CN208111135U - A kind of cooling cable - Google Patents

A kind of cooling cable Download PDF

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Publication number
CN208111135U
CN208111135U CN201721866642.5U CN201721866642U CN208111135U CN 208111135 U CN208111135 U CN 208111135U CN 201721866642 U CN201721866642 U CN 201721866642U CN 208111135 U CN208111135 U CN 208111135U
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core
cable
signal
copper
conductor
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张东杰
王雪松
祝军
李斌
刘雄军
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Jiangsu Shangshang Cable Group Co Ltd
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Jiangsu Shangshang Cable Group Co Ltd
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Abstract

A kind of cooling cable, including accessory power supply core, the first signal core group, second signal core group, third signal core group, wire core, active force core, hollow pipe.Accessory power supply core, the first signal core group, second signal core group, third signal core group, wire core, active force core and these function cable twists of circulating cooling hose circulating cooling hose are constituted big cable core, wrapped nonwoven fabric belts are overlapped outside big cable core and constitute nonwoven layer;Oversheath is wrapped up outside nonwoven layer, constitutes cable.This cooling cable realizes that coolant interface, cooling system can solve the heating problem of high power cable at low cost.

Description

A kind of cooling cable
Technical field
The technical program belongs to field of cable technology, specifically a kind of cooling cable making method and cable.
Background technique
That there is specific energies is low for the common lithium ion power storage battery of new-energy automobile at present, and the primary continual mileage that charges is short The problem of.Therefore, in the case where current driving force battery cannot provide more continual mileages, if the charging for being able to achieve battery is fast Speedization solves the short deadly defect of electric car continual mileage from another angle.Charge the rapid demand for becoming development. Three-element catalytic technology, gradually maturation, the specific energy of power accumulator of graphene technology are constantly being promoted simultaneously, and this requires not While realizing quick charge, meet the high-power charging of battery, realizes the powerful transmitting of charging.
Either hybrid vehicle, pure electric automobile or fuel cell car all be unable to do without high-voltage electric system.It is pure Electric car and plug-in hybrid-power automobile take more than the high voltage and several hundred amperes of high currents of 300V.The promotion meeting of voltage The requirement on electric performance of charging components, higher cost are improved, the estimated highest of following voltage is promoted to 1000V.The promotion of electric current Essential approach as high-power charging.Current electric current maximum may achieve 250A, and the cable of charging has used 90mm2Electricity Cable, to guarantee the safety of actual use.When electric current continues to true add to 350A, traditional charging cable needs reach 120mm2, it is inconvenient for use.If electric current rises to 400A again, the diameter needs of charging cable continue to increase, then bringing The disadvantages of cable is not heavy, flexible, purchase cost is high.
The electric current of high-power charging is larger (250A is promoted to 400A or more), for solve cable fever phenomenon, harness Therewith thicker (50mm or more), the operability of charging reduces diameter, and the economy of scheme reduces.So having to design new side Case solves the heating problem of high current, transmits biggish electric current with lesser cable.
High-power charging technique includes cooling system technology, cooling cable technology and coolant interface technology etc..
Summary of the invention
In order to solve the above-mentioned problems in the prior art, the technical program proposes a kind of cooling cable and its manufacturer Method, specially:
A kind of cooling cable, structure include following function cable:
A, accessory power supply core:Auxiliary electricity is constituted by wrapping up auxiliary power supply line core insulation layer outside accessory power supply core copper conductor Source core;Accessory power supply core has more;
B, the first signal core group:Signal core is constituted by wrapping up insulating layer outside copper foil conductor, more signal cores are twisted structure At signal core cable core, inner restrictive coating is wrapped up outside signal core cable core and constitutes the first signal core group;First signal core group has more;
C, second signal core group:Signal core is constituted by wrapping up insulating layer outside copper foil conductor, more signal cores are twisted structure At signal core cable core, signal core cable core is overlapped wrapped aluminium foil strip and constitutes aluminium foil wrapping layer, and tinned copper wire is wrapped up outside aluminium foil wrapping layer Braiding layer, tincopper fuse wire braided armor surface wrap up inner restrictive coating and constitute second signal core group;
D, third signal core group:Structure is identical as second signal core group;
E, wire core:Wire core is constituted by wrapping up ground wire core insulating barrier outside ground wire core conductor;
F, active force core:It is external insulation layer outside inner insulating layer by active force cable core conductor outsourcing inner insulating layer, it is inside and outside It is made of between insulating layer more dowel supports;Each dowel surrounds an axisymmetrical;
G, the hollow pipe constituted is squeezed out by cross-linking radiation elastomeric material;
Accessory power supply core, the first signal core group, second signal core group, third signal core group, wire core, the active line of force Core and these function cable twists of circulating cooling hose circulating cooling hose constitute big cable core, and big cable core gap uses non-hygroscopic It is overlapped wrapped nonwoven fabric belts outside 125 DEG C of big cable cores of gasket for packing of high temperature resistant and constitutes nonwoven layer;Oversheath, structure are wrapped up outside nonwoven layer At cable.
The radial section of the cable is round;According to line footpath size, including the biggish function cable of line footpath, line footpath is smaller Function cable outside, be arranged successively;The straight line of the identical immediate two functions cable of line footpath being located along across the center of circle at Axial symmetry.
The active force cable core conductor, ground wire core conductor are identical with the requirement of accessory power supply core copper conductor, they are all It is made of multiply naked copper monofilament;The diameter range of copper monofilament is 0.1mm~0.2mm;The twisted stranding distance of copper monofilament is no more than twisted 14 times of conductor diameter afterwards;Copper monofilament is annealing naked copper monofilament, and the oxygen content of copper is not more than 0.001% in copper monofilament, 20 DEG C of bodies Product resistivity is not more than 0.01701 Ω .mm2/m;
The requirement of the copper foil conductor of the first signal core group, second signal core group and third signal core group is identical;Copper Foil conductor is that copper foil is dredged after fiber, then is twisted and is constituted with copper monofilament;Copper monofilament is annealing naked copper monofilament, the oxygen of copper in copper monofilament Content is not more than 0.001%, and 20 DEG C of volume resistivities are not more than 0.01701 Ω .mm2/m;The wrapped overlap rate of aluminium foil strip is not small In 20%;
Metallic shield is woven using tinned copper wire, and braided wires diameter is not more than 0.15mm, count 88%~90%.
In active force core, inner insulating layer, dowel and external insulation layer are constituted in the three-layer co-extruded Insulation Material of conductive surface; Gasket for packing material composition is polypropylene;The wrapped overlap rate of nonwoven fabric belts be not less than 5mm, nonwoven fabric belts with a thickness of 0.1mm.
Preferably, the accessory power supply core, the first signal core group, active force core and circulating cooling hose respectively have two Root;Second signal core group, third signal core group and wire core respectively have one.
Above-mentioned cable encounters problem in actual production:Due to using new structure, using traditional processing technology, or It is that empirically equal be modified on traditional processing technology can not all produce the cable for reaching theoretical performance, or even can not give birth to Produce the cable for meeting custom requirements.For this purpose, the invention proposes a kind of new manufacturing method, it is exclusively used in the cable, specifically such as Under:
A kind of manufacturing method of the cooling cable of above-mentioned high-power quick charge, it is characterized in that step includes:
1) conductor and copper foil conductor are first manufactured:
A, conductor:It is to be constituted by multiply naked copper monofilament is twisted;The diameter range of copper monofilament is 0.1mm~0.2mm;Copper monofilament 14 times of twisted stranding distance no more than twisted rear conductor diameter;Copper monofilament is annealing naked copper monofilament, the oxygen content of copper in copper monofilament No more than 0.001%, 20 DEG C volume resistivity is not more than 0.01701 Ω .mm2/m;
The line footpath of conductor is of different sizes, respectively as active force cable core conductor, ground wire core conductor and accessory power supply core copper Conductor, it is spare;
During process, the hauling speed of conductor is 9.696 ± 2m/min, and traction revolving speed is 10~15 grades.With 1+6+12+ For 18 disk hauling cage machines, 1+6 cage revolving speed is (76 ± 3) r/min, and 12 disk cage revolving speeds are (75.9 ± 3) r/min, and 18 disks twist Cage revolving speed is (66 ± 3) r/min, and twisted wire outermost layer pitch is not more than 160mm;
B, copper foil conductor:By copper foil dredge around with copper monofilament is twisted constitutes;Copper monofilament is annealing naked copper monofilament, copper in copper monofilament Oxygen content be not more than 0.001%, 20 DEG C of volume resistivities are not more than 0.01701 Ω .mm2/m;
The line footpath of copper foil conductor is of different sizes, respectively as the first signal core group, second signal core group and third signal The copper foil conductor of core group, it is spare;
2) manufacture of each function cable:
2.1) active force core is manufactured:Power core conductor is taken, and in its outer extruded insulation material;It is spare;
2.2) accessory power supply core is manufactured:Accessory power supply core copper conductor is taken, and in its outer extruded insulation material;It is spare;
2.3) wire core is manufactured:Ground wire core conductor is taken, and in its outer extruded insulation material;It is spare;
2.4) the first signal core group is manufactured:The copper foil conductor of the first signal core group is taken, and in its outer extruded insulation material, is constituted Signal core;More cores are twisted to constitute signal core cable core, and gap uses 125 DEG C of gasket for packings of non-hygroscopic high temperature resistant;Finally exist Inner sheath material is extruded outside signal core cable core;It is spare;
2.5) second signal core group is manufactured:The copper foil conductor of second signal core group is taken, and in its outer extruded insulation material, is constituted Signal core;More cores are twisted to constitute signal core cable core, and gap uses 125 DEG C of gasket for packings of non-hygroscopic high temperature resistant;Signal core Wrapped aluminium foil strip is overlapped outside cable core, wrapped overlap rate is not less than 20%;Tincopper fuse wire braided armor is wrapped up outside aluminium foil strip again, it is tin plating Brass wire diameter is not more than 0.15mm, count 88%~90%;It is finally squeezed outside tincopper fuse wire braided armor and embraces inner sheath material;It is standby With;
2.6) third signal core group is manufactured:Identical as step 2.5), three groups of twisting pitch ranges are 20~35mm, to avoid The interference of signal core group, three groups of twisting pitch cannot be identical.
3) step 2.1~2.5) made from after function cable and circulating cooling hose be twisted into big cable core jointly, further around Packet nonwoven fabric belts:
The twisted equipment of big cable core uses back-twisting cable-former, and equipment easily uses 3+6 cable-former, and the line equipment of cable-former is total The wheeled unwrapping wire frame of pay off rack after 9 draw drums and 2;Draw drum is set to A1, A2, A3, A4, A5, A6, A7, A8 and A9;A1 The first signal core group 1 is placed, A2 places PE wire core, and A3 places auxiliary core 1, and A4 places auxiliary core 2, and A5 places the second letter Number core group, A6 place third signal core group 1, and A7 places master core 1, and A8 places third signal core group 2, and A9 places master core 2, and two The wheeled unwrapping wire frame of pay off rack places a circulating cooling hose respectively after a;
The stranding wire parallel module of cable-former uses tungsten steel die, and internal orifice dimension is equal to core and is twisted outer diameter, and stranding direction is dextrad;
Cable core gap uses 125 DEG C of gasket for packings of non-hygroscopic high temperature resistant;Gasket for packing filling diameter be respectively adopted 2 3.0mm, 4 2.0mm, 5 2.5mm, 1 4.0mm, 2 2.2mm;
Stranding twisting pitch range is outer diameter after 12~14 times of cores are twisted;
90~93r/min of cage revolving speed (preferably 92.2r/min), 8~8.4m/min of hauling speed (preferably 8.32m/ Min), 15~25r/min of taping head revolving speed;
Wrapped overlap rate is overlapped not less than 20% with nonwoven fabric belts;When wrapped, hauling speed is 8~15m/min, wrapped Pitch is 40 ± 5mm, and the tension on nonwoven fabric belts is 43~47N (preferably 45N);Lapping direction is left-hand, twining package tape with a thickness of 0.1mm;
4) oversheath material is extruded outside nonwoven fabric belts, and restrictive coating is made.
The step 2.1) and 2.2) in, Insulation Material is identical, according to insulation layer structure, using corresponding mold, extrude absolutely Edge material, and it is cooling;
Extruding machine and on head match mold core, die sleeve, mold core aperture=conductor diameter+0.3mm;
The step 2.1) and the temperature requirement that extrudes 2.2) are:
From being fed to discharging direction, extruding machine fuselage warm area is respectively:One 145 ± 5 DEG C of area, 150 ± 5 DEG C of 2nd area, 3rd area 160 ± 5 DEG C, 170 ± 5 DEG C of 4th area, 180 ± 5 DEG C of 5th area;The temperature of each warm area of head and machine neck is all 180 ± 5 DEG C;
For active force core, die sleeve is three-layer co-extruded die sleeve.
Insulating materials is environment-friendly halogen-free flame-proof elastomer.
The material is using elastomer as substrate, and cooperation toughened system, flame-retardant system, preventing aging system and lubricating system are through physics And chemical modification forms, tear resistance is not less than 15N/mm, water resistance by 80 DEG C × 168 test requirements documents, by resistance to gasoline, Diesel oil, electrolyte, battery acid requirement, change in outside diameter are not more than 15%, and insulation hardness is not less than 85 shore A, is not precipitated, Halogen Element, no red phosphorus.
Step 2.3)~2.6) in, the Insulation Material and inner sheath of the Insulation Material of the wire core, the first~tri- signal core group Material is identical CABLE MATERIALS, they are environment-friendly halogen-free flame-proof elastomer;
The material is using elastomer as substrate, and cooperation toughened system, flame-retardant system, preventing aging system and lubricating system are through physics And chemical modification forms, tear resistance is not less than 15N/mm, water resistance by 80 DEG C × 168 test requirements documents, by resistance to gasoline, Diesel oil, electrolyte, battery acid requirement, change in outside diameter are not more than 15%, and insulation hardness is not less than 85 shore A, is not precipitated, Halogen Element, no red phosphorus.
After CABLE MATERIALS assembles corresponding mold core and die sleeve using extruding machine, the outer of corresponding cable, the temperature extruded are extruded It is required that being:
From being fed to discharging direction, extruding machine fuselage warm area is:One 165 ± 5 DEG C of area, 170 ± 5 DEG C of 2nd area, three areas 175 ± 5 DEG C, 180 ± 5 DEG C of 4th area, 185 ± 5 DEG C of 5th area;The warm area temperature of head, machine neck:One 185 ± 5 DEG C of area, 185 ± 5 DEG C of 2nd area, Three 190 ± 5 DEG C of areas, 190 ± 5 DEG C of 4th area;
CABLE MATERIALS accelerates to complete irradiation, irradiation energy 2.1MEV, line 20mA, energy ratio 1.3, life by electronics after squeezing out 100~120m/min of producing line speed.
In the step 4), protective cover material be using elastomer as substrate, cooperation toughened system, flame-retardant system, preventing aging system with And lubricating system is changed to through physics and chemistry, has good flexibility, oil resistant, wear-resisting, anti-UV, hydrolysis are fire-retardant superior, no It is precipitated, halogen-free, no red phosphorus, the weather of resistance to 720h, by single vertical combustion test, tearing toughness is not less than 20N/mm.
Using extruding machine extrude sheath material;
From being fed to discharging direction, discharging direction, fuselage warm area is:One 145 ± 5 DEG C of area, 150 ± 5 DEG C of 2nd area, 3rd area 160 ± 5 DEG C, 170 ± 5 DEG C of 4th area, 180 ± 5 DEG C of 5th area;
Head, machine neck the temperature of each warm area be all 180 ± 5 DEG C.
The insulating layer, dowel material requirements are high electrical, ageing-resistant, resistance to -40 DEG C of low temperature, hydrolysis, chemically-resistant liquid Body.
The active force core require for by upper autonomous Design it is three-layer co-extruded go out mold, by insulating layer+dowel+ The three-layer co-extruded mode of insulating layer is extruded in conductive surface;See Fig. 2.
The protective cover material of the restrictive coating requires:It is high anti-tear, high abrasion, weather-proof, resistance to -40 DEG C of low temperature, fire-retardant, environmentally friendly, resistance to Chemical liquid.
The ground wire core insulating barrier, auxiliary core, signal wire core insulation layer material are:It is high electrical, resistance to -40 DEG C of low temperature, resistance to Aging hydrolysis, chemically-resistant liquid, fire-retardant and thermosetting property.
This cable passes through material, structure, the particular design of moulds of industrial equipment, is full of in charging time 15min, and continue a journey 400km, Cable weight, outer diameter reduce, charging fever temperature rise less than 35 DEG C, the application of the technology, can low cost solution China new energy The bottleneck problem of automobile charging time length, is conducive to the popularization and use of new-energy automobile.
Using cable made from this method, it is able to satisfy design requirement, meanwhile, qualification rate reaches 98% or more.
This cooling cable realizes coolant interface, cooling system, coolant design, the decline of active force insulated wire cores conductor It is full of in 30%, charging time 15min, cable weight, outer diameter reduce, the application of the technology, and solution China that can be inexpensive is new The bottleneck problem of energy automobile charging time length, is conducive to the popularization and use of new-energy automobile.
Detailed description of the invention
Fig. 1 is the radial cross section of the present embodiment cable,
Fig. 2 is the radial cross section of active force core,
In figure:Accessory power supply core copper conductor 1, auxiliary power supply line core insulation layer 2, second signal core group copper foil conductor 3, The tincopper fuse wire braided armor of the insulating layer 4 of second signal core group, the aluminium foil wrapping layer 5 of second signal core group, second signal core group 6, the inner restrictive coating 7 of second signal core group, ground wire core conductor 8, ground wire core insulating barrier 9, active force cable core conductor 10, inner insulating layer 11, dowel 12, external insulation layer 13, circulating cooling hose 14, nonwoven layer 15, oversheath 16, the first signal core group 17, second Signal core group 18.
Specific embodiment
The technical program is further described below combined with specific embodiments below:
Such as Fig. 1,2, a kind of cooling cable, structure includes following function cable:
A, accessory power supply core:Auxiliary electricity is constituted by wrapping up auxiliary power supply line core insulation layer outside accessory power supply core copper conductor Source core;Accessory power supply core has more;
B, the first signal core group:Signal core is constituted by wrapping up insulating layer outside copper foil conductor, more signal cores are twisted structure At signal core cable core, inner restrictive coating is wrapped up outside signal core cable core and constitutes the first signal core group;First signal core group has more;
C, second signal core group:Signal core is constituted by wrapping up insulating layer outside copper foil conductor, more signal cores are twisted structure At signal core cable core, signal core cable core is overlapped wrapped aluminium foil strip and constitutes aluminium foil wrapping layer, and tinned copper wire is wrapped up outside aluminium foil wrapping layer Braiding layer, tincopper fuse wire braided armor surface wrap up inner restrictive coating and constitute second signal core group;
D, third signal core group:Structure is identical as second signal core group;
E, wire core:Wire core is constituted by wrapping up ground wire core insulating barrier outside ground wire core conductor;
F, active force core:It is external insulation layer outside inner insulating layer by active force cable core conductor outsourcing inner insulating layer, it is inside and outside It is made of between insulating layer more dowel supports;Each dowel surrounds an axisymmetrical;
G,:The hollow pipe constituted is squeezed out by cross-linking radiation elastomeric material;
Accessory power supply core, the first signal core group, second signal core group, third signal core group, wire core, the active line of force Core and these function cable twists of circulating cooling hose circulating cooling hose constitute big cable core, and big cable core gap uses non-hygroscopic It is overlapped wrapped nonwoven fabric belts outside 125 DEG C of big cable cores of gasket for packing of high temperature resistant and constitutes nonwoven layer;Oversheath, structure are wrapped up outside nonwoven layer At cable.
The radial section of the cable is round;According to line footpath size, including the biggish function cable of line footpath, line footpath is smaller Function cable outside, be arranged successively;The straight line of the identical immediate two functions cable of line footpath being located along across the center of circle at Axial symmetry.
The active force cable core conductor, ground wire core conductor are identical with the requirement of accessory power supply core copper conductor, they are all It is made of multiply naked copper monofilament;The diameter range of copper monofilament is 0.1mm~0.2mm;The twisted stranding distance of copper monofilament is no more than twisted 14 times of conductor diameter afterwards;Copper monofilament is annealing naked copper monofilament, and the oxygen content of copper is not more than 0.001% in copper monofilament, 20 DEG C of bodies Product resistivity is not more than 0.01701 Ω .mm2/m;
The requirement of the copper foil conductor of the first signal core group, second signal core group and third signal core group is identical;Copper Foil conductor is that copper foil is dredged after fiber, then is twisted and is constituted with copper monofilament;Copper monofilament is annealing naked copper monofilament, the oxygen of copper in copper monofilament Content is not more than 0.001%, and 20 DEG C of volume resistivities are not more than 0.01701 Ω .mm2/m;The wrapped overlap rate of aluminium foil strip is not small In 20%;
Metallic shield is woven using tinned copper wire, and braided wires diameter is not more than 0.15mm, count 88%~90%.
In active force core, inner insulating layer, dowel and external insulation layer are constituted in the three-layer co-extruded Insulation Material of conductive surface; Gasket for packing material composition is polypropylene;The wrapped overlap rate of nonwoven fabric belts be not less than 5mm, nonwoven fabric belts with a thickness of 0.1mm.
In this example, the accessory power supply core, the first signal core group, active force core and circulating cooling hose respectively have two Root;Second signal core group, third signal core group and wire core respectively have one.
The manufacturing method of above-mentioned cable is described as follows:
A kind of cooling cable making method, step include:
1) select copper as conductive material;The metal monofilament that more are annealed is twisted to constitute conductor, the resistance of metal monofilament Rate is not more than 0.01701 Ω .mm2/m:More of the metal monofilament is twisted into a branch of, and multi beam wire from-inner-to-outer is divided into more Layer;Adjacent two strands of metal monofilaments in every layer of metal monofilament mutually fit closely;In adjacent two layers metal monofilament, inside and outside layer gold Belong to monofilament to fit closely;The direction of lay of outermost metal monofilament is left-hand, and the direction of lay of adjacent two layers metal monofilament is opposite; 16 times of the twisting pitch of outermost metal monofilament no more than twisted rear outer diameter.
2) use extrudes mode and inner insulating layer, dowel, external insulation layer is wrapped in outside conductor, extrusion molding and cooling:
Increase filler, color masterbatch, plasticiser, softening oil, SEBS, phase solvent, interleaving agent etc. in elastomeric base and dissolves modeling Change, pelletizing to active force core Insulation Material;
Using squash type production method Insulation Material tight outside conductor, form active force insulating layer, and cooling:Absolutely Edge matches mold core, die sleeve using extruding machine and on head;The aperture of mold core be greater than conductor diameter, mold core aperture=conductor diameter+ 0.3mm;Using the three-layer co-extruded die sleeve of autonomous Design.
Extruding machine uses low smoke and zero halogen screw rod.Extruding machine fuselage is cooling using cooling-water machine, is fed to discharging direction, fuselage certainly Warm area is:One 145 ± 5 DEG C of area, 150 ± 5 DEG C of 2nd area, 160 ± 5 DEG C of 3rd area, 170 ± 5 DEG C of 4th area, 180 ± 5 DEG C of 5th area;Head, Machine neck temperature:One 180 ± 5 DEG C of area, 180 ± 5 DEG C of 2nd area, 180 ± 5 DEG C of 3rd area, 4th area:180±5℃;Fuselage heating is using heat Galvanic couple heating;Fuselage is cooling to use air blower air cooling.
Machine utilization is maintained at 110A~125A when insulating exruded, and the degree of eccentricity is not more than 20%;
3) increase fire retardant, antioxygen lubricant, toner etc. in EVA (ethylene-vinyl acetate copolymer) base-material and dissolve modeling Change, pelletizing to wire core, signal core, inner sheath material.
Match mold core, die sleeve using extruding machine and on head;The aperture of mold core is greater than conductor (or cable core) diameter, mold core hole Diameter=conductor (or cable core) diameter+0.3mm;Die sleeve aperture=conductor (or cable core) diameter+2 × insulation nominal thickness (or 2 × interior Sheath nominal thickness)
Extruding machine uses low smoke and zero halogen screw rod.Extruding machine fuselage is cooling using cooling-water machine, is fed to discharging direction, fuselage certainly Warm area is:One 165 ± 5 DEG C of area, 170 ± 5 DEG C of 2nd area, 175 ± 5 DEG C of 3rd area, 180 ± 5 DEG C of 4th area, 185 ± 5 DEG C of 5th area;Head, Machine neck temperature:One 185 ± 5 DEG C of area, 185 ± 5 DEG C of 2nd area, 190 ± 5 DEG C of 3rd area, 4th area:190±5℃;Fuselage heating is using heat Galvanic couple heating;Fuselage is cooling to use air blower air cooling.
Machine utilization is maintained at 130A~146A when wire core, signal core, inner sheath material squeeze out, and the degree of eccentricity is not more than 20%;
The aperture of insulation mold core is greater than conductor diameter, mold core aperture=conductor diameter+0.3mm;Outside die sleeve aperture=conductor Diameter+2 × insulation nominal thickness+0.3mm;
The aperture of inner sheath mold core is greater than conductor assembly outer diameter, mold core aperture=conductor assembly outer diameter+0.1mm;Die sleeve aperture=cable core Outer diameter+2 × inner sheath nominal thickness+0.3mm;
Wire core, signal core, inner sheath material accelerate to complete irradiation by electronics after squeezing out.
4) twining package tape selected is aluminum foil material, and the material is non-hygroscopic twining package tape and the compound composition of pure aluminum foil, Thickness requirement is 0.03mm, is uniformly overlapped through double end winding machine around metallic shield surface, and wrapped overlap rate is not less than 20%. Wrapped no bottom pour ladle, without corrugation.
5) high conductivity, corrosion resistant tinned copper wire are selected in metal knitted shielding, and tinned copper wire surface is smooth, activity Well, when cable torsional bending, the frictional resistance between tinned wird is smaller, and knitting tension pressure control is at 2 grades~4 grades, metal Braid shielded density 88%~90%.
6) the circulating cooling hose selected, the material chemically-resistant liquid, soft pliable be bent, resistance to vehicle rolls, is ageing-resistant, Resistance to -40 DEG C of low temperature and thermosetting property.
7) the cable core twining package tape selected is non-woven fabrics, and the material thickness requires to be 0.1mm, uniform through double end winding machine Overlapping is not less than 20% around cable core surface, wrapped overlap rate.Wrapped no bottom pour ladle, without corrugation.
8) increase filler, color masterbatch, plasticiser, softening oil, SEBS, phase solvent, interleaving agent etc. in elastomeric base to dissolve Plasticizing, pelletizing to protective cover material;
Using squash type production method protective cover material tight outside cable core, form restrictive coating, and cooling:
Sheath matches mold core, die sleeve using extruding machine and on head;The aperture of mold core be greater than conductor assembly outer diameter, mold core aperture= Conductor assembly outer diameter+0.5mm.
Extruding machine uses low smoke and zero halogen screw rod.Extruding machine fuselage is cooling using cooling-water machine, is fed to discharging direction, fuselage certainly Warm area is:One 145 ± 5 DEG C of area, 150 ± 5 DEG C of 2nd area, 160 ± 5 DEG C of 3rd area, 170 ± 5 DEG C of 4th area, 180 ± 5 DEG C of 5th area;Head, Machine neck temperature:One 180 ± 5 DEG C of area, 180 ± 5 DEG C of 2nd area, 180 ± 5 DEG C of 3rd area, 4th area:180±5℃;Fuselage heating is using heat Galvanic couple heating;Fuselage is cooling to use air blower air cooling.
Machine utilization is maintained at 210A~235A when sheathing, and the degree of eccentricity is not more than 20%;
The aperture of sheath mold core is greater than conductor assembly outer diameter, mold core aperture=conductor assembly outer diameter+0.4mm;Outside die sleeve aperture=cable core Diameter+2 × sheath nominal thickness+0.4mm;
Example 1:
1) select copper as conductive material;The resistivity of metal monofilament is not more than 0.01701 Ω .mm2/m:The metal list Si Duogen is twisted into a branch of, and multi beam wire from-inner-to-outer is divided into multilayer;Adjacent two strands of metal monofilaments in every layer of metal monofilament Mutually fit closely;In adjacent two layers metal monofilament, inside and outside layer metal monofilament is fitted closely;Outermost metal monofilament is twisted Direction is left-hand, and the direction of lay of adjacent two layers metal monofilament is opposite;The twisting pitch of outermost metal monofilament is no more than twisted 16 times of outer diameter afterwards.
Illustrate so that cable specification is 2 × 35+1 × 6+2 × 4+2 × 1+1 root (2 × 1)+2 (4 × 1), twisted equipment For cage winch, conductor structure is altogether by 3 layers of twisted completion, and using 1+6+12 structural arrangement, direction of lay outermost layer is left-hand, adjacent For layer on the contrary, frame winch hauling speed is 10m/min, traction gear is 3 grades, and outermost layer twisting pitch is no more than twisted rear outer diameter 16 times.
2) the three-layer co-extruded die sleeve for using autonomous Design, using the mode that extrudes inner insulating layer, dowel, external insulation layer packet It is rolled in outside conductor and is wrapped in outside conductor.
The aperture of mold core is greater than conductor diameter, mold core aperture=conductor diameter+0.3mm;
Extruding machine uses low smoke and zero halogen screw rod.Extruding machine fuselage is cooling using cooling-water machine, is fed to discharging direction, fuselage certainly Warm area is:One 145 ± 5 DEG C of area, 150 ± 5 DEG C of 2nd area, 160 ± 5 DEG C of 3rd area, 170 ± 5 DEG C of 4th area, 180 ± 5 DEG C of 5th area;Head, Machine neck temperature:One 180 ± 5 DEG C of area, 180 ± 5 DEG C of 2nd area, 180 ± 5 DEG C of 3rd area, 4th area:180±5℃;Fuselage heating is using heat Galvanic couple heating;Fuselage is cooling to use air blower air cooling.
Machine utilization is maintained at 110A~125A when insulating exruded, and when extrusion applies circulating cooling air pressure, air pressure setting 3MPa, interior insulation are not bonded with external insulation, and spacing equal control is not more than 20% in 3mm, the degree of eccentricity;
3) when wire core, signal core, inner restrictive coating squeeze out, mold core, die sleeve are matched using extruding machine and on head;Mold core Aperture be greater than conductor (or cable core) diameter, mold core aperture=conductor (or cable core) diameter+0.3mm;Die sleeve aperture=conductor (or Cable core) diameter+2 × insulation nominal thickness (or 2 × inner sheath nominal thickness)
Extruding machine uses low smoke and zero halogen screw rod.Extruding machine fuselage is cooling using cooling-water machine, is fed to discharging direction, fuselage certainly Warm area is:One 165 ± 5 DEG C of area, 170 ± 5 DEG C of 2nd area, 175 ± 5 DEG C of 3rd area, 180 ± 5 DEG C of 4th area, 185 ± 5 DEG C of 5th area;Head, Machine neck temperature:One 185 ± 5 DEG C of area, 185 ± 5 DEG C of 2nd area, 190 ± 5 DEG C of 3rd area, 4th area:190±5℃;Fuselage heating is using heat Galvanic couple heating;Fuselage is cooling to use air blower air cooling.
Machine utilization is maintained at 130A~146A when wire core, signal core, inner sheath material squeeze out, and the degree of eccentricity is not more than 20%;
The aperture of insulation mold core is greater than conductor diameter, mold core aperture=conductor diameter+0.3mm;Outside die sleeve aperture=conductor Diameter+2 × insulation nominal thickness+0.3mm;
The aperture of inner sheath mold core is greater than conductor assembly outer diameter, mold core aperture=conductor assembly outer diameter+0.1mm;Die sleeve aperture=cable core Outer diameter+2 × inner sheath nominal thickness+0.3mm;
Wire core, signal core, inner sheath material accelerate to complete irradiation by electronics after squeezing out.
4) aluminum foil material, thickness requirement 0.03mm are uniformly overlapped through double end winding machine around metallic shield surface, around Packet overlap rate is not less than 20%.Wrapped no bottom pour ladle, without corrugation.
5) metal knitted shielding nominal diameter is 0.1mm, and knitting tension pressure control is at 2 grades~4 grades, metal knitted shielding Density 88%~90%.
6) the circulating cooling hose selected, the material chemically-resistant liquid, soft pliable be bent, resistance to vehicle rolls, is ageing-resistant, Resistance to -40 DEG C of low temperature and thermosetting property.
7) by active force insulated wire cores, insulated wire cores, supplementary insulation core, signal core group A, B, C, circulating cooling hose It is twisted into big cable core, cabling device selects back-twisting cable-former.
8) non-woven fabrics, the material thickness are required to be 0.1mm, be uniformly overlapped through double end winding machine around cable core Surface, wrapped overlap rate are not less than 20%.Wrapped no bottom pour ladle, without corrugation.
9) it uses squash type production method protective cover material tight outside cable core, forms restrictive coating, and cooling:
Sheath matches mold core, die sleeve using extruding machine and on head;The aperture of mold core be greater than conductor assembly outer diameter, mold core aperture= Conductor assembly outer diameter+0.5mm.
Extruding machine uses low smoke and zero halogen screw rod.Extruding machine fuselage is cooling using cooling-water machine, is fed to discharging direction, fuselage certainly Warm area is:One 145 ± 5 DEG C of area, 150 ± 5 DEG C of 2nd area, 160 ± 5 DEG C of 3rd area, 170 ± 5 DEG C of 4th area, 180 ± 5 DEG C of 5th area;Head, Machine neck temperature:One 180 ± 5 DEG C of area, 180 ± 5 DEG C of 2nd area, 180 ± 5 DEG C of 3rd area, 4th area:180±5℃;Fuselage heating is using heat Galvanic couple heating;Fuselage is cooling to use air blower air cooling.
Machine utilization is maintained at 210A~235A when sheathing, and the degree of eccentricity is not more than 20%;
The aperture of sheath mold core is greater than conductor assembly outer diameter, mold core aperture=conductor assembly outer diameter+0.4mm;Outside die sleeve aperture=cable core Diameter+2 × sheath nominal thickness+0.4mm;
Example 2:
It is only that in step 2) with the same place of example 1:
Using the three-layer co-extruded die sleeve of autonomous Design, inner insulating layer, dowel, external insulation layer are wrapped up using the mode that extrudes It is wrapped in outside conductor outside conductor.
The aperture of mold core is greater than conductor diameter, mold core aperture=conductor diameter+0.3mm;
Machine utilization is maintained at 110A~125A when insulating exruded, and air pressure sets 1MPa, and interior insulation and external insulation glue It closes, distance measurement 1mm, spacing is small, and cooling cycle flow is undesirable;
Example 3 (comparative example):
Using the three-layer co-extruded die sleeve of autonomous Design, inner insulating layer, dowel, external insulation layer are wrapped up using the mode that extrudes It is wrapped in outside conductor outside conductor.
The aperture of mold core is greater than conductor diameter, mold core aperture=conductor diameter+0.3mm;
Machine utilization is maintained at 110A~125A when insulating exruded, and air pressure sets 8MPa, and interior insulation is split with external insulation Mouthful, it can not squeeze out;
Wherein, cable yields highest is made in example 1, reaches 98.3%, example 2 reaches 85%, and example 3 does not meet production control and wants It asks.
As a result it detects, the characteristics of this cable includes:
1) charging time shortens
DC charging foreshortens to 15min, realizes that electric car is continued a journey 400 kilometers, and the cooling cable charging time shortens 90%.
2) cable purchase cost reduces:Cable buying drop sheet 15%~20%.
3) cable weight mitigation, outer diameter are small
The cooling outside diameter of cable control of high-power quick charge is in 46mm hereinafter, the 400A direct current charging cable finished product that compares Cable weight decline 25%.
4) temperature rise is small
High-power quick charge use cools down cable, is full of in 15min, realizes that electric car is continued a journey 400 kilometers, temperature rise does not surpass Cross 35 DEG C.
5) high electrical
The product of inspection is detected through third party's pattern, actual measurement insulation, the volume resistivity actual measurement 10 of sheath15Ω .mm, is filled up The world ISO, GB country new-energy automobile silicon rubber car high pressure 109Ω.mm。
6) high and low temperature resistance
Active force power supply meets 125 DEG C of operating conditions and uses.Meet -40 DEG C of low-temperature impacts, -40 DEG C of low temperature windings, -40 DEG C of low temperature Tension test requirement.
7) fire retardancy test:
Meet the single burning of GB/T18380.12.
8) chemical-resistant reagent
Meet method one, the method two, battery acid test requirements document in ISO6722-1 standard simultaneously, meets working condition requirement.
9) resistance to vehicle rolls
The cooling cable of high-power quick charge, is rolled through vehicle reciprocal 3 times, applies voltage tester, cooling cycle test, Meet and reuses.

Claims (5)

1. a kind of cooling cable, it is characterized in that structure includes following function cable:
A, accessory power supply core:Auxiliary power supply line is constituted by wrapping up auxiliary power supply line core insulation layer outside accessory power supply core copper conductor Core;Accessory power supply core has more;
B, the first signal core group:Signal core is constituted by wrapping up insulating layer outside copper foil conductor, more signal cores are twisted to constitute letter Number core cable core wraps up inner restrictive coating outside signal core cable core and constitutes the first signal core group;First signal core group has more;
C, second signal core group:Signal core is constituted by wrapping up insulating layer outside copper foil conductor, more signal cores are twisted to constitute letter Number core cable core, signal core cable core are overlapped wrapped aluminium foil strip and constitute aluminium foil wrapping layer, and tinned copper wire braiding is wrapped up outside aluminium foil wrapping layer Layer, tincopper fuse wire braided armor surface wrap up inner restrictive coating and constitute second signal core group;
D, third signal core group:Structure is identical as second signal core group;
E, wire core:Wire core is constituted by wrapping up ground wire core insulating barrier outside ground wire core conductor;
F, active force core:It is external insulation layer outside inner insulating layer by active force cable core conductor outsourcing inner insulating layer, inside and outside insulation It is made of between layer more dowel supports;Each dowel surrounds an axisymmetrical;
G, the hollow pipe constituted is squeezed out by cross-linking radiation elastomeric material;
Accessory power supply core, the first signal core group, second signal core group, third signal core group, wire core, active force core and These function cable twists of circulating cooling hose circulating cooling hose constitute big cable core, and the gap filling of big cable core has non-hygroscopic 125 DEG C of gasket for packings of high temperature resistant;Wrapped nonwoven fabric belts, which are overlapped, outside big cable core constitutes nonwoven layer;Oversheath is wrapped up outside nonwoven layer, Constitute cable.
2. cooling cable according to claim 1, it is characterized in that the radial section of the cable is round;
According to line footpath size, including the biggish function cable of line footpath, the lesser function cable of line footpath outside, is arranged successively;It is identical The immediate two functions cable of line footpath is located along the straight line across the center of circle into axial symmetry.
3. cooling cable according to claim 1, it is characterized in that the active force cable core conductor, ground wire core conductor and auxiliary The requirement of power supply core copper conductor is identical, they are made of multiply naked copper monofilament;The diameter range of copper monofilament be 0.1mm~ 0.2mm;14 times of the twisted stranding distance of copper monofilament no more than twisted rear conductor diameter;Copper monofilament is annealing naked copper monofilament, copper monofilament The oxygen content of middle copper is not more than 0.001%, and 20 DEG C of volume resistivities are not more than 0.01701 Ω .mm2/m;
The requirement of the copper foil conductor of the first signal core group, second signal core group and third signal core group is identical;Copper foil is led Body is that copper foil is dredged after fiber, then is twisted and is constituted with copper monofilament;Copper monofilament is annealing naked copper monofilament, the oxygen content of copper in copper monofilament No more than 0.001%, 20 DEG C volume resistivity is not more than 0.01701 Ω .mm2/m;The wrapped overlap rate of aluminium foil strip is not less than 20%;
Metallic shield is woven using tinned copper wire, and braided wires diameter is not more than 0.15mm, count 88%~90%.
4. cooling cable according to claim 1, it is characterized in that in active force core, inner insulating layer, dowel and it is outer absolutely Edge layer is constituted in the three-layer co-extruded Insulation Material of conductive surface;
Gasket for packing material composition is polypropylene;
The wrapped overlap rate of nonwoven fabric belts be not less than 5mm, nonwoven fabric belts with a thickness of 0.1mm.
5. cooling cable according to claim 1, it is characterized in that the accessory power supply core, the first signal core group, active Line of force core and circulating cooling hose respectively have two;Second signal core group, third signal core group and wire core respectively have one.
CN201721866642.5U 2017-12-27 2017-12-27 A kind of cooling cable Active CN208111135U (en)

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN108172331A (en) * 2017-12-27 2018-06-15 江苏上上电缆集团有限公司 A kind of cooling cable making method and cable
CN109461521A (en) * 2018-12-19 2019-03-12 江苏上上电缆集团有限公司 A kind of fluid insulation cable making method and cable
WO2020119308A1 (en) * 2018-12-11 2020-06-18 江苏上上电缆集团有限公司 Method for fabricating hollow electric cable for charging new energy vehicle and electric cable

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN108172331A (en) * 2017-12-27 2018-06-15 江苏上上电缆集团有限公司 A kind of cooling cable making method and cable
CN108172331B (en) * 2017-12-27 2023-10-27 江苏上上电缆集团有限公司 Manufacturing method of cooling cable
WO2020119308A1 (en) * 2018-12-11 2020-06-18 江苏上上电缆集团有限公司 Method for fabricating hollow electric cable for charging new energy vehicle and electric cable
CN109461521A (en) * 2018-12-19 2019-03-12 江苏上上电缆集团有限公司 A kind of fluid insulation cable making method and cable

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