A liquid-cooled charging gun cable

Abstract

The present invention relates to the field of charging cable technology, and in particular to a liquid-cooled charging gun cable. It includes an outer cable sheath, wherein at least two charging cores are wrapped in the outer cable sheath, and a cooling tube is sleeved on the outer surface of the charging core, and an insulating coolant can flow in the cooling tube, and the charging core is immersed in the insulating coolant as a whole; the outer surface of the charging core is covered with a metal sintered layer, and the surface of the metal sintered layer is a rough surface. The present invention reconstructs the surface structure of the charging core, and covers the outer surface of the charging core with a metal sintered layer. The metal sintered layer can increase the heat transfer area between the charging core and dimethyl silicone oil, thereby improving the heat exchange effect; at the same time, the metal sintered layer can increase the local turbulence of the dimethyl silicone oil, and the local turbulence can increase the fluidity of the dimethyl silicone oil, thereby further improving the heat exchange effect.

Description

Technical Field

[0001] The present invention relates to the technical field of charging cables, and in particular to a liquid-cooled charging gun cable. Background Art

[0002] Existing charging gun cables are specifically divided into two types: 1. A traditional charging gun cable that relies on natural cooling and uses two copper core cables (DC cables) with specified cross-sectional areas and multiple small-diameter core wires twisted together and then extruded into a cable with plastic or rubber materials when the rated current is determined according to national standards; 2. A water-cooled charging gun cable that adds liquid cooling pipes to the internal gaps in the internal basic structure of the traditional charging gun cable and uses coolant circulation to cool it down.

[0003] In the prior art, the traditional charging gun line is composed of copper cables and does not have a temperature regulation function. It can only dissipate heat by natural convection. However, the charging gun line needs to select the copper core cross-sectional area required by the DC cable according to the rated current it carries. The larger the required current, the higher the heat generated by the cable. Only DC cables with larger cross-sectional areas can be selected, which makes the traditional charging gun line have large outer diameter, heavy overall weight, inconvenient use, and high manufacturing cost. The existing traditional solutions have too low an upper limit on the carrying current. 250A is already the recognized limit carrying current of the traditional charging gun. The water-cooled charging gun line adds a cooling tube 3 on the basis of the traditional gun line. Figure 1 When working, the heat generated by the cable is taken away by the circulation of water or other coolant in the cooling tube 3, thereby increasing the maximum current that can be carried compared to the traditional gun wire. Summary of the invention

[0004] In response to the shortcomings in the above-mentioned existing production technology, the present application provides a liquid-cooled charging gun cable, in which a metal sintered layer is covered on the outer surface of the charging cable core. The metal sintered layer can increase the heat transfer area between the charging cable core and the dimethyl silicone oil, thereby improving the heat exchange effect; at the same time, the metal sintered layer can increase the local turbulence of the dimethyl silicone oil, and the local turbulence can increase the fluidity of the dimethyl silicone oil, thereby further improving the heat exchange effect.

[0005] The technical solution adopted by the present invention is as follows:

[0006] A liquid-cooled charging gun cable comprises an outer cable sheath, wherein at least two charging wire cores are wrapped in the outer cable sheath, a cooling tube is sleeved on the outer surface of the charging wire core, an insulating coolant can flow in the cooling tube, and the charging wire core is completely immersed in the insulating coolant; the outer surface of the charging wire core is covered with a metal sintered layer, and the surface of the metal sintered layer is a rough surface.

[0007] Furthermore, a plurality of signal wires are wrapped in the outer sheath of the cable, and the signal wires are used to transmit control signals.

[0008] Furthermore, an insulating filler is arranged in the outer sheath of the cable, and the insulating filler is filled in the gap between the charging cable core and the outer sheath of the cable.

[0009] Furthermore, the metal sintered layer is made of copper or aluminum, and the thickness of the metal sintered layer is 1-2 mm.

[0010] Furthermore, the metal sintered layer is a copper powder sintered layer. The copper powder sintered layer uses copper powder to sinter on the surface of the charging cable core and the outer surface of the charging cable core. The surface of the copper powder sintered layer has a capillary structure.

[0011] Furthermore, the preparation steps of the copper powder sintered layer are as follows: first, use sandpaper to polish the outer surface of the charging cable core to remove the burrs on the outer surface of the charging cable core; then, place the polished charging cable core in 25% by mass dilute sulfuric acid and use ultrasonic cleaning for 8 to 10 minutes; then, insert the cleaned charging cable core into the ceramic tube, the charging cable core must be precisely fixed in the center of the ceramic tube, and then close one end of the ceramic tube, pour the copper powder into the ceramic tube, and after filling, close the other end of the ceramic tube, and then take the ceramic tube to the sintering furnace for sintering. During the sintering process, the peak temperature range of the sintering furnace is 815~825℃, and the sintering time is 55~65min; finally, place the charging cable core in the air after sintering for natural cooling to form a copper powder sintered layer on the surface of the charging cable core. The thickness of the copper powder sintered layer ranges from 1 to 2mm, and the thickness of the charging cable core is controlled by the inner diameter of the ceramic tube.

[0012] Furthermore, the metal sintered layer is a copper mesh sintered layer, and the copper mesh sintered layer is sintered on the outer surface of the charging cable core using a copper mesh, and the surface of the copper mesh sintered layer has a mesh structure.

[0013] Furthermore, the preparation steps of the copper mesh sintered layer are as follows: first, use sandpaper to polish the outer surface of the charging cable core to remove burrs on the outer surface of the charging cable core; then, place the polished charging cable core in 25% by mass dilute sulfuric acid and use ultrasonic cleaning for 8 to 10 minutes; then, wrap the copper mesh on the cleaned outer surface of the charging cable core, and then take it to the sintering furnace to sinter the copper mesh. During the sintering process, the peak temperature range of the sintering furnace is 815 to 825°C, and the sintering time is 55 to 65 minutes; finally, place the sintered charging cable core in the air for natural cooling to form a copper mesh sintered layer on the surface of the charging cable core, and the thickness of the copper mesh sintered layer ranges from 1 to 2 mm.

[0014] Furthermore, the number of layers of the copper mesh wrapped around the charging cable core is less than 10 layers.

[0015] Furthermore, the insulating coolant uses dimethyl silicone oil.

[0016] The beneficial effects of the present invention are as follows:

[0017] The present invention reconstructs the surface structure of the charging cable core and covers a metal sintered layer on the outer surface of the charging cable core. The metal sintered layer can increase the heat transfer area between the charging cable core and dimethyl silicone oil, thereby improving the heat exchange effect; at the same time, the metal sintered layer can increase the local turbulence of the dimethyl silicone oil, and the local turbulence can increase the fluidity of the dimethyl silicone oil, thereby further improving the heat exchange effect; the metal sintered layer of the present invention covers the surface of the charging cable core without changing or increasing the main structure of the charging cable core. Under the same current intensity, the cross-sectional size of the charging cable core can be further reduced, thereby increasing the current carrying capacity of the charging cable core. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 This is a schematic diagram of the cross-section of a liquid-cooled charging gun cable in the prior art.

[0019] Figure 2 It is a schematic cross-sectional view of the liquid-cooled charging gun cable of the present invention.

[0020] Figure 3 This is a half-section diagram of a cable according to Embodiment 1 of the present invention.

[0021] Figure 4 This is a half-section diagram of a cable according to Embodiment 2 of the present invention.

[0022] Among them: 1. Cable outer sheath; 2. Charging cable core; 3. Cooling tube; 4. Signal line; 5. Metal sintered layer; 6. Copper powder sintered layer; 7. Copper mesh sintered layer. DETAILED DESCRIPTION

[0023] The specific implementation of the present invention will be described below in conjunction with the accompanying drawings.

[0024] like Figure 2 As shown, a liquid-cooled charging gun cable includes a cable outer sheath 1, at least two charging cores 2 are wrapped in the cable outer sheath 1, and a cooling tube 3 is sleeved on the outer surface of the charging core 2. Insulating coolant can flow in the cooling tube 3, and the insulating coolant is dimethyl silicone oil. The charging core 2 is immersed in the insulating coolant as a whole. When the charging core 2 is working, it generates heat. The outer surface of the charging core 2 contacts the insulating coolant for heat exchange, thereby taking away the heat generated by the charging core 2 in time.

[0025] like Figure 2 As shown, a plurality of signal wires 4 are wrapped in the cable outer sheath 1, and the signal wires 4 are used to transmit control signals.

[0026] like Figure 2 As shown, an insulating filler is arranged in the cable outer sheath 1 , and the insulating filler is filled in the gap between the charging cable core 2 and the cable outer sheath 1 .

[0027] like Figure 2As shown, the outer surface of the charging cable core 2 is covered with a metal sintered layer 5, and the surface of the metal sintered layer 5 is a rough surface. The rough surface of the metal sintered layer 5 can increase the heat transfer area between the charging cable core 2 and the dimethyl silicone oil, thereby improving the heat exchange effect. At the same time, although the dimethyl silicone oil has a better heat dissipation effect than water, it has poor fluidity. The rough surface of the metal sintered layer 5 can increase the local turbulence of the dimethyl silicone oil, and the local turbulence can increase the fluidity of the dimethyl silicone oil, thereby further improving the heat exchange effect.

[0028] The metal sintered layer 5 can be made of copper or aluminum with good thermal conductivity, and the thickness of the metal sintered layer 5 is 1-2 mm.

[0029] The metal sintered layer 5 covers the surface of the charging cable core 2 without changing or increasing the main structure of the charging cable core 2. Under the same current intensity, the cross-sectional size of the charging cable core 2 can be further reduced, thereby increasing the current carrying capacity of the charging cable core 2. Embodiment 1:

[0030] like Figure 3 As shown, the metal sintered layer 5 is a copper powder sintered layer 6. The copper powder sintered layer 6 uses copper powder to sinter on the surface of the charging core 2. The surface of the copper powder sintered layer 6 is a capillary structure. The capillary structure can increase the heat transfer area between the charging core 2 and the dimethyl silicone oil, thereby improving the heat exchange effect. At the same time, the capillary structure can increase the local turbulence of the dimethyl silicone oil, and the local turbulence can increase the fluidity of the dimethyl silicone oil, thereby further improving the heat exchange effect.

[0031] The steps for preparing the copper powder sintered layer 6 are as follows:

[0032] 1. Use sandpaper to polish the outer surface of the charging cable core 2 and remove the burrs on the outer surface of the charging cable core 2;

[0033] 2. Place the polished charging cable core 2 in 25% by mass dilute sulfuric acid and use ultrasonic cleaning for 8 to 10 minutes;

[0034] 3. Insert the cleaned charging core 2 into the ceramic tube. The charging core 2 must be precisely fixed in the center of the ceramic tube. Then close one end of the ceramic tube. Pour copper powder into the ceramic tube. After filling, close the other end of the ceramic tube. Then take the ceramic tube to the sintering furnace for sintering. During the sintering process, the peak temperature range of the sintering furnace is 815~825℃, and the sintering time is 55~65min.

[0035] The copper powder is spherical copper powder with a purity of 99.5%, and the particle size of the copper powder monomer ranges from 4 to 6 microns.

[0036] 4. After sintering, the charging cable core 2 is placed in the air for natural cooling, and a copper powder sintered layer 6 is formed on the surface of the charging cable core 2. The thickness of the copper powder sintered layer 6 ranges from 1 to 2 mm. The thickness of the charging cable core 2 is controlled by the inner diameter of the ceramic tube. Embodiment 2:

[0037] like Figure 4 As shown, the metal sintered layer 5 is a copper mesh sintered layer 7. The copper mesh sintered layer 7 is sintered on the outer surface of the charging cable core 2 using a copper mesh. The surface of the copper mesh sintered layer 7 has a mesh structure. The mesh structure can increase the heat transfer area between the charging cable core 2 and the dimethyl silicone oil, thereby improving the heat exchange effect. At the same time, the mesh structure can increase the local turbulence of the dimethyl silicone oil, and the local turbulence can increase the fluidity of the dimethyl silicone oil, thereby further improving the heat exchange effect.

[0038] The steps for preparing the copper mesh sintered layer 7 are as follows:

[0039] Use sandpaper to polish the outer surface of the charging cable core 2 to remove the burrs on the outer surface of the charging cable core 2;

[0040] Place the polished charging cable core 2 in 25% by mass dilute sulfuric acid and use ultrasonic cleaning for 8 to 10 minutes;

[0041] The copper mesh is wound around the outer surface of the cleaned charging cable core 2, and then taken to a sintering furnace to sinter the copper mesh. During the sintering process, the peak temperature range of the sintering furnace is 815-825°C, and the sintering time is 55-65 minutes.

[0042] After sintering, the charging cable core 2 is placed in the air for natural cooling, and finally a copper mesh sintered layer 7 is formed on the surface of the charging cable core 2, and the thickness of the copper mesh sintered layer 7 is in the range of 1 to 2 mm.

[0043] Copper mesh usually uses high-purity copper, such as C11000 oxygen-free copper, to ensure good thermal conductivity and corrosion resistance. The size of the copper mesh holes usually ranges from tens of microns to hundreds of microns, depending on the application requirements. Common specifications include 200 mesh, 300 mesh, etc. The porosity of the copper mesh refers to the proportion of the mesh to the entire copper mesh area, usually between 30% and 70%. The number of layers of copper mesh wrapped around the charging cable core 2 is less than 10.

[0044] The present invention provides a liquid-cooled charging gun line, which adopts an oil-copper cooling scheme to immerse the charging core 2 in dimethyl silicone oil. The shape of the traditional charging core 2 is a prototype twisted round cable. The present invention reconstructs the outer surface of the charging core 2, and covers the outer surface of the charging core 2 with a metal sintered layer 5. The metal sintered layer 5 can be sintered on the surface of the charging core 2 using copper powder to form a copper powder sintered layer 6, and the surface of the copper powder sintered layer 6 has a capillary structure. The capillary structure can increase the heat transfer area between the charging core 2 and the dimethyl silicone oil, thereby improving the heat exchange effect. At the same time, the capillary structure can increase the local turbulence of the dimethyl silicone oil, and the local turbulence can increase the fluidity of the dimethyl silicone oil, thereby further improving the heat exchange effect. The metal sintered layer 5 can also be sintered on the outer surface of the charging core 2 using a copper mesh, and the surface of the copper mesh sintered layer 7 has a mesh structure, which can increase the heat transfer area between the charging core 2 and the dimethyl silicone oil, thereby improving the heat exchange effect. At the same time, the mesh structure can increase the local turbulence of dimethyl silicone oil, and the local turbulence can improve the fluidity of dimethyl silicone oil, thereby further improving the heat exchange effect. The metal sintered layer 5 provided in the present invention does not change or increase most of the structure of the charging cable core 2, and can further reduce the cross-section of the cable under high current load.

[0045] The above description is an explanation of the present invention, not a limitation of the present invention. The scope of the present invention is defined in the claims. Any form of modification may be made within the scope of protection of the present invention.

Claims

1. A liquid-cooled charging gun cable, comprising a cable outer sheath (1), characterized in that: At least two charging cores (2) are wrapped in the cable outer sheath (1), and a cooling tube (3) is sleeved on the outer surface of the charging core (2). An insulating coolant can flow in the cooling tube (3), and the charging core (2) is completely immersed in the insulating coolant; the outer surface of the charging core (2) is covered with a metal sintered layer (5), the surface of the metal sintered layer (5) is a rough surface, the thickness of the metal sintered layer (5) is 1-2 mm, and the metal sintered layer (5) is a copper powder sintered layer (6) or a copper mesh sintered layer (7).

2. A liquid-cooled charging gun cable according to claim 1, characterized in that: A plurality of signal wires (4) are wrapped in the cable outer sheath (1), and the signal wires (4) are used to transmit control signals.

3. A liquid-cooled charging gun cable according to claim 2, characterized in that: An insulating filler is arranged inside the cable outer sheath (1), and the insulating filler is filled in the gap between the charging cable core (2) and the cable outer sheath (1).

4. A liquid-cooled charging gun cable according to claim 1, characterized in that: The copper powder sintered layer (6) is made of copper powder sintered on the outer surface of the charging cable core (2), and the surface of the copper powder sintered layer (6) has a capillary structure.

5. A liquid-cooled charging gun cable according to claim 4, characterized in that: The steps for preparing the copper powder sintered layer (6) are as follows: first, the outer surface of the charging cable core (2) is polished with sandpaper to remove the burrs on the outer surface of the charging cable core (2); then, the polished charging cable core (2) is placed in 25% by mass dilute sulfuric acid and ultrasonically cleaned for 8 to 10 minutes; then, the cleaned charging cable core (2) is inserted into a ceramic tube, and the charging cable core (2) must be accurately fixed at the center of the ceramic tube, and then one end of the ceramic tube is sealed, and copper powder is poured into the ceramic tube. After the filling is completed, the other end of the ceramic tube is sealed, and then the ceramic tube is taken to a sintering furnace for sintering. During the sintering process, the peak temperature range of the sintering furnace is 815 to 825°C, and the sintering time is 55 to 65 minutes; finally, after sintering, the charging cable core (2) is placed in the air for natural cooling, and a copper powder sintered layer (6) is formed on the surface of the charging cable core (2), and the thickness of the charging cable core (2) is controlled by the inner diameter size of the ceramic tube.

6. A liquid-cooled charging gun cable according to claim 1, characterized in that: The copper mesh sintered layer (7) is made of copper mesh sintered on the outer surface of the charging cable core (2), and the surface of the copper mesh sintered layer (7) has a mesh structure.

7. A liquid-cooled charging gun cable according to claim 6, characterized in that: The steps for preparing the copper mesh sintered layer (7) are as follows: first, use sandpaper to polish the outer surface of the charging cable core (2) to remove burrs on the outer surface of the charging cable core (2); then, place the polished charging cable core (2) in 25% by mass dilute sulfuric acid and use ultrasonic cleaning for 8 to 10 minutes; then, wrap the copper mesh around the cleaned outer surface of the charging cable core (2), and then take it to a sintering furnace to sinter the copper mesh. During the sintering process, the peak temperature range of the sintering furnace is 815 to 825°C, and the sintering time is 55 to 65 minutes; finally, place the sintered charging cable core (2) in the air for natural cooling to form a copper mesh sintered layer (7) on the surface of the charging cable core (2).

8. A liquid-cooled charging gun cable according to claim 7, characterized in that: The number of layers of the copper mesh wound around the charging cable core (2) is less than 10.

9. The liquid-cooled charging gun cable according to claim 1, characterized in that: The insulating coolant is dimethyl silicone oil.

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