CN221262008U

CN221262008U - Liquid cooling charging cable and processing device thereof

Info

Publication number: CN221262008U
Application number: CN202323172586.3U
Authority: CN
Inventors: 潘宝成; 吕伟; 程海雨; 施沈宇; 徐嘉尧; 茅佳楠; 席铭铭
Original assignee: Jiangsu Hengtong Electronic Cable Technology Co Ltd
Current assignee: Jiangsu Hengtong Electronic Cable Technology Co Ltd
Priority date: 2023-11-23
Filing date: 2023-11-23
Publication date: 2024-07-02
Anticipated expiration: 2033-11-23

Abstract

The utility model discloses a liquid cooling charging cable and a processing device thereof, and belongs to the technical field of liquid cooling charging cables. The liquid cooling charging cable comprises a liquid cooling pipe and a plurality of power line conductors, the cross section of the liquid cooling pipe is star-shaped, the liquid cooling pipe comprises a pipe body and a plurality of convex angles which are arranged around the pipe body at intervals, the pipe body is communicated with the convex angles, and adjacent convex angles form gaps positioned on the outer side of the pipe body; the power line conductors comprise a plurality of power line cores, and the power line conductors are arranged in the gaps in a one-to-one correspondence mode. The liquid cooling charging cable and the processing device thereof have the advantages of simple structure, convenient manufacture, improved cooling effect and reduced size of the finished liquid cooling charging cable.

Description

Liquid cooling charging cable and processing device thereof

Technical Field

The utility model relates to the technical field of liquid cooling charging cables, in particular to a liquid cooling charging cable and a processing device thereof.

Background

Along with new energy automobile's popularization, more and more electric piles appear in the life, and current new energy automobile faces the slow scheduling problem of charging speed, in order to adapt to market demand, the charging cable of rifle that charges includes conductor and liquid cooling tube, reduces the conductor temperature through liquid cooling tube refrigerated mode in order to increase the conductor current-carrying capacity to diameter and the weight of charging cable have been reduced, the cost of charging has been reduced.

In the prior art, the charging cable is cooled by a liquid cooling pipe, and comprises the following schemes:

The first is that the liquid-cooled tube and the main insulation wire core are twisted into a cable, the processing is simple, and the heat dissipation effect is poor because the liquid-cooled tube and the conductor are not contacted.

The second is that the liquid cooling round tube is embedded into the conductor to contact with the conductor, the heat dissipation effect inside the conductor is good, the extruded insulating layer is coated outside the conductor, the heat dissipation at the place where the periphery of the conductor contacts with the extruded insulating layer is poor, and the heat dissipation is uneven.

The third is that the liquid cooling medium is sleeved outside the main insulating wire core, is positioned between the extrusion insulating layer and the liquid cooling pipe, is contacted with the extrusion insulating layer, has obvious cooling effect on the extrusion insulating layer, is not contacted with the conductor, has no influence on the heating of the conductor, and has poor cooling effect.

The fourth is that the heat conduction liquid cooling medium is located between the extrusion insulating layer and the conductor, the extrusion insulating layer bears the effect of the liquid cooling pipe simultaneously, the cooling effect is obvious, but the wire harness processor is required to carry out pipe penetrating, the product processing is complex, the requirement on connection of the charging cable and the connector is very high, and the problem is easy to occur.

Therefore, there is a need for a liquid-cooled charging cable and a processing device thereof to solve the above problems.

Disclosure of utility model

The utility model aims to provide a liquid cooling charging cable and a processing device thereof, which have the advantages of simple structure, convenience in manufacturing, improvement of cooling effect and reduction of the size of a finished liquid cooling charging cable.

To achieve the purpose, the utility model adopts the following technical scheme:

a liquid cooled charging cable comprising:

The liquid cooling pipe is characterized by comprising a pipe body and a plurality of convex angles which are arranged around the pipe body at intervals, wherein the pipe body is communicated with the convex angles, and adjacent convex angles form gaps positioned on the outer side of the pipe body;

The power line conductors comprise a plurality of power line cores, and the power line conductors are arranged in the gaps in a one-to-one correspondence mode.

In some possible embodiments, the power line conductor further comprises a strap wrapped around the plurality of power line conductors and the liquid cooling tube.

In some possible embodiments, the power line conductors have a strand pitch that is 35 times the strand diameter.

In some possible embodiments, the liquid-cooled tube and the plurality of power line conductors are disposed within a sheath.

In some possible embodiments, the sheath further comprises:

The first signal line unit comprises a plurality of signal wire cores and a filling reinforcing core, wherein the plurality of signal wire cores are arranged on the periphery of the filling reinforcing core in a surrounding mode, and the transverse base surface of the first signal line unit is circular;

and the second signal line units comprise two signal line cores.

In some possible embodiments, the sheath further comprises a filling cord, and the filling cord is filled in the sheath.

In some possible embodiments, the liquid-cooled tube is a nylon tube or a fluoroplastic tube.

The processing device of the liquid cooling charging cable also comprises a wrapping belt which is wrapped on a plurality of power line conductors, the processing device of the liquid cooling charging cable comprises a branching component, a shaping mould and a wrapping machine which are sequentially arranged,

The branching assembly comprises a branching disc and a positioning die, wherein the branching disc is provided with a mounting hole and a plurality of first through holes arranged on the periphery of the mounting hole, the positioning die is arranged in the mounting hole, the middle part of the positioning die is provided with a second through hole, and the shape of the second through hole is adapted to the shape of the liquid cooling pipe;

The shaping die is provided with a plurality of first through holes and second through holes, the first through holes are arranged in one-to-one correspondence with the first through holes, and the second through holes are arranged in correspondence with the second through holes.

In some possible embodiments, an end of the second through hole facing the branching assembly is provided with a guide hole communicating with the second through hole.

The utility model has the beneficial effects that:

According to the liquid cooling charging cable and the processing device thereof, the star-shaped structure is adopted by the liquid cooling pipe, the power line core is divided into the power line conductors and the power line conductors are respectively arranged in the gaps, and the power line conductors are in contact with the liquid cooling pipe, so that the contact area is increased, the cooling effect is improved, the size of the finished liquid cooling charging cable is reduced, the charging efficiency is improved, the purpose of ultra-fast charging is achieved, and better quality experience is provided for users. Simple structure, convenient processing and manufacturing.

Drawings

FIG. 1 is a cross-sectional view of a liquid cooled charging cable provided in accordance with an embodiment of the present utility model;

FIG. 2 is a schematic diagram of a processing device for a liquid-cooled charging cable according to an embodiment of the present utility model;

FIG. 3 is a schematic illustration of a branching assembly provided in accordance with an embodiment of the present utility model;

fig. 4 is a flowchart of a processing process of a liquid-cooled charging cable according to an embodiment of the present utility model.

In the figure:

1. A liquid-cooled tube; 11. a tube body; 12. a lobe; 2. a power line conductor; 3. a belting; 4. a sheath; 5. a first signal line unit; 51. a signal wire core; 52. filling a reinforcing core; 6. a second signal line unit; 7. a filling rope; 8. an auxiliary power supply core; 9. a ground wire core; 10. extruding the insulating layer; 110. a first isolation layer; 120. a shielding layer; 130. a second isolation layer;

100. A branching assembly; 101. a distribution board; 1011. a first via; 102. positioning a mold; 1021. a second via; 200. shaping a mold; 201. a first through hole; 202. a second through hole; 203. a guide hole; 300. and wrapping machine.

Detailed Description

In order to make the technical problems solved by the present utility model, the technical solutions adopted and the technical effects achieved more clear, the technical solutions of the embodiments of the present utility model will be described in further detail below with reference to the accompanying drawings, and it is obvious that the described embodiments are only some embodiments of the present utility model, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the utility model without making any inventive effort, are intended to be within the scope of the utility model.

In the description of the present utility model, unless explicitly stated and limited otherwise, the terms "connected," "connected," and "fixed" are to be construed broadly, and may be, for example, fixedly connected, detachably connected, or integrally formed; can be mechanically or electrically connected; can be directly connected or indirectly connected through an intermediate medium, and can be communicated with the inside of two elements or the interaction relationship of the two elements. The specific meaning of the above terms in the present utility model will be understood in specific cases by those of ordinary skill in the art.

In the present utility model, unless expressly stated or limited otherwise, a first feature "above" or "below" a second feature may include both the first and second features being in direct contact, as well as the first and second features not being in direct contact but being in contact with each other through additional features therebetween. Moreover, a first feature being "above," "over" and "on" a second feature includes the first feature being directly above and obliquely above the second feature, or simply indicating that the first feature is higher in level than the second feature. The first feature being "under", "below" and "beneath" the second feature includes the first feature being directly under and obliquely below the second feature, or simply means that the first feature is less level than the second feature.

As shown in fig. 1, this embodiment provides a liquid cooling charging cable, including a liquid cooling tube 1 and a plurality of power line conductors 2, the cross section of the liquid cooling tube 1 is star-shaped, the liquid cooling tube 1 includes a tube body 11 and a plurality of convex corners 12 around the tube body 11 at intervals, the tube body 11 is communicated with the convex corners 12, and adjacent convex corners 12 form a gap outside the tube body 11. The power line conductors 2 comprise a plurality of power line cores, and the power line conductors 2 are arranged in the gaps in a one-to-one correspondence mode. The liquid cooling pipe 1 adopts a star-shaped structure, and particularly any convex angle 12, namely, the star-shaped structure with all angles, is used for dividing a power line core into a plurality of power line conductors 2 and respectively arranged in gaps, and the power line conductors 2 are in contact with the liquid cooling pipe 1, so that the contact area is increased, the cooling effect is improved, the size of a finished liquid cooling charging cable is reduced, the charging efficiency is improved, the purpose of ultra-fast charging is achieved, and the user experience is better. The liquid cooling pipe 1 has simple structure and is convenient to process and manufacture.

Four-corner star-shaped tubes are used, i.e. the cooling tube comprises four lobes 12, forming four gaps. The power line core conductors are six types of conductors conforming to the standard, the maximum diameter of each monofilament is 0.21mm, the conductors are exemplarily composed of 1600 annealed soft copper wires with the diameter of each monofilament of 0.2mm, the total cross-sectional area of the conductors is 50mm ², the 1600 monofilaments are divided into four groups, namely four power line conductors 2, the cross-sectional area of each power line conductor 2 is 12.5mm ², and the power line conductors 2 are arranged in the gaps.

The liquid cooling pipe 1 is a nylon pipe or a fluorine plastic pipe. The nylon and fluoroplastic materials have the characteristics of high stability, hardness, difficult deformation during cable twisting, shaping function, and difficult deformation of the liquid-cooled tube 1 during bending of the finished cable.

The liquid cooling charging cable also comprises a wrapping belt 3, the wrapping belt 3 is wrapped on the power line conductors 2 and the liquid cooling pipe 1, and the wrapping belt 3 plays a binding role to avoid loosening.

The normal conductor twisting pitch is about 20 times of the twisting diameter, the smaller the pitch is, the closer the twisting is, in this embodiment, the twisting pitch of the power line conductor 2 is 35 times of the twisting diameter, the power line conductor 2 is filled in the gap, the loose the power line core of the power line conductor 2 is, the more compact the filling is, and the better the heat dissipation effect is.

The outer layer of the wrapping belt 3 is provided with an extrusion insulating layer 10 to realize insulation between the power line conductor 2 and the outside.

The liquid cooling charging cable further comprises a sheath 4, wherein the liquid cooling pipe 1 and the power line conductors 2 are arranged in the sheath 4, and specifically, the wrapping belt 3 wrapping the liquid cooling pipe 1 and the power line conductors 2 is arranged in the sheath 4. Illustratively, the sheath 4 made of polyurethane material has a surface with a fog effect, and polyurethane has excellent mechanical properties, ozone resistance, high tear resistance, special wear resistance and the like, and the thickness of the sheath 4 is about 1.0mm thinner than that of the thermoplastic elastomer TPE, so that the outer diameter of the charging cable is smaller. The liquid cooling charging cable further comprises a first isolation layer 110, a shielding layer 120 and a second isolation layer 130 which are sequentially arranged, wherein the first isolation layer 110 is wrapped outside the extrusion insulating layer 10, and the first isolation layer 110 is made of non-woven fabrics or polyester tapes. The shielding layer 120 is woven outside the first isolating layer 110, the second isolating layer 130 is wrapped outside the shielding layer 120, the second isolating layer 130 is made of cotton paper or non-woven fabric, and the sheath 4 is extruded outside the second isolating layer 130. The shielding layer 120 can be made of aluminum-plastic composite tape with braided tinned copper wires or just braided tinned copper wires according to practical application.

The liquid cooling charging cable further comprises a first signal line unit 5 and a plurality of second signal line units 6 which are arranged in the sheath 4, the first signal line unit 5 comprises a plurality of signal wire cores 51 and a filling reinforcing core 52, the plurality of signal wire cores 51 are arranged on the periphery of the filling reinforcing core 52 in a surrounding mode, and the transverse base surface of the first signal line unit 5 is circular. The second signal line unit 6 includes two signal line cores 51. Illustratively, the signal wire cores 51 are divided into three groups, the first signal wire unit 5 includes six signal wire cores 51, the two second signal units 6 include two signal wire cores 51 respectively, the six signal wire cores 51 just enclose a circle, and the hollow part is filled and reinforced by the filling and reinforcing core 52, so that the strength is increased, and the signal wire cores 51 are protected. Specifically, the inside of the filling reinforcing core 52 is made of aramid fiber, and the outside layer is made of the same material as the first signal line unit 5, so that the first signal line unit 5 is protected. The signal wire core conductor is added with copper foil wires and aramid fibers for reinforcement treatment, so that the problem that the signal wire core 51 is broken when in use due to the fact that the signal wire core 51 is very thin is avoided.

The liquid cooling charging cable further comprises an auxiliary power supply core 8 and a ground wire core 9 which are arranged in parallel with the first signal wire unit 5, the second signal unit 6 and the like in the first isolation layer 110. Optionally, the exterior of the signal core 51, the filler reinforcing core 52, the auxiliary power core 8 and the ground core 9 are all provided with an extruded insulation layer 10 of the extruded insulation layer 10. The extruded insulation layer 10 may be made of Thermoplastic (TPE) or thermoset (XLPO) or the like.

The liquid cooling charging cable also comprises a filling rope 7, wherein the filling rope 7 is filled in the sheath 4, a large number of gaps are formed between conductors in the sheath 4, the inside is plump through filling, and the filling rope 7 is a PP rope, and is particularly a polypropylene mesh belt.

As shown in fig. 2 and fig. 3, this embodiment further provides a processing device for a liquid cooling charging cable, where the liquid cooling charging cable further includes a wrapping band 3, the wrapping band 3 is wrapped around the plurality of power line conductors 2, and the processing device for a liquid cooling charging cable includes a branching component 100, a shaping mold 200 and a wrapping machine 300 that are sequentially set. The branching assembly 100 comprises a branching disc 101 and a positioning die 102, wherein the branching disc 101 is provided with a mounting hole and a plurality of first through holes 1011 formed in the periphery of the mounting hole, the positioning die 102 is mounted in the mounting hole, the middle part of the positioning die 102 is provided with a second through hole 1021, and the shape of the second through hole 1021 is adapted to the shape of the liquid cooling tube 1. The shaping mold 200 is provided with a plurality of first through holes 201 and second through holes 202, the first through holes 201 and the first through holes 1011 are arranged in one-to-one correspondence, and the second through holes 202 and the second through holes 1021 are arranged in correspondence.

The plurality of power line conductors 2 and the liquid cooling pipe 1 are separated by the separating assembly 100, and then the shaping die 200 is used for shaping, and the wrapping machine 300 is used for wrapping the shaped power line conductors 2 and the separating assembly 100. Specifically, the number of holes of the distribution board 101 should be equal to or greater than the number of star-shaped tube corners, and as shown in fig. 3, the distribution board 101 includes six first through holes 201, of which four first through holes 201 are selected for passing through the power line conductor 2. Because the shaping die 200 has a certain length, the shaping die is used as a carrying wire to perform shaping, and the filled conductor can be wound with the wrapping belt 3 after being discharged from the shaping die, so that the power wire core is not loosened. Since the power line conductor 2 and the liquid cooling pipe 1 are not twisted while passing through the branching assembly 100 and the sizing die 200, the positions of the die 102 and the first via 1011 should be positioned correspondingly well, ensuring that the power line conductor 2 can be located in the corresponding gap.

One end of the second through hole 202 facing the branching assembly 100 is provided with a guide hole 203 communicated with the second through hole 202, and when the liquid cooling pipe 1 penetrates into the second through hole 202, the guide hole 203 plays a guiding role, so that the liquid cooling pipe is convenient to use.

As shown in fig. 4, this embodiment further provides a processing technology of a liquid-cooled charging cable, which adopts the processing device of the liquid-cooled charging cable, and the processing technology of the liquid-cooled charging cable includes the following steps:

s1, dividing a power line core into a plurality of power line conductors 2 according to the number of angles of cooling pipes, wherein the number of the power line conductors 2 is the same as the number of angles of the cooling pipes;

s2, twisting the power line conductor 2;

S3, the power line conductor 2 correspondingly penetrates through the first through hole 1011 and the first through hole 201 in sequence, and the liquid-cooled tube 1 penetrates through the second through hole 1021 and the second through hole 202 in sequence;

S4, wrapping the power line conductor 2 and the liquid cooling pipe 1 by wrapping the wrapping belt 3 by the wrapping machine 300.

Specifically, the power line conductors 2 are uniformly grouped according to the angle number of the liquid cooling pipe 1, the pre-twisting of the power line conductors 2 and the total twisting of the liquid cooling charging cable are twisted by adopting large pitches, and the specific twisting pitch is 35 times of the twisting diameter, so that each power line conductor 2 can be more uniformly distributed between gaps formed by two convex corners 12 of the liquid cooling pipe 1. The power line conductor 2 and the liquid cooling pipe 1 are not twisted, the power line conductor 2 is directly distributed on the gap of the liquid cooling pipe 1 through paying-off, and then the wrapping belt 3 such as a non-woven fabric belt (the wrapping material is selected according to actual conditions) is fixed; and in the forming process, the processing device for customizing the liquid cooling charging cable is used for auxiliary forming, so that the method is simple and reliable.

The pre-twisting of the first signal line unit 5 and the second signal line unit 6 is opposite to the total twisting direction of the liquid cooling charging cable, the liquid cooling charging cable is twisted in the right direction, and the first signal line unit 5 and the second signal line unit 6 are twisted in the left direction.

It is to be understood that the above examples of the present utility model are provided for clarity of illustration only and are not limiting of the embodiments of the present utility model. Other variations or modifications of the above teachings will be apparent to those of ordinary skill in the art. It is not necessary here nor is it exhaustive of all embodiments. Any modification, equivalent replacement, improvement, etc. which come within the spirit and principles of the utility model are desired to be protected by the following claims.

Claims

1. A liquid cooled charging cable, comprising:

the liquid cooling pipe (1) is star-shaped in cross section, the liquid cooling pipe (1) comprises a pipe body (11) and a plurality of convex corners (12) which are arranged around the pipe body (11) at intervals, the pipe body (11) is communicated with the convex corners (12), and adjacent convex corners (12) form gaps positioned on the outer side of the pipe body (11);

The power line conductors (2) comprise a plurality of power line cores, and the power line conductors (2) are arranged in the gaps in a one-to-one correspondence mode.

2. The liquid cooled charging cable according to claim 1, further comprising a strap (3), the strap (3) being wrapped around a plurality of the power line conductors (2) and the liquid cooled tube (1).

3. Liquid cooled charging cable according to claim 1, characterized in that the twist pitch of the power line conductor (2) is 35 times the twist diameter.

4. A liquid cooled charging cable according to any of claims 1-3, further comprising a sheath (4), said liquid cooled tube (1) and a plurality of said power line conductors (2) being arranged within said sheath (4).

5. The liquid cooled charging cable according to claim 4, further comprising a sheath (4) disposed therein:

The first signal line unit (5) comprises a plurality of signal wire cores (51) and a filling reinforcing core (52), wherein the plurality of signal wire cores (51) are arranged on the periphery of the filling reinforcing core (52) in a surrounding mode, and the transverse base surface of the first signal line unit (5) is circular;

And a plurality of second signal line units (6) comprising two signal line cores (51).

6. Liquid cooled charging cable according to claim 4, further comprising a filling cord (7), the filling cord (7) filling within the sheath (4).

7. Liquid cooled charging cable according to claim 1, characterized in that the liquid cooled tube (1) is a nylon tube or a fluoroplastic tube.

8. A processing device of a liquid cooling charging cable according to any one of claims 1-7, wherein the liquid cooling charging cable further comprises a wrapping belt (3), the wrapping belt (3) is wrapped on a plurality of power line conductors (2), the processing device of the liquid cooling charging cable comprises a branching component (100), a shaping mould (200) and a wrapping machine (300) which are sequentially arranged,

The branching assembly (100) comprises a branching disc (101) and a positioning die (102), wherein the branching disc (101) is provided with a mounting hole and a plurality of first through holes (1011) arranged on the periphery of the mounting hole, the positioning die (102) is installed in the mounting hole, the middle part of the positioning die (102) is provided with a second through hole (1021), and the shape of the second through hole (1021) is matched with the shape of the liquid cooling tube (1);

The shaping die (200) is provided with a plurality of first through holes (201) and second through holes (202), the first through holes (201) and the first through holes (1011) are arranged in one-to-one correspondence, and the second through holes (202) and the second through holes (1021) are arranged in correspondence.

9. The processing device for the liquid-cooled charging cable according to claim 8, wherein one end of the second through hole (202) facing the branching assembly (100) is provided with a guide hole (203) communicating with the second through hole (202).