Liquid-cooled cable

Abstract

The application discloses a liquid cooling cable, comprising an inner support pipe, an outer support pipe sleeved outside the inner support pipe, and at least one support connecting piece arranged between the inner support pipe and the outer support pipe, wherein the support connecting piece divides the space between the inner support pipe and the outer support pipe into at least one first cavity, at least one conductor is arranged in the first cavity, and cooling liquid flows in the inner support pipe and the at least one first cavity. According to the liquid cooling cable, the cooling liquid flows in the inner support pipe and the first cavity, so that the heat of the conductor arranged in the first cavity can be quickly taken away, the heat generated by the conductor during charging is effectively reduced, the service life of the cable is prolonged, and the current carrying capacity of the conductor is improved.

Description

Technical Field

[0001] This invention relates to the field of cable technology, and more specifically, to a liquid-cooled cable. Background Technology

[0002] With the increasing popularity of new energy vehicles, related infrastructure, such as charging stations, also needs improvement. Existing charging stations connect to charging guns via cables. As electric vehicles increasingly enter homes and businesses, users have higher demands for battery capacity, driving range, and charging speed, leading to the development of high-power charging technology. During charging, cables inevitably generate heat, limiting their lifespan and reducing charging efficiency.

[0003] Therefore, there is an urgent need in the field of cable technology for a liquid-cooled cable that can suppress temperature rise during the charging process. Summary of the Invention

[0004] One objective of this invention is to provide a new technical solution for liquid-cooled cables.

[0005] According to a first aspect of the present invention, a liquid-cooled cable is provided, comprising: an inner support tube, an outer support tube sleeved outside the inner support tube, and at least one support connector disposed between the inner support tube and the outer support tube, the support connector dividing the space between the inner support tube and the outer support tube into at least one first cavity, the first cavity being provided with at least one conductor, and coolant flowing through the inner support tube and / or at least one first cavity.

[0006] Optionally, there may be multiple first cavities, which together form a first cooling circulation system. Each of the multiple first cavities includes at least one first liquid inlet channel and at least one first liquid outlet channel.

[0007] Optionally, the liquid-cooled cable further includes an outer sheath sleeved on the outside of the outer support tube and at least one bracket disposed between the outer support tube and the outer sheath, the bracket dividing the space between the outer sheath and the outer support tube into at least one second cavity.

[0008] Optionally, the inner support tube, the first cavity, and the second cavity include at least one liquid inlet channel and at least one liquid outlet channel.

[0009] Optionally, the total cross-sectional area of ​​the second cavity accounts for 10%-40% of the cross-sectional area of ​​the liquid-cooled cable.

[0010] Optionally, the ratio of the total cross-sectional area of ​​the brackets to the total cross-sectional area of ​​the second cavity is 3%-20%.

[0011] Optionally, the inner support tube and at least one of the second cavities form a second cooling circulation system, wherein one of the inner support tube and at least one of the second cavities is configured as a second liquid inlet channel and the other is configured as a second liquid outlet channel.

[0012] Optionally, the bracket and / or the outer sheath are made of metal.

[0013] Optionally, when an insulating layer is provided on the outside of the conductor, at least the outer support tube and / or the outer sheath are made of metal.

[0014] Optionally, the support connector is integrally formed with the inner support tube and / or the outer support tube; and / or

[0015] The bracket is integrally formed with the outer support tube and / or outer sheath.

[0016] Optionally, the bracket is configured as a strip plate extending through the second cavity in the axial direction, with the first side of the strip plate connected to the outer wall of the outer support tube, and the second side of the strip plate opposite to the first side connected to the inner wall of the outer sheath.

[0017] Optionally, the strip plate is provided with a plurality of first through holes, the first through holes connecting the second cavities on both sides of the bracket.

[0018] Optionally, the first end of the cross-section of the support connector is connected to the outer wall of the inner support tube, and the second end of the cross-section of the support connector opposite to the first end is connected to the inner wall of the outer support tube.

[0019] Optionally, there are multiple support connectors, and the multiple support connectors are evenly arranged along the circumferential direction of the inner support tube.

[0020] Optionally, the support connector is continuously provided from one end to the other along the axial direction of the liquid-cooled cable.

[0021] Optionally, the cross-sectional area of ​​the inner support tube accounts for 10%-30% of the cross-sectional area of ​​the liquid-cooled cable.

[0022] Optionally, the total cross-sectional area of ​​the first cavity accounts for 10%-30% of the cross-sectional area of ​​the liquid-cooled cable.

[0023] Optionally, the ratio of the total cross-sectional area of ​​the supporting connectors to the cross-sectional area of ​​the first cavity is 3%-20%.

[0024] Optionally, the flow rate of the coolant is 0.5 ml / s to 50 ml / s.

[0025] Optionally, the cooling rate of the coolant is greater than or equal to 0.2°C / min.

[0026] Optionally, the support connector is provided with a channel along the axial direction of the liquid-cooled cable, and coolant flows through the channel.

[0027] Optionally, the outer support tube corresponding to the channel is provided with a second through hole, the second through hole connecting the second cavity and the channel, the second through hole extending continuously along the axial direction of the outer support tube, or the second through hole being spaced apart along the axial direction of the cable.

[0028] According to the liquid-cooled cable disclosed herein, the following advantages are achieved:

[0029] 1. The inner support tube and the outer support tube are connected by a support connector, which serves to fix the structure. At the same time, the coolant flowing in the inner support tube can quickly remove the heat of the conductor in the first cavity, effectively reducing the heat generated by the conductor during charging, extending the service life of the cable, and improving the current carrying capacity of the conductor.

[0030] Meanwhile, coolant can also circulate in the first cavity. The coolant circulating in the first cavity is in direct contact with the outer periphery of the conductor. The heat generated by the conductor during charging can be carried away by the coolant in time, thereby reducing the temperature rise of the cable and improving the current carrying capacity of the conductor.

[0031] 2. By setting an outer sheath, a second cavity can be formed outside the first cavity. The second cavity can accelerate the dissipation of heat from the conductor in the first cavity. Coolant can flow through the second cavity, which can liquid cool the first cavity from the outside, thereby improving the current carrying capacity of the conductor.

[0032] 3. Two cooling circulation systems are formed inside the liquid-cooled cable: a first cooling circulation system and a second cooling circulation system. Depending on the heat generated by the liquid-cooled cable during charging, one of the cooling circulation systems can be activated, or both the first and second cooling circulation systems can be activated simultaneously to cool the conductor placed in the first cavity. This reduces the temperature rise of the liquid-cooled cable and improves the current carrying capacity of the conductor.

[0033] 4. By making at least the outer support tube and the outer sheath of the inner support tube, the outer support tube, the support connector, the bracket, and the outer sheath metal, a double-layer shielding effect can be achieved for the liquid-cooled cable. This prevents the electromagnetic waves or magnetic fields generated by the positive or negative conductor inside the liquid-cooled cable during the charging process from interfering with the normal operation of other control systems, or prevents the signal transmission in the control lines inside the liquid-cooled cable from being distorted due to interference from other electromagnetic fields.

[0034] 5. By integrally molding the support connector with at least one of the inner support tube and the outer support tube, the stability of the connection structure between the inner support tube and the outer support tube can be increased, and the uneven force between the outer support tube and the inner support tube due to the change of the position of the support connector can be avoided, which would cause the cross-section of a certain first cavity to change.

[0035] 6. By integrally molding the bracket with at least one of the outer support tube and the outer sheath, the stability of the connection structure between the outer support tube and the outer sheath can be increased. This avoids uneven stress between the outer sheath and the outer support tube due to changes in the position of the bracket, which would result in unequal distances between the outer wall of the outer support tube and the inner wall of the outer sheath. This would prevent some brackets from playing a supporting role, causing uneven flow of coolant in the second cavity between the outer support tube and the outer sheath, and failing to remove the heat generated by the conductor in a certain first cavity in time, thus preventing the conductor temperature from rising and improving the conductor's current carrying capacity.

[0036] Other features and advantages of the invention will become clear from the following detailed description of exemplary embodiments of the invention with reference to the accompanying drawings. Attached Figure Description

[0037] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments of the invention and, together with their description, serve to explain the principles of the invention.

[0038] Figure 1 This is a schematic diagram of the structure of a first embodiment of a liquid-cooled cable according to the present invention;

[0039] Figure 2 This is a schematic diagram of the structure of a second embodiment of a liquid-cooled cable according to the present invention;

[0040] Figure 3 This is a schematic diagram of the structure of a third embodiment of a liquid-cooled cable according to the present invention;

[0041] Figure 4 This is a schematic diagram of the fourth embodiment of a liquid-cooled cable according to the present invention;

[0042] Figure 5 This is a structural schematic diagram of the fifth embodiment of a liquid-cooled cable of the present invention.

[0043] The diagram is marked as follows:

[0044] 1-Inner support tube; 2-Support connector; 3-Outer support tube; 4-First cavity; 5-Conductor; 6-Outer sheath; 7-Support; 8-Second cavity; 201-Channel; 301-Second through hole; 701-First through hole. Detailed Implementation

[0045] Various exemplary embodiments of the present invention will now be described in detail with reference to the accompanying drawings. It should be noted that, unless otherwise specifically stated, the relative arrangement, numerical expressions, and values ​​of the components and steps set forth in these embodiments do not limit the scope of the invention.

[0046] The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the invention or its application or use.

[0047] Techniques, methods, and equipment known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and equipment should be considered part of the specification.

[0048] In all the examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values.

[0049] According to a liquid-cooled cable disclosed herein, such as Figures 1 to 5 As shown, it includes: an inner support tube 1, an outer support tube 3 sleeved on the outside of the inner support tube 1, and at least one support connector 2 disposed between the inner support tube 1 and the outer support tube 3. The support connector 2 divides the space between the inner support tube 1 and the outer support tube 3 into at least one first cavity 4. At least one conductor 5 is disposed in the first cavity 4. Coolant flows through the inner support tube 1 and / or at least one first cavity 4.

[0050] like Figure 1 As shown, the inner support tube 1 and the outer support tube 3 are connected by the support connector 2, which serves to fix the structure. At the same time, the coolant flowing in the inner support tube 1 can quickly remove the heat of the conductor 5 set in the first cavity 4, effectively reducing the heat generated by the conductor 5 during charging, extending the service life of the liquid-cooled cable, and improving the current carrying capacity of the conductor 5.

[0051] Meanwhile, coolant can also circulate in the first cavity 4. The coolant circulating in the first cavity 4 is in direct contact with the outer periphery of the conductor 5. The heat generated by the conductor 5 during charging can be carried away by the coolant in time, thereby reducing the temperature rise of the cable and improving the current carrying capacity of the conductor 5.

[0052] When a support connector 2 is set between the inner support tube 1 and the outer support tube 3, a first cavity 4 is formed. At least one conductor 5 is placed in the first cavity 4. At this time, the unique first cavity 4 and the inner liquid cooling tube can be used as the inlet channel and outlet channel of the coolant, respectively.

[0053] According to one embodiment of a liquid-cooled cable of the present disclosure, such as Figures 2 to 4As shown, there are multiple first cavities 4, which together form a first cooling circulation system. Each of the multiple first cavities 4 includes at least one first liquid inlet channel and at least one first liquid outlet channel.

[0054] By configuring multiple first cavities 4 into a first cooling circulation system, wherein at least one first cavity 4 is a first liquid inlet channel and at least one first cavity 4 is a first liquid outlet channel, when the cable needs further cooling, the coolant in the first cooling circulation system is circulated, thereby reducing the temperature rise of the cable and improving the current carrying capacity of the conductor.

[0055] When the liquid-cooled cable has multiple first cavities 4, the following situations exist:

[0056] In one embodiment, the liquid-cooled cable may have four first cavities 4, wherein a positive conductor and a negative conductor may be placed in any two first cavities 4 respectively, and one of these two first cavities 4 serves as the first liquid inlet channel of the first cooling circulation system, and the other serves as the first liquid outlet channel of the first cooling circulation system. The other two first cavities 4 are used to place the control line and the ground line respectively. Since the control line and the ground line do not generate heat during charging, the first cavities 4 containing the control line and the ground line do not need to be circulated with coolant.

[0057] In one embodiment, the liquid-cooled cable may have three first cavities 4, wherein a positive conductor and a negative conductor may be placed in any two of the first cavities 4, and one of these two first cavities 4 serves as the first liquid inlet channel of the first cooling circulation system, and the other serves as the first liquid outlet channel of the first cooling circulation system. The third first cavity 4 houses the control wire and the ground wire. Since the control wire and the ground wire do not generate heat during charging, the first cavity 4 housing the control wire and the ground wire may not be circulated with coolant.

[0058] In one embodiment: the liquid-cooled cable may have two first cavities 4, wherein a positive conductor and a negative conductor may be placed in any two first cavities 4 respectively, and one of the two first cavities 4 serves as the first liquid inlet channel of the first cooling circulation system, and the other serves as the first liquid outlet channel of the first cooling circulation system.

[0059] In one embodiment: the liquid-cooled cable may have more than four first cavities 4, wherein a conductor 5 placed in one or more of the first cavities 4 serves as a positive conductor, a conductor 5 placed in one or more of the first cavities 4 serves as a negative conductor, a conductor 5 placed in one or more of the first cavities 4 serves as a ground wire, and a conductor 5 placed in one or more of the first cavities 4 serves as a control wire. The first cavity 4 placed in the positive conductor serves as the first liquid inlet channel of the first cooling circulation system, and the remaining first cavities 4 placed in the positive conductor and the first cavity 4 placed in the negative conductor can serve as the first liquid outlet channel of the first cooling circulation system. The configuration of the first liquid inlet channel and the first liquid outlet channel allows for arbitrary combination of the first cavities 4 containing the positive and negative conductors as the first liquid inlet channel and the first liquid outlet channel of the first cooling circulation system, as needed.

[0060] The number of first cavities 4 is not specifically limited and can be set according to actual needs.

[0061] According to one embodiment of a liquid-cooled cable of the present disclosure, such as Figure 2 As shown, the liquid-cooled cable also includes an outer sheath 6 sleeved on the outside of the outer support tube 3 and at least one bracket 7 disposed between the outer support tube 3 and the outer sheath 6. The bracket 7 divides the space between the outer sheath 6 and the outer support tube 3 into at least one second cavity 8.

[0062] By providing an outer sheath 6, at least one second cavity 8 can be formed outside the first cavity 4. The second cavity 8 can accelerate the dissipation of heat from the conductor 5 in the first cavity 4. Coolant can flow through the second cavity 8, which can provide liquid cooling to the first cavity 4 from the outside. Coolant flows through both the second cavity 8 and the inner support tube 1, which can provide liquid cooling to the first cavity 4 from both the inside and outside, thereby improving the current carrying capacity of the conductor 5.

[0063] The first end of the bracket 7 is connected to the outer wall of the outer support tube 3, and the second end of the bracket 7 opposite to the first end is connected to the inner wall of the outer sheath 6. The bracket 7 supports the second cavity 8 in the radial direction of the inner support tube 1; or, the bracket 7 divides the space between the outer sheath 6 and the outer support tube 3 into at least one second cavity 8.

[0064] By supporting the second cavity 8 with bracket 7, the relative positional relationship between the outer support tube 3 and the outer sheath 6 can be ensured, keeping the second cavity 8 from deforming and ensuring the flow of coolant, so that the coolant can cool the first cavity 4 in a timely manner and improve the current carrying capacity of the liquid-cooled cable.

[0065] Furthermore, the inner support tube 1, the first cavity 4, and the second cavity 8 each include at least one liquid inlet channel and at least one liquid outlet channel.

[0066] By forming liquid inlet and liquid outlet channels in the inner support tube 1, at least one first cavity 4 and a second cavity 8, a complete liquid cooling system can be formed inside the cable, avoiding the need to add extra pipes outside the cable, which would complicate the cable structure and cause inconvenience to the user.

[0067] The inner support tube 1, the first cavity 4 and the second cavity 8 can be arbitrarily combined to form an inlet channel and an outlet channel to cool the liquid-cooled cable and improve the cable's current carrying capacity.

[0068] Furthermore, the total cross-sectional area of ​​the second cavity 8 accounts for 10%-40% of the cross-sectional area of ​​the liquid-cooled cable.

[0069] To verify the effect of the percentage of the total cross-sectional area of ​​the second cavity 8 to the area of ​​the liquid-cooled cable on the temperature rise of the cable, the inventors selected multiple liquid-cooled cables with the same cross-sectional area, material, and length. The multiple cables had external liquid-cooling pipes of the same size and were connected to the same current. For each experimental specimen, only the percentage of the total cross-sectional area of ​​the second cavity 8 to the cross-sectional area of ​​the liquid-cooled cable was adjusted. Coolant was circulated in the second cavity 8 to cool the cable, and the temperature rise value of each cable was read and recorded in Table 1.

[0070] The experimental method involves using cables in a closed environment with different percentages of the total cross-sectional area of ​​the second cavity 8 relative to the liquid-cooled cable area, conducting the same current, recording the temperature before energization and the temperature after stabilization, and taking the absolute value of the difference. In this embodiment, a temperature rise of less than 50K is considered acceptable.

[0071]

[0072] As can be seen from Table 1 above, when the total cross-sectional area of ​​the second cavity 8 accounts for less than 10% of the liquid-cooled cable area, the temperature rise value of the liquid-cooled cable is unqualified. When the total cross-sectional area of ​​the second cavity 8 accounts for more than or equal to 10% of the liquid-cooled cable area, the temperature rise value of the liquid-cooled cable is qualified. However, when the total cross-sectional area of ​​the second cavity 8 accounts for more than 40% of the liquid-cooled cable area, the temperature rise of the liquid-cooled cable does not decrease significantly. Moreover, the larger the percentage of the total cross-sectional area of ​​the second cavity 8 accounts for of the liquid-cooled cable area, the larger the outer diameter of the liquid-cooled cable. Increasing the percentage of the total cross-sectional area of ​​the second cavity 8 accounts for of the liquid-cooled cable area has lost its practical significance. Therefore, the inventors selected the percentage of the total cross-sectional area of ​​the second cavity 8 to account for of the liquid-cooled cable area as 10%-40%.

[0073] According to one embodiment of a liquid-cooled cable disclosed herein, the total cross-sectional area of ​​the brackets 7 accounts for 3%-20% of the cross-sectional area of ​​the second cavity 8.

[0074] To verify the ratio of the total cross-sectional area of ​​the bracket 7 to the total cross-sectional area of ​​the second cavity 8, the inventors selected multiple cables with different ratios but the same outer support tube 3, applied the maximum pressure that the cables could withstand during the design, and observed whether the cables deformed. If the cables did not deform, they were considered qualified. At the same time, the outer diameter of the cables was measured to see if it exceeded the standard diameter during the design. If it exceeded the standard diameter, it was considered unqualified.

[0075]

[0076] As can be seen from Table 2 above, when the ratio of the total cross-sectional area of ​​the brackets 7 to the cross-sectional area of ​​the second cavity 8 is less than 3%, the cable will deform under the maximum pressure it can withstand according to the cable design, which is considered an unacceptable ratio. When the ratio of the total cross-sectional area of ​​the brackets 7 to the cross-sectional area of ​​the second cavity 8 is greater than 20%, the outer diameter of the cable exceeds the standard diameter designed for the cable. Therefore, the ratio of the total cross-sectional area of ​​the brackets 7 to the cross-sectional area of ​​the second cavity 8 is also unacceptable. Therefore, the inventors selected a ratio of 3%-20% for the total cross-sectional area of ​​the brackets 7 to the cross-sectional area of ​​the second cavity 8.

[0077] Furthermore, the inner support tube 1 and at least one of the second cavities 8 form a second cooling circulation system, wherein one of the inner support tube 1 and at least one of the second cavities 8 is configured as a second liquid inlet channel and the other is configured as a second liquid outlet channel.

[0078] By using the inner support tube 1 and the second cavity 8 as a second cooling circulation system, one of which is a second liquid inlet channel and the other is a second liquid inlet channel, the coolant in the second cooling circulation system can be circulated according to the temperature rise of the cable during the charging process, thereby reducing the temperature rise of the cable and improving the current carrying capacity of the conductor 5.

[0079] Furthermore, the bracket 7 and / or the outer sheath 6 are made of metal.

[0080] When the material of the first cavity 4 is an insulating material, the outer periphery of the conductor 5 set in the first cavity 4 may not be provided with an insulating layer. In this case, the side wall of the first cavity 4 plays an insulating role, preventing electrical connection between wires with different functions, preventing the functional wires of the liquid-cooled cable from failing to perform their normal functions, and avoiding short circuit due to electrical connection between the positive and negative conductors.

[0081] The bracket 7 can be made of metal to ensure the stability of the second cavity 8 structure. At the same time, the outer sheath 6 made of metal can shield the conductor 5 located inside the first cavity 4, preventing electromagnetic waves or magnetic fields generated by the positive or negative conductor inside the liquid-cooled cable during the charging process from interfering with the normal operation of other control systems, or preventing signal transmission in the control lines inside the liquid-cooled cable from being distorted due to interference from other electromagnetic fields.

[0082] Furthermore, with an insulating layer covering the outside of the conductor 5, at least the outer support tube 3 and / or the outer sheath 6 are made of metal material, among the inner support tube 1, the outer support tube 3, the support connector 2, the bracket 7, and the outer sheath 6.

[0083] An insulating layer and a metal shielding layer can be sequentially provided around the outer periphery of conductor 5. When conductor 5 is used as a positive or negative conductor, this prevents electromagnetic waves or magnetic fields generated during the charging process from interfering with the normal operation of other control systems. Alternatively, when conductor 5 is used as a control line, this prevents signal transmission in the control line from being distorted due to interference from other electromagnetic fields. Even if the inner support tube 1, support connector 2, outer support tube 3, outer sheath 6, and bracket 7 are all made of metal, the insulating layer on the outside of conductor 5 can prevent electrical connections between conductors with different functions, prevent the functional conductors of the liquid-cooled cable from malfunctioning, and avoid short circuits caused by electrical connections between the positive and negative conductors.

[0084] By using metal materials for the outer support tube 3 and the outer sheath 6, the liquid-cooled cable can also achieve a double-layer shielding effect, preventing the electromagnetic waves or magnetic fields generated by the positive or negative conductors inside the liquid-cooled cable during the charging process from interfering with the normal operation of other control systems, or preventing the signal transmission in the control lines inside the liquid-cooled cable from being distorted due to interference from other electromagnetic fields.

[0085] When the supporting connector 2 and the inner supporting tube 1 are also made of metal, the cavity of the first cavity 4 is made of metal. The first cavity 4 can shield the conductor 5 set inside it, so as to prevent the electromagnetic waves or magnetic fields generated by the positive or negative conductor inside the liquid-cooled cable during the charging process from interfering with the normal use of other control systems, or to prevent the signal transmission in the control line inside the liquid-cooled cable from being distorted by other electromagnetic fields.

[0086] When the supporting connector 2 and the inner supporting tube 1 are also made of metal, the cavity of the first cavity 4 is made of metal. The conductor 5 can include the conductor 5 and the insulation layer from the inside out. In this case, the first cavity 4 made of metal can be used to shield the liquid-cooled cable.

[0087] The support 7 can be made of metal to ensure the stability of the second cavity 8 structure.

[0088] When both the cavity 4 and the outer sheath 6 are made of metal, the coolant is an insulating cooling medium to keep the conductors 5 in each of the first cavities 4 insulated from each other, ensuring the safe use of the cable and preventing electric shock accidents; alternatively, an insulating protective layer can be fitted on the outside of the outer sheath 6 to ensure the safe use of the cable and prevent electric shock accidents.

[0089] Furthermore, the support connector 2 is integrally formed with the inner support tube 1 and / or the outer support tube 3; and / or, the bracket 7 is integrally formed with the outer support tube 3 and / or the outer sheath 6.

[0090] By integrally forming the support connector 2 with at least one of the inner support tube 1 and the outer support tube 3, the stability of the connection structure between the inner support tube 1 and the outer support tube 3 can be increased. This avoids uneven stress between the outer support tube 3 and the inner support tube 1 due to changes in the position of the support connector 2, which would cause changes in the cross-section of each first cavity 4. Therefore, by integrally forming the support connector 2 with at least one of the inner support tube 1 and the outer support tube 3, changes in the cross-section of a certain part of the first cavity 4 can be avoided.

[0091] Similarly, the bracket 7 is integrally formed with at least one of the outer support tube 3 and the outer sheath 6, which can increase the stability of the connection structure between the outer support tube 3 and the outer sheath 6. This avoids uneven force between the outer sheath 6 and the outer support tube 3 due to changes in the position of the bracket 7, which would result in unequal distances between the outer wall of the outer support tube 3 and the inner wall of the outer sheath 6. This would prevent some brackets 7 from playing a supporting role, causing uneven flow of coolant in the second cavity 8 between the outer support tube 3 and the outer sheath 6. This would also prevent the coolant from carrying away the heat generated by the conductor 5 in a certain first cavity 4 in time, thus preventing the conductor 5 from overheating and improving the current carrying capacity of the conductor 5.

[0092] Furthermore, the bracket 7 is configured as a strip plate extending through the second cavity 8 in the axial direction. The first side of the strip plate is connected to the outer wall of the outer support tube 3, and the second side of the strip plate opposite to the first side is connected to the inner wall of the outer sheath 6.

[0093] The second cavities 8 on both sides of the bracket 7 are not connected at the strip plate. When more than two strip plates are set in the second cavity 8, the second cavities 8 on both sides of the strip plate are independent and not connected to each other.

[0094] Furthermore, the strip plate is provided with a plurality of first through holes 701, which connect the second cavities 8 on both sides of the bracket 7.

[0095] According to one embodiment of a liquid-cooled cable disclosed herein, the first end of the cross-section of the support connector 2 is connected to the outer wall of the inner support tube 1, and the second end of the cross-section of the support connector 2 opposite to the first end is connected to the inner wall of the outer support tube 3.

[0096] The first and second ends of the support connector 2 are fixedly connected to the outer wall of the inner support tube 1 and the inner wall of the outer support tube 3, respectively. This ensures that the liquid-cooled cable maintains a stable structure during dragging, pulling, and bending. It also prevents the cross-sectional area of ​​the first cavity 4 from increasing or decreasing during use, which would affect the flow of coolant and block the coolant in the first inlet or outlet channel. This would prevent the coolant from being blocked and affecting the circulation of the coolant, which would prevent the coolant from carrying away the heat generated by the conductor 5 in time during the charging process, thus affecting the current carrying capacity of the cable.

[0097] According to one embodiment of a liquid-cooled cable of the present disclosure, the number of the support connectors 2 is multiple, and the multiple support connectors 2 are evenly arranged along the circumferential direction of the inner support tube 1.

[0098] The support connector 2 is evenly arranged along the circumferential direction of the inner support tube 1, which makes the connection between the outer support tube 3 and the inner support tube 1 more secure and extends the service life of the liquid-cooled cable.

[0099] When the liquid-cooled cable has more than two first cavities 4, the positive and negative conductors are placed in two of the first cavities 4 respectively. This separates the positive and negative conductors, facilitating the connection of the cable to charging piles, charging guns, and other equipment. The other two first cavities 4 can house control wires or ground wires separately, ensuring that the conductors 5 for various functions in the cable are located in independent first cavities 4, preventing interference between them.

[0100] Multiple support connectors 2 are evenly distributed along the circumferential direction of the inner support tube 1. The included angle between each adjacent support connector 2 is equal. For example:

[0101] In one embodiment, the number of support connectors 2 can be two, and the two support connectors 2 are arranged opposite to each other.

[0102] In one embodiment, the number of support connectors 2 can be three, and the included angle between two adjacent support connectors 2 is 120°.

[0103] In one embodiment, the number of support connectors 2 can be four, and the included angle between two adjacent support connectors 2 is 90°.

[0104] The number of support connectors 2 is not limited and can be set according to actual needs.

[0105] According to one embodiment of a liquid-cooled cable disclosed herein, the support connector 2 is continuously disposed from one end to the other along the axial direction of the liquid-cooled cable.

[0106] By providing a support connector 2 that runs through the inner support tube 1 and the outer support tube 3 along the axis of the liquid cooling cable, the first cavity 4 is defined. This prevents adjacent first cavities 4 from communicating with each other at the location of the support connector 2, maintains the independence of each first cavity 4, and ensures that the coolant flowing in the first cavity 4 does not overflow into the adjacent first cavities 4.

[0107] According to one embodiment of a liquid-cooled cable disclosed herein, the cross-sectional area of ​​the inner support tube 1 accounts for 10%-30% of the cross-sectional area of ​​the liquid-cooled cable.

[0108] To verify the effect of the percentage of the cross-sectional area of ​​the inner support tube 1 to the cross-sectional area of ​​the liquid-cooled cable on the temperature rise of the cable, the inventors selected multiple liquid-cooled cables with the same cross-sectional area, material, and length, and conducted the same current. They adjusted the ratio of the cross-sectional area of ​​the inner support tube 1 to the cross-sectional area of ​​the liquid-cooled cable for each test piece, using different percentages of the cross-sectional area of ​​the inner support tube 1 to the cross-sectional area of ​​the liquid-cooled cable. Coolant was circulated in the inner support tube 1 to cool the cable, and the temperature rise value of each cable was read and recorded in Table 3.

[0109] The experimental method involves using cables with different percentages of the cross-sectional area of ​​the inner support tube 1 relative to the cross-sectional area of ​​the liquid-cooled cable in a closed environment, conducting the same current, recording the temperature before energization and the temperature after energization stabilizing, and taking the absolute value of the difference. In this embodiment, a temperature rise of less than 50K is considered acceptable.

[0110]

[0111] As can be seen from Table 3 above, when the percentage of the cross-sectional area of ​​the inner support tube 1 to the cross-sectional area of ​​the liquid-cooled cable is less than 10%, the temperature rise value of the liquid-cooled cable is unqualified. When the percentage of the cross-sectional area of ​​the inner support tube 1 to the cross-sectional area of ​​the liquid-cooled cable is greater than or equal to 10%, the temperature rise value of the liquid-cooled cable is qualified. However, when the percentage of the cross-sectional area of ​​the inner support tube 1 to the cross-sectional area of ​​the liquid-cooled cable is greater than 30%, the temperature rise of the liquid-cooled cable does not decrease significantly. Moreover, the larger the percentage of the cross-sectional area of ​​the inner support tube 1 to the cross-sectional area of ​​the liquid-cooled cable, the larger the outer diameter of the liquid-cooled cable. Or, even if the outer diameter of the liquid-cooled cable remains unchanged, the thinner the wire diameter of the conductor 5 set in the liquid-cooled cable, the easier the conductor 5 is to be damaged. Therefore, increasing the percentage of the cross-sectional area of ​​the inner support tube 1 to the cross-sectional area of ​​the liquid-cooled cable has lost its practical significance. Therefore, the inventors selected the percentage of the cross-sectional area of ​​the inner support tube 1 to the cross-sectional area of ​​the liquid-cooled cable as 10%-30%.

[0112] According to one embodiment of a liquid-cooled cable disclosed herein, the total cross-sectional area of ​​the first cavity 4 accounts for 10%-30% of the area of ​​the liquid-cooled cable.

[0113] To verify the effect of the percentage of the total cross-sectional area of ​​the first cavity 4 to the area of ​​the liquid-cooled cable on the temperature rise of the cable, the inventors selected multiple liquid-cooled cables with the same cross-sectional area, material, and length. The multiple cables had internal liquid-cooling pipes of the same size and were connected to the same current. The percentage of the total cross-sectional area of ​​the first cavity 4 to the area of ​​the liquid-cooled cable was adjusted only for each test piece. Coolant was circulated in the first cavity 4 to cool the cable, and the temperature rise value of each cable was read and recorded in Table 4.

[0114] The experimental method involves using cables in a closed environment with different percentages of the total cross-sectional area of ​​the first cavity 4 relative to the liquid-cooled cable area, conducting the same current, recording the temperature before and after stabilization, and taking the absolute value of the difference. In this embodiment, a temperature rise of less than 50K is considered acceptable.

[0115]

[0116] As can be seen from Table 4 above, when the total cross-sectional area of ​​the first cavity 4 accounts for less than 10% of the liquid-cooled cable area, the temperature rise value of the liquid-cooled cable is unqualified. When the total cross-sectional area of ​​the first cavity 4 accounts for more than or equal to 10% of the liquid-cooled cable area, the temperature rise value of the liquid-cooled cable is qualified. However, when the total cross-sectional area of ​​the first cavity 4 accounts for more than 30% of the liquid-cooled cable area, the temperature rise of the liquid-cooled cable does not decrease significantly. Moreover, the larger the percentage of the total cross-sectional area of ​​the first cavity 4 accounts for the liquid-cooled cable area, the larger the outer diameter of the liquid-cooled cable. Increasing the percentage of the total cross-sectional area of ​​the first cavity 4 accounts for the liquid-cooled cable area has lost its practical significance. Therefore, the inventors selected the percentage of the total cross-sectional area of ​​the first cavity 4 to the liquid-cooled cable area as 10%-30%.

[0117] According to one embodiment of a liquid-cooled cable disclosed herein, the ratio of the total cross-sectional area of ​​the supporting connector 2 to the total cross-sectional area of ​​the first cavity 4 is 3%-20%.

[0118] To verify the ratio of the total cross-sectional area of ​​the support connector 2 to the total cross-sectional area of ​​the first cavity 4, the inventors selected multiple liquid-cooled cables with the same cross-sectional area, material, and length. They adjusted only the ratio of the total cross-sectional area of ​​the support connector 2 to the total cross-sectional area of ​​the first cavity 4, but used multiple test pieces with the same inner support tube 1. They applied the maximum pressure that the cable could withstand during the cable design and observed whether the cable deformed. If the cable did not deform, it was considered qualified. At the same time, they measured whether the outer diameter of the cable exceeded the standard diameter during the cable design. If it exceeded the standard diameter, it was considered unqualified.

[0119]

[0120] As can be seen from Table 5 above, when the ratio of the total cross-sectional area of ​​the supporting connector 2 to the total cross-sectional area of ​​the first cavity 4 is less than 3%, the cable deformation under the maximum pressure that the cable can withstand during design is unacceptable. When the ratio of the total cross-sectional area of ​​the supporting connector 2 to the total cross-sectional area of ​​the first cavity 4 is greater than 20%, the outer diameter of the cable exceeds the standard diameter during cable design. Therefore, the ratio of the total cross-sectional area of ​​the supporting connector 2 to the total cross-sectional area of ​​the first cavity 4 is also unacceptable. Therefore, the inventors selected the ratio of the total cross-sectional area of ​​the supporting connector 2 to the total cross-sectional area of ​​the first cavity 4 to be 3%-20%.

[0121] According to one embodiment of a liquid-cooled cable of the present disclosure, the flow rate of the coolant is 0.5 ml / s-50 ml / s.

[0122] To verify the effect of the flow rate of coolant in the inner support tube 1, the first cavity 4, and the second cavity 8 on the temperature rise of the cable, the inventors selected multiple liquid-cooled cables with the same cross-sectional area, material, and length, and conducted the same current. The coolant was used to cool the liquid-cooled cables by passing through one of the inner support tube 1, the first cavity 4, and the second cavity 8 at different flow rates, and the temperature rise values ​​of each liquid-cooled cable were read and recorded in Table 6.

[0123] The experimental methods were conducted in the following three forms:

[0124] The first experimental method: In a closed environment, coolant is circulated through the inner support tube 1 at different flow rates while the same current is applied. The temperature before energizing and the temperature when the temperature stabilizes after energizing are recorded, and the absolute value of the difference is taken. In this embodiment, a temperature rise of less than 50K is considered acceptable.

[0125] The second experimental method: In a closed environment, only the coolant is circulated through the first cavity 4 at different flow rates (with a positive and a negative conductor installed in the first cavity 4), and the same current is applied. The temperature before energizing and the temperature when the temperature stabilizes after energizing are recorded, and the absolute value of the difference is taken. In this embodiment, a temperature rise of less than 50K is considered acceptable.

[0126] The second experimental method: In a closed environment, only the coolant is circulated through the second cavity 8 at different flow rates, while the same current is applied. The temperature before energizing and the temperature when the temperature stabilizes after energizing are recorded, and the absolute value of the difference is taken. In this embodiment, a temperature rise of less than 50K is considered acceptable.

[0127]

[0128] As can be seen from Table 6 above, when the flow rate of the coolant in any of the inner support tube 1, the first cavity 4 (where the positive and negative conductors are installed), and the second cavity 8 is greater than or equal to 0.5 ml / s, the temperature rise of the liquid-cooled cable is acceptable. However, when the flow rate is greater than 50 ml / s, the temperature rise of the liquid-cooled cable does not decrease significantly. Moreover, the higher the flow rate, the higher the quality requirements for the inner support tube 1, the outer support tube 3, the outer sheath 6, the support connector 2, and the quality requirements for the circulating pump or compressor that facilitates the flow of coolant. At this point, the temperature rise of the liquid-cooled cable no longer decreases significantly. Therefore, the inventors set the coolant flow rate to be between 0.5 ml / s and 50 ml / s.

[0129] According to one embodiment of a liquid-cooled cable of the present disclosure, the cooling rate of the coolant is greater than or equal to 0.2°C / min.

[0130] To verify the effect of the cooling rate of the coolant on the temperature rise of the liquid-cooled cable, the inventors selected multiple liquid-cooled cables with the same cross-sectional area, material, and length, and passed the same current through them. They used experimental specimens with different cooling rates in any of the following: inner support tube 1, first cavity 4 (in which positive and negative conductors are placed) and second cavity 8. The temperature rise values ​​of each liquid-cooled cable were then recorded in Table 7.

[0131] The experimental methods were conducted in the following three forms:

[0132] The first experimental method: In a closed environment, coolant with different cooling rates is circulated through the inner support tube 1. The same current is applied to each specimen, and the temperature before energization and the temperature at which the temperature stabilizes are recorded. The absolute value of the difference is then taken. In this embodiment, a temperature rise of less than 50K is considered acceptable.

[0133] The second experimental method: In a closed environment, only the specimens in the first cavity 4 (with a positive and a negative conductor installed in the first cavity 4) with different cooling rates are subjected to the same current. The temperature before energizing and the temperature when the temperature stabilizes after energizing are recorded, and the absolute value of the difference is taken. In this embodiment, a temperature rise of less than 50K is considered acceptable.

[0134] The second experimental method: In a closed environment, the same current is applied to each specimen in the second cavity 8 with different cooling rates. The temperature before energizing and the temperature when the temperature stabilizes after energizing are recorded, and the absolute value of the difference is taken. In this embodiment, a temperature rise of less than 50K is considered acceptable.

[0135]

[0136] As can be seen from Table 7 above, when the cooling rate of the coolant is less than 0.2 ℃ / min, the temperature rise of the liquid-cooled cable is unqualified; when the cooling rate of the coolant is greater than 0.2 ℃ / min, the temperature rise of the liquid-cooled cable is qualified. The higher the cooling rate of the coolant, the lower the temperature rise of the liquid-cooled cable. Therefore, the inventors set the cooling rate of the liquid-cooled cable to be greater than or equal to 0.2 ℃ / min.

[0137] According to one embodiment of a liquid-cooled cable disclosed herein, the support connector 2 is provided with a channel 201 along the axial direction of the liquid-cooled cable, and coolant flows through the channel 201.

[0138] A channel 201 can be set in the middle of the support connector 2, through which coolant can flow, which can reduce the temperature rise of the cable more quickly and the cooling effect of the liquid-cooled cable is better.

[0139] Furthermore, the outer support tube 3 corresponding to the channel 201 is provided with a second through hole 301, the second through hole 301 connects the second cavity 8 and the channel 201, the second through hole 301 extends continuously along the axial direction of the outer support tube 3, or the second through hole 301 is spaced apart along the axial direction of the cable.

[0140] When the bracket 7 can avoid the support connector 2, the support connector 2 can be provided with a channel 201, through which coolant can also flow. The outer support tube 3 corresponding to the channel 201 can be provided with a second through hole 301. The second through hole 301 connects the second cavity 8 and the channel 201. The channel 201 can be connected to the second cavity 8 through the second through hole 301, so that the connected second cavity 8 and the channel 201 can serve as either the second liquid inlet channel or the second liquid outlet channel of the second cooling circulation system.

[0141] While specific embodiments of the invention have been described in detail by way of examples, those skilled in the art should understand that the examples are for illustrative purposes only and not intended to limit the scope of the invention. Those skilled in the art should understand that modifications can be made to the above embodiments without departing from the scope and spirit of the invention. The scope of the invention is defined by the appended claims.

Claims

1. A liquid-cooled cable, characterized by, The liquid cooling cable comprises: an inner support tube, an outer support tube sleeved outside the inner support tube, and at least one support connecting piece arranged between the inner support tube and the outer support tube, the support connecting piece separating a space between the inner support tube and the outer support tube into at least one first cavity, the first cavity being provided with at least one conductor, the inner support tube and the at least one first cavity being used for flowing cooling liquid; the number of the first cavities is plural, the plural first cavities forming a first cooling circulation system, and the plural first cavities comprising at least one first liquid inlet channel and at least one first liquid outlet channel; the liquid cooling cable further comprises an outer sheath sleeved outside the outer support tube and at least one support bracket arranged between the outer support tube and the outer sheath, the support bracket separating a space between the outer sheath and the outer support tube into at least one second cavity; in the inner support tube, the first cavities and the second cavities, at least one liquid inlet channel and at least one liquid outlet channel are arranged; a ratio of a total cross-sectional area of the second cavities to a cross-sectional area of the liquid cooling cable is 10%-40%; a ratio of a total cross-sectional area of the support brackets to the total cross-sectional area of the second cavities is 3%-20%.

2. The liquid-cooled cable of claim 1, wherein, the inner support tube and the at least one second cavity form a second cooling circulation system, one of the inner support tube and the at least one second cavity being configured as a second liquid inlet channel and the other being configured as a second liquid outlet channel.

3. The liquid-cooled cable of claim 1, wherein, the material of the support bracket and / or the outer sheath is metal material.

4. The liquid-cooled cable of claim 1, wherein, in a state that an insulating layer is sleeved outside the conductor, the material of at least the outer support tube and / or the outer sheath among the inner support tube, the outer support tube, the support connecting piece, the support bracket and the outer sheath is metal material.

5. The liquid-cooled cable of claim 1, wherein, the support connecting piece is integrally formed with the inner support tube and / or the outer support tube; and / or the support bracket is integrally formed with the outer support tube and / or the outer sheath.

6. The liquid-cooled cable of claim 1, wherein, the support bracket is a strip-shaped plate arranged through the second cavities in an axial direction, a first side of the strip-shaped plate being connected with an outer wall of the outer support tube, and a second side opposite to the first side of the strip-shaped plate being connected with an inner wall of the outer sheath.

7. The liquid-cooled cable of claim 6, wherein, a plurality of first through holes are arranged on the strip-shaped plate, the first through holes being connected with the second cavities on both sides of the support bracket.

8. The liquid-cooled cable of claim 1, wherein, a first end of a cross section of the support connecting piece is connected with an outer wall of the inner support tube, and a second end opposite to the first end of the cross section of the support connecting piece is connected with an inner wall of the outer support tube.

9. The liquid-cooled cable of claim 1, wherein, the number of the support connecting pieces is plural, and the plural support connecting pieces are uniformly arranged along a circumferential direction of the inner support tube.

10. The liquid-cooled cable of claim 1, wherein, the support connecting pieces are continuously arranged through from one end to the other end of the liquid cooling cable in an axial direction of the liquid cooling cable.

11. The liquid-cooled cable of claim 1, wherein, a ratio of a cross-sectional area of the inner support tube to a cross-sectional area of the liquid cooling cable is 10%-30%.

12. The liquid-cooled cable of claim 1, wherein, a ratio of a total cross-sectional area of the first cavities to the cross-sectional area of the liquid cooling cable is 10%-30%.

13. The liquid-cooled cable of claim 1, wherein, a ratio of a total cross-sectional area of the support connecting pieces to the cross-sectional area of the first cavities is 3%-20%.

14. The liquid-cooled cable of claim 1, wherein, a flow rate of the cooling liquid is 0.5ml / s-50ml / s.

15. The liquid-cooled cable of claim 1, wherein, The cooling rate of the cooling liquid is greater than or equal to 0.2 ℃ / min.

16. The liquid-cooled cable of claim 1, wherein, The support connecting piece is provided with a channel in the axial direction of the liquid cooling cable, and the cooling liquid flows through the channel.

17. The liquid-cooled cable of claim 1, wherein, The outer support pipe corresponding to the channel is provided with a second through hole, the second through hole communicates the second cavity and the channel, and the second through hole is continuously arranged in the axial direction of the outer support pipe, or the second through hole is arranged at intervals in the axial direction of the cable.

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