CN118073017B - High-power liquid cooling cable - Google Patents
High-power liquid cooling cableInfo
- Publication number
- CN118073017B CN118073017B CN202410502108.4A CN202410502108A CN118073017B CN 118073017 B CN118073017 B CN 118073017B CN 202410502108 A CN202410502108 A CN 202410502108A CN 118073017 B CN118073017 B CN 118073017B
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- layer
- conductor
- cooling
- cooling pipe
- insulating
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- 238000001816 cooling Methods 0.000 title claims abstract description 186
- 239000007788 liquid Substances 0.000 title claims abstract description 63
- 239000004020 conductor Substances 0.000 claims abstract description 197
- 238000009954 braiding Methods 0.000 claims description 58
- 125000006850 spacer group Chemical group 0.000 claims description 17
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 14
- 229910052802 copper Inorganic materials 0.000 claims description 14
- 239000010949 copper Substances 0.000 claims description 14
- 239000002184 metal Substances 0.000 claims description 12
- 229910052751 metal Inorganic materials 0.000 claims description 12
- 238000009941 weaving Methods 0.000 claims description 11
- 239000011152 fibreglass Substances 0.000 claims description 9
- 229910000831 Steel Inorganic materials 0.000 claims description 4
- 239000010959 steel Substances 0.000 claims description 4
- 238000000034 method Methods 0.000 claims description 3
- 238000005452 bending Methods 0.000 abstract description 17
- 230000017525 heat dissipation Effects 0.000 abstract description 16
- 230000000694 effects Effects 0.000 abstract description 9
- 230000002349 favourable effect Effects 0.000 abstract description 6
- 230000009286 beneficial effect Effects 0.000 description 14
- 238000005516 engineering process Methods 0.000 description 10
- 230000006835 compression Effects 0.000 description 9
- 238000007906 compression Methods 0.000 description 9
- 238000001125 extrusion Methods 0.000 description 8
- 239000004033 plastic Substances 0.000 description 8
- 229920003023 plastic Polymers 0.000 description 8
- 239000000110 cooling liquid Substances 0.000 description 6
- 125000000118 dimethyl group Chemical group [H]C([H])([H])* 0.000 description 6
- 229920002545 silicone oil Polymers 0.000 description 6
- 238000009413 insulation Methods 0.000 description 5
- 238000004804 winding Methods 0.000 description 5
- 239000002826 coolant Substances 0.000 description 4
- 239000000463 material Substances 0.000 description 4
- 239000012466 permeate Substances 0.000 description 4
- 238000013461 design Methods 0.000 description 3
- 230000000149 penetrating effect Effects 0.000 description 3
- 230000001066 destructive effect Effects 0.000 description 2
- 238000011161 development Methods 0.000 description 2
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- 230000007547 defect Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
- 230000014509 gene expression Effects 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000012778 molding material Substances 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 238000004080 punching Methods 0.000 description 1
- 239000004065 semiconductor Substances 0.000 description 1
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Abstract
The invention relates to the technical field of cables, and particularly discloses a high-power liquid cooling cable, which is provided with a cooling pipe with a hollow structure, and a conductor layer and an insulating layer which are sequentially arranged on the periphery of the cooling pipe from inside to outside; the wall of the cooling pipe is of a net structure communicated with the internal and external environments; the hollow structure of the cooling pipe forms a cooling channel for introducing the insulating liquid in the working condition environment to flow, and the insulating liquid flowing in the cooling channel is in direct contact with the conductor layer through meshes on the pipe wall of the cooling pipe to exchange heat. The invention ensures that the heat exchange between the insulating liquid and the conductor is quick and sufficient, has excellent heat dissipation effect, is favorable for the light weight and bending flexibility of the formed cable to be greatly improved, and can stably maintain the excellent heat exchange effect in a complex working condition environment.
Description
Technical Field
The invention relates to the technical field of cables, in particular to a high-power liquid cooling cable which is particularly suitable for charging a new energy automobile.
Background
The rechargeable automobile is taken as a new energy automobile, has an energy saving advantage which is incomparable with the traditional fuel automobile, and is a trend of automobile development in the future. In recent years, new energy charging automobiles are rapidly developed, and the market popularity is high.
For a long time, a major technical bottleneck restricting the popularization of new energy charging automobiles is mainly that the charging time is too long, and the convenience and experience of the users for using the automobiles are directly reduced. In order to solve the technical problem that the charging time of a charging car is too long, the rapid charging technology becomes a direction of attention and important development in the industry.
The quick charging technology is to charge a car with direct current, and the charging cable should have high power current carrying capacity. The high-power current-carrying charging cable has good heat dissipation characteristics so as to avoid the occurrence of wire burning safety accidents caused by overheat of the conductor under the working condition of high-power current carrying.
The traditional heat dissipation technical problem of solving high-power current-carrying cable is enough big with the cross section structure size design of cable, makes the sheath of cable have enough big radiating surface, and the heat of conductor pierces through insulating sheath and dispels the heat to outside environment, realizes the heat exchange. The technical means has the technical problems of low heat exchange rate, heavy cable structure, poor bending performance and the like, is difficult to adapt to the rapid charging working condition environment of the charging automobile, is time-consuming and labor-consuming in dragging operation in the working condition environment, is inconvenient to use, and also has the technical problems of more manufacturing materials and higher cost.
In recent years, a technology of providing a cooling pipe inside a cable to introduce a cooling medium to exchange heat with a conductor has been disclosed in the prior art, and for example, a technology of "cooled charging cable" disclosed in chinese patent literature, a publication number CN 116057646A, a publication number 2023, a publication number 05, a publication number 02, a publication number CN101546626 a, a publication number 2009, a publication number 09, a publication number 30, a publication number CN 107039117A, a publication number 2017, a publication number 08, a publication number 11, and the like are disclosed. In these techniques, a cooling tube with a complete wall and close to the conductor is extruded from an extrudable plastic material, and a cooling medium, liquid or air, is introduced into the cooling tube, the cooling medium exchanging heat with the conductor through the wall of the cooling tube.
The cable structure with the cooling pipe has far better heat dissipation performance than the traditional cable with large cross section structure. However, in the cable structure having the cooling tube with the complete tube wall, the cooling medium exchanges heat with the conductor through the tube wall of the cooling tube, and cannot form direct contact with the conductor, so that the heat dissipation effect is still insufficient. In addition, the cooling pipes with complete pipe walls are arranged in the cable structure, which is not beneficial to light weight forming and bending flexibility improvement of the cable structure.
In the above-mentioned publication CN 116057646A, there is also disclosed a technique of directly penetrating a conductor into a cooling tube to allow the cooling liquid introduced into the cooling tube to directly contact and impregnate the conductor for sufficient heat exchange, and the heat dissipation performance of the cooling tube is far better than that of a cable structure in which heat exchange is performed through the wall of the cooling tube. However, in the cable structure in which the conductor is directly immersed in the cooling liquid to perform heat exchange, high coaxiality between the conductor and the cooling pipe is required to be maintained, so that a cooling liquid flow channel between the outer wall of the conductor and the inner wall of the cooling pipe is ensured to be kept smooth at the periphery, otherwise, the cooling liquid flow is blocked or extruded and deviated so as not to perform heat exchange on the conductor, and the rapid rise of the temperature of the conductor is easy to cause a fever line accident. However, in the practical application working condition environment, the charging cable needs to be frequently bent, dragged and even stressed by external force, and the theoretical coaxiality of the conductor in the cooling pipe and the penetrating design between the cooling pipes can be directly damaged all the time during the use operation, that is, in the practical use, the conductor is difficult to coaxially penetrate in the cooling pipe, the cooling liquid flow channel in the cooling pipe cannot be stably maintained, and the heat exchange stability is poor. Therefore, the design structure is too theoretical and cannot be reliably applied to the application working condition environment of the charging cable.
Disclosure of Invention
The technical purpose of the invention is that: aiming at the particularity of the charging cable for the rapid charging technology and the defects of the prior art, the high-power liquid cooling cable with excellent heat dissipation effect, excellent bending softness, stable heat exchange and light weight molding is provided.
The technical aim of the invention is achieved by the following technical scheme that the high-power liquid cooling cable is provided with a cooling pipe with a hollow structure, and a conductor layer and an insulating layer which are sequentially arranged on the periphery of the cooling pipe from inside to outside;
the wall of the cooling pipe is of a net structure communicated with the internal and external environments;
the hollow structure of the cooling pipe forms a cooling channel for introducing the insulating liquid in the working condition environment to flow, and the insulating liquid flowing in the cooling channel is in direct contact with the conductor layer through meshes on the pipe wall of the cooling pipe to exchange heat.
The technical measures aim at the particularity of the charging cable, the cooling pipe with meshes on the pipe wall is used as the lining supporting structure of the hollow arrangement of the conductor, and insulating liquid is introduced into the conductor to form direct contact heat exchange with the conductor, so that the heat exchange between the insulating liquid and the conductor is quick and sufficient, the heat exchange efficiency is greatly improved, and the cooling pipe has excellent heat dissipation effect and is far superior to a cable structure with heat exchange on the pipe wall of the cooling pipe. Meanwhile, the mesh-shaped cooling pipe on the pipe wall has less molding material, which is beneficial to the weight reduction of the molded cable; and the cooling pipe has good axial bending performance, is favorable for greatly reducing the bending radius, and ensures that the formed cable has excellent bending flexibility.
Compared with the technology disclosed in the technology of the publication No. CN 116057646A that the conductor is directly penetrated in the cooling pipe, the conductor is arranged on the periphery of the cooling pipe, the cooling pipe forms a lining for supporting the conductor, and the cooling channel in the cooling pipe can be kept stably and smoothly no matter in a bending working condition environment, a dragging working condition environment or a reasonable external force compression working condition environment (except for destructive compression), so that the flow of insulating liquid in the cooling pipe cannot be interrupted due to bending, dragging and reasonable compression, namely, stable heat exchange can be kept under the working condition environment, and the cooling pipe can be stably adapted to the application working condition environment of a charging cable.
As one preferable scheme, the cooling pipe is a woven structure of fiber yarns, and the weaving density is 15-60%.
Further, the cooling pipe is a woven structure of glass fiber reinforced plastic wires with the diameter of 0.8-3.0 mm;
The thickness of the cooling pipe is 1.5-5.5 mm.
The cooling pipe with the technical measures is beneficial to the easy, quick and regular forming of the mesh structure of the pipe wall, and has the technical characteristics of small forming technical difficulty, regular meshes and easy realization compared with extrusion forming; the cooling pipe formed in the two aspects is lighter and softer, so that the formed cable is favorable for realizing light weight and improving bending softness; the three-aspect glass fiber reinforced plastic wire has good strength, the cooling pipe woven and formed by the glass fiber reinforced plastic wire can be reliably shaped to form a hollow tubular structure, has good tensile property, can keep a stable cooling channel in a working condition environment, and can be stably adapted to dragging and pulling.
As one of the preferable schemes, the conductor layer is a braided structure of copper wires at the periphery of the cooling tube, and the braiding density is more than or equal to 80%.
Further, the conductor layer is of at least two layers of braiding structures of copper wires on the periphery of the cooling pipe;
in the structure of two adjacent conductor braiding layers, the braiding density of the outer conductor braiding layer is larger than that of the inner conductor braiding layer.
Still further, in the conductor braid structure, the braid density of the outermost conductor braid next to the insulating layer is not less than 95%.
The conductors of the technical measures are formed in a braided structure on the periphery of the cooling pipe, have excellent bending flexibility, and are favorable for cooperating with the cooling pipe of the braided structure to ensure that the cooling channel is stably maintained in various working condition environments. The layered arrangement structure with different braiding densities is beneficial to effectively penetrating insulating liquid in conductors of the braided structure so as to improve heat exchange efficiency.
As one of preferable embodiments, the outer periphery of the conductor layer is wrapped with a spacer layer, and the spacer layer is located between the conductor layer and the insulating layer. The technical measure is beneficial to rounding the periphery of the conductor, further beneficial to extrusion molding of the insulating layer outside the conductor, and avoiding the insulating layer being embedded into the conductor to prevent the conductive performance and the heat dissipation performance of the conductor from being hindered.
As one of the preferable schemes, the insulating layer is internally spirally wrapped with a metal armor layer;
the metal armor layer is buried in the insulating layer and is in clearance fit with the conductor layer in the radial direction.
Further, the metal armor layer is a spiral wrapping structure of steel wires with the diameter of 1.5-3.0 mm in the insulating layer.
The technical measures are beneficial to improving the compression resistance and the tensile resistance of the formed cable and improving the adaptability of the formed cable in complex working condition environments.
As one of the preferable schemes, the insulating liquid is insulating heat conducting oil. The technical measure not only meets the direct contact heat exchange with the conductor, but also has good safety conforming to the conductivity.
The beneficial technical effects of the invention are as follows: the technical measures aim at the particularity of the charging cable, a cooling pipe with soft and meshed pipe walls is used as a lining supporting structure with hollow conductors, insulating liquid is introduced into the conductors to form direct contact heat exchange with the conductors, so that the heat exchange between the insulating liquid and the conductors is quick and sufficient, the heat exchange efficiency is greatly improved, and the cooling cable has an excellent heat dissipation effect and is far superior to a cable structure with heat exchange through the pipe walls of the cooling pipe. Meanwhile, the mesh-shaped cooling pipe with the woven structure is small in forming material and light in weight, and is beneficial to the weight reduction of formed cables; and the bending performance is good, the bending radius is reduced greatly, and the bending softness of the formed cable is excellent.
Compared with the technology disclosed in the technology of the publication No. CN 116057646A that the conductor is directly arranged in the cooling pipe, the conductor is arranged on the periphery of the cooling pipe, the cooling pipe with the braided structure forms a lining support for the conductor, and the cooling channel in the cooling pipe can be kept stably and smoothly no matter in a bending working condition environment, a dragging working condition environment or a reasonable external force compression working condition environment (except for destructive compression), so that the flow of insulating liquid in the cooling pipe is not interrupted due to bending, dragging and reasonable compression, namely, stable heat exchange can be kept under the working condition environment, and the cooling pipe can be stably adapted to the application working condition environment of a charging cable.
Drawings
Fig. 1 is a schematic structural view of the present invention.
Fig. 2 is a schematic diagram of another embodiment of the present invention.
The meaning of the symbols in the figures: 1-a cooling tube; 2-a conductor layer; 3-an insulating layer; 4-a cooling channel; 5-metal armor layer.
Detailed Description
The invention relates to the technical field of cables, in particular to a high-power liquid cooling cable which is particularly suitable for charging a new energy automobile, and the technical scheme of the main body of the invention is specifically described below by combining a plurality of embodiments. Wherein, the embodiment 1 is combined with the attached drawing of the specification, namely, fig. 1, to clearly and specifically explain the technical scheme of the invention; example 2 the technical solution of the present invention is clearly and specifically explained with reference to the attached drawing in the specification, namely, fig. 2; other embodiments, although not drawn separately, may refer to the drawings of embodiment 1 or embodiment 2 for its main structure.
It is to be noted here in particular that the figures of the invention are schematic, which for the sake of clarity have simplified unnecessary details in order to avoid obscuring the technical solutions of the invention which contribute to the state of the art. In addition, the following expressions of "about", "substantially" and the like with respect to the number or the fitting relation mean that the existence of fitting errors, processing errors and the like which are reasonable in the industry is allowed, and the absolute number or fitting relation is not expressed literally.
Example 1
Referring to fig. 1, the cable of the present invention has a cooling tube 1 of a hollow structure, and a conductor layer 2 and an insulation layer 3 arranged in this order from the inside to the outside on the outer periphery of the cooling tube 1.
Specifically, the cooling tube 1 is a woven structure of glass fiber reinforced plastic wires with a diameter of about 1.5mm, the weaving density is about 48%, and the wall thickness of the woven cooling tube 1 is about 2.8mm. So that a plurality of meshes which are respectively communicated with the internal environment and the external environment (namely the environment where the inner wall is positioned and the environment where the outer wall is positioned) are arranged on the wall of the whole cooling pipe 1 in a basic regular and dense way, namely the wall of the cooling pipe 1 is of a net structure.
The conductor layer 2 is of a braided structure of tinned copper wires at the periphery of the cooling tube 1, namely the conductor layer 2 takes the cooling tube 1 as a lining supporting structure, is braided and formed at the periphery of the cooling tube 1, and the braiding density is more than or equal to 80%. In order to enable the conductor layer 2 to realize sufficient heat exchange with the insulating liquid in the cooling tube 1 and improve heat dissipation efficiency, the copper wires constituting the conductor layer 2 are formed in a three-layer braided structure sequentially arranged on the periphery of the cooling tube 1, namely, the conductor braided layer structure adjacent to the cooling tube 1 is an inner braided conductor, the conductor braided layer structure adjacent to a spacer layer described below is an outer braided conductor, the conductor braided layer structure between the inner braided conductor and the outer braided conductor is an intermediate braided conductor, the braiding density (about 82%) of the inner braided conductor is smaller than that of the intermediate braided conductor (about 90%), that is, the braiding density of the outer braided conductor is greater than that of the inner braided conductor in the adjacent two-layer conductor braided layer structure, so that the insulating liquid is favorable to permeate the inner braided conductor layer and directly contact the outer braided conductor layer for heat exchange. In addition, the high braiding density of the outer conductor braiding layer is beneficial to the smoothness and rounding of the outer wall of the whole conductor layer 2.
Since the conductor layer 2 has a woven structure, it is difficult to achieve the smoothness of the outer wall of the single-core conductor or the twisted conductor even if the weaving density is high, so that the insulating layer 3 is prevented from being extruded into the woven mesh of the conductor layer 2, and the outer periphery of the conductor layer 2 is covered with the non-woven insulating layer in a two-layer overlapping wrapping structure, and the overlapping wrapping rate of each layer is about 30%. I.e. the spacer layer is located between the conductor layer 2 and the insulating layer 3.
The insulating layer 3 is an extruded structure of conventional insulating rubber or insulating plastic, which is extruded outside the spacer layer.
In the above cable structure, the hollow structure of the cooling tube 1 forms a cooling channel 4 through which the insulating liquid in the working condition environment (for example, at the charging pile) is introduced into the flow, and the insulating liquid flowing in the cooling channel 4 is directly contacted with the conductor layer 2 through the mesh of the tube wall of the cooling tube 1 to exchange heat. When the cable is applied in a working condition environment, two cable sets are usually formed, one end of each cable set is connected with the charging pile, the other end of each cable set is connected with the charging gun, and the insulating liquid forms a flow loop in the two cables, the charging gun and the charging pile.
The insulating liquid entering the cooling channel 4 is insulating heat conducting oil, such as dimethyl silicone oil.
Example 2
Referring to fig. 2, the cable of the present invention has a cooling tube 1 of a hollow structure, and a conductor layer 2 and an insulation layer 3 sequentially arranged on the outer periphery of the cooling tube 1 from the inside to the outside.
Specifically, the cooling tube 1 is a woven structure of glass fiber reinforced plastic wires with a diameter of about 0.8mm, the weaving density is about 60%, and the wall thickness of the woven cooling tube 1 is about 1.5mm. So that a plurality of meshes which are respectively communicated with the internal environment and the external environment (namely the environment where the inner wall is positioned and the environment where the outer wall is positioned) are arranged on the wall of the whole cooling pipe 1 in a basic regular and dense way, namely the wall of the cooling pipe 1 is of a net structure.
The conductor layer 2 is a braided structure of copper wires at the periphery of the cooling tube 1, namely the conductor layer 2 takes the cooling tube 1 as a lining supporting structure, is braided and formed at the periphery of the cooling tube 1, and the braiding density is more than or equal to 80%. In order to enable the conductor layer 2 to realize sufficient heat exchange with the insulating liquid in the cooling tube 1 and improve heat dissipation efficiency, the copper wires forming the conductor layer 2 are formed in a three-layer braided structure sequentially arranged on the periphery of the cooling tube 1, namely, the conductor braided layer structure adjacent to the cooling tube 1 is an inner braided conductor, the conductor braided layer structure adjacent to a spacer layer described below is an outer braided conductor, the conductor braided layer structure between the inner braided conductor and the outer braided conductor is an intermediate braided conductor, the braiding density (about 85%) of the inner braided conductor is smaller than that of the intermediate braided conductor (about 92%), that is, the braiding density of the intermediate braided conductor is smaller than that of the outer braided conductor (about 98%) in the adjacent two-layer conductor braided layer structure, that is, the braiding density of the outer braided conductor is greater than that of the inner braided conductor layer, so that the insulating liquid can permeate the inner braided conductor layer to be in direct contact with the outer braided conductor layer for heat exchange. In addition, the high braiding density of the outer conductor braiding layer is beneficial to the smoothness and rounding of the outer wall of the whole conductor layer 2.
Since the conductor layer 2 has a woven structure, it is difficult to achieve the smoothness of the outer wall of the single-core conductor or the twisted conductor even if the weaving density is high, so that the insulating layer 3 is prevented from being extruded into the woven mesh of the conductor layer 2, and the outer periphery of the conductor layer 2 is covered with the non-woven insulating layer in a two-layer overlapping wrapping structure, and the overlapping wrapping rate of each layer is about 25%. I.e. the spacer layer is located between the conductor layer 2 and the insulating layer 3.
The insulating layer 3 is an extruded structure of conventional insulating rubber or insulating plastic, which is extruded outside the spacer layer. In order to enhance the compression resistance and tensile resistance of the cable, a metal armor layer 5 is pre-embedded in the insulating layer 3 in a spiral wrapping structure, namely, steel wires with the diameter of about 2.0mm are spirally wrapped in the insulating layer 3, and are not in direct contact with the conductor layer 2 on the inner side of the insulating layer 3 or exposed on the outside, namely, the metal armor layer 5 is embedded in the insulating layer 3 and is in interval fit with the conductor layer 2 in the radial direction.
In the above cable structure, the hollow structure of the cooling tube 1 forms a cooling channel 4 through which the insulating liquid in the working condition environment (for example, at the charging pile) is introduced into the flow, and the insulating liquid flowing in the cooling channel 4 is directly contacted with the conductor layer 2 through the mesh of the tube wall of the cooling tube 1 to exchange heat. When the cable is applied in a working condition environment, two cable sets are usually formed, one end of each cable set is connected with the charging pile, the other end of each cable set is connected with the charging gun, and the insulating liquid forms a flow loop in the two cables, the charging gun and the charging pile.
The insulating liquid entering the cooling channel 4 is insulating heat conducting oil, such as dimethyl silicone oil.
Example 3
The cable of the invention is provided with a cooling pipe with a hollow structure, and a conductor layer and an insulating layer which are sequentially arranged on the periphery of the cooling pipe from inside to outside.
Specifically, the cooling tube is a woven structure of glass fiber reinforced plastic wires with a diameter of about 3.0mm, the weaving density is about 15%, and the wall thickness of the woven formed cooling tube is about 5.5mm. Thus, a plurality of meshes which are respectively communicated with the internal environment and the external environment (namely the environment where the inner wall is positioned and the environment where the outer wall is positioned) are arranged on the wall of the whole cooling pipe in a basic regular and dense way, namely the wall of the cooling pipe is of a net structure.
The conductor layer is a braided structure of tinned copper wires at the periphery of the cooling pipe, namely the conductor layer takes the cooling pipe as a lining supporting structure, is braided and formed at the periphery of the cooling pipe, and has a braiding density of about 90%.
Since the conductor layer is of a woven structure, even if the weaving density is high, the smoothness of the outer wall of the single-core conductor or the stranded conductor is difficult to achieve, so that in order to prevent the insulation layer from being extruded into the woven mesh of the conductor layer, the periphery of the conductor layer is coated with the insulating layer of the semiconductor film in a three-layer overlapped wrapping structure, and the overlapped wrapping rate of each layer is about 30%. I.e. the spacer layer is located between the conductor layer and the insulating layer.
The insulating layer is an extrusion structure of conventional insulating rubber or insulating plastic, and is extruded outside the insulating layer.
In the cable structure, the hollow structure of the cooling pipe forms a cooling channel for introducing the insulating liquid in a working condition environment (such as a charging pile) to flow, and the insulating liquid flowing in the cooling channel is directly contacted with the conductor layer through meshes of the wall of the cooling pipe to exchange heat. When the cable is applied in a working condition environment, two cable sets are usually formed, one end of each cable set is connected with the charging pile, the other end of each cable set is connected with the charging gun, and the insulating liquid forms a flow loop in the two cables, the charging gun and the charging pile.
The insulating liquid entering the cooling channel is insulating heat conducting oil, such as dimethyl silicone oil and the like.
Example 4
The cable of the invention is provided with a cooling pipe with a hollow structure, and a conductor layer and an insulating layer which are sequentially arranged on the periphery of the cooling pipe from inside to outside.
Specifically, the cooling pipe is of a plastic material extrusion structure, the pipe wall thickness is about 2.5mm, a plurality of meshes which are densely distributed and respectively communicated with the internal environment and the external environment (namely the environment where the inner wall is positioned and the environment where the outer wall is positioned) are formed in the pipe wall of the cooling pipe in a punching mode, namely the pipe wall of the cooling pipe is of a net structure.
The conductor layer is of a braided structure of tinned copper wires at the periphery of the cooling pipe, namely the conductor layer takes the cooling pipe as a lining supporting structure, is braided and formed at the periphery of the cooling pipe, and the braiding density is more than or equal to 80%. In order to enable the conductor layer to realize sufficient heat exchange with the insulating liquid in the cooling pipe and improve heat dissipation efficiency, the copper wires forming the conductor layer are formed in a two-layer braided structure sequentially arranged on the periphery of the cooling pipe, namely, the conductor braided layer structure adjacent to the cooling pipe is an inner braided conductor, the conductor braided layer structure adjacent to the spacer layer is an outer braided conductor, and the braiding density (about 90%) of the inner braided conductor is smaller than that of the outer braided conductor (about 97%), namely, in the adjacent two-layer conductor braided layer structure, the braiding density of the outer conductor braided layer is greater than that of the inner conductor braided layer, so that the insulating liquid is beneficial to permeate the inner conductor braided layer to directly contact the outer conductor braided layer for heat exchange. In addition, the high braiding density of the outer conductor braiding layer is beneficial to the smoothness and rounding of the outer wall of the whole conductor layer.
Since the conductor layer is of a woven structure, even if the weaving density is high, the smoothness of the outer wall of the single-core conductor or the stranded conductor is difficult to achieve, so that in order to prevent the insulation layer from being extruded into the woven mesh of the conductor layer, the periphery of the conductor layer is coated with the non-woven fabric spacer layer in a two-layer overlapped wrapping structure, and the overlapped wrapping rate of each layer is about 30%. I.e. the spacer layer is located between the conductor layer and the insulating layer.
The insulating layer is an extrusion structure of conventional insulating rubber or insulating plastic, and is extruded outside the insulating layer. In order to enhance the compression resistance and tensile resistance of the cable, a metal armor layer is pre-buried in the insulating layer in a spiral wrapping structure, namely, a steel wire with the diameter of about 3.0mm is spirally wrapped in the insulating layer, and the metal armor layer is not in direct contact with a conductor layer on the inner side of the insulating layer, or is exposed from the outside, namely, the metal armor layer is buried in the insulating layer and is in clearance fit with the conductor layer in the radial direction.
In the cable structure, the hollow structure of the cooling pipe forms a cooling channel for introducing the insulating liquid in a working condition environment (such as a charging pile) to flow, and the insulating liquid flowing in the cooling channel is directly contacted with the conductor layer through meshes of the wall of the cooling pipe to exchange heat. When the cable is applied in a working condition environment, two cable sets are usually formed, one end of each cable set is connected with the charging pile, the other end of each cable set is connected with the charging gun, and the insulating liquid forms a flow loop in the two cables, the charging gun and the charging pile.
The insulating liquid entering the cooling channel is insulating heat conducting oil, such as dimethyl silicone oil and the like.
The cable formed by the embodiment has excellent heat dissipation effect, but the mesh forming technology difficulty of the pipe wall is increased due to the extrusion forming structure of the cooling pipe, and the bending softness performance is inferior to that of the braided structure (but superior to that of the pipe wall complete structure), so that the cable is not preferred.
Example 5
The cable of the invention is provided with a cooling pipe with a hollow structure, and a conductor layer and an insulating layer which are sequentially arranged on the periphery of the cooling pipe from inside to outside.
Specifically, the cooling tube is a woven structure of glass fiber reinforced plastic wires with a diameter of about 1.2mm, the weaving density is about 40%, and the wall thickness of the woven formed cooling tube is about 2.2mm. Thus, a plurality of meshes which are respectively communicated with the internal environment and the external environment (namely the environment where the inner wall is positioned and the environment where the outer wall is positioned) are arranged on the wall of the whole cooling pipe in a basic regular and dense way, namely the wall of the cooling pipe is of a net structure.
The conductor layer is a braided structure of copper wires at the periphery of the cooling pipe, namely the conductor layer takes the cooling pipe as a lining supporting structure, is braided and formed at the periphery of the cooling pipe, and the braiding density is more than or equal to 80%. In order to enable the conductor layer to realize sufficient heat exchange with the insulating liquid in the cooling pipe and improve the heat dissipation efficiency, the copper wires forming the conductor layer are formed in a three-layer braiding structure sequentially arranged on the periphery of the cooling pipe, namely, the conductor braiding layer structure adjacent to the cooling pipe is an inner layer braiding conductor, the conductor braiding layer structure adjacent to the next-described spacer layer is an outer layer braiding conductor, the conductor braiding layer structure between the inner layer braiding conductor and the outer layer braiding conductor is an intermediate braiding conductor, the braiding density (about 80%) of the inner layer braiding conductor is smaller than the braiding density (about 90%) of the intermediate braiding conductor, namely, the braiding density of the intermediate braiding conductor is smaller than the braiding density (about 98%) of the outer layer braiding conductor in the adjacent two-layer conductor braiding layer structure, and the braiding density of the outer layer braiding layer is larger than the braiding density of the inner layer braiding conductor braiding layer, so that the insulating liquid can permeate the inner layer braiding to be in direct contact with the outer layer braiding for heat exchange. In addition, the high braiding density of the outer conductor braiding layer is beneficial to the smoothness and rounding of the outer wall of the whole conductor layer.
The insulating layer is an extrusion structure of conventional insulating rubber or insulating plastic, and is extruded outside the conductor layer.
In the cable structure, the hollow structure of the cooling pipe forms a cooling channel for introducing the insulating liquid in a working condition environment (such as a charging pile) to flow, and the insulating liquid flowing in the cooling channel is directly contacted with the conductor layer through meshes of the wall of the cooling pipe to exchange heat. When the cable is applied in a working condition environment, two cable sets are usually formed, one end of each cable set is connected with the charging pile, the other end of each cable set is connected with the charging gun, and the insulating liquid forms a flow loop in the two cables, the charging gun and the charging pile.
The insulating liquid entering the cooling channel is insulating heat conducting oil, such as dimethyl silicone oil and the like.
Example 6
The cable of the invention is provided with a cooling pipe with a hollow structure, and a conductor layer and an insulating layer which are sequentially arranged on the periphery of the cooling pipe from inside to outside.
Specifically, the cooling tube is a woven structure of glass fiber reinforced plastic wires with a diameter of about 2.5mm, the weaving density is about 30%, and the wall thickness of the woven formed cooling tube is about 4.8mm. Thus, a plurality of meshes which are respectively communicated with the internal environment and the external environment (namely the environment where the inner wall is positioned and the environment where the outer wall is positioned) are arranged on the wall of the whole cooling pipe in a basic regular and dense way, namely the wall of the cooling pipe is of a net structure.
The conductor layer is a spiral wrapping structure (or a sparse wrapping structure) of the tinned copper wires on the periphery of the cooling pipe, namely the conductor layer takes the cooling pipe as a lining supporting structure, and is spirally sparse-wound on the periphery of the cooling pipe.
Because the conductor layer is of a spiral sparse winding structure, in order to prevent the insulation layer from being extruded into the spiral sparse winding gap of the conductor layer, the periphery of the conductor layer is coated with the non-woven fabric spacer layer in a two-layer overlapped winding structure, and the overlapped winding rate of each layer is about 40%. I.e. the spacer layer is located between the conductor layer and the insulating layer.
The insulating layer is an extrusion structure of conventional insulating rubber or insulating plastic, and is extruded outside the conductor layer.
In the cable structure, the hollow structure of the cooling pipe forms a cooling channel for introducing the insulating liquid in a working condition environment (such as a charging pile) to flow, and the insulating liquid flowing in the cooling channel is directly contacted with the conductor layer through meshes of the wall of the cooling pipe to exchange heat. When the cable is applied in a working condition environment, two cable sets are usually formed, one end of each cable set is connected with the charging pile, the other end of each cable set is connected with the charging gun, and the insulating liquid forms a flow loop in the two cables, the charging gun and the charging pile.
The insulating liquid entering the cooling channel is insulating heat conducting oil, such as dimethyl silicone oil and the like.
Although the cable formed by the embodiment has excellent heat dissipation effect, the spiral sparse winding structure of the conductor layer has lower tensile and dragging stability, and is not favorable for forming a stable cooling channel by being matched with the cooling pipe of the woven structure, which is not preferred.
The above examples are only intended to illustrate the present invention, not to limit it.
Although the invention has been described in detail with reference to the above embodiments, it will be understood by those of ordinary skill in the art that: the specific technical scheme in the embodiments can be modified or part of technical features in the specific technical scheme can be replaced equivalently; such modifications and substitutions do not depart from the spirit and scope of the invention.
Claims (8)
1. The high-power liquid cooling cable comprises a cooling pipe (1) with a hollow structure, and a conductor layer (2) and an insulating layer (3) which are sequentially arranged on the periphery of the cooling pipe (1) from inside to outside;
The method is characterized in that:
The cooling pipe (1) is of a woven structure of glass fiber reinforced plastic wires with the diameter of 0.8-3.0 mm, the weaving density is 15-60%, the pipe wall of the cooling pipe (1) is of a net structure communicated with the internal and external environments, and the pipe wall thickness of the cooling pipe (1) is 1.5-5.5 mm;
The hollow structure of the cooling pipe (1) forms a cooling channel (4) for introducing and flowing insulating liquid in a working condition environment, and the insulating liquid flowing in the cooling channel (4) is in direct contact with the conductor layer (2) through meshes of the pipe wall of the cooling pipe (1) to exchange heat.
2. The high power liquid cooled cable of claim 1, wherein:
the conductor layer (2) is a braided structure of copper wires at the periphery of the cooling tube (1), and the braiding density is more than or equal to 80%.
3. The high power liquid cooled cable of claim 2, wherein:
The conductor layer (2) is of at least two layers of braiding structures of copper wires on the periphery of the cooling tube (1);
in the structure of two adjacent conductor braiding layers, the braiding density of the outer conductor braiding layer is larger than that of the inner conductor braiding layer.
4. A high power liquid cooled cable according to claim 3, wherein:
In the conductor braid structure, the braid density of the outermost conductor braid close to the insulating layer (3) is more than or equal to 95%.
5. The high power liquid cooled cable of any one of claims 1, 2 or 3, wherein:
the periphery of the conductor layer (2) is wrapped with a spacer layer, and the spacer layer is arranged between the conductor layer (2) and the insulating layer (3).
6. The high power liquid cooled cable of claim 1, wherein:
the insulating layer (3) is internally spirally wrapped with a metal armor layer (5);
The metal armor layer (5) is buried in the insulating layer (3) and is in clearance fit with the conductor layer (2) in the radial direction.
7. The high power liquid cooled cable according to claim 6, wherein:
The metal armor layer (5) is of a spiral wrapping structure of steel wires with diameters of 1.5-3.0 mm in the insulating layer (3).
8. The high power liquid cooled cable of claim 1, wherein:
The insulating liquid is insulating heat conducting oil.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202410502108.4A CN118073017B (en) | 2024-04-25 | High-power liquid cooling cable |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202410502108.4A CN118073017B (en) | 2024-04-25 | High-power liquid cooling cable |
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| Publication Number | Publication Date |
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| CN118073017A CN118073017A (en) | 2024-05-24 |
| CN118073017B true CN118073017B (en) | 2024-07-09 |
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Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN101894611A (en) * | 2010-07-21 | 2010-11-24 | 郑州电缆有限公司 | High-temperature resistant wire tube double armature logging cable |
| CN116206812A (en) * | 2022-11-08 | 2023-06-02 | 无锡市明珠电缆有限公司 | Quick charging cable for electric automobile |
| CN117497243A (en) * | 2023-11-30 | 2024-02-02 | 江苏亨通电子线缆科技有限公司 | Liquid-cooled flexible cable and preparation method thereof |
Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN101894611A (en) * | 2010-07-21 | 2010-11-24 | 郑州电缆有限公司 | High-temperature resistant wire tube double armature logging cable |
| CN116206812A (en) * | 2022-11-08 | 2023-06-02 | 无锡市明珠电缆有限公司 | Quick charging cable for electric automobile |
| CN117497243A (en) * | 2023-11-30 | 2024-02-02 | 江苏亨通电子线缆科技有限公司 | Liquid-cooled flexible cable and preparation method thereof |
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