WO2024094081A1 - 一种液冷导线以及液冷线缆 - Google Patents

一种液冷导线以及液冷线缆 Download PDF

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Publication number
WO2024094081A1
WO2024094081A1 PCT/CN2023/129154 CN2023129154W WO2024094081A1 WO 2024094081 A1 WO2024094081 A1 WO 2024094081A1 CN 2023129154 W CN2023129154 W CN 2023129154W WO 2024094081 A1 WO2024094081 A1 WO 2024094081A1
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WO
WIPO (PCT)
Prior art keywords
liquid
cooling
cooled
wire
insulating tube
Prior art date
Application number
PCT/CN2023/129154
Other languages
English (en)
French (fr)
Inventor
王超
Original Assignee
长春捷翼汽车科技股份有限公司
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Publication of WO2024094081A1 publication Critical patent/WO2024094081A1/zh

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/0009—Details relating to the conductive cores
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L53/00—Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles
    • B60L53/10—Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles characterised by the energy transfer between the charging station and the vehicle
    • B60L53/14—Conductive energy transfer
    • B60L53/18—Cables specially adapted for charging electric vehicles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L53/00—Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles
    • B60L53/30—Constructional details of charging stations
    • B60L53/302—Cooling of charging equipment
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B5/00—Non-insulated conductors or conductive bodies characterised by their form
    • H01B5/12—Braided wires or the like
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/02—Disposition of insulation
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/04—Flexible cables, conductors, or cords, e.g. trailing cables
    • H01B7/041—Flexible cables, conductors, or cords, e.g. trailing cables attached to mobile objects, e.g. portable tools, elevators, mining equipment, hoisting cables
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
    • H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/42—Insulated conductors or cables characterised by their form with arrangements for heat dissipation or conduction
    • H01B7/421—Insulated conductors or cables characterised by their form with arrangements for heat dissipation or conduction for heat dissipation
    • H01B7/423—Insulated conductors or cables characterised by their form with arrangements for heat dissipation or conduction for heat dissipation using a cooling fluid
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/60—Other road transportation technologies with climate change mitigation effect
    • Y02T10/70—Energy storage systems for electromobility, e.g. batteries
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/60—Other road transportation technologies with climate change mitigation effect
    • Y02T10/7072—Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T90/00—Enabling technologies or technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02T90/10—Technologies relating to charging of electric vehicles
    • Y02T90/14—Plug-in electric vehicles

Definitions

  • the present invention relates to the field of cable technology, and more specifically, to a liquid-cooled wire and a liquid-cooled cable.
  • liquid-cooled wires have been used as charging cables.
  • the liquid-cooling tubes may be blocked due to cable bending, how to avoid the blockage of the liquid-cooling tubes due to bending and how to quickly remove the heat generated by the liquid-cooling wires have become technical problems that need to be urgently solved in this field.
  • An object of the present invention is to provide a new technical solution for liquid cooling wires.
  • a liquid-cooled wire comprising an insulating tube and at least one conductor braided layer embedded in a tube body of the insulating tube, wherein the cross-sectional profile of the conductor braided layer is annular, a cooling liquid flows in the cavity of the insulating tube, and the conductor braided layer is formed by braiding a plurality of first braided belts and a plurality of second braided belts, wherein the first braided belts and the second braided belts are respectively inclined relative to the axial direction of the liquid-cooled wire and the angles formed are opposite to each other, and a first spacing between adjacent first braided belts and a second spacing between adjacent second braided belts do not differ by more than 90% of the larger of the first spacing and the second spacing.
  • the braiding density of the conductor braided layer is greater than or equal to 50%.
  • an angle formed by the intersection of the first braid and the second braid is in the range of 20°-70°.
  • conductor braided layers there are multiple conductor braided layers, and adjacent conductor braided layers are nested with each other.
  • gaps between adjacent conductor braided layers are impregnated with conductive glue, and the conductive glue electrically connects the conductor braided layers.
  • a third distance between the radially innermost conductor braided layer and the inner wall of the insulating tube is less than or equal to a fourth distance between the radially outermost conductor braided layer and the outer wall of the insulating tube.
  • a ratio of the third spacing to the fourth spacing is 1 to 1.5.
  • the insulating tube is made of thermally conductive insulating material.
  • a heat insulation layer is provided on the outer periphery of the insulating tube.
  • a liquid-cooling cable comprising an outer sheath, wherein at least one liquid-cooling wire as described above is sleeved in a sheath cavity of the outer sheath.
  • liquid-cooling wires there are multiple liquid-cooling wires, and the multiple liquid-cooling wires are arranged in at least one of parallel arrangement and sleeve arrangement.
  • a shielding layer is provided at least on the outer wall of the inner periphery of the outer sheath, the outer wall and the inner wall of the insulating tube of the liquid-cooling wire.
  • the shielding layer is provided on the inner wall of the insulating tube, and an auxiliary wire is provided in the cavity of the insulating tube.
  • the shielding layer is arranged on the inner periphery of the outer sheath, and an auxiliary wire is arranged in the sheath cavity of the outer sheath.
  • a plurality of the liquid-cooled conductors are sheathed to form an annular cavity between the inner wall of the radially outer insulating tube and the outer wall of the radially inner insulating tube sheathed and adjacent thereto, and cooling liquid flows through the annular cavity.
  • the conductor braided layer is cross-woven by a plurality of first metal wires and a plurality of second metal wires to form a tubular metal mesh.
  • the spacing between adjacent first metal wires is selected to be equal to the wire diameter of the second metal wire.
  • the spacing between adjacent second metal wires is equal to the wire diameter of the first metal wire.
  • the tubular metal mesh obtained at this time is used as the conductor of the liquid-cooled wire.
  • the liquid-cooled wire with a tubular structure is formed by embedding the conductor braided layer into an insulating tube.
  • the first metal wires and the second metal wires cross-arranged in the metal mesh can protect the tubular structure of the liquid-cooled wire, thereby improving the pressure resistance of the tubular structure liquid-cooled wire.
  • the inner cavity of the tubular structure (the cavity of the insulating tube) can carry high-pressure and high-speed coolant, thereby improving the cable cooling efficiency and reducing the outer diameter of the cable.
  • the conductor part of the liquid cooling wire is set as a conductor braided layer to make the cable flexible and highly pressure-resistant, which facilitates the bending of the liquid cooling wire and prevents the cavity of the liquid cooling wire from being deformed or blocked, thereby affecting the circulation of the coolant.
  • the liquid-cooled wire as at least one conductor braided layer embedded in the insulating tube, there is no need to arrange a supporting structure in the cavity of the insulating tube, thereby reducing the processing steps, the use of supporting accessories and production equipment, and reducing the weight and production cost of the liquid-cooled wire.
  • the thermally conductive insulating material can be a thermally conductive solid silica gel, and the thermally conductive insulating material can effectively protect the conductor braided layer.
  • the outer insulation layer is provided with an insulation layer made of heat-insulating insulating material, which can prevent the heat generated by the conductor braided layer from being transferred to the outer sheath, prevent the insulation layer of the auxiliary wire and the insulation layer of the ground wire arranged inside the outer sheath from aging, and prevent the temperature of the periphery of the liquid-cooled wire from being too high.
  • the outer sheath can be set to a circular or flat shape, and at least one of an auxiliary wire and a ground wire is arranged on both sides of the outer sheath defined by the line connecting the axes of adjacent liquid-cooling wires to fill the internal space of the outer sheath.
  • the liquid-cooling wire set in a sheathing manner can reduce the wire diameter of the liquid-cooling cable.
  • the magnetic field generated by the liquid cooling wire during the power-on process is prevented from interfering with the normal use of other control systems.
  • the signal transmission of the auxiliary line in the liquid cooling cable is prevented from being distorted by other electromagnetic fields.
  • an auxiliary line can be set in the cavity or annular cavity of the insulating tube when the adjacent liquid cooling wires are set in a sleeve manner; the auxiliary line in this application can be a signal line or a control line, which can prevent the signal transmission in the auxiliary line in the liquid cooling cable from being distorted by other electromagnetic fields.
  • the cavity of the insulating tube can be provided with a ground wire as needed.
  • a shielding layer may also be provided on the inner periphery of the outer sheath.
  • an auxiliary wire and a ground wire is provided on both sides of the outer sheath defined by the line connecting the axes of adjacent liquid-cooling wires.
  • an auxiliary wire may be provided between the shielding layer on the inner side of the outer sheath and the shielding layer of the radially outermost insulating tube to prevent distortion of signal transmission in the auxiliary wire provided between the liquid-cooling wire and the outer sheath due to interference from electromagnetic fields.
  • the liquid-cooling wires are arranged in a state where an annular cavity is formed between adjacent liquid-cooling wires, the annular cavity located at the outermost radial direction flows with cooling liquid, and the remaining annular cavities and the annular cavity at the outermost radial direction flow with cooling liquid alternately.
  • the cooling liquid can be used to the minimum extent to cool the liquid-cooling cable, thereby reducing the weight of the liquid-cooling cable.
  • FIG1 is a schematic structural diagram of a cross section of a liquid-cooled wire
  • FIG2 is a schematic diagram of the structure of a conductor braided layer in a liquid-cooled wire
  • FIG3 is a schematic structural diagram of a liquid cooling cable according to a first embodiment
  • FIG4 is a schematic structural diagram of a liquid cooling cable according to a second embodiment
  • FIG5 is a schematic structural diagram of a liquid cooling cable according to a third embodiment
  • FIG6 is a schematic structural diagram of a liquid cooling cable according to a fourth embodiment
  • FIG7 is a schematic structural diagram of a liquid cooling cable according to a fifth embodiment
  • FIG8 is a schematic structural diagram of a liquid cooling cable according to a sixth embodiment.
  • a liquid-cooled conductor 2 according to the present disclosure, as shown in FIGS. 1 to 8 , comprises an insulating tube 21 and at least one conductor braided layer 23 embedded in the body of the insulating tube 21 , wherein the cross-sectional profile of the conductor braided layer 23 is annular, and cooling liquid flows in a cavity 24 of the insulating tube 21 .
  • the conductor braided layer 23 is formed by cross-weaving a plurality of first metal wires and a plurality of second metal wires to form a tubular metal mesh.
  • the spacing between adjacent first metal wires is selected to be equal to the wire diameter of the second metal wire.
  • the spacing between adjacent second metal wires is equal to the wire diameter of the first metal wire.
  • the tubular metal mesh obtained at this time is used as the conductor of the liquid-cooled wire 2.
  • the liquid-cooled wire 2 with a tubular structure is formed by embedding the conductor braided layer 23 into the insulating tube 21.
  • the first metal wires and the second metal wires cross-arranged in the metal mesh can protect the tubular structure of the liquid-cooled wire 2, thereby improving the pressure resistance of the tubular structure liquid-cooled wire 2.
  • the inner cavity of the tubular structure (the cavity 24 of the insulating tube 21) can carry high-pressure and high-speed coolant, thereby improving the cable cooling efficiency and reducing the outer diameter of the cable.
  • the conductor part of the liquid cooling wire 2 is set as a conductor braided layer 23, so that the wire has the characteristics of flexibility and high pressure resistance, which facilitates the bending of the liquid cooling wire 2 and prevents the cavity 24 of the liquid cooling wire 2 from being deformed or blocked, thereby affecting the circulation of the cooling liquid.
  • liquid-cooled wire 2 By arranging the liquid-cooled wire 2 to be embedded in at least one conductor braided layer 23 of the insulating tube 21, there is no need to arrange a supporting structure in the cavity 24 of the insulating tube 21, thereby reducing the processing steps, the use of supporting accessories and production equipment, and reducing the weight and production cost of the liquid-cooled wire 2.
  • the braiding density of the conductor braided layer 23 is greater than or equal to 50%.
  • the insulating tube is divided into an insulating inner tube located inside the conductor braided layer and an insulating outer tube located outside the conductor braided layer;
  • the braiding density is the percentage of the coverage area of the conductor braided layer on the outer surface of the insulating inner tube to the surface area of the outer surface of the insulating inner tube, which indicates the degree of effective coverage of the conductor braided layer on the surface area of the insulating inner tube.
  • the conductor braided layer 23 is cooled by circulating the cooling liquid in the cavity 24 of the insulating tube 21.
  • the maximum current that can be conducted by the conductor braided layer 23 is equal to the maximum current that can be conducted by a solid conductor with the outer diameter of the conductor braided layer 23 as the wire diameter. This can achieve a better conductive effect and reduce the diameter of the conductor braided layer 23, thereby achieving the purpose of reducing the diameter of the liquid-cooled wire 2 and reducing the use of conductor materials.
  • the liquid-cooling wire 2 When the braiding density is less than 50%, the liquid-cooling wire 2 is bent, and when the bending radius is 5 times the outer diameter of the liquid-cooling wire 2, the inner wall of the liquid-cooling wire 2 is easily deformed or blocked, affecting the circulation of the coolant, and the heat generated by the liquid-cooling wire 2 during operation cannot be promptly removed through the circulation of cooling heat.
  • the conductor braided layer 23 is formed by braiding a plurality of first braided belts 231 and a plurality of second braided belts 232 .
  • first metal wires can be woven into a group to form a first braided belt 231
  • second metal wires can be woven into a group to form a second braided belt 232
  • first braided belts 231 and second braided belts 232 are further woven into the conductor braided layer 23 .
  • the distance of the first spacing between adjacent first braids 231 is the first distance d1
  • the distance of the second spacing between adjacent second braids 232 is the second distance d2.
  • the sizes of the first distance d1 and the second distance d2 can be freely defined. In some embodiments, the first distance d1 and the second distance d2 can be equal. However, in other embodiments, the first distance d1 and the second distance d2 can also be unequal. In some other embodiments, at least one of the first distance d1 and the second distance d2 can be zero.
  • the conductor braided layer 23 When the first distance d1 and the second distance d2 are not zero, a plurality of through holes will be evenly formed in the conductor braided layer 23.
  • the conductor braided layer 23 When the conductor braided layer 23 is embedded in the insulating tube 21, the insulating material as the material of the insulating tube 21 will be penetrated with through holes, so that the conductor braided layer 23 is embedded in the insulating tube 21, so that the structure of the liquid-cooled wire 2 is more stable.
  • the cavity 24 of the insulating tube 21 is not easily deformed, which can ensure that the coolant circulates quickly in the cavity 24, quickly taking away the heat generated by the liquid-cooled wire 2 during the charging process, thereby improving the current carrying capacity of the cable and extending the service life of the cable.
  • the structure of the conductor braided layer 23 obtained at this time is the most stable, and the current that can be conducted is the largest.
  • the conductor braided layer 23 forms uneven surfaces on both sides. Therefore, when the conductor braided layer 23 is embedded in the insulating tube 21, the insulating material of the insulating tube 21 will be embedded in the recessed part of the conductor braided layer 23, and the structure of the tubular structure liquid-cooling wire 2 formed is stable.
  • the cavity 24 of the insulating tube 21 is not easily deformed, thereby extending the service life of the liquid-cooling wire 2.
  • first braided belt 231 and the second braided belt 232 are respectively inclined relative to the axial direction of the liquid-cooling wire 2 and the angles formed are opposite to each other.
  • Two angles with the same rotation amount but different rotation directions are called opposite angles.
  • the structure of the conductor braided layer 23 can be made neat.
  • the end of the liquid-cooling wire 2 is connected to the terminal of the charging gun or the charging pile, the connection between the end of the conductor braided layer 23 and the terminal is facilitated, saving the installation time of the end of the conductor braided layer 23 and the terminal.
  • the angle formed by the intersection of the first braided belt 231 and the second braided belt 232 is in the range of 20°-70°.
  • the angle formed by the intersection of the first braided belt 231 and the second braided belt 232 is in the range of 20°-70° (i.e., the angle formed in the circumferential direction of the liquid-cooled wire 2 when the first braided belt 231 and the second braided belt 232 intersect), and the inclination angle of the first braided belt 231 and the second braided belt 232 is moderate, which facilitates the connection between the end of the conductor braided layer 23 and the terminal, saves the installation time of the end of the conductor braided layer 23 and the terminal, and ensures the stability of the connection structure between the conductor braided layer 23 and the terminal.
  • the difference between the first spacing between adjacent first braided belts 231 and the second spacing between adjacent second braided belts 232 does not exceed 90% of the larger one of the first spacing and the second spacing.
  • the conductor braided layer 23 will evenly form through holes of the same size.
  • the conductor braided layer 23 is embedded in the insulating tube 21, the insulating material of the insulating tube 21 will penetrate through holes to connect the conductor braided layer 23, so that the structure of the liquid-cooled wire 2 is more stable and not easy to deform, which can ensure that the coolant circulates quickly in the cavity 24 of the insulating tube 21, quickly taking away the heat generated by the liquid-cooled wire 2 during the charging process, thereby improving the current carrying capacity of the cable and extending the service life of the cable.
  • the first spacing between adjacent first braided belts 231 and the second spacing between adjacent second braided belts 232 do not exceed 90% of the larger of the first spacing and the second spacing (the first distance d1 is not equal to the second distance d2), and the conductor braided layer 23 will evenly form through holes of different sizes.
  • the insulating material of the insulating tube 21 will penetrate through holes to connect the conductor braided layer 23, so that the structure of the liquid-cooled wire 2 is more stable and not easy to deform, which can ensure that the coolant circulates quickly in the cavity 24 of the insulating tube 21, quickly taking away the heat generated by the liquid-cooled wire 2 during the charging process, improving the current carrying capacity of the cable, and extending the service life of the cable.
  • liquid-cooled wire 2 there are a plurality of conductor braided layers 23 , and adjacent conductor braided layers 23 are nested with each other.
  • the current that can be conducted by the liquid-cooled wire 2 can be increased, and the current-carrying capacity of the liquid-cooled wire 2 can be improved.
  • displacement between the conductor braided layers 23 can be avoided.
  • relative displacement between the conductor braided layers 23 during use of the liquid-cooled wire 2 can be avoided.
  • gaps between adjacent conductor braided layers 23 are impregnated with conductive glue, and the conductive glue electrically connects the conductor braided layers 23 .
  • the stability of the connection structure between adjacent conductor braided layers 23 can also be ensured.
  • the difficulty of extruding the insulating tube 21 is reduced, and relative displacement between the conductor braided layers 23 is avoided; at the same time, relative displacement between the conductor braided layers 23 is avoided during the use of the liquid-cooled wire 2.
  • the conductive glue has elasticity, which can ensure the flexibility of the conductor braided layer 23, ensure that the conductor braided layer 23 in the liquid-cooled wire 2 will not be damaged when the cable is bent and dragged during use, and avoid deformation or blockage of the cavity 24 of the inner insulating tube 21.
  • the flow conductivity of the conductor braided layer 23 can be increased, and the charging time of the liquid-cooled wire 2 as a charging line for the new energy vehicle can be reduced.
  • a third distance d3 between the radially innermost conductor braided layer 23 and the inner wall of the insulating tube 21 is less than or equal to a fourth distance d4 between the radially outermost conductor braided layer 23 and the outer wall of the insulating tube 21 .
  • the third spacing d3 is defined as the radial distance between the inner wall of the insulating tube 21 and the nearest conductor braided layer 23 (i.e., the shortest distance)
  • the fourth spacing d4 is defined as the radial distance between the outer wall of the insulating tube 21 and the nearest conductor braided layer 23 (i.e., the shortest distance).
  • the ratio of the third interval d3 to the fourth interval d4 is 1 to 1.5.
  • the present disclosure selects the same number of conductor braided layers 23, the insulating tube 21 of the same material, and the liquid-cooled wire 2 of the same length, and conducts the same current.
  • the liquid-cooled wire 2 used in the experiment only adjusts the ratio of the third spacing d3 to the fourth spacing d4. Cooling liquid flows in the cavity 24 of the insulating tube 21 of each liquid-cooled wire 2 used in the experiment to cool the liquid-cooled wire 2, and the temperature rise value of each liquid-cooled wire 2 is read and recorded in Table 1.
  • the experimental method is to use liquid cooling wires 2 with different ratios of the third spacing d3 to the fourth spacing d4 in a closed environment, conduct the same current, record the temperature before power-on and the temperature when the temperature is stable after power-on, and take the absolute value of the difference.
  • a temperature rise of less than 50K is a qualified value.
  • the present disclosure conducts a bending test on the liquid-cooled wire 2 with a qualified temperature rise value.
  • the bending radius is 5 times the diameter of the liquid-cooled wire 2.
  • the insulating tube 21 is cut along the axial direction of the liquid-cooled wire 2. If cracks are generated on the outer wall or inner wall of the insulating tube 21 at the bend, it is unqualified.
  • the insulating tube 21 is made of a thermally conductive insulating material.
  • the material of the insulating tube 21 can be a thermally conductive insulating material, the heat generated by the conductor braided layer 23 can be quickly transferred to the coolant flowing in the cavity 24 of the insulating tube 21.
  • the thermally conductive insulating material can be thermally conductive solid silicone, and the thermally conductive insulating tube 21 can effectively protect the conductor braided layer 23.
  • a heat insulation layer 5 is sheathed on the outer periphery of the insulating tube 21 .
  • the heat generated by the conductor braided layer 23 can be prevented from being transferred to the outer sheath 1, the aging of the insulation layer of the auxiliary wire 4 and the insulation layer of the ground wire 3 arranged inside the outer sheath 1 can be prevented, and the temperature of the periphery of the liquid-cooled wire 2 can be prevented from being too high.
  • Thermal insulation materials can be glass fiber, asbestos, rock wool, silicate, aerogel felt, vacuum board, etc.
  • a liquid-cooling cable according to the present disclosure as shown in FIG. 3 to FIG. 8 , comprises an outer sheath 1 , in which a sheath cavity of the outer sheath 1 is sleeved at least one liquid-cooling wire 2 as described above.
  • a liquid-cooled cable is formed by arranging at least one liquid-cooled wire 2 in the outer sheath 1.
  • the number of the liquid-cooled wires 2 is set as required.
  • the outer sheath 1 protects the internal structure of the liquid-cooled cable, and each liquid-cooled wire 2 realizes a specific function.
  • the number of the liquid-cooled wires 2 is multiple, and the multiple liquid-cooled wires 2 are arranged in at least one of parallel and sleeved configurations. mode settings.
  • the liquid cooling wires 2 in the liquid cooling cable can be set according to the actual application scenario of the liquid cooling cable.
  • the outer sheath 1 can be set to be circular or flat, and at least one of the auxiliary wires 4 and the ground wire 3 is arranged on both sides of the outer sheath 1 defined by the connecting line between the axes of adjacent liquid cooling wires 2 to fill the internal space of the outer sheath 1.
  • a liquid cooling cable in which multiple liquid cooling wires 2 are arranged in a sleeve manner can reduce the wire diameter of the liquid cooling cable.
  • the liquid-cooling cable shown in FIG. 3 is a first embodiment of the present application.
  • the liquid-cooling cable of the first embodiment is structured such that two liquid-cooling wires 2 are arranged in parallel in an outer sheath 1 .
  • the liquid-cooled cable shown in Figure 8 is the sixth embodiment of the present application.
  • the liquid-cooled cable of the sixth embodiment is constructed such that two liquid-cooled wires 2 are arranged in an outer sheath 1 and are nested with each other, and a shielding layer 6 is provided on the outer wall and the inner wall of the insulating tube 21 of the two liquid-cooled wires 2 nested with each other.
  • At least the shielding layer 6 is provided on the outer wall.
  • the shielding layer 6 By providing the shielding layer 6, the magnetic field generated by the liquid cooling wire 2 during the power-on process is prevented from interfering with the normal use of other control systems. At the same time, the signal transmission of the auxiliary line 4 in the liquid cooling cable is prevented from being distorted by other electromagnetic fields.
  • the liquid-cooled cable shown in FIG6 is the fourth embodiment of the present application, and is constructed by adding a shielding layer 6 to the outer side of the liquid-cooled wire 2 and the inner wall of the outer sheath 1.
  • the shielding layer 6 can be arranged on the periphery of the heat-insulating layer 5 as shown in FIG6 and FIG7, or can be directly arranged on the periphery of the insulating tube 21 (not shown in the figure).
  • a shielding layer 6 is provided on the outer wall and the inner wall of the insulating tube 21 of the two liquid-cooled wires 2 that are nested with each other; the shielding layer 6 can be directly provided on the outer wall and the inner wall of the insulating tube 21 as shown in Figure 8; or a heat insulation layer 5 (not shown in the figure) can be provided between the shielding layer 6 and the outer wall of the insulating tube 21, or a heat insulation layer 5 (not shown in the figure) can be provided between the shielding layer 6 and the inner wall of the insulating tube 21.
  • the shielding layer 6 is disposed on the inner wall of the insulating tube 21 , and the auxiliary line 4 is disposed in the cavity 24 of the insulating tube 21 .
  • an auxiliary wire 4 can be provided in the cavity 24 or the annular cavity 25 of the insulating tube 21; when the liquid-cooling wires 2 are arranged in parallel, an auxiliary wire 4 (not shown in the figure) can also be provided in the cavity 24 of the insulating tube 21.
  • the auxiliary wire 4 in the present application can be a signal wire or a control wire, which can prevent the auxiliary wire 4 in the liquid-cooling cable from being damaged. The signal transmission in 4 is distorted by interference from other electromagnetic fields.
  • the cavity 24 of the insulating tube 21 can be provided with a ground wire 3 as required.
  • the shielding layer 6 is disposed on the inner periphery of the outer sheath 1 , and an auxiliary wire 4 is disposed in the sheath cavity of the outer sheath 1 .
  • a shielding layer 6 may also be provided on the inner periphery of the outer sheath 1, an auxiliary wire is provided in the sheath cavity of the outer sheath 1, and when the liquid-cooling wires 2 are arranged side by side in the insulating tube 21, auxiliary wires 4 are provided on both sides of the sheath cavity defined by the connecting line between the axes of adjacent liquid-cooling wires 2, and a ground wire 3 may also be provided at the same time; or, when the liquid-cooling wires 2 are mutually nested, an auxiliary wire 4 may be provided between the shielding layer 6 on the inner side of the outer sheath 1 and the shielding layer 6 of the radially outermost insulating tube 21 to prevent the signal transmission of the auxiliary wire 4 in the sheath cavity from being distorted due to electromagnetic field interference.
  • the liquid cooling cable shown in FIG. 4 is a second embodiment of the present application.
  • the second embodiment is based on the first embodiment, and an auxiliary line 4 and a ground line 3 are additionally provided in the outer sheath 1 .
  • the liquid-cooled cable shown in FIG. 5 is a third embodiment of the present application.
  • the third embodiment is based on the second embodiment, and a heat insulating layer 5 is added to the outer side of the insulating tube of the liquid-cooled wire 2 .
  • the liquid-cooled cable shown in FIG. 6 is a fourth embodiment of the present application.
  • a shielding layer 6 is additionally provided on the outer side of the liquid-cooled wire 2 and the inner wall of the outer sheath 1 in the third embodiment.
  • the liquid-cooled cable shown in FIG. 7 is the fifth embodiment of the present application.
  • the fifth embodiment is based on the fourth embodiment, and the cross-sectional shape of the outer sheath 1 is designed to be a quadrilateral.
  • the cross-sectional shape of the outer sheath 1 can be set as needed and is not limited to the circular or quadrilateral shape provided in the six implementations.
  • a plurality of the liquid-cooled conductors 2 are sleeved to form an annular cavity 25 between the inner wall of the radially outer insulating tube 21 and the outer wall of the radially inner insulating tube 21 sleeved therewith and adjacent thereto, and the cooling liquid flows through the annular cavity 25 .
  • An annular cavity 25 is formed between adjacent liquid-cooled wires 2. Cooling liquid flows in the annular cavity 25 to cool down each liquid-cooled wire 2 serving as a positive wire and a negative wire, quickly remove the heat generated by the liquid-cooled wire during operation, and improve the current carrying capacity of the cable.
  • Cooling liquid can also be circulated in the radially outermost annular cavity 25, and the remaining annular cavities and the radially outermost annular cavity are arranged in a manner of alternatingly circulating cooling liquid (that is, cooling liquid is circulated in the remaining annular cavities 25 at intervals relative to the radially outermost annular cavity 25), so that the cooling liquid can be used to the minimum extent to cool the liquid-cooled cable and reduce the weight of the liquid-cooled cable.
  • the annular cavity 25 through which the coolant flows may be provided with a support member to prevent two adjacent insulating tubes 21 from contacting each other.
  • the wire diameter of the liquid cooling cable can be reduced.
  • At least one of the auxiliary wire 4 and the ground wire 3 is set in the annular cavity 25 where no coolant flows, so that the annular cavity 25 is fully utilized and the auxiliary wire 4 can be set as needed.
  • the signal transmission function of the liquid-cooled wire 2 during the charging process is completed through the set auxiliary wire 4.

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Abstract

本发明公开了一种液冷导线以及液冷线缆，包括绝缘管和嵌入所述绝缘管内的至少一导体编织层，所述绝缘管的空腔中流通冷却液，所述导体编织层由若干第一编织带和若干第二编织带编织形成，所述第一编织带与所述第二编织带分别相对于所述液冷导线的轴线方向倾斜且形成的角互为相反角，相邻所述第一编织带的第一间距与相邻所述第二编织带的第二间距相差不超过所述第一间距和所述第二间距中较大者的90％。根据本发明的一种液冷导线，提高管型结构液冷导线的耐压性，管型结构的内腔可以承载高压高速的冷却液，进而提高线缆降温效率，缩小线缆外径。

Description

一种液冷导线以及液冷线缆
本发明要求享有2022年11月4日递交、申请号为202211374862.1、发明名称为“一种液冷导线以及液冷线缆”的中国专利的优先权，该专利的所有内容在此全部引入。
技术领域
本发明涉及电缆技术领域，更具体地，涉及一种液冷导线以及液冷线缆。
背景技术
近年来，随着新能源技术的快速发展，电动汽车大量进入家庭和商业领域，使用者对电池容量、续驶里程、充电速度的要求也越来越高，大功率充电技术逐渐发展起来。大功率充电桩的电压高、电流大，在使用的过程中会产生大量的热量，而且功率越大，线缆越容易发热，发热后的线缆存在引发火灾的风险。
因此，近年来将液冷导线作为充电线缆使用，但由于液冷管会因线缆弯折而堵塞，所以，如何避免液冷管因弯折而堵塞以及快速带走液冷导线产生热量的液冷导线成为本领域亟需解决的技术难题。
发明内容
本发明的一个目的是提供一种液冷导线的新技术方案。
根据本发明的第一方面，提供了一种液冷导线，包括绝缘管和嵌入所述绝缘管管体内的至少一导体编织层，所述导体编织层的截面轮廓为环形，所述绝缘管的空腔中流通冷却液，所述导体编织层由若干第一编织带和若干第二编织带编织形成，所述第一编织带与所述第二编织带分别相对于所述液冷导线的轴线方向倾斜且形成的角互为相反角，相邻所述第一编织带的第一间距与相邻所述第二编织带的第二间距相差不超过所述第一间距和所述第二间距中较大者的90％。
可选地，所述导体编织层的编织密度大于等于50％。
可选地，所述第一编织带与所述第二编织带交叉形成的角度范围为20°-70°。
可选地，所述导体编织层数量为多个，相邻所述导体编织层相互套设。
可选地，相邻所述导体编织层的缝隙浸渗有导电胶，所述导电胶电连接各所述导体编织层。
可选地，径向最内侧的所述导体编织层与所述绝缘管的内壁之间的第三间距小于等于径向最外侧的所述导体编织层与所述绝缘管的外壁之间的第四间距。
可选地，所述第三间距与所述第四间距的比值为1～1.5。
可选地，所述绝缘管的材质为导热性绝缘材料。
可选地，所述绝缘管外周套设隔热层。
根据本发明的第二方面，提供了一种液冷线缆，包括外护套，所述外护套的护套空腔内套设至少一个如上所述的液冷导线。
可选地，所述液冷导线的数量为多个，多个所述液冷导线以并列设置、套设设置两种方式中的至少一种方式设置。
可选地，所述外护套的内周、所述液冷导线的绝缘管的外壁和内壁中，至少在所述外壁上设置屏蔽层。
可选地，所述绝缘管的所述内壁设置所述屏蔽层，所述绝缘管的空腔中设置有辅助线。
可选地，所述外护套的内周设置所述屏蔽层，所述外护套的护套空腔中设置有辅助线。
可选地，多个所述液冷导线套设设置，位于径向外侧绝缘管的内壁和与其套设且相邻的位于径向内侧绝缘管的外壁之间形成环形空腔，所述环形空腔流通冷却液。
根据本公开的一种液冷导线，具有如下有益技术效果：
1、导体编织层由若干根第一金属丝和若干根第二金属丝交叉编织形成管型金属网，为使导体编织层两侧表面平整，选择相邻第一金属丝的间距等于第二金属丝的线径，同理可得，相邻第二金属丝的间距等于第一金属丝的线径，此时得到的管型金属网作为液冷导线的导体，通过将导体编织层嵌入绝缘管形成管型结构的液冷导线，金属网中交叉设置的第一金属丝和第二金属丝又可保护液冷导线的管型结构，提高管型结构液冷导线的耐压性，管型结构的内腔(绝缘管的空腔)可以承载高压高速的冷却液，进而提高线缆降温效率，缩小线缆外径。
2、将液冷导线的导体部分设置成导体编织层，使电缆具备柔软性，高耐压的特点，方便液冷导线弯曲，同时避免液冷导线的空腔发生变形或堵塞，影响冷却液的流通。
3、通过将液冷导线设置成嵌入绝缘管的至少一导体编织层，无需在绝缘管的空腔中设置支撑结构，减少了加工工序，支撑配件以及生产设备的使用，降低了液冷导线的重量以及生产成本。
4、通过将绝缘管由导热性绝缘材料制成，可以快速将导体编织层产生的热量传递给空腔中流通的冷却液，导热性绝缘材料可以是导热性固体硅胶，导热性绝缘材料又可对导体编织层起到有效保护作用。
5、通过外绝缘层套设有隔热性绝缘材料制成的隔热层，可避免导体编织层产生的热量传递给外护套，避免外护套内部设置的辅助线的绝缘层以及地线的绝缘层老化，同时避免液冷导线外周的温度过高。
6、液冷导线并排设置形成液冷线缆的状态下，外护套可以设定成圆形或者扁形，外护套内部以相邻的液冷导线的轴线之间的连线限定的两侧，设置有辅助线和地线中的至少一种，以填充外护套内部空间。
7、液冷导线套设方式设置形成液冷线缆的状态下，套设方式设置的液冷导线可以减小液冷线缆的线径。
8、通过设置屏蔽层，防止液冷导线在通电的过程中产生的磁场干扰其他控制系统的正常使用，同时，防止液冷线缆中辅助线的信号传输受其他电磁场干扰导致失真。
9、通过在绝缘管的内壁也设置屏蔽层，可在相邻的液冷导线以套设方式设置的状态下，可以在绝缘管的空腔或者环形空腔中设置辅助线；本申请中的辅助线可以是信号线或者控制线，可以防止液冷线缆中辅助线中的信号传输受其他电磁场干扰导致失真。同时，绝缘管的空腔可以根据需要设置地线。
10、外护套内周也可以设置屏蔽层，液冷导线在绝缘管中并排设置的状态下，外护套内部以相邻的液冷导线的轴线之间的连线限定的两侧，设置有辅助线和地线中的至少一种；或者，液冷导线相互套设的状态下，可以在外护套内侧的屏蔽层与径向最外侧的绝缘管的屏蔽层之间设置辅助线，防止设置液冷导线与外护套之间的辅助线中的信号传输受电磁场干扰导致失真。
11、所述液冷导线相互套设设置的状态，相邻所述液冷导线之间形成环形空腔，位于径向最外侧的环形空腔流通冷却液，其余所述环形空腔与径向最外侧的所述环形空腔以交替流通冷却液的方式设置。可以最小程度的使用冷却液对液冷线缆进行降温，降低液冷线缆的重量。
通过以下参照附图对本发明的示例性实施例的详细描述，本发明的其它特征及其优点将会变得清楚。
附图说明
被结合在说明书中并构成说明书的一部分的附图示出了本发明的实施例，并且连同其说明一起用于解释本发明的原理。
图1为液冷导线的横截面的结构示意图；
图2为液冷导线中的导体编织层的结构示意图；
图3为第一实施方式的液冷线缆的结构示意图；
图4为第二实施方式的液冷线缆的结构示意图；
图5为第三实施方式的液冷线缆的结构示意图；
图6为第四实施方式的液冷线缆的结构示意图；
图7为第五实施方式的液冷线缆的结构示意图；
图8为第六实施方式的液冷线缆的结构示意图。
图中标示如下：
1、外护套；2、液冷导线；3、地线；4、辅助线；5、隔热层；6、屏蔽层；
21、绝缘管；23、导体编织层；24、空腔；25、环形空腔；
231、第一编织带；232、第二编织带；
d1、第一距离；d2、第二距离；d3、第三间距；d4、第四间距。
具体实施方式
现在将参照附图来详细描述本发明的各种示例性实施例。应注意到：除非另外具体说明，否则在这些实施例中阐述的部件和步骤的相对布置、数字表达式和数值不限制本发明的范围。
以下对至少一个示例性实施例的描述实际上仅仅是说明性的，决不作为对本发明及其应用或使用的任何限制。
对于相关领域普通技术人员已知的技术、方法和设备可能不作详细讨论，但在适当情况下，所述技术、方法和设备应当被视为说明书的一部分。
在这里示出和讨论的所有例子中，任何具体值应被解释为仅仅是示例性的，而不是作为限制。因此，示例性实施例的其它例子可以具有不同的值。
根据本公开的一种液冷导线2，如图1至图8所示，包括绝缘管21和嵌入所述绝缘管21管体内的至少一导体编织层23，所述导体编织层23的截面轮廓为环形，所述绝缘管21的空腔24中流通冷却液。
导体编织层23由若干根第一金属丝和若干根第二金属丝交叉编织形成管型金属网，为使导体编织层23两侧表面平整，选择相邻第一金属丝的间距等于第二金属丝的线径，同理可得，相邻第二金属丝的间距等于第一金属丝的线径，此时得到的管型金属网作为液冷导线2的导体，通过将导体编织层23嵌入绝缘管21形成管型结构的液冷导线2，金属网中交叉设置的第一金属丝和第二金属丝又可保护液冷导线2的管型结构，提高管型结构液冷导线2的耐压性，管型结构的内腔(绝缘管21的空腔24)可以承载高压高速的冷却液，进而提高线缆降温效率，缩小线缆外径。
将液冷导线2的导体部分设置成导体编织层23，使导线具备柔软性，高耐压的特点，方便液冷导线2弯曲，同时避免液冷导线2的空腔24发生变形或堵塞，影响冷却液的流通。
通过将液冷导线2设置成嵌入绝缘管21的至少一导体编织层23，无需在绝缘管21的空腔24中设置支撑结构，减少了加工工序，支撑配件以及生产设备的使用，降低了液冷导线2的重量以及生产成本。
根据本公开的一种液冷导线2的一实施例中，所述导体编织层23的编织密度大于等于50％。
在此将绝缘管分成位于导体编织层内侧的绝缘内管和位于导体编织层外侧的绝缘外管；编织密度是导体编织层在绝缘内管的外表面的覆盖面积与绝缘内管的外表面的表面积之比的百分数，表示了导体编织层对绝缘内管表面积的有效覆盖的程度。
编织密度大于等于50％时，通过绝缘管21的空腔24内流通冷却液对导体编织层23降温，导体编织层23可导通的最大电流，等于将导体编织层23的外径作为线径的实心导体能够导通的最大电流，能够达到更好的导电效果，减小导体编织层23的直径，以此达到减小液冷导线2直径的目的，同时减少导体材料的使用。
编织密度小于50％时，对液冷导线2进行折弯，折弯半径为液冷导线2的外径的5倍时，液冷导线2的内壁容易变形或者堵塞，影响冷却液的流通，不能通过冷却热的流通及时带走液冷导线2在工作过程中产生的热量。
根据本公开的一种液冷导线2的一实施例中，如图2所示，所述导体编织层23由若干第一编织带231和若干第二编织带232编织形成。
在导体编织层23编织的过程中，可以先将一定数量的第一金属丝编织为一组形成第一编织带231，将一定数量的第二金属丝编织为一组形成第二编织带232，进而多个第一编织带231与第二编织带232继续编织成导体编织层23。
相邻第一编织带231的第一间距的距离为第一距离d1，相邻第二编织带232的第二间距的距离为第二距离d2，第一距离d1以及第二距离d2的尺寸可以自由限定。在一些实施例中，第一距离d1和第二距离d2可以相等。然而在其他实施例中，第一距离d1和第二距离d2也可以不相等。在另外一些实施例中，第一距离d1以及第二距离d2两者中至少一者可以为零。
第一距离d1和第二距离d2均不为零时，导体编织层23会均匀形成多个通孔，导体编织层23在嵌入绝缘管21时，作为绝缘管21的材质绝缘材料会穿设通孔，使得导体编织层23嵌入绝缘管21内，使得液冷导线2结构更为稳定，在线缆折弯时，绝缘管21的空腔24不易发生形变，可保证冷却液在空腔24内快速流通，快速带走液冷导线2在充电过程中产生的热量，提高线缆的载流能力，延长线缆的使用寿命。
第一距离d1和第二距离d2均为零时，此时得到的导体编织层23的结构最为稳定，可以导通的电流最大，导体编织层23在编织的过程中，导体编织层23形成凸凹不平的两侧表面，所以，导体编织层23在嵌入绝缘管21时，绝缘管21的绝缘材料会嵌入导体编织层23的凹部，形成的管型结构液冷导线2的结构稳定，在液冷导线2弯折或者缠绕的过程中，绝缘管21的空腔24不易形变，延长液冷导线2的使用寿命。
具体的，所述第一编织带231与所述第二编织带232分别相对于所述液冷导线2的轴线方向倾斜且形成的角互为相反角。
旋转量相同但旋转方向不同的两个角叫做相反角，通过将第一编织带231与第二编织带232相对于所述液冷导线2的轴线形成的角互为相反角(可以理解为第一编织带231和第二编织带232交叉设置)，可使得导体编织层23的结构整齐，在液冷导线2端部连接充电枪或者充电桩的端子时，方便导体编织层23端部与端子之间的连接，节省导体编织层23端部与端子的安装时间。
具体的，所述第一编织带231与所述第二编织带232交叉形成的角度范围为20°-70°。
所述第一编织带231与所述第二编织带232交叉形成的角度范围为20°-70°(即：第一编织带231与所述第二编织带232交叉时在液冷导线2的周向方向形成的角)，第一编织带231与第二编织带232的倾斜角度适中，方便导体编织层23端部与端子之间的连接，节省导体编织层23端部与端子的安装时间，确保导体编织层23与端子之间连接结构的稳定。
具体的，相邻所述第一编织带231的第一间距与相邻所述第二编织带232的第二间距相差不超过所述第一间距和所述第二间距中较大者的90％。
相邻所述第一编织带231的第一间距与相邻所述第二编织带232的第二间距相差为0时(第一距离d1等于第二距离d2)，导体编织层23会均匀形成尺寸相同的通孔，导体编织层23在嵌入所述绝缘管21内部时，绝缘管21的绝缘材料会穿设通孔连接导体编织层23，使得液冷导线2结构更为稳定，不易发生形变，可保证冷却液在绝缘管21的空腔24内快速流通，快速带走液冷导线2在充电过程中产生的热量，提高线缆的载流能力，延长线缆的使用寿命。
相邻所述第一编织带231的第一间距与相邻所述第二编织带232的第二间距相差不超过所述第一间距和所述第二间距中较大者的90％(第一距离d1不等于第二距离d2)，导体编织层23会均匀形成尺寸不相同的通孔，导体编织层23在嵌入所述绝缘管21内部时，绝缘管21的绝缘材料会穿设通孔连接导体编织层23，使得液冷导线2结构更为稳定，不易发生形变，可保证冷却液在绝缘管21的空腔24内快速流通，快速带走液冷导线2在充电过程中产生的热量，提高线缆的载流能力，延长线缆的使用寿命。
根据本公开的一种液冷导线2的一实施例中，所述导体编织层23数量为多个，相邻所述导体编织层23相互套设。
通过将相邻的导体编织层23相互套设，可增大液冷导线2可导通的电流，提高液冷导线2的载流能力，通过将相互套设的相邻导体编织层23至少部分进行压接，可避免各导体编织层23之间发生位移；同时，避免在液冷导线2在使用过程中，导体编织层23之间发生相对位移。
根据本公开的一种液冷导线2的一实施例中，相邻所述导体编织层23的缝隙浸渗有导电胶，所述导电胶电连接各所述导体编织层23。
通过在导体编织层23之间浸渗有导电胶，同样可保证相邻的导体编织层23之间连接结构的稳定性，在液冷导线2在加工过程中，降低挤制绝缘管21的难度，避免各导体编织层23之间发生相对位移；同时，避免液冷导线2使用过程中导体编织层23之间发生相对位移。
通过设置导电胶，因导电胶具有弹性，可保证导体编织层23的柔性，确保线缆在使用过程中发生弯折以及拖拽时，液冷导线2内的导体编织层23不会损伤，以及避免内绝缘管21的空腔24的变形或堵塞。
通过将导电胶浸渗到导体编织层23的缝隙，可以增加导体编织层23的导流能力，减少液冷导线2作为充电线为新能源汽车充电时间。
根据本公开的一种液冷导线2，径向最内侧的所述导体编织层23与所述绝缘管21的内壁之间的第三间距d3小于等于径向最外侧的所述导体编织层23与所述绝缘管21的外壁之间的第四间距d4。
如图1所示，第三间距d3限定为绝缘管21的内壁距离与其最近的导体编织层23的径向距离(即：最短距离)，第四间距d4限定为绝缘管21的外壁距离与其最近的导体编织层23的径向距离(即：最短距离)，第三间距d3小于第四间距d4时，冷却热流通绝缘管21的空腔24时可以更快的带走导体编织层23在工作中产生的热量，提高液冷导线2的载流能力。
通过设定第三间距d3小于第四间距d4，可在液冷导线2弯折的过程中，防止绝缘管21的内壁出现褶皱或者绝缘管21内壁出现材质堆积，在褶皱或者材质堆积处，防止冷却液无法及时带走液冷导线2在工作过程中产生的热量。
具体的，所述第三间距d3与所述第四间距d4的比值为1～1.5。
本公开为了验证第三间距d3与第四间距d4的比值，对液冷导线2温升的影响，选用相同数量的导体编织层23、相同材质的绝缘管21、相同长度的液冷导线2，并导通相同的电流，实验所用液冷导线2只调整第三间距d3与第四间距d4的比值，实验所用的各液冷导线2的在绝缘管21的空腔24中流通冷却液，对液冷导线2进行冷却，并读取各个液冷导线2的温升值，记录在表1中。
实验方法是在封闭的环境中，采用第三间距d3与第四间距d4的比值不同的液冷导线2，导通相同的电流，记录通电前的温度和通电后温度稳定时的温度，并作差取绝对值。在本实施例中，温升小于50K为合格值。
本公开将上述温升值合格的液冷导线2进行弯折实验，折弯半径为液冷导线2直径的5倍，连续弯折次数2000次时，沿液冷导线2轴向方向剪开绝缘管21，如在折弯处的绝缘管21的外壁或者内壁产生裂痕即为不合格。
表1：第三间距d3与第四间距d4的比值对液冷导线2温升的影响

从上表1中可以看出，第三间距d3与所述第四间距d4的比值小于1时，在液冷导线2连续折弯2000次时产生裂痕，所以，第三间距d3与所述第四间距d4的比值不合格；第三间距d3与所述第四间距d4的比值大于1.5时，液冷导线2的温升大于50K，液冷导线2的温升值不合格。因此，本公开将第三间距d3与第四间距d4的比值设定为1～1.5。
根据本公开的一种液冷导线2的一实施例中，所述绝缘管21的材质为导热性绝缘材料。
通过将绝缘管21的材质设计成导热性绝缘材料，可以快速将导体编织层23产生的热量传递给绝缘管21的空腔24中流通的冷却液，导热性绝缘材料可以是导热性固体硅胶，导热性绝缘管21又可对导体编织层23起到有效保护作用。
根据本公开的一种液冷导线2的一实施例中，如图5和图7所示，所述绝缘管21外周套设隔热层5。
通过绝缘管21外周套设有隔热性绝缘材料制成的隔热层5，可避免导体编织层23产生的热量传递给外护套1，避免外护套1内部设置的辅助线4的绝缘层以及地线3的绝缘层老化，同时避免液冷导线2外周的温度过高。
隔热性绝缘材料可以是玻璃纤维、石棉、岩棉、硅酸盐，气凝胶毡、真空板等。
根据本公开的一种液冷线缆，如图3至图8所示，包括外护套1，所述外护套1的护套空腔内套设至少一个如上所述的液冷导线2。
通过在外护套1内设置至少一根液冷导线2形成液冷线缆，液冷导线2的数量根据需要设置，外护套1起到保护液冷线缆内部结构的作用，各液冷导线2实现特定功能。
根据本公开的一种液冷线缆的一实施例中，如图3至图8所示，所述液冷导线2的数量为多个，多个所述液冷导线2以并列设置、套设设置两种方式中的至少一种方 式设置。
液冷线缆中的液冷导线2可以根据液冷线缆的实际应用场景进行设定。液冷导线2并排设置的状态下，外护套1可以设定成圆形或者扁形，外护套1内部以相邻的液冷导线2的轴线之间的连线限定的两侧，设置有辅助线4和地线3中的至少一种，以填充外护套1内部空间。液冷导线2套设方式设置的状态下，多个液冷导线2以套设方式设置的液冷线缆可以减小液冷线缆的线径。
如图3所示的液冷线缆为本申请的第一实施方式，第一实施方式的液冷线缆构造为在外护套1内并列设置两根液冷导线2。
如图8所示的液冷线缆为本申请的第六实施方式，第六实施方式的液冷线缆构造为外护套1内设置的两根液冷导线2相互套设设置，且相互套设的两液冷导线2的绝缘管21的外壁和内壁均设置屏蔽层6。
具体的，如图6所示，所述外护套1的内周、所述液冷导线2的绝缘管21的外壁和内壁中，至少在所述外壁上设置屏蔽层6。
通过设置屏蔽层6，防止液冷导线2在通电的过程中产生的磁场干扰其他控制系统的正常使用，同时，防止液冷线缆中辅助线4的信号传输受其他电磁场干扰导致失真。
如图6所示的液冷线缆为本申请的第四实施方式，构造为液冷导线2外侧以及外护套1内壁增设屏蔽层6。屏蔽层6可以如图6和图7所示设置在隔热层5外周，也可以直接设置在绝缘管21外周(图中未示出)。
如图8所示的液冷线缆的第六实施方式中，相互套设的两液冷导线2的绝缘管21的外壁和内壁均设置屏蔽层6；屏蔽层6可以如图8所示直接设置在绝缘管21的外壁和内壁；也可以在屏蔽层6与绝缘管21的外壁之间设置隔热层5(图中未示出)、或者，在屏蔽层6与绝缘管21的内壁之间设置隔热层5(图中未示出)。
具体的，所述绝缘管21的所述内壁设置所述屏蔽层6，所述绝缘管21的空腔24中设置有辅助线4。
通过在绝缘管21的内壁也设置屏蔽层6，如图8所示，可在相邻的液冷导线2以套设方式设置的状态下，可以在绝缘管21的空腔24或者环形空腔25中设置辅助线4；液冷导线2并列设置的状态下，绝缘管21的空腔24也可以设置辅助线4(图中未示出)，本申请中的辅助线4可以是信号线或者控制线，可以防止液冷线缆中辅助线 4中的信号传输受其他电磁场干扰导致失真。同时，绝缘管21的空腔24可以根据需要设置地线3。
具体的，如图4至图7所示，所述外护套1的内周设置所述屏蔽层6，所述外护套1的所述护套空腔中设置有辅助线4。
外护套1内周也可以设置屏蔽层6，所述外护套1的所述护套空腔中设置辅助线，液冷导线2在绝缘管21中并排设置的状态下，护套空腔中以相邻的液冷导线2的轴线之间的连线限定的两侧，设置有辅助线4，也可以同时设置地线3；或者，液冷导线2相互套设的状态下，可以在外护套1内侧的屏蔽层6与径向最外侧的绝缘管21的屏蔽层6之间设置辅助线4，防止护套空腔内的辅助线4的信号传输受电磁场干扰导致失真。
如图4所示的液冷线缆为本申请的第二实施方式，第二实施方式是在第一实施方式的基础上，在外护套1内增设辅助线4以及地线3。
如图5所示的液冷线缆为本申请的第三实施方式，第三实施方式是在第二实施方式的基础上，在液冷导线2的绝缘管外侧增设隔热层5。
如图6所示的液冷线缆为本申请的第四实施方式，第四实施方式是在第三实施方式中的液冷导线2外侧以及外护套1内壁增设屏蔽层6。
如图7所示的液冷线缆为本申请的第五实施方式，第五实施方式是在第四实施方式的基础上，将外护套1的截面形状设计成四边形。
本申请的六种实施方式中，外护套1的截面形状可以根据需要进行设置，不局限于六种实施方式中提供的圆形或者四边形。
具体的，多个所述液冷导线2套设设置，位于径向外侧绝缘管21的内壁和与其套设且相邻的位于径向内侧绝缘管21的外壁之间形成环形空腔25，所述环形空腔25流通冷却液。
相邻所述液冷导线2之间形成环形空腔25，环形空腔25中流通冷却液，可对作为正极导线和负极导线的各液冷导线2进行降温，快速带走液冷导线在工作过程中产生的热量，提高线缆的载流能力。
也可以在径向最外侧的环形空腔25中流通冷却液，并且其余所述环形空腔与径向最外侧的所述环形空腔以交替流通冷却液的方式设置(即：其余环形空腔25相对径向最外侧的环形空腔25以间隔方式流通冷却液)，可以最小程度的使用冷却液对液冷线缆进行降温，降低液冷线缆的重量。
流通冷却液的环形空腔25可以设置支撑件，用于避免相邻的两绝缘管21相互接触。未流通冷却液的所述环形空腔25两侧的绝缘管21相互接触，或者，未流通冷却液的所述环形空腔25中设置辅助线4和地线3中的至少一种。
通过将未流通冷却液的所述环形空腔25两侧的绝缘管21相互接触，可以减小液冷线缆的线径。
未流通冷却液的所述环形空腔25中设置辅助线4和地线3中的至少一种，充分利用环形空腔25，能够根据需要设置辅助线4，在液冷导线2作为正极导线或负极导线工作的过程中，通过设置的辅助线4完成液冷导线2在充电过程中的信号传递功能。
虽然已经通过例子对本发明的一些特定实施例进行了详细说明，但是本领域的技术人员应该理解，以上例子仅是为了进行说明，而不是为了限制本发明的范围。本领域的技术人员应该理解，可在不脱离本发明的范围和精神的情况下，对以上实施例进行修改。本发明的范围由所附权利要求来限定。

Claims (15)

  1. 一种液冷导线，其特征在于，包括绝缘管和嵌入所述绝缘管管体内的至少一导体编织层，所述导体编织层的截面轮廓为环形，所述绝缘管的空腔中流通冷却液，所述导体编织层由若干第一编织带和若干第二编织带编织形成，所述第一编织带与所述第二编织带分别相对于所述液冷导线的轴线方向倾斜且形成的角互为相反角，相邻所述第一编织带的第一间距与相邻所述第二编织带的第二间距相差不超过所述第一间距和所述第二间距中较大者的90％。
  2. 根据权利要求1所述的液冷导线，其特征在于，所述导体编织层的编织密度大于等于50％。
  3. 根据权利要求1所述的液冷导线，其特征在于，所述第一编织带与所述第二编织带交叉形成的角度范围为20°-70°。
  4. 根据权利要求1所述的液冷导线，其特征在于，所述导体编织层数量为多个，相邻所述导体编织层相互套设。
  5. 根据权利要求1所述的液冷导线，其特征在于，相邻所述导体编织层的缝隙浸渗有导电胶，所述导电胶电连接各所述导体编织层。
  6. 根据权利要求4所述的液冷导线，其特征在于，径向最内侧的所述导体编织层与所述绝缘管的内壁之间的第三间距小于等于径向最外侧的所述导体编织层与所述绝缘管的外壁之间的第四间距。
  7. 根据权利要求6所述的液冷导线，其特征在于，所述第三间距与所述第四间距的比值为1～1.5。
  8. 根据权利要求1所述的液冷导线，其特征在于，所述绝缘管的材质为导热性绝缘材料。
  9. 根据权利要求1所述的液冷导线，其特征在于，所述绝缘管外周套设隔热层。
  10. 一种液冷线缆，其特征在于，包括外护套，所述外护套的护套空腔内套设至少一个如权利要求1至9中任一项所述的液冷导线。
  11. 根据权利要求10所述的液冷线缆，其特征在于，所述液冷导线的数量为多个，多个所述液冷导线以并列设置、套设设置两种方式中的至少一种方式设置。
  12. 根据权利要求10所述的液冷线缆，其特征在于，所述外护套的内周、所述液冷导线的绝缘管的外壁和内壁中，至少在所述外壁上设置屏蔽层。
  13. 根据权利要求12所述的液冷线缆，其特征在于，所述绝缘管的所述内壁设置所述屏蔽层，所述绝缘管的空腔中设置有辅助线。
  14. 根据权利要求12所述的液冷线缆，其特征在于，所述外护套的内周设置所述屏蔽层，所述外护套的所述护套空腔中设置有辅助线。
  15. 根据权利要求12所述的液冷线缆，其特征在于，多个所述液冷导线套设设置，位于径向外侧绝缘管的内壁和与其套设且相邻的位于径向内侧绝缘管的外壁之间形成环形空腔，所述环形空腔流通冷却液。
PCT/CN2023/129154 2022-11-04 2023-11-01 一种液冷导线以及液冷线缆 WO2024094081A1 (zh)

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CN219163067U (zh) * 2022-12-07 2023-06-09 长春捷翼汽车科技股份有限公司 一种液冷线缆
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