CN116018656A - Liquid-cooled charging cable for new energy vehicles and its production process - Google Patents

Abstract

The application provides a liquid cooling charging cable for a new energy automobile and a production process thereof. Wherein, liquid cooling charging cable includes bus core cable core, cooling tube, back flow, total cable core band and oversheath, and bus core cable core includes: the power cable core, the ground connection core, control cable core, signal cable core and auxiliary cable core, two power cable cores distribute side by side, every power cable core overcoat is equipped with the cooling tube, and a plurality of support piece of circumference direction equipartition has in the annular space between cooling tube and the power cable core that the cover was established, the ground connection core circumscribes with two cooling tubes simultaneously, and circumscribes with two cooling tubes simultaneously with the back flow that the ground connection core set up relatively, the total cable core band of wrapping has outside the bus core cable core, the outer oversheath that extrudes of total cable core band has.

Description

Liquid-cooled charging cable for new energy vehicles and its production process

technical field

This application relates to the field of wire and cable technology, for example, it relates to a liquid-cooled 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 round tube is preset in the cable, and the temperature of the cable is lowered through liquid circulation. However, due to the low strength of the liquid-cooled tube and insufficient support, the cable often suffers from flattening and deformation. It leads to problems such as poor liquid circulation, cable deformation, and heat dissipation failure, which affects the actual use of the cable.

Contents of the invention

This application provides a liquid-cooled charging cable for new energy vehicles and its production process, which ensures the roundness and structural strength of the liquid-cooled tube, provides support for the overall structure of the cable, and ensures structural stability.

This application provides a liquid-cooled charging cable for new energy vehicles, including a bus core cable, a cooling pipe, a return pipe, a total cable core tape and an outer sheath, wherein,

The bus core and cable core include: power core, grounding core, control core, signal core and auxiliary core. The two power cores are arranged side by side, and each power core is equipped with a cooling tube , and in the annular gap between the cooling tube and the set power core, there are a plurality of supports evenly distributed along the circumferential direction, and the grounding core is circumscribed with the two cooling tubes at the same time, and is set opposite to the grounding core The return pipe circumscribes the two cooling pipes at the same time, the two control wire cores are distributed on both sides of the grounding wire core and are respectively circumscribed with the grounding wire core and the cooling pipe on the same side, the signal wire core and the The auxiliary cores and cables are distributed on both sides of the return pipe and are respectively circumscribed with the return pipe and the cooling pipe on the same side. jacket.

The present application also provides a production process based on the above-mentioned liquid-cooled charging cable for new energy vehicles, including:

Prepare core conductors for power cores, ground cores, control cores, signal cores and auxiliary cores;

Prepare insulation layers for grounding cores, control cores, signal cores and auxiliary cores;

Prepare the power core insulation layer, and install a cooling pipe on the power core insulation layer;

Making control cores, signal cores and auxiliary cores;

The power core, cooling pipe, grounding core, control core, signal core, auxiliary core and return pipe are twisted into a bus core, and the bus core is wrapped around the bus core. Cable core tape;

Extrude the outer sheath outside the total cable core tape.

Description of drawings

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

In the picture:

1-power core; 11-power core conductor; 12-power core insulation layer; 13-support;

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

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

4-signal core cable core; 41-signal core conductor; 42-signal core insulation layer; 43-metal braided shielding layer;

5-auxiliary core cable core; 51-auxiliary core conductor; 52-auxiliary core insulation layer; 53-auxiliary cable core tape;

6 - Cooling pipe;

7- return pipe;

8- total cable core tape;

9 - 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 Fig. 1, the present embodiment provides a liquid-cooled charging cable for new energy vehicles, including a bus core cable core, the bus core cable core includes a power core 1, a ground core 2, a control core cable 3, Signal core cable core 4, auxiliary core cable core 5, cooling pipe 6 and return pipe 7, the bus core cable core is wrapped with a total cable core tape 8, and the total cable core tape 8 is extruded with an outer sheath 9.

The liquid-cooled charging cable for new energy vehicles provided in this embodiment includes a bus core cable core, a cooling pipe 6, a return pipe 7, a total cable core tape 8 and an outer sheath 9, wherein the bus core cable core includes: a power line Core 1, grounding core 2, control core and cable core 3, signal core and cable core 4 and auxiliary core and cable 5, two power cores 1 are arranged side by side, and each power core 1 is provided with a cooling pipe 6 , and in the annular space between the cooling pipe 6 and the sheathed power line core 1, there are a plurality of supports 13 evenly distributed along the circumferential direction, and the grounding line core 2 is circumscribed with the two cooling pipes 6 at the same time, and is connected with the grounding line The return pipe 7 opposite to the core 2 is circumscribed with the two cooling pipes 6 at the same time, and the two control wire cores 3 are distributed on both sides of the grounding core 2 and are respectively connected to the grounding core 2 and the cooling pipe 6 on the same side. Cut, the signal core cable core 4 and the auxiliary core cable core 5 are distributed on both sides of the return pipe 7 and are respectively circumscribed with the return pipe 7 and the cooling pipe 6 on the same side, and the bus core cable core is wrapped with a total cable core Tape 8, outer sheath 9 is extruded outside total cable core strap 8.

In this embodiment, two power line cores 1 are arranged side by side, and each power line core 1 is provided with a cooling pipe 6, and a plurality of support members are evenly distributed in the annular gap between the cooling pipe 6 and the power line core 1 13.

Each power core 1 comprises a plurality of stranded power core conductors 11, a plurality of power core conductors 11 are wrapped with a power core insulation layer 12 of thermoplastic elastomer (Thermoplastic Elastomer, TPE) material, and the power core insulation The layer 12 is extruded integrally with a plurality of supports 13 .

The plurality of supports 13 may include three supports 13 of the same size, and a radial gap of 0.8mm˜1.5mm is left between each support 13 and the cooling pipe 6 .

The power core 1 includes a plurality of twisted power core conductors 11, the power core conductors 11 are wrapped with a power core insulation layer 12 of TPE material, and the power core insulation layer 12 is extruded integrally with three supports 13, The support member 13 is made of high-strength and high-hardness thermoplastic polyurethane elastomer rubber (Thermoplastic Polyurethanes, TPU) material, which can effectively support the cooling pipe 6 outside the insulation layer, and ensure that the cooling pipe 6 will not be squeezed and deformed when the cable is bent and moved. Ensure the coolant flow rate and the stability of the cooling tube 6.

A radial gap of 0.8 mm to 1.5 mm is left between the support member 13 and the cooling tube 6, which can ensure the rapid flow of the cooling liquid. While being squeezed by external force and other wire cores, the flow rate of the cooling liquid in the cooling tube 6 can be ensured, effectively The heat dissipation effect of the power core 1 is improved, the ampacity of the cable is provided, and the service life of the cable is prolonged.

In addition, the grounding wire core 2 is circumscribed with one side of the two cooling pipes 6 at the same time, and the other side of the two cooling pipes 6 is circumscribed with a return pipe 7, and the two control wire cores 3 are distributed on the grounding wire core 2 and are respectively circumscribed with the ground core 2 and the cooling pipe 6, and the signal core cable 4 and the auxiliary core cable 5 are distributed on both sides of the return pipe 7 and are respectively connected with the return pipe 7 and the cooling pipe 6. cut.

The cooling pipe 6 is made of irradiated ethylene propylene material, the return pipe 7 and the outer sheath 9 are made of TPU material, and the flow direction of the cooling liquid in the cooling pipe 6 and the return pipe 7 is opposite.

The cooling pipe 6 is made of irradiated ethylene-propylene material, and the cooling pipe 6 is directly worn outside the power core 1 to ensure the best heat dissipation effect of the power core 1, effectively increase the current carrying capacity of the cable, and prolong the service life of the cable.

The return pipe 7 is made of TPU material, and the flow direction of the cooling liquid in the cooling pipe 6 and the return pipe 7 is opposite.

The grounding core 2 includes a plurality of stranded grounding core conductors 21, and the grounding core conductors 21 are wrapped with a grounding core insulating layer 22 of TPE material, which has high strength and high flexibility.

The control wire core cable 3 is formed by twisting five control wire cores in a circular arrangement and is wrapped with a control cable core tape 33 made of non-woven fabric material. The control wire core includes a plurality of twisted control wire core conductors 31, The control core conductor 31 is wrapped with a control core insulating layer 32 of TPE material, which has high strength and high flexibility.

The signal core cable core 4 is formed by twisting two signal cores and wrapped with a metal braided shielding layer 43. The signal core includes a plurality of twisted signal core conductors 41, and the signal core conductors 41 are wrapped with TPE material. The insulating layer 42 of the signal wire core.

The signal wire core cable core 4 is formed by excision and twisting of two signal wire cores and wrapped with a metal braided shielding layer 43. The signal wire core includes a plurality of twisted signal wire core conductors 41, and the signal wire core conductors 41 are wrapped with The signal core insulation layer 42 made of TPE material has high strength and high flexibility.

The auxiliary core cable core 5 is formed by twisting two auxiliary cores and is wrapped with an auxiliary core tape 53. The auxiliary core includes a plurality of twisted auxiliary core conductors 51, and the auxiliary core conductor 51 is wrapped with Auxiliary core insulation layer 52 made of TPE material.

The auxiliary core cable core 5 is formed by twisting two auxiliary cores in a circular arrangement and is wrapped with an auxiliary core tape 53 made of non-woven fabric material. The auxiliary core includes a plurality of twisted auxiliary core conductors 51, The auxiliary core conductor 51 is wrapped with an auxiliary core insulating layer 52 of TPE material, which has high strength and high flexibility.

The outer diameter of the grounding core 2 is the same as that of the return pipe 7, the outer diameter of the signal core cable 4 is the same as that of the auxiliary core cable 5, and even the outer diameter of the control core cable 3 is also the same, thereby ensuring that the overall cable The structure is symmetrical and stable, which can effectively increase the stability of the overall structure of the cable and ensure that the cable will not be deformed under bending and twisting conditions.

Total cable core wrapping tape 8 adopts reinforced non-woven fabric.

Outer sheath 9 adopts TPU material, has high softness, wear-resisting property.

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

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

The preparation method of the power core conductor 11 is as follows: making copper conductor strands, twisting the copper monofilament bundles into copper conductor bundles by a Nihoff beam machine, the diameter of the monofilaments is 0.140 mm to 0.145 mm, and the stranding pitch is The outer diameter of the strands is 11 to 13 times; the copper conductor strands are stranded 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.

The preparation method of the ground core conductor 21, the control core conductor 31, the signal core conductor 41 and the auxiliary core conductor 51 is as follows: the copper monofilament bundle is twisted into a copper conductor bundle by a Nihoff beam machine, and the monofilament wire The diameter is 0.140mm~0.145mm, and the stranding pitch is 12~14 times the outer diameter of the strand.

S200: Prepare insulation layers of the grounding core 2, the control core, the signal core, and the auxiliary core.

The preparation method of ground core insulation layer 22 , control core insulation layer 32 , signal core insulation layer 42 and auxiliary core insulation layer 52 is to extrude high-strength and high-flexibility TPE material outside the corresponding core conductors.

S300: Prepare the power line core insulation layer 12, and put the cooling pipe 6 on the outside of the power line core insulation layer 12.

The preparation method of the power core insulating layer 12 is to extrude TPE material outside the power core conductor 11, and extrude three supports 13 integrally on the power core insulating layer 12, and put a cooling pipe on the outside of the power core 1 6. Keep a distance of 0.8 mm to 1.5 mm between the three support members 13 and the cooling pipe 6 .

S400: making the control wire core 3, the signal wire core 4 and the auxiliary wire core 5.

The preparation method of the control wire core cable core 3 is to divide ten control wire cores into two equal parts, twist them into a cable in the form of 0+5, and wrap the control cable core tape 33 of white non-woven fabric on the outside. 25% to 30%.

The preparation method of the signal wire core and the cable core 4 is to twist two signal wire cores, the twist pitch is 12 to 16 times the twisted outer diameter, and after twisting, copper wires are braided to form a metal braided shielding layer 43, and the copper wires are single Wire diameter 0.10mm, weaving density ≥ 85%.

The preparation method of the auxiliary wire core cable core 5 is to twist two auxiliary wire cores, the twisting pitch is 12 to 16 times the outer diameter of the twisting, and the auxiliary cable core tape 53 wrapped with white non-woven fabric is wrapped around the bag. The coverage rate is 25% to 30%.

S500: Twist the power core 1, cooling pipe 6, grounding core 2, control core 3, signal core 4, auxiliary core 5 and return pipe 7 into a bus core, and The total cable core tape 8 is wrapped around the bus core and the cable core. The total cable core tape 8 is a reinforced non-woven fabric, and the wrapping and covering rate is 20% to 30%.

S600: The outer sheath 9 is extruded outside the total cable core tape 8, and the outer sheath 9 can be formed by extruding a tube with a thickness of 2.5mm to 3.0mm by using highly soft and wear-resistant soft TPU material.

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

(1) The insulating layer 12 of the power core and the support 13 of the cooling pipe 6 are integrally formed, and the insulating layer 12 of the power core and the three supporting members 13 are made of high-strength and high-hardness materials, which can effectively support the insulating layer of the power core The cooling pipe 6 outside 12 ensures that the cooling pipe 6 will not be squeezed and deformed when the cable is bent and moved, ensuring the flow rate of the cooling liquid and the stability of the cooling pipe 6;

(2) There is a distance of 0.8 mm to 1.5 mm between the three supports 13 outside the insulating layer 12 of the power core and the cooling pipe 6, which can ensure the rapid flow of the cooling liquid and ensure The flow rate of the coolant in the cooling pipe 6 effectively improves the heat dissipation effect of the power core, provides the current carrying capacity of the cable, and prolongs the service life of the cable;

(3) The outer diameters of the two control cores 3, the signal core 4 and the auxiliary core 5 are the same as possible, the return pipe 7 is the same as the grounding core 2, and multiple cores Maintaining a tangent structure ensures that the overall structure of the cable is symmetrical and stable, which can effectively increase the stability of the overall structure of the cable and ensure that the cable does not deform when used under bending and twisting conditions;

(4) The cooling pipe 6 is directly passed outside the power core 1 to ensure the best heat dissipation effect of the power core 1, effectively increase the ampacity of the cable, and prolong the service life of the cable.

Claims (10)

1. A liquid-cooled charging cable for new energy vehicles, comprising a bus core cable core, a cooling pipe, a return pipe, a total cable core tape and an outer sheath, wherein, The bus core and cable core include: power core, grounding core, control core, signal core and auxiliary core. The two power cores are arranged side by side, and each power core is provided with a The cooling pipe, and a plurality of supports are evenly distributed along the circumferential direction in the annular gap between the cooling pipe and the set power line core, and the grounding line core is circumscribed with the two cooling pipes at the same time, and The return pipe arranged opposite to the grounding core is circumscribed with the two cooling pipes at the same time, and the two control wire cores are distributed on both sides of the grounding core and connected to the grounding core and the grounding core respectively. The cooling pipe on the same side is circumscribed, and the signal wire core and the auxiliary wire core are distributed on both sides of the return pipe and are respectively circumscribed to the return pipe and the cooling pipe on the same side. The total cable core tape is wrapped around the bus core and the cable core, and the outer sheath is extruded from the total cable core tape. 2. The cable of claim 1, wherein each power core comprises a plurality of stranded power core conductors wrapped with a power core insulation of thermoplastic elastomer TPE material layer, the insulating layer of the power core is extruded integrally with the plurality of supports. 3. The cable according to claim 2, wherein the plurality of supports includes three supports of the same size, and a radial gap of 0.8 mm to 1.5 mm is left between each support and the cooling pipe . 4. The cable according to claim 1, wherein the cooling pipe is made of irradiated ethylene-propylene material, the return pipe and the outer sheath are made of thermoplastic polyurethane elastomer rubber TPU material, and the cooling pipe and the The flow direction of the cooling liquid in the return pipe is reversed. 5. 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. 6. The cable according to claim 1, wherein each control wire core is formed by twisting five control wire cores in a circular arrangement and wrapped with a control cable core tape, and each control wire core includes multiple A twisted control core conductor, each of the control core conductors is wrapped with a control core insulation layer of TPE material. 7. The cable according to claim 1, wherein the signal core cable is formed by twisting two signal cores and wrapped with a metal braided shielding layer, each signal core comprising a plurality of twisted signal cores As for the core conductors, each of the signal core conductors included in each signal core is wrapped with a signal core insulating layer of TPE material. 8. The cable according to claim 1, wherein the auxiliary core cable is formed by twisting two auxiliary cores and wrapped with an auxiliary core tape, and each auxiliary core includes a plurality of twisted Auxiliary core conductors, each of the auxiliary core conductors is wrapped with an auxiliary core insulation layer of TPE material. 9. The cable according to claim 1, wherein the ground core has the same outer diameter as the return pipe, and the signal core has the same outer diameter as the auxiliary core. 10. A production process applied to the liquid-cooled charging cable for new energy vehicles according to any one of claims 1 to 9, comprising: Prepare core conductors for power cores, ground cores, control cores, signal cores and auxiliary cores; preparing insulation layers for the grounding core, the control core, the signal core, and the auxiliary core; Prepare a power wire core insulation layer, and install a cooling pipe on the power wire core insulation layer; Making control cores, signal cores and auxiliary cores; Twisting the power core, the cooling pipe, the grounding core, the control core, the signal core, the auxiliary core and the return pipe into a bus core cable core, and the total cable core tape is wrapped around the bus core cable core; An outer sheath is extruded outside the total cable core tape.

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