase the thermal conductivity of the filling layer 5 and improve the thermal conductivity of the filling layer 5. The heat dissipation speed of the cable improves the current carrying capacity of the cable, and can ensure that the extrusion force on the control core 3 is reduced, which can protect the control core 3 from extrusion deformation and broken core during use, and can effectively improve the flexibility of the cable. , It can also reduce the weight of the cable and improve the portability of the cable.

Total cable core wrapping tape 6 adopts reinforced non-woven fabric.

The outer sheath 7 is made of thermoplastic polyurethane elastomer (Thermoplastic Polyurethanes, TPU) material, which has high softness and wear resistance.

In addition, this embodiment also provides a production process based on the above-mentioned high-power charging cable for new energy vehicles, including the following steps.

S100: Prepare a power core and a ground core 2, and split the power core into a positive power core 1 and a negative power core 1'.

The preparation method of the power core conductor 11 and the grounding core conductor 21 is as follows: making copper conductor strands, twisting the copper monofilament strands into copper conductor strands by a Nihoff stranding machine, and the diameter of the monofilaments is 0.190 mm to 0.195 mm. mm, the stranding pitch is 11 to 13 times the outer diameter of the strands; the copper conductor strands are twisted to form a corresponding core conductor, and the stranding pitch is 13 to 15 times the outer diameter of the power core conductor 11.

The preparation method of the power core insulating layer 12 and the grounding core insulating layer 22 is to extrude a TPE material with high strength and high flexibility outside the corresponding core conductor, and the power core insulating layer 12 and the grounding core insulating layer 22 The thickness is 1.4mm ~ 1.6mm.

In this embodiment, the power wire cores are divided into two, the positive pole and the negative pole, and there are four in total.

S200: Prepare the control wire core 3, and make the control cable core.

The preparation method of the control wire core conductor 31 is as follows: the copper monofilament bundle is twisted into a copper conductor bundle by a Nihoff wire bundle machine, the diameter of the monofilament is 0.140 mm to 0.145 mm, and the twisting pitch is 12 to 14 times the number of strands Wire outer diameter.

The preparation method of the control core insulation layer 32 is to extrude the TPE material with high strength and high flexibility on the control core conductor 31, and the thickness of the control core insulation layer 32 is 0.5mm-0.6mm.

The production method of the control cable core is to twist two control wire cores 3 pairs into a cable, the twisting pitch is 10 to 12 times the outer diameter of the control wire core 3, and the control cable core tape 33 is wrapped with white non-woven fabric. The rate of wrapping and covering is 25% to 30%.

In this embodiment, there are four control wire cores 3 and two control cable cores.

S300: making a liquid cooling tube 4.

In this embodiment, there are two liquid cooling tubes 4, which are made of radiation cross-linked polyolefin material, with an inner diameter of 8 mm and an outer diameter of 10 mm.

S400: Twisting the positive power core 1, the negative power core 1', the grounding core 2, the liquid cooling tube 4, the control core 3 and the control cable into a bus core, and set it outside the bus core The filling layer 5 is a complete circle, wherein the filling layer 5 is made of highly soft and highly thermally conductive foaming filling material, with high-density polyethylene as the base material, filled with graphite and carbon fiber for modification.

S500: Wrap the total cable core tape 6 outside the filling layer 5, the total cable core tape 6 is reinforced non-woven fabric, and the covering rate of the wrap is ≥30%.

S600: Extrude the outer sheath 7 out of the total cable core tape 6, the outer sheath 7 is made of highly soft and wear-resistant thermoplastic TPU material, with a thickness of 1.8mm ~ 2.0mm, produced by extruded tube.

A production process based on the above-mentioned high-power charging cable for new energy vehicles provided in this embodiment includes the following steps: preparing a power core and a grounding core, and splitting the power core into a positive power core and a negative power core. Wire core; preparing control wire core; making liquid cooling tube; twisting the positive power core, the negative power core, the grounding core, the liquid cooling tube, and the control wire core into a bus Core cable core, and set a filling layer outside the bus core cable core to make the cable round; wrap the total cable core tape outside the filling layer; extrude the outer sheath outside the total cable core tape .

The production process also includes: making the control cable core;

Wherein, said twisting said positive power wire core, said negative power wire core, said grounding wire core, said liquid cooling tube, and said control wire core into a bus core cable includes: The positive power core, the negative power core, the ground core, the liquid cooling tube, the control core and the control cable are stranded to form the bus core.

In summary, the effects of the high-power charging cable for new energy vehicles and its production process provided by this application are as follows:

(1) Split the positive power core 1 and the negative power core 1' to increase the contact area between the power core and the liquid-cooled tube 4, the cooling effect is better, and the current carrying capacity of the cable is effectively increased;

(2) The four split power wire cores have the same outer diameter as the liquid cooling tube 4, and are distributed symmetrically around the ground wire core 2, with uniform force and stable structure;

(3) The control wire core 3 is distributed in the gap between the power wire core and the liquid cooling tube 4 after being cabled, which can effectively reduce the outer diameter of the cable and improve the portability of the cable;

(4) The bus core and the cable core are filled with high softness and high thermal conductivity foaming material, with high density polyethylene as the base material, which is light in weight and has good heat resistance. Graphite and carbon fiber are added to increase the thermal conductivity of the filling layer 5 and improve the cable Heat dissipation speed, improve cable carrying capacity;

(5) The filling layer 5 can ensure that the extrusion force on the control wire core 3 becomes smaller, protect the control wire core 3 from extrusion deformation and broken core during use, effectively improve the flexibility of the cable, and reduce the weight of the cable , to improve the portability of the cable.

Claims (11)

1. A high-power charging cable for new energy vehicles, comprising a bus core cable core, a liquid cooling tube, a filling layer, a total cable core wrapping tape and an outer sheath, wherein, The bus core cable includes a positive power core, a negative power core, a grounding core and a control core, the grounding core is located at the center of the bus core, two positive power cores and two negative power cores The power core is distributed on both sides of the ground core and is tangent to the ground core; Each of the two liquid-cooled tubes is respectively tangent to the positive power line core and the negative power line core arranged opposite to the same side and is tangent to the grounding line core at the same time; the control line core is arranged on the positive power line Core, the negative electrode power line core and the outer edge of the liquid cooling tube; The filling layer is formed outside the bus core cable and is arranged to make the cable round. The filling layer is wrapped with the total cable core tape, and the total cable core tape is extruded with the outer sheath. 2. The cable of claim 1, wherein each positive power core, and each negative power core comprises a plurality of twisted power core conductors, each positive power core comprising said A plurality of power core conductors are wrapped with a power core insulation layer of thermoplastic elastomer TPE material, and each of the power core conductors included in each negative power core conductor is wrapped with a power core insulation layer of TPE material . 3. The cable of claim 1, wherein the ground core comprises a plurality of stranded ground core conductors wrapped with a ground core insulation layer of TPE material. 4. The cable according to claim 1, wherein each control core comprises a plurality of twisted control core conductors, and each control core comprises a plurality of control core conductors wrapped with TPE material Control core insulation. 5. The cable according to claim 1, wherein a control cable core tangent to the two positive power cores is arranged in the gap between the two positive power cores, and the two negative power cores A control cable core tangent to the two negative power cores is set in the gap between the power cores, and each control core is formed by twisting two control cores and wrapped with a control cable core. bring. 6. The cable according to claim 1, wherein the liquid-cooled pipe is made of radiation cross-linked polyolefin material, and the flow directions of the cooling liquid in the two liquid-cooled pipes are opposite. 7. The cable according to claim 1, wherein the filling layer is based on high-density polyethylene and modified by adding graphite and carbon fiber. 8. The cable according to claim 1, wherein the outer sheath is made of thermoplastic polyurethane elastomer TPU material. 9. The cable according to claim 1, wherein the outer diameters of the positive power core, the negative power core, and the liquid cooling tube are the same. 10. A production process applied to the high-power charging cable for new energy vehicles according to any one of claims 1 to 9, comprising: Prepare a power core and a ground core, and split the power core into a positive power core and a negative power core; Prepare the control wire core; Make liquid cooling tubes; Twisting the positive power core, the negative power core, the grounding core, the liquid cooling tube, and the control core into a bus core cable, and outside the bus core cable Set the padding to make the cable a full circle; Wrapping the total cable core tape outside the filling layer; An outer sheath is extruded outside the total cable core tape. 11. The production process according to claim 10, further comprising: Make control cable core; Wherein, the twisting of the positive power core, the negative power core, the grounding core, the liquid cooling tube, and the control core into a bus core cable includes: Twisting the positive power core, the negative power core, the ground core, the liquid cooling tube, the control core and the control cable into the bus core cable.

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