A flexible high-power charging cable for new energy vehicles and a preparation method thereof

Abstract

The application discloses a flexible high-power charging cable for new energy vehicles and a preparation method, and relates to the field of new energy vehicles. The flexible high-power charging cable for new energy vehicles prepared by the application comprises, from inside to outside, a reinforced cable core layer, a wrapping tape layer and a sheath. The reinforced cable core layer comprises a cable core and a reinforcing unit. The reinforcing unit is arranged inside the cable core. The cable core comprises a ground wire core, a control wire core group, a power wire core and a return flow pipe. The power wire core comprises, from inside to outside, a power wire core conductor, a copper wire braiding layer, a cooling liquid flow channel, a supporting unit and a cooling pipe. The supporting unit is obtained by continuously dipping and sintering a supporting conductor with nano-isolating heat insulation paint. The return flow pipe and the cooling pipe are made of AEM rubber vulcanized by an inner-outer double-steam vulcanization process. The cooling pipe and the return flow pipe in the flexible high-power charging cable for new energy vehicles are long, soft, good in toughness, easy to bend, good in anti-blast performance and long in service life.

Description

Technical Field

[0001] This invention relates to the field of new energy vehicles, specifically to a flexible high-power charging cable for new energy vehicles and its preparation method. Background Technology

[0002] In recent years, with the rapid development of new energy vehicles, the charging speed has greatly affected the user experience, and the utilization efficiency of charging piles is also low. Traditional DC charging cables have a current of no more than 250A and a charging time of more than 2 hours. Therefore, technicians have tried to increase the charging speed by increasing the conductor cross-section, but this method increases the weight of the charging cable, making it very inconvenient to use.

[0003] Technicians have discovered that liquid cooling can significantly increase current carrying capacity, reduce the diameter and weight of charging cables, and improve the user experience. However, liquid-cooled high-power charging cables are prone to bending, dragging, and coiling during use, which can easily lead to the cooling pipe and connector detaching, cooling pipe rupture, and liquid leakage. This can cause core breakage during movement and use, and the stability of the cooling liquid flow also affects the cooling effect on the conductor, posing a significant safety hazard for charging new energy vehicles.

[0004] Therefore, existing technology produces a cable that, from the inside out, comprises a cable core, a wrapping tape, and a sheath. The cable core contains a reinforcement unit and includes a ground core, a control core group, a power core, and a return tube. The ground core is a single unit located at one end inside the wrapping tape. Two power cores are located on one side of the ground core, and the control core group is located on both sides of the ground core. The return tube is located on the side of the power core furthest from the ground core. The reinforcement unit connects the charging pile and the connector, and it withstands tensile forces, effectively preventing the power core insulation from detaching, the return tube from the connector from falling off, and the control core from breaking during mobile use. However, during the use of this cable, technicians discovered that the heat from the power conductor in the power core of the cable would be transferred to the inner wall surface of the cooling tube through the support conductor, causing the cooling tube to be scalded and thus shortening its service life. Furthermore, the cooling tube and return tube are made of radiation-crosslinked polyolefin or fluoroplastic with a Shore A hardness of 95~97. The high hardness means that the tube cannot recover after being bent at 90° and is difficult to bend, making it difficult to install the cooling tube into the gun and resulting in a poor user experience for customers.

[0005] Therefore, the technicians solved this problem by using high-strength AEM rubber, which has high heat resistance, high resistance to cooling media, high burst force, high flexibility, good toughness, and easy bending. However, when manufacturing cooling pipes and return pipes with AEM rubber, the technicians found that the mandrel could not be extracted due to long-distance production, and the longest production length did not exceed 10 meters. Moreover, the long rubber pipes prepared by this method were extremely prone to vulcanization deformation and had a large number of pores inside the pipe wall. The burst force at room temperature was only 6~8 bar, which greatly affected the mechanical properties of the cooling pipe and shortened its service life.

[0006] Therefore, it is necessary to design a flexible high-power charging cable for new energy vehicles with long cooling pipes and return pipes that have excellent properties such as high flexibility, good toughness, easy bending, and good mechanical properties, and to develop its preparation method. Summary of the Invention

[0007] To address existing technical problems, this invention provides a flexible high-power charging cable for new energy vehicles, comprising, from the inside out, a reinforcing core layer, a wrapping tape, and a sheath; the reinforcing core layer includes a cable core and a reinforcing unit; the reinforcing unit is disposed inside the cable core; the cable core includes a ground core, a control core group, a power core, and a return tube; the ground core is located at one end inside the wrapping tape, two power cores are disposed on one side of the ground core, the control core group is disposed on both sides of the ground core, and the return tube is located on the side of the power core away from the ground core.

[0008] The power core consists of a power core conductor, a copper wire braided layer, a cooling liquid channel, and a cooling pipe, arranged sequentially from the inside out. The return pipe and cooling pipe employ a dual steam vulcanization process. This process solves the problems of conventional methods, such as extruding AEM rubber onto a mandrel and then vulcanizing it under high-pressure steam, which prevents the mandrel from being extracted during long-distance production, limiting production to short sections, and also addresses issues like deformation and internal porosity in long rubber tubes.

[0009] Preferably or optionally, the material of the wrapping tape is lightweight non-woven fabric with an overlap rate of 15-25%; the reinforcing unit is bulletproof yarn of 15,000-25,000 denier.

[0010] Preferably or optionally, the ground wire core includes, from the inside out, a ground conductor and ground insulation; Preferably or optionally, the control core group includes at least 4 control core units, each control core unit including 4 control core conductors and control core insulation from the inside out; the cable core also includes a control core unit pair; each control core unit pair is composed of two control core units; there is at least one control core unit pair; the control core unit pair is disposed in the gap between the ground core, the power core, and the return tube.

[0011] Preferably or optionally, the power conductor also includes at least one support unit; the support unit is disposed inside the cooling liquid flow channel and spirally wound on the copper wire braid layer, effectively preventing the power conductor from contacting the cooling pipe wall and causing the cooling pipe to be scalded; the support unit includes a support conductor and a support insulation from the inside out; the support insulation is made of nano-insulating heat insulation coating.

[0012] Preferably or optionally, the nano-insulating heat-insulating coating is prepared by mixing 64-69.5% liquid silicone, 10-15% nano-tungsten oxide, 20% TiO2, and 0.5-1% 2,4-dichloroperoxybenzoyl by mass fraction. The present invention uses 2,4-dichloroperoxybenzoyl for cross-linking, and a chemical cross-linking reaction occurs at 250-300℃, which is different from the high-temperature physical melting and sintering method on the market. It has a lower temperature and lower energy consumption.

[0013] Preferably or optionally, the cooling liquid flow channel and return pipe are circulated with cooling liquid; the cooling liquid includes a mixture of dimethyl silicone oil, machine oil, water and ethylene glycol; the present invention cools the power conductor by circulating cooling liquid in the gap between the cooling pipe and the power conductor, i.e., the cooling liquid flow channel, thereby increasing the current carrying capacity.

[0014] Preferably or optionally, the cooling pipe and return pipe are made of peroxide-cured AEM rubber, which meets the requirements of retaining ≥70% of tensile strength and elongation at break after aging in hot air at 135℃ for 7 days, retaining ≥70% of tensile strength and elongation at break after immersion in cooling liquid at 120℃ for 7 days, and having a swelling rate ≤10%; the peroxide is dicumyl peroxide or di-tert-butyl peroxide; the use of vulcanized AEM rubber to prepare the cooling pipe solves the problems of high hardness, difficulty in bending, and poor toughness of cooling pipes and return pipes made of irradiated cross-linked polyolefin materials, while greatly improving the flexibility of the cable, allowing for assembly in a smaller space and improving the customer experience.

[0015] This invention also provides a method for preparing a flexible high-power charging cable for new energy vehicles, comprising the following preparation steps: Step 1: Determine the structure and material selection for the flexible high-power charging cable for new energy vehicles as described above; Step 2: Fabricate the ground conductor, control conductor, and power conductor; Step 3: Fabricate the cooling pipes and return pipes; Step 4: Extrude the ground wire insulation outside the ground wire conductor to obtain the ground wire core; extrude the control wire insulation outside the control wire core conductor to obtain the control wire core unit; Step 5: Irradiate crosslinking to the ground wire insulation and control wire core insulation, and perform internal and external double steam vulcanization process on the cooling pipe and return pipe; Step Six: Braid a copper wire layer around the power conductor core; Step 7: Coat the support conductor with support insulation to prepare the support unit, and spirally wind the support conductor around the copper wire braid layer; Step 8: Install the cooling pipe over the supporting conductor; Step 9: The control core units are divided into groups and cabled to form control core pairs and control core groups; Step 10: Assemble the reinforcement unit, ground wire core, control wire core group, power wire core, control wire core pair and return tube into a cable, and wrap it with wrapping tape, with an overlap rate of 15~25%; Step 11: Extrude the outer sheath around the packaging tape at an extrusion temperature of 150~170℃.

[0016] Preferably or optionally, the method for performing internal and external double steam vulcanization on the cooling pipe and the return pipe is as follows: the cooling pipe and the return pipe are arranged horizontally in a spiral in the vulcanization tank, the cooling pipe and the return pipe are filled with steam at a pressure of 1~3 bar, the two ends of the cooling pipe and the return pipe are sealed, the vulcanization tank is filled with steam at a pressure of 5~10 bar, and maintained for 5~15 minutes to complete the vulcanization of the cooling pipe and the return pipe.

[0017] Preferably or optionally, the specific steps for preparing the support unit by coating the support conductor with support insulation are as follows: continuously impregnating the support conductor with a nano-insulating heat-insulating coating and sintering it at a temperature of 250~350℃ for 10 minutes to prepare the support unit; this can avoid changes in the flow rate of the cooling liquid channel due to cable bending or external mechanical pressure, and effectively prevent the power conductor from contacting the cooling pipe wall and causing the cooling pipe to be scalded while ensuring a stable and excellent cooling effect.

[0018] Compared with the prior art, the beneficial effects of the present invention are as follows: (1) The cooling pipe and return pipe of the present invention are prepared by internal and external double steam vulcanization process, which can solve the problems of conventional extrusion of AEM rubber on the mandrel and vulcanization in high pressure steam, which makes it impossible to extract the mandrel during long-distance production, with the longest production length not exceeding 10 meters, as well as the problems of deformation of long rubber pipes and air holes inside the pipe wall. The cooling pipe and return pipe produced by the internal and external double steam vulcanization process of the present invention can reach 100m and have good burst resistance. The cable of the present invention has higher flexibility, better toughness, and is easier to bend.

[0019] (2) The cooling pipe and return pipe of the present invention are made of AEM rubber material, which has high heat resistance, high resistance to cooling medium, high burst resistance, high flexibility, good toughness and easy bending. The cooling pipe and return pipe made of irradiated cross-linked polyolefin material have a Shore A hardness of 95~97, cannot recover after 90° bending, are not easy to bend and have poor toughness. However, the cooling pipe and return pipe made of AEM rubber material have a Shore A hardness of 80~82, and can recover after 90° bending. At the same time, the flexibility of the cable is greatly improved, which can be assembled in a smaller space and improve the customer experience.

[0020] (3) The present invention uses a nano-insulating heat-insulating coating on the surface of the supporting conductor, a continuous dip coating process and sintering, and the supporting conductor is spirally wound around the copper wire braid layer. This avoids the flow rate change of the cooling liquid channel due to cable bending or external mechanical pressure, ensuring a stable and excellent cooling effect. At the same time, it effectively avoids the problem in the prior art where the supporting conductor will transfer the heat of the power conductor to the inner wall surface of the cooling pipe, causing the cooling pipe to be scalded, thereby shortening the service life of the cooling pipe.

[0021] (4) The present invention cools the power conductor by passing cooling liquid through the gap between the cooling pipe and the power conductor, i.e., the cooling liquid flow channel, thereby increasing the current carrying capacity.

[0022] (5) The nano-insulating heat insulation coating of the present invention uses 2,4-dichlorobenzoyl peroxide for cross-linking, and a chemical cross-linking reaction occurs at 250~300℃, which is different from the high-temperature physical melting and sintering method on the market. It has a low temperature and low energy consumption.

[0023] (6) The cooling pipe and return pipe of the flexible high-power charging cable for new energy vehicles prepared by the present invention are long, soft, tough, easy to bend, and have a long service life. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the structure of the flexible high-power charging cable for new energy vehicles according to the present invention. Figure 2 This is a structural diagram showing the arrangement of the cooling pipes in the vulcanizing tank according to the present invention.

[0025] The attached diagram is labeled as follows: Reinforcement unit 1, Cable core 2, Ground core 21, Ground conductor 21-1, Ground insulation 21-2, Control core group 22, Control conductor 22-1, Control insulation 22-2, Power core 23, Power conductor 23-1, Copper wire braided layer 23-2, Cooling liquid channel 23-3, Support conductor 23-4, Support insulation 23-5 and Cooling pipe 23-6, Return pipe 24, Wrapping tape 3, Sheath 4, Vulcanizing tank 5. Detailed Implementation

[0026] The present invention will be further described in detail below with reference to the accompanying drawings and embodiments, but the following embodiments should not be construed as limiting the present invention. Example

[0027] See Figure 1 This embodiment of a flexible high-power charging cable for new energy vehicles includes, from the inside out, a reinforcing core layer, a wrapping tape 3, and a sheath 4. The reinforcing core layer includes a cable core 2 and a reinforcing unit 1. The reinforcing unit 1 is disposed inside the cable core 2. The cable core 2 includes a ground core 21, a control core group 22, a power core 23, and a return pipe 24. The ground core 21 is located at one end inside the wrapping tape 3. Two power cores 23 are disposed on one side of the ground core 21, and the control core group 22 is disposed on both sides of the ground core 21. The side of the power core 23 away from the ground core 21 is the return pipe 24. The power core 23 is arranged from the inside out... The cable includes a power conductor core 23-1, a copper wire braided layer 23-2, a cooling liquid channel 23-3, and a cooling pipe 23-6. The return pipe 24 and the cooling pipe 23-6 are produced using an internal and external double steam vulcanization process. This process solves the problems of conventional methods, such as extruding AEM rubber onto a mandrel and then vulcanizing it under high-pressure steam, which makes it impossible to remove the mandrel during long-distance production, limiting the maximum production length to no more than 10 meters, and causing deformation and pores inside the pipe wall in long-length rubber tubes. The present invention uses an internal and external double steam vulcanization process to produce 100-meter cooling pipes and return pipes. The cable of the present invention has higher flexibility, better toughness, and is easier to bend.

[0028] In this embodiment, the wrapping tape 3 is made of lightweight non-woven fabric with an overlap rate of 15-25%.

[0029] In this embodiment, the reinforcement unit 1 is a bulletproof wire of 15,000 to 25,000 denier.

[0030] In this embodiment, the ground wire core 21 includes, from the inside out, a ground wire conductor 21-1 and a ground wire insulator 21-2; The control core assembly 22 in this embodiment includes at least four control core units. Each control core unit includes four control core conductors 22-1 and control core insulation 22-2 from the inside out. The cable core also includes a control core unit pair. Each control core unit pair is composed of two control core units. The control core unit pair is disposed in the gap between the ground core 21, the power core 23 and the return tube 24.

[0031] The power core 23 in this embodiment also includes at least one support unit; the support unit is disposed inside the cooling liquid flow channel 23-3 and spirally wound on the copper wire braid layer 23-2; the support unit includes a support conductor 23-4 and a support insulation 23-5 from the inside out; the support insulation 23-5 is made of nano-insulating heat-insulating coating; this solves the problem in the prior art where the support conductor transfers heat from the power conductor to the inner wall surface of the cooling pipe, causing the cooling pipe to be scalded, thereby shortening the service life of the cooling pipe; the nano-insulating coating... The insulating coating is prepared by mixing 64-69.5% liquid silicone, 10-15% nano-tungsten oxide, 20% TiO2, and 0.5-1% 2,4-dichloroperoxybenzoyl by mass fraction. Crosslinking is performed using 2,4-dichloroperoxybenzoyl at 250-300℃, a chemical crosslinking reaction occurring at this temperature. This method differs from the high-temperature physical melting and sintering method used in the market, resulting in lower temperatures and lower energy consumption.

[0032] In this embodiment, the cooling liquid flow channel 23-3 and the return pipe 24 are circulated with cooling liquid; the cooling liquid includes a mixture of dimethyl silicone oil, machine oil, water and ethylene glycol.

[0033] The cooling pipes 23-6 and return pipes 24 in this embodiment are made of peroxide-cured AEM rubber, which meets the requirements of retaining ≥70% of tensile strength and elongation at break after aging in hot air at 135℃ for 7 days, retaining ≥70% of tensile strength and elongation at break after immersion in cooling liquid at 120℃ for 7 days, and having a swelling rate ≤10%. The peroxide is dicumyl peroxide or di-tert-butyl peroxide. The AEM rubber material has high heat resistance, high resistance to cooling media, high burst resistance, high flexibility, good toughness, and is easy to bend. Cooling pipes and return pipes made of irradiated cross-linked polyolefin materials have a Shore A hardness of 95~97, cannot recover after a 90° bend, are not easy to bend, and have poor toughness. However, the cooling pipes and return pipes made of AEM rubber material have a Shore A hardness of 80~82, and can recover after a 90° bend. At the same time, the flexibility of the cable is greatly improved, which can be assembled in a smaller space and improve the customer experience.

[0034] This embodiment provides a method for preparing a flexible high-power charging cable for new energy vehicles, which includes the following preparation steps: Step 1: Determine the structure and material selection for the flexible high-power charging cable for new energy vehicles as described in this embodiment; Step 2: Fabricate ground conductor 21-1, control conductor 22-1, and power conductor 23-1; Step 3: Fabricate cooling pipe 23-6 and return pipe 24; Step 4: Extrude ground wire insulation 21-2 outside ground wire conductor 21-1 to obtain ground wire core 21; extrude control wire insulation 22-2 outside control wire core conductor 22-1 to obtain control wire core unit; Step 5: Irradiate crosslinking to ground wire insulation 21-2 and control wire core insulation 22-2, and perform internal and external double steam vulcanization process on cooling pipe 23-6 and return pipe 24; Step 6: Braid a copper wire braid layer 23-2 around the power conductor 23-1; Step 7: Coat the supporting conductor 23-4 with supporting insulation 23-5 to prepare the supporting unit. That is, continuously impregnate the supporting conductor 23-4 with a nano-insulating heat-insulating coating and sinter at a temperature of 250~350℃ for 10 minutes to prepare the supporting unit. This method is different from the high-temperature physical melting sintering method on the market. It has a lower temperature and lower energy consumption. The supporting conductor 23-4 is spirally wound around the copper wire braided layer 23-2. Step 8: Fit the cooling pipe 23-6 over the supporting conductor 23-4; Step 9: The control core unit is divided into groups and cabled to form control core pairs and control core groups 22; Step 10: Assemble the reinforcement unit 1, ground wire core 21, control wire core group 22, power wire core 23, control wire core pair and return tube 24 into a cable with an assembly pitch of 200~300mm and wrap it with wrapping tape 3. Step 11: Wrap the outer sheath 4 around the packaging tape 3 and extrude it at an extrusion temperature of 150~170℃. In this embodiment, the preferred extrusion temperature is 165±5℃.

[0035] The method for performing internal and external double steam vulcanization on cooling pipe 23-6 and return pipe 24 in this embodiment is as follows: Cooling pipe 23-6 and return pipe 24 are as follows... Figure 2 The horizontal spiral arrangement shown is in the vulcanizing tank 5. The cooling pipes 23-6 and the return pipe 24 are filled with steam at a pressure of 1~3 bar. The two ends of the cooling pipes 23-6 and the return pipe 24 are sealed. The vulcanizing tank 5 is filled with steam at a pressure of 5~10 bar. In this embodiment, the preferred vulcanizing tank 5 is filled with steam at a pressure of 8±1 bar. The process is maintained for 5~15 minutes to complete the vulcanization of the cooling pipes 23-6 and the return pipe 24. Conventionally, AEM rubber is extruded onto a mandrel and then vulcanized in high-pressure steam. When preparing cooling pipes and return pipes, it is impossible to remove the mandrel for long-distance production, so only short sections of 10m can be produced. In addition, long-length rubber pipes are deformed and there are pores inside the pipe wall. The bursting force at room temperature is only 6~8 bar. The cooling pipes and return pipes prepared by the internal and external double steam vulcanization process of this invention can be as long as 100 meters without deformation, and there are no pores inside the pipe wall. The bursting force at room temperature is 12~16 bar.

[0036] It should also be noted that the various specific technical features described in the above embodiments can be combined in any suitable manner without contradiction. To avoid unnecessary repetition, the present invention will not describe the various possible combinations separately.

Claims

1. A flexible high-power charging cable for new energy vehicles, characterized in that, From the inside out, it includes a reinforcing core layer, a wrapping tape (3), and a sheath (4); the reinforcing core layer includes a cable core (2) and a reinforcing unit (1); the reinforcing unit (1) is disposed inside the cable core (2); The cable core (2) includes a ground core (21), a control core group (22), a power core (23), and a return tube (24); the ground core (21) is located at one end inside the wrapping tape (3), two power cores (23) are provided on one side of the ground core (21), and the control core group (22) is provided on both sides of the ground core (21). The side of the power core (23) away from the ground core (21) is the return tube (24); The power core (23) includes, from the inside out, a power core conductor (23-1), a copper wire braided layer (23-2), a cooling liquid channel (23-3), and a cooling pipe (23-6); the power core (23) also includes a support unit, which is disposed inside the cooling liquid channel (23-3); The power core (23) includes at least one support unit; the support unit is spirally wound on a copper wire braided layer (23-2); the support unit includes a support conductor (23-4) and a support insulation (23-5) from the inside out; the support insulation (23-5) is made of a nano-insulating heat-insulating coating; the nano-insulating heat-insulating coating is prepared by mixing 64-69.5% liquid silicone, 10-15% nano tungsten oxide, 20% TiO2, and 0.5-1% 2,4-dichlorobenzoyl peroxide by mass fraction; The return pipe (24) and cooling pipe (23-6) are made of AEM rubber material using an internal and external double steam vulcanization process.

2. The flexible high-power charging cable for new energy vehicles according to claim 1, characterized in that, The reinforcing unit (1) is a bulletproof wire of 15,000 to 25,000 denier; the ground core (21) includes a ground conductor (21-1) and a ground insulation (21-2) from the inside to the outside.

3. The flexible high-power charging cable for new energy vehicles according to claim 1, characterized in that, The control core group (22) includes at least 4 control core units, and the control core unit includes 4 control core conductors (22-1) and control core insulation (22-2) from the inside to the outside; the cable core also includes a control core unit pair; the control core unit pair is composed of two control core units; the control core unit pair is disposed in the gap between the ground core (21), the power core (23) and the return tube (24).

4. The flexible high-power charging cable for new energy vehicles according to claim 1, characterized in that, The cooling liquid flow channel (23-3) and return pipe (24) are circulated with cooling liquid; the cooling liquid includes a mixture of dimethyl silicone oil, machine oil, water and ethylene glycol.

5. A flexible high-power charging cable for new energy vehicles according to claim 1, characterized in that, The cooling pipe (23-6) and the return pipe (24) are made of peroxide-cured AEM rubber, which meets the requirements of retaining ≥70% of tensile strength and elongation at break after aging in hot air at 135℃ for 7 days, retaining ≥70% of tensile strength and elongation at break after immersion in cooling liquid at 120℃ for 7 days, and having a swelling rate ≤10%; the peroxide is dicumyl peroxide or di-tert-butyl peroxide (DTBP).

6. A method for preparing a flexible high-power charging cable for new energy vehicles, characterized in that, The preparation process includes the following steps: Step 1: Determine the structure and material selection of the flexible high-power charging cable for new energy vehicles as described in any one of claims 1 to 5; Step 2: Make the ground conductor (21-1), control conductor (22-1), and power conductor (23-1); Step 3: Fabricate the cooling pipe (23-6) and the return pipe (24); Step 4: Extrude ground insulation (21-2) outside ground conductor (21-1) to obtain ground core (21); Extrude control core insulation (22-2) outside control core conductor (22-1) to obtain control core unit; Step 5: Irradiate crosslinking to the ground wire insulation (21-2) and control wire core insulation (22-2), and perform internal and external double steam vulcanization process on the cooling pipe (23-6) and return pipe (24); Step 6: Braid a copper wire braid (23-2) around the power conductor (23-1); Step 7: Coat the support insulation (23-5) on the outside of the support conductor (23-4) to prepare the support unit, and spirally wind the support conductor (23-4) around the outside of the copper wire braid layer; Step 8: Place the cooling pipe (23-6) over the supporting conductor (23-4); Step 9: The control core unit is divided into groups and cabled to form control core pairs and control core groups (22). Step 10: Assemble the reinforcement unit (1), ground wire core (21), control wire core group (22), power wire core (23), control wire core pair and return tube (24) into a cable and wrap it with wrapping tape (3). Step 11: Wrap the strap (3) around the outer sheath (4).

7. A method for preparing a flexible high-power charging cable for new energy vehicles according to claim 6, characterized in that, The method for performing internal and external double steam vulcanization on the cooling pipe (23-6) and return pipe (24) is as follows: the cooling pipe (23-6) and return pipe (24) are arranged horizontally in a spiral in the vulcanizing tank (5), the cooling pipe (23-6) and return pipe (24) are filled with steam at a pressure of 1~3 bar, the two ends of the cooling pipe (23-6) and return pipe (24) are sealed, the vulcanizing tank (5) is filled with steam at a pressure of 5~10 bar, and maintained for 5~15 minutes to complete the vulcanization of the cooling pipe (23-6) and return pipe (24).

8. A method for preparing a flexible high-power charging cable for new energy vehicles according to claim 6, characterized in that, The specific steps for preparing the support unit by coating the support conductor (23-4) with support insulation (23-5) are as follows: continuously dip-coating the support conductor (23-4) with nano-insulating heat insulation coating and sintering at a temperature of 250~350℃ for 10 min to prepare the support unit.

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