WO2024098252A1 - 新能源汽车用液冷充电电缆及其生产工艺 - Google Patents

新能源汽车用液冷充电电缆及其生产工艺 Download PDF

Info

Publication number
WO2024098252A1
WO2024098252A1 PCT/CN2022/130649 CN2022130649W WO2024098252A1 WO 2024098252 A1 WO2024098252 A1 WO 2024098252A1 CN 2022130649 W CN2022130649 W CN 2022130649W WO 2024098252 A1 WO2024098252 A1 WO 2024098252A1
Authority
WO
WIPO (PCT)
Prior art keywords
core
cable
auxiliary
power
signal
Prior art date
Application number
PCT/CN2022/130649
Other languages
English (en)
French (fr)
Inventor
孙延蒙
陈兴武
张宇鸥
周斌
查剑
许杏花
邵鹏
孙前程
Original Assignee
远东电缆有限公司
新远东电缆有限公司
远东复合技术有限公司
远东电气股份有限公司
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 远东电缆有限公司, 新远东电缆有限公司, 远东复合技术有限公司, 远东电气股份有限公司 filed Critical 远东电缆有限公司
Priority to CN202280005289.9A priority Critical patent/CN116018656B/zh
Priority to PCT/CN2022/130649 priority patent/WO2024098252A1/zh
Publication of WO2024098252A1 publication Critical patent/WO2024098252A1/zh

Links

Images

Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or 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
    • H01B7/04—Flexible cables, conductors, or cords, e.g. trailing 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
    • 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
    • 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 application relates to the field of wire and cable technology, for example, to a liquid-cooled charging cable for new energy vehicles and a production process thereof.
  • the present application provides a liquid-cooled charging cable for new energy vehicles and a production process thereof, which ensures the roundness and structural strength of the liquid cooling tube, provides support for the overall structure of the cable, and ensures structural stability.
  • the present application provides a liquid-cooled charging cable for new energy vehicles, comprising a bus core cable core, a cooling tube, a return tube, a main cable core wrapping tape and an outer sheath, wherein:
  • the bus core cable core includes: a power core, a ground core, a control core cable core, a signal core cable core and an auxiliary core cable core.
  • the two power cores are distributed side by side.
  • a cooling pipe is arranged on the outer sleeve of each power core.
  • a plurality of supporting members are evenly distributed in the circumferential direction in the annular gap between the cooling pipe and the power core.
  • the ground core is circumscribed with the two cooling pipes at the same time, and the return pipe arranged opposite to the ground core is circumscribed with the two cooling pipes at the same time.
  • the two control core cable cores are distributed on both sides of the ground core and are respectively circumscribed with the ground core and the cooling pipe on the same side.
  • the signal core cable core and the auxiliary core cable core are distributed on both sides of the return pipe and are respectively circumscribed with the return pipe and the cooling pipe on the same side.
  • the bus core cable core is wrapped with a main cable core tape, and an outer sheath is extruded outside the main cable core tape.
  • the present application also provides a production process for the liquid-cooled charging cable for new energy vehicles based on the above, comprising:
  • the power core, cooling tube, grounding core, control core cable core, signal core cable core, auxiliary core cable core and return tube are twisted into a bus core cable core, and the bus core cable core is wrapped with a general cable core tape;
  • FIG1 is a schematic diagram of the structure of a liquid-cooled charging cable for a new energy vehicle provided in an embodiment of the present application.
  • 3-control cable core 31-control cable core conductor; 32-control cable core insulation layer; 33-control cable core wrapping tape;
  • connection should be understood in a broad sense, for example, it can be a fixed connection, or a detachable connection, it can be a mechanical connection, it can be an electrical connection, it can be indirectly connected through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements.
  • connection can be a fixed connection, or a detachable connection, it can be a mechanical connection, it can be an electrical connection, it can be indirectly connected through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements.
  • a first feature being “above” or “below” a second feature may include the first feature and the second feature being in direct contact, or may include the first feature and the second feature being in contact not directly but through another feature between them.
  • a first feature being “above”, “above” and “above” a second feature includes the first feature being directly above and obliquely above the second feature, or simply indicates that the first feature is higher in level than the second feature.
  • a first feature being “below”, “below” and “below” a second feature includes the first feature being directly below and obliquely below the second feature, or simply indicates that the first feature is lower in level than the second feature.
  • This embodiment provides a liquid-cooled charging cable for new energy vehicles, including a bus core cable core.
  • the bus core cable core includes a power core 1, a ground core 2, a control core cable core 3, a signal core cable core 4, an auxiliary core cable core 5, a cooling pipe 6 and a return pipe 7.
  • the bus core cable core is wrapped with a main cable core tape 8, and an outer sheath 9 is extruded outside the main cable core tape 8.
  • the liquid-cooled charging cable for new energy vehicles includes a bus core cable core, a cooling pipe 6, a return pipe 7, a main cable core wrapping tape 8 and an outer sheath 9, wherein the bus core cable core includes: a power core 1, a ground core 2, a control core cable core 3, a signal core cable core 4 and an auxiliary core cable core 5, two power cores 1 are arranged side by side, each power core 1 is provided with a cooling pipe 6, and a plurality of support members are evenly distributed in the annular gap between the cooling pipe 6 and the power core 1 provided thereon along the circumferential direction 13.
  • the grounding core 2 is circumscribed with two cooling tubes 6 at the same time, and the return tube 7 arranged opposite to the grounding core 2 is circumscribed with the two cooling tubes 6 at the same time.
  • the two control core cable cores 3 are distributed on both sides of the grounding core 2 and are circumscribed with the grounding core 2 and the cooling tube 6 on the same side respectively.
  • the signal core cable core 4 and the auxiliary core cable core 5 are distributed on both sides of the return tube 7 and are circumscribed with the return tube 7 and the cooling tube 6 on the same side respectively.
  • the main bus core cable core is wrapped with a main cable core tape 8, and an outer sheath 9 is extruded outside the main cable core tape 8.
  • two power cores 1 are arranged side by side, a cooling tube 6 is disposed on the outer sleeve of each power core 1 , and a plurality of support members 13 are evenly distributed on the circumference in the annular space between the cooling tube 6 and the power core 1 .
  • Each power line core 1 includes a plurality of twisted power line core conductors 11, and the plurality of power line core conductors 11 are wrapped with a power line core insulation layer 12 made of thermoplastic elastomer (TPE) material.
  • TPE thermoplastic elastomer
  • the power line core insulation layer 12 is extruded integrally with a plurality of supporting members 13.
  • the plurality of support members 13 may include three support members 13 of the same size, and a radial gap of 0.8 mm to 1.5 mm is left between each support member 13 and the cooling pipe 6 .
  • the power core 1 includes a plurality of twisted power core conductors 11, and a power core insulation layer 12 made of TPE material is wrapped outside the power core conductor 11.
  • the power core insulation layer 12 and three support members 13 are extruded integrally.
  • the support members 13 are made of high-strength and high-hardness thermoplastic polyurethane elastomer rubber (Thermoplastic Polyurethanes, TPU) material, which can effectively support the cooling tube 6 outside the insulation layer to ensure that the cooling tube 6 will not be squeezed and deformed when the cable bends and moves, thereby ensuring the coolant flow rate and the stability of the cooling tube 6.
  • TPU thermoplastic Polyurethanes
  • a radial gap of 0.8mm to 1.5mm is left between the support 13 and the cooling tube 6, which can ensure the rapid flow of the coolant. While being squeezed by external forces and other wire cores, the flow rate of the coolant in the cooling tube 6 is guaranteed, effectively improving the heat dissipation effect of the power core 1, providing the cable current carrying capacity, and extending the service life of the cable.
  • grounding core 2 is simultaneously circumscribed with one side of the two cooling tubes 6, and a return tube 7 is provided on the other side of the two cooling tubes 6.
  • the two control core cable cores 3 are distributed on both sides of the grounding core 2 and are respectively circumscribed with the grounding core 2 and the cooling tube 6.
  • the signal core cable core 4 and the auxiliary core cable core 5 are distributed on both sides of the return tube 7 and are respectively circumscribed with the return tube 7 and the cooling tube 6.
  • the cooling pipe 6 is made of irradiated ethylene propylene material
  • the return pipe 7 and the outer sheath 9 are made of TPU material, and the flow directions of the cooling liquid in the cooling pipe 6 and the return pipe 7 are opposite.
  • the cooling tube 6 is made of irradiated ethylene-propylene material, and the cooling tube 6 is directly passed through the outside of the power core 1, ensuring the best heat dissipation effect of the power core 1, effectively improving the current carrying capacity of the cable, and extending the service life of the cable.
  • the return pipe 7 is made of TPU material, and the flow directions of the cooling liquid in the cooling pipe 6 and the return pipe 7 are opposite.
  • the grounding wire core 2 includes a plurality of twisted grounding wire core conductors 21 .
  • the grounding wire core conductors 21 are wrapped with a grounding wire core insulation layer 22 made of TPE material, which has high strength and high flexibility.
  • the control core cable core 3 is composed of five control cores twisted in a ring arrangement and wrapped with a control cable core tape 33 made of non-woven fabric.
  • the control core includes multiple twisted control core conductors 31.
  • the control core conductors 31 are wrapped with a control core insulation layer 32 made of TPE material, which has high strength and high flexibility.
  • the signal core cable core 4 is formed by twisting two signal cores and wrapped with a metal braided shielding layer 43 .
  • the signal core includes a plurality of twisted signal core conductors 41 .
  • the signal core conductors 41 are wrapped with a signal core insulation layer 42 made of TPE material.
  • the signal core cable core 4 is formed by twisting two signal cores and wrapped with a metal braided shielding layer 43.
  • the signal core includes multiple twisted signal core conductors 41.
  • the signal core conductors 41 are wrapped with a signal core insulation layer 42 made of TPE material, which has high strength and high flexibility.
  • the auxiliary core cable core 5 is formed by twisting two auxiliary cores and wrapped with an auxiliary core tape 53.
  • the auxiliary core includes a plurality of twisted auxiliary core conductors 51.
  • the auxiliary core conductors 51 are wrapped with an auxiliary core insulation layer 52 made of TPE material.
  • the auxiliary core cable core 5 is formed by two auxiliary cores twisted in a ring arrangement and wrapped with an auxiliary cable core tape 53 made of non-woven fabric.
  • the auxiliary core includes multiple twisted auxiliary core conductors 51.
  • the auxiliary core conductors 51 are wrapped with an auxiliary core insulation layer 52 made of TPE material, which has high strength and high flexibility.
  • the outer diameter of the grounding core 2 is the same as that of the return pipe 7, and the outer diameter of the signal core cable 4 is the same as that of the auxiliary core cable 5 and even the control core cable 3, thereby ensuring that the overall structure of the cable is symmetrical and stable, which can effectively increase the stability of the overall structure of the cable and ensure that the cable will not be deformed when bent and twisted.
  • the main cable core wrapping tape 8 is made of reinforced non-woven fabric.
  • the outer sheath 9 is made of TPU material, which has high softness and wear resistance.
  • this embodiment also provides a production process for the liquid-cooled charging cable for new energy vehicles, which includes the following steps.
  • S100 Prepare conductors of a power core 1, a ground core 2, a control core, a signal core, and an auxiliary core.
  • the preparation method of the power line core conductor 11 is as follows: making copper conductor strands, twisting copper monofilament bundles into copper conductor bundles by a Niehoff wire bundling machine, the monofilament diameter is 0.140mm ⁇ 0.145mm, and the twisting pitch is 11 ⁇ 13 times the outer diameter of the strand; twisting the copper conductor strands into the power line core conductor 11, and the twisting pitch is 13 ⁇ 15 times the outer diameter of the power line core conductor 11.
  • the preparation method of the grounding core conductor 21, the control core conductor 31, the signal core conductor 41 and the auxiliary core conductor 51 is as follows: the copper monofilament bundles are twisted into copper conductor bundles by a Niehoff wire bundler, the monofilament diameter is 0.140mm ⁇ 0.145mm, and the twisting pitch is 12 ⁇ 14 times the outer diameter of the strand.
  • S200 Prepare insulation layers of the ground core 2, the control core, the signal core, and the auxiliary core.
  • the ground core insulation layer 22, the control core insulation layer 32, the signal core insulation layer 42 and the auxiliary core insulation layer 52 are prepared by extruding a high-strength and high-flexibility TPE material outside the corresponding core conductors.
  • S300 Prepare a power line core insulation layer 12 and put a cooling tube 6 on the outside of the power line core insulation layer 12 .
  • the preparation method of the power core insulation layer 12 is to extrude TPE material on the outside of the power core conductor 11, and extrude three support members 13 integrally on the power core insulation layer 12, and put the cooling tube 6 on the outside of the power core 1, and keep a distance of 0.8mm to 1.5mm between the three support members 13 and the cooling tube 6.
  • the control core cable core 3 is prepared by dividing ten control cores into two equal parts, twisting them into a cable in the form of 0+5, and wrapping them with a control core wrapping tape 33 of white non-woven fabric, with a wrapping coverage rate of 25% to 30%.
  • the signal wire core cable core 4 is prepared by twisting two signal wire cores with a twisting pitch of 12 to 16 times the twisted outer diameter, and then braiding copper wires to form a metal braided shielding layer 43, with a single copper wire diameter of 0.10 mm and a braiding density of ⁇ 85%.
  • the preparation method of the auxiliary core cable core 5 is to twist two auxiliary cores, with a twisting pitch of 12 to 16 times the twisted outer diameter, and wrap the auxiliary core wrapping tape 53 of white non-woven fabric with a wrapping coverage rate of 25% to 30%.
  • the power core 1, cooling tube 6, ground core 2, control core cable core 3, signal core cable core 4, auxiliary core cable core 5 and return tube 7 are twisted into a bus core cable core, and a total cable core wrapping tape 8 is wrapped around the bus core cable core.
  • the total cable core wrapping tape 8 is a reinforced non-woven fabric with a wrapping coverage rate of 20% to 30%.
  • the outer sheath 9 can be formed by using a highly soft and wear-resistant soft TPU material through tube extrusion production, with a thickness of 2.5 mm to 3.0 mm.
  • the power core insulation layer 12 and the support member 13 of the cooling tube 6 are integrally formed.
  • the power core insulation layer 12 and the three support members 13 are made of high-strength and high-hardness materials, which can effectively support the cooling tube 6 outside the power core insulation layer 12, ensuring that the cooling tube 6 will not be squeezed and deformed when the cable is bent and moved, and ensuring the coolant flow rate and the stability of the cooling tube 6;
  • a distance of 0.8 mm to 1.5 mm is left between the three support members 13 outside the power core insulation layer 12 and the cooling tube 6, which can ensure the rapid flow of the coolant.
  • the flow rate of the coolant in the cooling tube 6 is guaranteed, which effectively improves the heat dissipation effect of the power core, provides the cable current carrying capacity, and prolongs the service life of the cable;
  • the cooling pipe 6 is directly passed through the outside of the power line core 1 to ensure the best heat dissipation effect of the power line core 1, effectively improve the current carrying capacity of the cable, and extend the service life of the cable.

Landscapes

  • Insulated Conductors (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)

Abstract

本申请提供一种新能源汽车用液冷充电电缆及其生产工艺。其中，液冷充电电缆包括总线芯缆芯、冷却管、回流管、总缆芯包带和外护套，总线芯缆芯包括：动力线芯、接地线芯、控制线芯缆芯、信号线芯缆芯以及辅助线芯缆芯，两个动力线芯并排分布，每个动力线芯外套设有冷却管，且冷却管与所套设的动力线芯之间的环形空隙中沿圆周方向均布有多个支撑件，接地线芯同时与两个冷却管外切，且与接地线芯相对设置的回流管同时与两个冷却管外切，总线芯缆芯外绕包有总缆芯包带，总缆芯包带外挤出有外护套。

Description

新能源汽车用液冷充电电缆及其生产工艺 技术领域
本申请涉及电线电缆技术领域，例如涉及一种新能源汽车用液冷充电电缆及其生产工艺。
背景技术
新能源汽车与传统汽车相比，具有动力强、成本低和节能环保等优点，但新能源汽车因充电效率较低而发展受限。为解决新能源汽车充电时长问题，需要设计开发大功率充电电缆。
大功率充电电缆多为液冷型，即在电缆内预设圆管，通过液体循环降低电缆温度，但由于液冷管材强度较低，支撑力不足，在电缆内经常出现压扁变形的情况，导致液体流通不畅、电缆变形、以及散热失效等问题，影响电缆实际使用。
发明内容
本申请提供一种新能源汽车用液冷充电电缆及其生产工艺，确保液冷管的圆整性和结构强度，为电缆整体结构提供支持，保证结构稳定性。
本申请提供了一种新能源汽车用液冷充电电缆，包括总线芯缆芯、冷却管、回流管、总缆芯包带和外护套，其中，
总线芯缆芯包括：动力线芯、接地线芯、控制线芯缆芯、信号线芯缆芯以及辅助线芯缆芯，两个动力线芯并排分布，每个动力线芯外套设有冷却管，且冷却管与所套设的动力线芯之间的环形空隙中沿圆周方向均布有多个支撑件，接地线芯同时与两个冷却管外切，且与所述接地线芯相对设置的所述回流管同时与两个冷却管外切，两个控制线芯缆芯分布于接地线芯的两侧且分别与接地线芯和同侧的冷却管外切，信号线芯缆芯和辅助线芯缆芯分布于回流管的两侧且分别与回流管和同侧的冷却管外切，总线芯缆芯外绕包有总缆芯包带，总缆芯包带外挤出有外护套。
本申请还提供了一种基于上述的新能源汽车用液冷充电电缆的生产工艺，包括：
制备动力线芯、接地线芯、控制线芯、信号线芯和辅助线芯的线芯导体；
制备接地线芯、控制线芯、信号线芯和辅助线芯的绝缘层；
制备动力线芯绝缘层，在动力线芯绝缘层外套设上冷却管；
制作控制线芯缆芯、信号线芯缆芯和辅助线芯缆芯；
将动力线芯、冷却管、接地线芯、控制线芯缆芯、信号线芯缆芯、辅助线芯缆芯与回流管绞合为总线芯缆芯，并在总线芯缆芯外绕包总缆芯包带；
在总缆芯包带外挤出外护套。
附图说明
图1是本申请实施例提供的新能源汽车用液冷充电电缆的结构示意图。
图中：
1-动力线芯；11-动力线芯导体；12-动力线芯绝缘层；13-支撑件；
2-接地线芯；21-接地线芯导体；22-接地线芯绝缘层；
3-控制线芯缆芯；31-控制线芯导体；32-控制线芯绝缘层；33-控制缆芯包带；
4-信号线芯缆芯；41-信号线芯导体；42-信号线芯绝缘层；43-金属编织屏蔽层；
5-辅助线芯缆芯；51-辅助线芯导体；52-辅助线芯绝缘层；53-辅助缆芯包带；
6-冷却管；
7-回流管；
8-总缆芯包带；
9-外护套。
具体实施方式
下面描述本申请的实施例，实施例的示例在附图中示出，其中自始至终相同或类似的标号表示相同或类似的零部件或具有相同或类似功能的零部件。下面通过参考附图描述的实施例是示例性的，旨在用于解释本申请，而不能理解为对本申请的限制。
在本申请的描述中，除非另有规定和限定，术语“相连”、“连接”、“固定”应做广义理解，例如，可以是固定连接，也可以是可拆卸连接，可以是机械连接，也可以是电连接，也可以通过中间媒介间接相连，可以是两个元件内部的连通或两个元件的相互作用关系。可以根据实际情况理解上述术语在本申请中的含义。
在本申请的描述中，除非另有规定和限定，第一特征在第二特征之“上” 或之“下”可以包括第一特征和第二特征直接接触，也可以包括第一特征和第二特征不是直接接触而是通过它们之间的另外的特征接触。而且，第一特征在第二特征“之上”、“上方”和“上面”包括第一特征在第二特征正上方和斜上方，或仅仅表示第一特征水平高度高于第二特征。第一特征在第二特征“之下”、“下方”和“下面”包括第一特征在第二特征正下方和斜下方，或仅仅表示第一特征水平高度小于第二特征。下面结合附图并通过实施方式来说明本申请的技术方案。
请参阅图1所示，本实施例提供一种新能源汽车用液冷充电电缆，包括总线芯缆芯，总线芯缆芯包括动力线芯1、接地线芯2、控制线芯缆芯3、信号线芯缆芯4、辅助线芯缆芯5、冷却管6和回流管7，总线芯缆芯外绕包有总缆芯包带8，总缆芯包带8外挤出有外护套9。
本实施例提供的新能源汽车用液冷充电电缆，包括总线芯缆芯、冷却管6、回流管7、总缆芯包带8和外护套9，其中，总线芯缆芯包括：动力线芯1、接地线芯2、控制线芯缆芯3、信号线芯缆芯4以及辅助线芯缆芯5，两个动力线芯1并排分布，每个动力线芯1外套设有冷却管6，且冷却管6与所套设的动力线芯1之间的环形空隙中沿圆周方向均布有多个支撑件13，接地线芯2同时与两个冷却管6外切，且与接地线芯2相对设置的回流管7同时与两个冷却管6外切，两个控制线芯缆芯3分布于接地线芯2的两侧且分别与接地线芯2和同侧的冷却管6外切，信号线芯缆芯4和辅助线芯缆芯5分布于回流管7的两侧且分别与回流管7和同侧的冷却管6外切，总线芯缆芯外绕包有总缆芯包带8，总缆芯包带8外挤出有外护套9。
本实施例中，两个动力线芯1并排分布，每个动力线芯1外套设有冷却管6，且冷却管6与动力线芯1之间的环形空隙中圆周均布有多个支撑件13。
每个动力线芯1包括多个绞合的动力线芯导体11，多个动力线芯导体11外包裹有热塑性弹性体(Thermoplastic Elastomer，TPE)材料的动力线芯绝缘层12，动力线芯绝缘层12与多个支撑件13一体挤出。
多个支撑件13可以包括三个大小相同的支撑件13，每个支撑件13与冷却管6之间留有0.8mm～1.5mm的径向间隙。
动力线芯1包括多个绞合的动力线芯导体11，动力线芯导体11外包裹有TPE材料的动力线芯绝缘层12，动力线芯绝缘层12与三个支撑件13一体挤出，支撑件13采用高强度、且高硬度的热塑性聚氨酯弹性体橡胶(Thermoplastic Polyurethanes，TPU)材料，可以有效支撑绝缘层外冷却管6，确保电缆在弯曲移动时冷却管6不会受到挤压变形，确保冷却液流速和冷却管6的稳定性。
支撑件13与冷却管6之间留有0.8mm～1.5mm的径向间隙，可以确保冷却液快速流动，在受到外力及其他线芯挤压的同时，保证冷却管6中冷却液流速，有效提升动力线芯1的散热效果，提供电缆载流量，延长了电缆使用寿命。
此外，接地线芯2同时与两个冷却管6的一侧外切，且两个冷却管6的另一侧外切设置有回流管7，两个控制线芯缆芯3分布于接地线芯2的两侧且分别与接地线芯2和冷却管6外切，信号线芯缆芯4和辅助线芯缆芯5分布于回流管7的两侧且分别与回流管7和冷却管6外切。
冷却管6采用辐照乙丙材料，回流管7和外护套9采用TPU材料，冷却管6与回流管7内的冷却液体的流向相反。
冷却管6采用辐照乙丙材料，冷却管6直接穿于动力线芯1外，确保动力线芯1的散热效果最佳，有效提升电缆载流量，延长电缆使用寿命。
回流管7采用TPU材料，冷却管6与回流管7内的冷却液体的流向相反。
接地线芯2包括多个绞合的接地线芯导体21，接地线芯导体21外包裹有TPE材料的接地线芯绝缘层22，具有高强度和高柔性特性。
控制线芯缆芯3由五个控制线芯按环形排列绞合而成并绕包有无纺布材质的控制缆芯包带33，控制线芯包括多个绞合的控制线芯导体31，控制线芯导体31外包裹有TPE材料的控制线芯绝缘层32，具有高强度、和高柔性特性。
信号线芯缆芯4由两个信号线芯对绞而成并包裹有金属编织屏蔽层43，信号线芯包括多个绞合的信号线芯导体41，信号线芯导体41外包裹有TPE材料的信号线芯绝缘层42。
信号线芯缆芯4由两个信号线芯外切绞合而成并包裹有金属编织屏蔽层43，信号线芯包括多个绞合的信号线芯导体41，信号线芯导体41外包裹有TPE材料的信号线芯绝缘层42，具有高强度、和高柔性特性。
辅助线芯缆芯5由两个辅助线芯对绞而成并绕包有辅助缆芯包带53，辅助线芯包括多个绞合的辅助线芯导体51，辅助线芯导体51外包裹有TPE材料的辅助线芯绝缘层52。
辅助线芯缆芯5由两个辅助线芯按环形排列绞合而成并绕包有无纺布材质的辅助缆芯包带53，辅助线芯包括多个绞合的辅助线芯导体51，辅助线芯导体51外包裹有TPE材料的辅助线芯绝缘层52，具有高强度、和高柔性特性。
接地线芯2与回流管7的外径相同，信号线芯缆芯4与辅助线芯缆芯5的外径相同甚至与控制线芯缆芯3的外径也相同，由此保证线缆整体结构对称稳定，可有效增加电缆整体结构的稳定性，保证电缆在弯曲、以及扭转等情况下 使用不变形。
总缆芯包带8采用加强型无纺布。
外护套9采用TPU材料，具有高柔软、耐磨特性。
此外，本实施例还提供一种基于上述新能源汽车用液冷充电电缆的生产工艺，包括以下步骤。
S100：制备动力线芯1、接地线芯2、控制线芯、信号线芯和辅助线芯的导体。
动力线芯导体11的制备方法为：制作铜导体股线，由尼霍夫束丝机将铜单丝束绞成铜导体束线，单丝丝径为0.140mm～0.145mm，绞合节距为11～13倍股线外径；将铜导体股线绞合而成动力线芯导体11，绞合节距为13～15倍动力线芯导体11的外径。
接地线芯导体21、控制线芯导体31、信号线芯导体41和辅助线芯导体51的制备方法为：由尼霍夫束丝机将铜单丝束绞成铜导体束线，单丝丝径0.140mm～0.145mm，绞合节距12～14倍股线外径。
S200：制备接地线芯2、控制线芯、信号线芯和辅助线芯的绝缘层。
接地线芯绝缘层22、控制线芯绝缘层32、信号线芯绝缘层42和辅助线芯绝缘层52的制备方法为在对应线芯导体外挤包高强度、和高柔软特性的TPE材料。
S300：制备动力线芯绝缘层12，在动力线芯绝缘层12外穿上冷却管6。
动力线芯绝缘层12的制备方法为在动力线芯导体11外挤包TPE材料，并在动力线芯绝缘层12上一体挤出三个支撑件13，在动力线芯1外穿上冷却管6，保持三个支撑件13与冷却管6间留有0.8mm～1.5mm距离。
S400：制作控制线芯缆芯3、信号线芯缆芯4和辅助线芯缆芯5。
控制线芯缆芯3的制备方法为将十根控制线芯两等分，以0+5形式绞合成缆，外绕包白色无纺布的控制缆芯包带33，绕包搭盖率为25％～30％。
信号线芯缆芯4的制备方法为将两根信号线芯对绞，对绞节距12～16倍绞合外径，对绞后外进行铜丝编织成金属编织屏蔽层43，铜丝单丝直径0.10mm，编织密度≥85％。
辅助线芯缆芯5的制备方法为将两根辅助线芯对绞，对绞节距12～16倍绞合外径，外绕包白色无纺布的辅助缆芯包带53，绕包搭盖率为25％～30％。
S500：将动力线芯1、冷却管6、接地线芯2、控制线芯缆芯3、信号线芯 缆芯4、辅助线芯缆芯5与回流管7绞合为总线芯缆芯，并在总线芯缆芯外绕包总缆芯包带8，总缆芯包带8为加强型无纺布，绕包搭盖率为20％～30％。
S600：在总缆芯包带8外挤出外护套9，外护套9可以采用高柔软、耐磨的软质TPU材料通过挤管式生产形成，厚度2.5mm～3.0mm。
综上，本申请提供的新能源汽车用液冷充电电缆及其生产工艺的效果为：
(1)动力线芯绝缘层12和冷却管6的支撑件13采用一体成型加工，动力线芯绝缘层12和三个支撑件13采用高强度、高硬度材料，可以有效支撑动力线芯绝缘层12外的冷却管6，确保电缆在弯曲移动时冷却管6不会受到挤压变形，确保冷却液流速和冷却管6的稳定性；
(2)动力线芯绝缘层12外的三个支撑件13与冷却管6间留有0.8mm～1.5mm距离，可以确保冷却液快速流动，在受到外力及其他线芯挤压的同时，保证冷却管6中冷却液流速，有效提升动力线芯的散热效果，提供电缆载流量，延长了电缆使用寿命；
(3)两个控制线芯缆芯3与信号线芯缆芯4及辅助线芯缆芯5的外径尽可能相同，回流管7与接地线芯2的外径相同，且多个缆芯保持相切结构，保证了电缆整体结构对称稳定，可有效增加电缆整体结构的稳定性，保证电缆在弯曲、以及扭转等情况下使用不变形；
(4)冷却管6直接穿于动力线芯1外，确保动力线芯1的散热效果最佳，有效提升电缆载流量，延长电缆使用寿命。

Claims (10)

  1. 一种新能源汽车用液冷充电电缆，包括总线芯缆芯、冷却管、回流管、总缆芯包带和外护套，其中，
    所述总线芯缆芯包括：动力线芯、接地线芯、控制线芯缆芯、信号线芯缆芯以及辅助线芯缆芯，两个动力线芯并排分布，每个动力线芯外套设有所述冷却管，且所述冷却管与所套设的动力线芯之间的环形空隙中沿圆周方向均布有多个支撑件，所述接地线芯同时与两个冷却管外切，且与所述接地线芯相对设置的所述回流管同时与所述两个冷却管外切，两个控制线芯缆芯分布于所述接地线芯的两侧且分别与所述接地线芯和同侧的冷却管外切，所述信号线芯缆芯和所述辅助线芯缆芯分布于所述回流管的两侧且分别与所述回流管和同侧的冷却管外切，所述总线芯缆芯外绕包有所述总缆芯包带，所述总缆芯包带外挤出有所述外护套。
  2. 根据权利要求1所述的电缆，其中，每个动力线芯包括多个绞合的动力线芯导体，所述多个动力线芯导体外包裹有热塑性弹性体TPE材料的动力线芯绝缘层，所述动力线芯绝缘层与所述多个支撑件一体挤出。
  3. 根据权利要求2所述的电缆，其中，所述多个支撑件包括三个大小相同的支撑件，每个支撑件与所述冷却管之间留有0.8mm～1.5mm的径向间隙。
  4. 根据权利要求1所述的电缆，其中，所述冷却管采用辐照乙丙材料，所述回流管和所述外护套采用热塑性聚氨酯弹性体橡胶TPU材料，所述冷却管与所述回流管内的冷却液体的流向相反。
  5. 根据权利要求1所述的电缆，其中，所述接地线芯包括多个绞合的接地线芯导体，所述多个接地线芯导体外包裹有TPE材料的接地线芯绝缘层。
  6. 根据权利要求1所述的电缆，其中，每个控制线芯缆芯由五个控制线芯按环形排列绞合而成并绕包有控制缆芯包带，每个控制线芯包括多个绞合的控制线芯导体，每个控制线芯包括的所述多个控制线芯导体外包裹有TPE材料的控制线芯绝缘层。
  7. 根据权利要求1所述的电缆，其中，所述信号线芯缆芯由两个信号线芯对绞而成并包裹有金属编织屏蔽层，每个信号线芯包括多个绞合的信号线芯导体，每个信号线芯包括的所述多个信号线芯导体外包裹有TPE材料的信号线芯绝缘层。
  8. 根据权利要求1所述的电缆，其中，所述辅助线芯缆芯由两个辅助线芯对绞而成并绕包有辅助缆芯包带，每个辅助线芯包括多个绞合的辅助线芯导体，每个辅助线芯包括的所述多个辅助线芯导体外包裹有TPE材料的辅助线芯绝缘层。
  9. 根据权利要求1所述的电缆，其中，所述接地线芯与所述回流管的外径相同，所述信号线芯缆芯与所述辅助线芯缆芯的外径相同。
  10. 一种应用于权利要求1至9中任一项所述的新能源汽车用液冷充电电缆的生产工艺，包括：
    制备动力线芯、接地线芯、控制线芯、信号线芯和辅助线芯的线芯导体；
    制备所述接地线芯、所述控制线芯、所述信号线芯和所述辅助线芯的绝缘层；
    制备动力线芯绝缘层，在所述动力线芯绝缘层外套设上冷却管；
    制作控制线芯缆芯、信号线芯缆芯和辅助线芯缆芯；
    将所述动力线芯、所述冷却管、所述接地线芯、所述控制线芯缆芯、所述信号线芯缆芯、所述辅助线芯缆芯与回流管绞合为总线芯缆芯，并在所述总线芯缆芯外绕包总缆芯包带；
    在所述总缆芯包带外挤出外护套。
PCT/CN2022/130649 2022-11-08 2022-11-08 新能源汽车用液冷充电电缆及其生产工艺 WO2024098252A1 (zh)

Priority Applications (2)

Application Number Priority Date Filing Date Title
CN202280005289.9A CN116018656B (zh) 2022-11-08 2022-11-08 新能源汽车用液冷充电电缆及其生产工艺
PCT/CN2022/130649 WO2024098252A1 (zh) 2022-11-08 2022-11-08 新能源汽车用液冷充电电缆及其生产工艺

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/CN2022/130649 WO2024098252A1 (zh) 2022-11-08 2022-11-08 新能源汽车用液冷充电电缆及其生产工艺

Publications (1)

Publication Number Publication Date
WO2024098252A1 true WO2024098252A1 (zh) 2024-05-16

Family

ID=86032118

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/CN2022/130649 WO2024098252A1 (zh) 2022-11-08 2022-11-08 新能源汽车用液冷充电电缆及其生产工艺

Country Status (2)

Country Link
CN (1) CN116018656B (zh)
WO (1) WO2024098252A1 (zh)

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN211181729U (zh) * 2020-01-03 2020-08-04 江苏上上电缆集团有限公司 一种用于低温环境的新能源冷却电缆
CN113192674A (zh) * 2021-05-06 2021-07-30 远东电缆有限公司 一种智能芯片馈温加扰动冷却的液冷充电电缆及制备方法
CN217280131U (zh) * 2022-04-24 2022-08-23 西安西电光电缆有限责任公司 一种电动汽车大功率充电液冷电缆
WO2022217432A1 (zh) * 2021-04-12 2022-10-20 浙江吉利控股集团有限公司 高压大功率液冷充电电缆
WO2022226730A1 (zh) * 2021-04-26 2022-11-03 浙江吉利控股集团有限公司 一种液冷充电电缆及电动车充电桩

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3624141B1 (de) * 2018-09-14 2023-11-01 BRUGG eConnect AG Kühlbare einzelleitung und ladekabel
CN209232433U (zh) * 2018-12-19 2019-08-09 江苏上上电缆集团有限公司 一种中空电缆

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN211181729U (zh) * 2020-01-03 2020-08-04 江苏上上电缆集团有限公司 一种用于低温环境的新能源冷却电缆
WO2022217432A1 (zh) * 2021-04-12 2022-10-20 浙江吉利控股集团有限公司 高压大功率液冷充电电缆
WO2022226730A1 (zh) * 2021-04-26 2022-11-03 浙江吉利控股集团有限公司 一种液冷充电电缆及电动车充电桩
CN113192674A (zh) * 2021-05-06 2021-07-30 远东电缆有限公司 一种智能芯片馈温加扰动冷却的液冷充电电缆及制备方法
CN217280131U (zh) * 2022-04-24 2022-08-23 西安西电光电缆有限责任公司 一种电动汽车大功率充电液冷电缆

Also Published As

Publication number Publication date
CN116018656B (zh) 2024-04-12
CN116018656A (zh) 2023-04-25

Similar Documents

Publication Publication Date Title
WO2024094081A1 (zh) 一种液冷导线以及液冷线缆
CN110570992B (zh) 一种磁浮轨道交通长定子电缆的生产工艺
CN107967959A (zh) 大功率冷却型直流充电桩电缆及其制造方法
JP5032405B2 (ja) 超電導ケーブル用のフォーマと、その製造方法及び超電導ケーブル
WO2024098252A1 (zh) 新能源汽车用液冷充电电缆及其生产工艺
CN107978388B (zh) 冷却型直流充电桩电缆及其制造方法
CN216849357U (zh) 一种大电流轻柔型充电桩快充外部连接电缆
WO2024098251A1 (zh) 新能源汽车用大功率充电电缆及其生产工艺
WO2022021623A1 (zh) 一种无人机用耐高低温抗干扰综合软电缆
CN213459161U (zh) 一种耐扭转、高强度、强耐磨的屏蔽型机器人用电缆
CN115312242A (zh) 新能源汽车用充电电缆及其制备方法
WO2024098250A1 (zh) 新能源汽车用液冷大功率充电电缆及其生产工艺
CN112542264A (zh) 一种超柔高可靠性焊接机器人用电源电缆及制备方法
CN207637520U (zh) 一种高柔性电动汽车高压电缆
CN217767868U (zh) 塔机用橡套软电缆
CN115985562A (zh) 新能源汽车充电用液冷大功率电缆及生产工艺
CN219716543U (zh) 一种超柔软油冷式充电枪电缆
CN110164591A (zh) 大功率冷却型充电桩电缆及其制造方法
CN215183139U (zh) 软电缆
CN214796798U (zh) 一种单芯大截面超柔性低压电力电缆
CN221262008U (zh) 液冷充电线缆及其加工装置
CN118073017B (zh) 一种高功率液冷电缆
CN216487427U (zh) 一种抗磁抗干扰特种电缆
CN217361215U (zh) 具有报警线芯的轻质7芯通信电缆
CN107993751A (zh) 一种高柔性电动汽车高压电缆及其制造方法

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 22964727

Country of ref document: EP

Kind code of ref document: A1