Liquid-cooled charging cable and cable production process

Abstract

The application provides a liquid-cooled charging cable and a cable production process, which comprise a protective layer, a main cable core and a plurality of auxiliary cable cores, the protective layer comprises a plurality of supporting rings and a plurality of expansion rings, the plurality of supporting rings and the plurality of expansion rings are sequentially and spacedly connected together, and the expansion rings are made of elastic material; a plurality of elastic cooling rings are sleeved on the main cable core, the plurality of cooling rings correspond to the plurality of expansion rings one by one, and the cooling rings are located between the main cable core and the plurality of auxiliary cable cores; the plurality of cooling rings are connected through a refrigeration pipe group, an inlet valve is arranged at an inlet end of the refrigeration pipe group, and a discharge valve is arranged at a discharge end of the refrigeration pipe group; after the discharge end of the refrigeration pipe group is closed through the discharge valve, the cooling ring can be filled with refrigerant liquid to expand. Through expansion of the cooling ring, the plurality of auxiliary cable cores are supported apart, so that the main cable core and the auxiliary cable cores and two adjacent auxiliary cable cores can be separated, which is beneficial to heat dissipation of the main cable core and the auxiliary cable cores, and further improves the heat dissipation effect.

Description

Technical Field

[0001] This invention relates to the field of cables, and in particular to a liquid-cooled charging cable and a cable manufacturing process. Background Technology

[0002] Charging cables are a type of cable, mainly used in electric or hybrid vehicles to handle high-power charging.

[0003] Charging cables in related technologies typically include a protective layer, a main cable core, and multiple auxiliary cable cores. The main cable core and auxiliary cable cores are located within the protective layer, and the multiple auxiliary cable cores surround the main cable core.

[0004] When charging cables are in use, the main core and auxiliary cores generate a lot of heat. However, in related technologies, the main core and auxiliary cores are in close contact, and adjacent auxiliary cores are also in close contact. This makes it difficult for the heat between the main core and auxiliary cores, and between adjacent auxiliary cores, to dissipate quickly, resulting in poor heat dissipation. This can easily lead to overheating of the cable, affecting its service life, and needs to be improved. Summary of the Invention

[0005] In view of the shortcomings of the existing technology, the purpose of this invention is to provide a liquid-cooled charging cable and cable manufacturing process, which has the advantage of improving heat dissipation.

[0006] The above-mentioned technical objective of the present invention is achieved through the following technical solution: In a first aspect, this application provides a liquid-cooled charging cable, including a protective layer, a main cable core and a plurality of auxiliary cable cores. The protective layer includes a plurality of support rings and a plurality of expansion rings, wherein the plurality of support rings and the plurality of expansion rings are sequentially and spaced apart, and the expansion rings are made of an elastic material. The main cable core is fitted with multiple elastic cooling rings, each of which corresponds to one of the expansion rings, and the cooling rings are located between the main cable core and the multiple auxiliary cable cores. Multiple cooling rings are connected by a refrigeration pipe assembly. The inlet end of the refrigeration pipe assembly is equipped with an inlet valve, and the outlet end of the refrigeration pipe assembly is equipped with a outlet valve. After the outlet end of the refrigeration pipe assembly is closed by controlling the outlet valve, the cooling ring can be filled with refrigerant and expand.

[0007] Through the above technical solution, after the external refrigeration device is connected to the refrigeration components, the refrigerant flows within the refrigeration pipe assembly. The drain valve is closed periodically. When the drain valve is closed, the refrigerant can fill the cooling ring, causing it to expand. During the expansion of the cooling ring, the secondary cable core is stretched apart, separating it from the main cable core. At this time, the heat between the main and secondary cable cores, as well as the heat between adjacent secondary cable cores, can be quickly dissipated, thereby improving heat dissipation, reducing the risk of cable overheating, and ultimately improving the cable's safety and service life.

[0008] Furthermore, the refrigeration pipe assembly includes: An inlet pipe is used to connect to the drain end of an external cooling device, and the inlet valve is provided on the inlet pipe; A drain pipe is used to connect to the liquid inlet of an external cooling device, and the drain valve is provided on the drain pipe; There are multiple cooling pipes, each connected to each of the cooling rings; The cooling pipe is connected at both ends to the liquid inlet pipe and the liquid outlet pipe, respectively.

[0009] The above technical solution involves introducing refrigerant into the inlet pipe via an external refrigeration unit. The refrigerant then flows through multiple cooling pipes and is finally discharged through the drain pipe, returning to the external refrigeration unit, thus achieving refrigerant circulation. By setting multiple cooling pipes, the contact area with the main and auxiliary cable cores is increased, improving the cooling effect. Furthermore, each cooling pipe is connected to a cooling ring, allowing the cooling ring to expand rapidly when the drain valve is closed, thus enabling rapid heat dissipation.

[0010] Furthermore, the drain valve is equipped with a controller, which is used to control the intermittent opening and closing of the drain valve.

[0011] The above technical solution utilizes a controller to automatically close the drain valve at regular intervals, eliminating the need for manual operation and reducing the workload of staff while increasing automation.

[0012] Furthermore, the plurality of cooling pipes and the plurality of auxiliary cable cores are alternately distributed along the circumferential direction of the main cable core, and the plurality of cooling pipes are respectively located on the inner side of the cooling ring.

[0013] Through the above technical solution, the cooling pipes can surround the main cable core, increasing the contact area and contact time with the main cable core, thereby improving the heat dissipation effect on the main cable core. At the same time, the cooling pipes are distributed at intervals with the secondary cable cores, effectively improving the cooling effect on the secondary cable cores and also improving the cooling uniformity of the secondary cable cores, so that multiple secondary cable cores can be cooled simultaneously, improving the heat dissipation effect of the cable.

[0014] Furthermore, the outer surface of the cooling ring is uniformly connected with a plurality of expansion balls along its circumference. The plurality of expansion balls are alternately distributed with the plurality of secondary cable cores. After the expansion balls are filled with refrigerant and expand, they can be squeezed between two adjacent secondary cable cores.

[0015] With the above technical solution, when the cooling ring expands, multiple expansion balls can expand and squeeze into the space between two adjacent sub-cores, thereby temporarily separating the two adjacent sub-cores. This facilitates the rapid dissipation of heat between the two adjacent sub-cores and further improves the heat dissipation effect.

[0016] Furthermore, heat dissipation holes are provided on the expansion ring and the support ring respectively.

[0017] The above technical solution, by setting heat dissipation holes, facilitates the rapid dissipation of heat between the main cable core and the auxiliary cable core, thereby improving the heat dissipation effect of the cable.

[0018] Furthermore, the main cable core is fitted with multiple hollow heat dissipation rings, each of which corresponds to one of the multiple support rings. Multiple exhaust holes are evenly opened on the heat dissipation rings, and an air inlet pipe is connected to the heat dissipation rings, with the air inlet pipe extending to the outside of the support rings.

[0019] The above technical solution connects the air intake pipe to an external air supply device, and the external air supply device delivers cold air into the air intake pipe. The cold air is then discharged through multiple heat dissipation holes on the heat dissipation ring, thereby removing the heat between the main cable core and the auxiliary cable core and improving the heat dissipation effect.

[0020] Furthermore, a support frame is fixedly connected to the support ring, and a support ring is fixedly connected to the support frame. The support ring and the corresponding expansion ring are coaxial, and the expansion ring is located inside the support ring. The inner wall of the receiving ring is fixedly connected to an elastic airbag ring along its circumference, and the expansion ring can compress the airbag ring after expansion. An air inlet and an air outlet are connected to the airbag ring. The air outlet is connected to the air inlet pipe. A one-way valve is provided in the air inlet to ensure that external gas can only enter the airbag ring.

[0021] Through the above technical solution, when the cooling ring expands after being filled with refrigerant, the expansion ring expands outward under the action of the secondary cable core. At this time, the expansion ring can squeeze the airbag ring and compress it. Subsequently, the air inside the airbag ring enters the intake pipe through the exhaust port, thereby achieving air supply to the intake pipe. When the expansion ring returns to its original position, the airbag ring returns to its original position under its own elasticity, and external gas is filled into the airbag ring. This design allows the gas inside the airbag ring to automatically enter the heat dissipation ring after the expansion ring expands, eliminating the need for an external air supply device. This improves the linkage effect between components and also increases resource utilization efficiency.

[0022] Secondly, this application also provides a cable manufacturing process for producing liquid-cooled charging cables, comprising the following steps: S1, arrange the main cable core and multiple auxiliary cable cores neatly, and make the multiple auxiliary cable cores surround the main cable core; S2, a support ring is formed by injection molding on the outside of multiple sub-cores using an injection molding machine; S3, an expansion ring is formed by injection molding between two adjacent support rings using an injection molding machine.

[0023] In summary, the present invention has the following beneficial effects: 1. By utilizing the expansion of the cooling ring, multiple secondary cable cores are spread apart, thereby allowing the main cable core and secondary cable cores, as well as adjacent secondary cable cores, to separate. This facilitates the rapid dissipation of heat between the main cable core and secondary cable cores, thus improving the heat dissipation effect.

[0024] 2. By setting expansion balls, when the cooling ring expands, multiple expansion balls can expand and squeeze between two adjacent sub-cores, thereby temporarily separating the two adjacent sub-cores, which is conducive to the rapid dissipation of heat between the two adjacent sub-cores and further improves the heat dissipation effect.

[0025] 3. By setting heat dissipation holes, the heat between the main cable core and the auxiliary cable core can be quickly dissipated through the heat dissipation holes, thereby improving the heat dissipation effect of the cable. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the overall structure of Embodiment 1; Figure 2 This is a schematic diagram of the protective layer structure in Example 1; Figure 3 This is a cross-sectional view of Embodiment 1; Figure 4 This is a cross-sectional view of the expansion ring in Embodiment 1; Figure 5 yes Figure 3 Enlarged view of region A in the middle; Figure 6 yes Figure 3Enlarged schematic diagram of region B in the middle.

[0027] Reference numerals in the attached diagram: 1. Protective layer; 101. Support ring; 102. Expansion ring; 2. Main cable core; 3. Secondary cable core; 4. Heat dissipation hole; 5. Cooling ring; 6. Refrigeration pipe assembly; 61. Liquid inlet pipe; 62. Liquid outlet pipe; 63. Cooling pipe; 7. Liquid inlet valve; 8. Liquid outlet valve; 9. Controller; 10. Expansion ball; 11. Heat dissipation ring; 12. Exhaust hole; 13. Air inlet pipe; 14. Support frame; 15. Support ring; 16. Airbag ring; 17. Air inlet nozzle; 18. Exhaust nozzle; 19. One-way valve. Detailed Implementation

[0028] The present invention will be further described in detail below with reference to the accompanying drawings. Example 1:

[0029] Reference Figure 1 and Figure 2 A liquid-cooled charging cable includes a protective layer 1, a main cable core 2, and multiple auxiliary cable cores 3. The main cable core 2 and auxiliary cable cores 3 are located within the protective layer 1, and the multiple auxiliary cable cores 3 surround the main cable core 2. The protective layer 1 includes multiple support rings 101 and multiple expansion rings 102, which are sequentially and spaced apart. Each support ring 101 and expansion ring 102 has heat dissipation holes 4 to improve heat dissipation.

[0030] Reference Figure 3 and Figure 4 The expansion ring 102 is made of high-elastic rubber or other elastic material, and multiple elastic cooling rings 5 ​​are sleeved on the main cable core 2. The cooling rings 5 ​​are made of high-elastic latex or high-elastic rubber material. At the same time, the multiple cooling rings 5 ​​correspond one-to-one with the multiple expansion rings 102, and the cooling rings 5 ​​are located between the main cable core 2 and the multiple auxiliary cable cores 3.

[0031] Reference Figure 3 and Figure 4 Multiple cooling rings 5 ​​are connected by a refrigeration pipe assembly 6, which is used to connect to an external refrigeration device. The inlet end of the refrigeration pipe assembly 6 is equipped with an inlet valve 7, and the outlet end of the refrigeration pipe assembly 6 is equipped with a drain valve 8.

[0032] When the external refrigeration unit is connected to the refrigeration assembly, the refrigerant flows within the refrigeration pipe assembly 6. The drain valve 8 is closed periodically. When the drain valve 8 is closed, the refrigerant can fill the cooling ring 5, causing it to expand. During the expansion of the cooling ring 5, the secondary cable core 3 is opened, separating it from the main cable core 2. At this time, the heat between the main cable core 2 and the secondary cable core 3, as well as the heat between two adjacent secondary cable cores 3, can be quickly dissipated, thereby improving the heat dissipation effect.

[0033] Reference Figure 3, Figure 4 and Figure 5 The refrigeration pipe assembly 6 includes an inlet pipe 61, a drain pipe 62, and multiple cooling pipes 63. The inlet pipe 61 is connected to the drain end of an external cooling device, and an inlet valve 7 is installed on the inlet pipe 61. The drain pipe 62 is connected to the inlet end of an external cooling device, and a drain valve 8 is installed on the drain pipe 62. Meanwhile, both ends of the cooling pipes 63 are connected to the inlet pipe 61 and the drain pipe 62 respectively, and each cooling pipe 63 is connected to a cooling ring 5.

[0034] Refrigerant is introduced into the inlet pipe 61 by an external refrigeration unit, and then the refrigerant flows through multiple cooling pipes 63, and is finally discharged through the drain pipe 62 and flows back to the external refrigeration unit, thereby realizing the circulation of refrigerant.

[0035] Reference Figure 3 and Figure 5 The drain valve 8 is equipped with a controller 9, which is used to control the drain valve 8 to automatically close once every certain period of time, eliminating the need for staff to open and close the drain valve 8, reducing the burden on staff and improving the degree of automation.

[0036] Reference Figure 4 Multiple cooling pipes 63 and multiple auxiliary cable cores 3 are alternately distributed along the circumference of the main cable core 2, with the cooling pipes 63 located inside the cooling ring 5. The cooling pipes 63 surround the main cable core 2, increasing the contact area and contact time, thereby improving the heat dissipation effect on the main cable core 2. Simultaneously, the spaced distribution of the cooling pipes 63 and auxiliary cable cores 3 effectively improves the cooling effect on the auxiliary cable cores 3 and also enhances the uniformity of cooling, allowing multiple auxiliary cable cores 3 to be cooled simultaneously, thus improving the overall heat dissipation of the cable.

[0037] Reference Figure 4 Multiple elastic expansion balls 10 are uniformly connected along the circumference of the outer surface of the cooling ring 5. The expansion balls 10 are made of high-elastic latex material. The multiple expansion balls 10 are alternately distributed with multiple secondary cable cores 3, and after the expansion balls 10 are filled with refrigerant and expand, they can be squeezed between two adjacent secondary cable cores 3.

[0038] When the cooling ring 5 expands, multiple expansion balls 10 can expand and squeeze into the space between two adjacent sub-cores 3, thereby temporarily separating the two adjacent sub-cores 3, which is conducive to the rapid dissipation of heat between the two adjacent sub-cores 3 and further improves the heat dissipation effect.

[0039] Reference Figure 3 and Figure 6Multiple hollow heat dissipation rings 11 are fitted on the main cable core 2. Each heat dissipation ring 11 corresponds to a support ring 101. Multiple exhaust holes 12 are evenly opened on the heat dissipation ring 11. An air inlet pipe 13 is connected to the heat dissipation ring 11 and extends to the outside of the support ring 101.

[0040] The air inlet pipe 13 is connected to an external air supply device, and cold air is sent into the air inlet pipe 13 through the external air supply device. Then the cold air is discharged through multiple heat dissipation holes 4 on the heat dissipation ring 11, thereby carrying away the heat between the main cable core 2 and the auxiliary cable core 3, thus improving the heat dissipation effect.

[0041] Reference Figure 3 and Figure 6 A support frame 14 is fixedly connected to the support ring 101, and a support ring 15 is fixedly connected to the support frame 14. The support ring 15 and the corresponding expansion ring 102 are coaxial, and the expansion ring 102 is located inside the support ring 15.

[0042] Reference Figure 3 and Figure 6 An elastic airbag ring 16 is fixedly connected to the inner wall of the receiving ring 15 along its circumference, and the expansion ring 102 can compress the airbag ring 16 after expansion. An air inlet 17 and an exhaust 18 are connected to the airbag ring 16. The exhaust 18 is connected to the air inlet pipe 13. A one-way valve 19 is provided in the air inlet 17, so that external gas can only enter the airbag ring 16.

[0043] When the cooling ring 5 expands after being filled with refrigerant, the expansion ring 102 expands outward under the action of the auxiliary cable core 3. At this time, the expansion ring 102 can squeeze the airbag ring 16, causing the airbag ring 16 to compress. Subsequently, the air inside the airbag ring 16 enters the air intake pipe 13 through the exhaust nozzle 18, thereby achieving air supply to the air intake pipe 13. When the expansion ring 102 returns to its original position, the airbag ring 16 returns to its original position under the action of its own elasticity, and external gas fills the airbag ring 16. Example 2:

[0044] A cable manufacturing process for producing the liquid-cooled charging cable of Example 1 includes the following steps:

[0045] S1, the cooling ring 5 and the heat dissipation ring 11 are respectively fitted onto the main cable core 2, and then the main cable core 2, multiple auxiliary cable cores 3 and multiple cooling pipes 63 and other components are neatly arranged in their corresponding positions, and the multiple auxiliary cable cores 3 are tightly surrounded around the main cable core 2. Subsequently, the main cable core 2 and auxiliary cable cores 3 and other components are pre-positioned by means of cable ties and other devices.

[0046] S2, a support ring 101 is formed by injection molding on the outside of multiple secondary cable cores 3 using an injection molding machine. At this time, the support ring 101 can wrap the main cable core 2 and secondary cable cores 3 and other components. Then, heat dissipation holes 4 are opened on the support ring 101 by a hole-opening device.

[0047] S3, an expansion ring 102 is formed by injection molding between two adjacent support rings 101 using an injection molding machine. At this time, the support rings 101 and the expansion rings 102 together form a protective layer 1 to protect components such as the main cable core 2. Then, heat dissipation holes 4 are opened on the expansion rings 102 using a hole-opening device.

[0048] S4. By connecting the receiving frame 14 to the support ring 101 and installing components such as the airbag ring 16, the production and processing of cables can be realized.

[0049] This specific embodiment is merely an explanation of the present invention and is not intended to limit the invention. After reading this specification, those skilled in the art can make modifications to this embodiment without contributing any inventive step, but such modifications are protected by patent law as long as they are within the scope of the claims of the present invention.

Claims

1. A liquid-cooled charging cable, comprising a protective layer (1), a main cable core (2), and a plurality of auxiliary cable cores (3), characterized in that: The protective layer (1) includes a plurality of support rings (101) and a plurality of expansion rings (102), wherein the plurality of support rings (101) and the plurality of expansion rings (102) are connected together in sequence at intervals, and the expansion rings (102) are made of elastic material; Multiple elastic cooling rings (5) are fitted on the main cable core (2), and the multiple cooling rings (5) correspond one-to-one with the multiple expansion rings (102), and the cooling rings (5) are located between the main cable core (2) and the multiple auxiliary cable cores (3); Multiple cooling rings (5) are connected by a refrigeration pipe assembly (6). The inlet end of the refrigeration pipe assembly (6) is equipped with an inlet valve (7), and the outlet end of the refrigeration pipe assembly (6) is equipped with an outlet valve (8). After the outlet end of the refrigeration pipe assembly (6) is closed by the outlet valve (8), the cooling ring (5) can be filled with refrigerant and expand. The expansion ring (102) and the support ring (101) are respectively provided with heat dissipation holes (4); The main cable core (2) is fitted with a plurality of hollow heat dissipation rings (11), and the plurality of heat dissipation rings (11) correspond one-to-one with the plurality of support rings (101). The heat dissipation rings (11) are evenly provided with a plurality of exhaust holes (12), and the heat dissipation rings (11) are connected to an air inlet pipe (13), and the air inlet pipe (13) extends to the outside of the support rings (101). A support frame (14) is fixedly connected to the support ring (101), and a support ring (15) is fixedly connected to the support frame (14). The support ring (15) is coaxial with the corresponding expansion ring (102), and the expansion ring (102) is located inside the support ring (15). An elastic airbag ring (16) is fixedly connected to the inner wall of the receiving ring (15) along its circumference, and the expansion ring (102) can compress the airbag ring (16) after expansion. An air inlet (17) and an exhaust nozzle (18) are connected to the airbag ring (16). The exhaust nozzle (18) is connected to the air inlet pipe (13). A one-way valve (19) is provided in the air inlet (17) so that external gas can only enter the airbag ring (16).

2. The liquid-cooled charging cable according to claim 1, characterized in that: The refrigeration pipe assembly (6) includes: The liquid inlet pipe (61) is used to connect to the drain end of the external cooling device, and the liquid inlet valve (7) is provided on the liquid inlet pipe (61); A drain pipe (62) is used to connect to the liquid inlet of an external cooling device, and the drain valve (8) is provided on the drain pipe (62); Multiple cooling pipes (63) are connected to each of the cooling rings (5); The two ends of the cooling pipe (63) are respectively connected to the liquid inlet pipe (61) and the liquid outlet pipe (62).

3. The liquid-cooled charging cable according to claim 2, characterized in that: The drain valve (8) is equipped with a controller (9), which is used to control the intermittent opening and closing of the drain valve (8).

4. The liquid-cooled charging cable according to claim 2, characterized in that: Multiple cooling pipes (63) and multiple secondary cable cores (3) are alternately distributed along the circumferential direction of the main cable core (2), and the multiple cooling pipes (63) are respectively located on the inner side of the cooling ring (5).

5. The liquid-cooled charging cable according to claim 2, characterized in that: The outer surface of the cooling ring (5) is uniformly connected with a plurality of expansion balls (10) along its circumference. The plurality of expansion balls (10) and the plurality of sub-cable cores (3) are alternately distributed. After the expansion balls (10) are filled with refrigerant and expand, they can be squeezed into the space between two adjacent sub-cable cores (3).

6. A cable manufacturing process for producing liquid-cooled charging cables according to any one of claims 1-5, characterized in that: Includes the following steps: S1, arrange the main cable core (2) and multiple auxiliary cable cores (3) neatly, and make the multiple auxiliary cable cores (3) surround the main cable core (2); S2, a support ring (101) is formed by injection molding on the outside of multiple sub-cores (3) using an injection molding machine; S3, an expansion ring (102) is formed by injection molding between two adjacent support rings (101) using an injection molding machine.

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