Small-section filling-free liquid-cooled cable

Abstract

The invention relates to the field of new energy charging cables, and discloses a small-section filling-free liquid-cooled cable, which comprises two main power wire cores, a control wire group and a signal wire group are respectively bunched in conductors of the two main power wire cores, the two main power wire cores and a ground wire are tightly pressed and twisted to form a cable body, and the two main power wire cores and the ground wire are tightly twisted to form the cable body. The ground wire is tightly pressed in the center of the cable body by the two main power wire cores, a cooling pipe is spirally wrapped outside the cable body, and an outer sheath is extruded outside the cooling pipe. According to the invention, the problem that the overall manufacturing cost is high due to the fact that a large amount of insulating materials must be used for meeting the requirements of large-current transmission, efficient heat dissipation and strict insulation protection in an existing liquid cooling charging cable, and the sectional area is large can be solved.

Description

Technical Field

[0001] The present invention relates to the field of new energy charging cables, and in particular to a small-section non-filled liquid-cooled cable. Background Art

[0002] With the vigorous development of the new energy vehicle industry, efficient and fast charging technology has become one of the key factors driving the continuous progress in this field. As an important bridge connecting charging equipment and electric vehicles, the performance of new energy charging cables is directly related to charging efficiency, safety and cost-effectiveness. Especially in high-power fast charging scenarios, charging cables must not only be able to withstand high-load operation caused by high currents, but also effectively manage the heat generated to ensure the safety and stability of the charging process. Therefore, liquid-cooled charging cables came into being, and with their excellent heat dissipation performance, they have become an effective solution to the challenge of high-current charging.

[0003] Existing liquid-cooled charging cables are usually designed to include multiple key structures such as the main power line core, liquid cooling circulation pipeline, insulation layer, protective layer, etc. Among them, the main power line core is responsible for transmitting large currents and is the core component for achieving fast charging. In order to ensure that it can carry high-rated charging currents, the main power line core must be designed with a large cross-sectional area, which directly leads to a significant increase in the overall heat generation of the cable. In order to effectively dissipate heat, the liquid cooling circulation pipeline is embedded in the cable, and the heat is removed through the circulating cooling medium (such as water, ethylene glycol, etc.) to maintain the cable operating temperature within a safe range.

[0004] However, the main power line core with a large cross-sectional area not only increases the heat generation, but also places higher requirements on insulation protection. The insulation layer needs to be made of high-performance materials to ensure that it does not break down under high electric field strength, and at the same time has good heat resistance to prevent aging and failure due to long-term high-temperature operation. In addition, in order to ensure the stable operation of the liquid cooling circulation pipeline and prevent the leakage of the cooling medium, the cable also needs to be designed with a complex sealing structure and an additional mechanical protection layer, which requires the use of a large amount of insulating materials and filling materials.

[0005] As mentioned above, in order to meet the requirements of high current transmission, efficient heat dissipation and strict insulation protection, liquid-cooled charging cables must use a large amount of high-performance, high-cost insulation materials and special alloy conductors, resulting in high overall manufacturing costs. The large cross-sectional area of ​​the wire core, multi-layer insulation structure and complex cooling system make liquid-cooled charging cables more bulky than traditional cables, which is not conducive to installation, transportation and use. Although existing liquid-cooled charging cables have shown significant advantages in solving high-current charging problems, their high cost and complex structure are still the key factors restricting their widespread application. Summary of the invention

[0006] The present invention aims to provide a small-section, unfilled liquid-cooled cable to improve the problem that existing liquid-cooled charging cables must use a large amount of insulating material to meet the requirements of large current transmission, efficient heat dissipation and strict insulation protection, resulting in a large cross-sectional area and high overall manufacturing cost.

[0007] To achieve the above-mentioned purpose, the present invention adopts the following technical scheme: a small-section non-filled liquid-cooled cable, comprising two main power line cores, the conductors of the two main power line cores are respectively bundled with a control line group and a signal line group, the two main power line cores and a ground wire are tightly twisted together to form a cable body, the ground wire is pressed tightly by the two main power line cores in the center of the cable body, a cooling tube is spirally wrapped around the outside of the cable body, and an outer sheath is extruded around the outside of the cooling tube.

[0008] Preferably, as an improvement, the cooling pipe comprises a liquid inlet pipe and a liquid discharge pipe, and the liquid inlet pipe and the liquid discharge pipe are spirally wrapped side by side on the cable body.

[0009] Preferably, as an improvement, the control wire group includes a control wire group insulation layer and a plurality of twisted control wire cores.

[0010] Preferably, as an improvement, the signal wire group includes a signal wire group insulation layer and a plurality of twisted signal wire cores.

[0011] Preferably, as an improvement, the liquid inlet pipe and the liquid discharge pipe are nylon tubes.

[0012] Preferably, as an improvement, the cross-sectional areas of the two main power line cores are the same.

[0013] Preferably, as an improvement, the ground wire includes a ground wire conductor and a ground wire insulation layer.

[0014] Preferably, as an improvement, the conductor of the main power line core is a soft Category 6 conductor.

[0015] Preferably, as an improvement, a main power insulation layer is extruded outside the conductor of the main power line core, and the main power insulation layers of the two main power line cores respectively wrap the conductor and the control line group and the signal line group.

[0016] The core concept of the small-section non-filled liquid-cooled cable design of the present invention is to achieve dual optimization of performance and cost through the efficient combination of structural optimization and material selection. Specifically, the cable design uses soft Category 6 conductors as the basis of the main power line core. This type of conductor not only has excellent electrical conductivity, but also is easy to process and arrange tightly due to its softness. Inside the main power line core, the control line group and the signal line group are cleverly integrated and wrapped by their own insulation layers, which not only ensures the independence of the signal and control functions, but also maintains the overall compact structure.

[0017] Next, the two main power cores that have completed the above treatment and the ground wire are compressed and twisted to form a cable body. In this process, the two main power cores press the ground wire tightly at the center of the cable body. Through this compression method, the pressure is used to tightly combine the cores, which not only ensures the mechanical strength of the cable body, but also does not require additional filling of other materials to maintain the stability of the structure, thereby streamlining the cable structure and reducing the amount of materials used.

[0018] Finally, a cooling tube is spirally wrapped around the outside of the cable body. This solution uses a nylon inlet and outlet tube that are spirally wrapped side by side on the cable body. The spiral wrapping method greatly increases the path for the coolant to circulate back, and significantly increases the contact area between the cooling tube and each wire core, which can achieve heat exchange more efficiently and quickly remove the heat generated by the cable during power-on operation. In addition, the nylon tube itself also plays a certain mechanical protection role, enhancing the cable's ability to resist external damage.

[0019] After the cooling pipe is wrapped, an outer sheath is extruded on its outside. The outer sheath plays a further protective role and protects the internal structure from the influence of external environmental factors.

[0020] The advantages of this solution include:

[0021] 1. Double optimization of material cost and volume: Through the compacting process, the overall cross-sectional size of the cable is effectively reduced without affecting the current carrying capacity of the cable. On the one hand, the reduction in cross-section directly reduces the material usage of major components such as the main power core, insulation layer, and outer sheath during the manufacturing process. On the other hand, the compact and aggregated design eliminates the need to use other filling materials to maintain the cable structure, avoiding unnecessary loss of filling materials, reducing material costs in many ways, and improving the cost-effectiveness of the product. In addition, the miniaturization of the volume not only facilitates installation and transportation, but also improves space utilization efficiency.

[0022] 2. Efficient heat dissipation and enhanced protection: The spirally wrapped nylon inlet and outlet pipes greatly increase the circulation path of the coolant inside the cable. The longer circulation path means that the coolant can fully contact each core, and the larger contact area makes the heat transfer more efficient. This design can quickly and effectively remove the heat generated during the operation of the cable, ensuring that the cable always operates within a safe temperature range. At the same time, the nylon tube serves as an additional protective layer, effectively enhancing the cable's resistance to mechanical damage and improving the reliability and service life of the cable.

[0023] 3. Simple structure and convenient maintenance: Compared with the complex multi-layer structure and the use of a large amount of filling materials of the traditional liquid-cooled charging cable, the small-section non-filled liquid-cooled cable structure of the present invention is more concise and clear. Removing unnecessary filling materials and complex structural design not only simplifies the manufacturing process, reduces production difficulty and cost, but also makes the cable lighter and more flexible during installation, transportation and use, which is conducive to the wide application and promotion of the product. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 It is a schematic diagram of the cross-sectional structure of an embodiment of the present invention.

[0025] Figure 2 Schematic diagram of the cooling tube winding method in an embodiment of the present invention. DETAILED DESCRIPTION

[0026] The following is further described in detail through specific implementation methods:

[0027] The reference numerals in the drawings of the specification include: outer sheath 1, liquid inlet pipe 2, conductor 3, main power insulation layer 4, control line group 5, liquid discharge pipe 6, ground wire 7, signal line group 8, cable body 9.

[0028] The embodiment is basically as shown in the attached Figure 1 As shown: a small-section non-filled liquid-cooled cable includes two main power cores. The conductor 3 of the main power core is a soft Category 6 conductor 3. The conductor 3 of the main power core is extruded with a main power insulation layer 4. The main power insulation layer 4 is made of soft polyvinyl chloride, and in this embodiment, nitrile polyvinyl chloride is used. The control wire group 5 and the signal wire group 8 are respectively twisted inside the conductors 3 of the two main power cores. The main power insulation layer 4 of the two main power cores wraps the conductor 3 with the control wire group 5 and the signal wire group 8 respectively. The control wire group 5 includes a control wire group 5 insulation layer and four twisted control wire cores, and the signal wire group 8 includes a signal wire group 8 insulation layer and four twisted signal wire cores. The two main power cores have the same cross-sectional area. The two main power cores and a ground wire 7 are twisted together by pressing to form a circular cable body 9. The ground wire 7 is pressed by the two main power cores in the center of the cable body 9. The ground wire 7 includes a ground wire 7 conductor 3 and a ground wire 7 insulation layer. Combined with Figure 2 As shown, a cooling pipe is spirally wrapped around the cable body 9, and an outer sheath 1 is extruded outside the cooling pipe. The cooling pipe includes a liquid inlet pipe 2 and a liquid discharge pipe 6, which are nylon pipes and are spirally wrapped around the cable body 9 side by side.

[0029] The present invention also provides a production process for a small-section non-filled liquid-cooled cable, comprising:

[0030] 1. Main power line core manufacturing

[0031] Selection and preparation of conductor 3: Select soft Category 6 conductor 3 as the conductor 3 of the main power line core, because of its good flexibility and conductivity, it can meet the requirements of current transmission and bending performance of the cable in complex use scenarios. Pre-treat the selected conductor 3 to ensure that the surface is clean and free of impurities to ensure the quality of subsequent bundling and insulation extrusion.

[0032] Control line group 5 and signal line group 8 are twisted together:

[0033] Preparation of control wire group 5: The control wire group 5 consists of a control wire group 5 insulation layer and a plurality of twisted control wire cores. The plurality of control wire cores are firstly twisted to form a compact assembly, and then the control wire group 5 insulation layer is extruded on the outside to achieve electrical insulation and structural protection.

[0034] Preparation of signal wire group 8: The signal wire group 8 includes an insulation layer of the signal wire group 8 and a plurality of twisted signal wire cores. After the plurality of signal wire cores are twisted, the insulation layer of the signal wire group 8 is extruded to complete the preparation of the signal wire group 8.

[0035] Twisting with conductor 3: Twisting the prepared control wire group 5 and signal wire group 8 with the conductors 3 of the two main power line cores respectively. The twisting process strictly controls the twisting pitch and direction to ensure that each wire group is tightly combined with the conductor 3 and the overall structure is uniform and stable.

[0036] Extrusion of the main power insulation layer 4: After the control line group 5, the signal line group 8 and the conductor 3 are twisted together, the main power insulation layer 4 is extruded on the outside. The main power insulation layer 4 is made of nitrile polyvinyl chloride to ensure that it does not break down under high electric field strength. It also has good heat resistance to prevent aging failure due to long-term high-temperature operation. It also has good softness and elasticity to facilitate subsequent compression and twisting processing. The extrusion process requires precise control of parameters such as temperature, pressure and extrusion speed to ensure that the insulation layer is uniform in thickness, free of bubbles and impurities. The main power insulation layer 4 of the two main power line cores completely wraps the conductor 3 and the control line group 5 and the signal line group 8 respectively.

[0037] 2. Cable body preparation

[0038] Preparation of ground wire 7: The ground wire 7 is composed of a ground wire 7 conductor 3 and a ground wire 7 insulation layer. The ground wire 7 conductor 3 is first processed to ensure that it meets the electrical performance and mechanical strength requirements, and then the ground wire 7 insulation layer is extruded on its outer side to complete the preparation of the ground wire 7.

[0039] Tight compression and twisting: The two main power cores with the main power insulation layer 4 extruded and the ground wire 7 are twisted together to form the cable body 9. During the twisting process, pressure is applied so that the two main power cores tightly press the ground wire 7 at the center of the cable body 9. After tight compression and twisting, a layer of PP tape is wrapped around the surface at the outlet to improve the overall roundness, stabilize the tight compression structure and prevent the strands from falling apart, and the thickness of the layer of PP tape is thin enough not to affect the cooling and heat dissipation process. By precisely controlling the twisting parameters, such as the twisting pitch, speed and pressure, the cable body 9 is ensured to have a tight and round structure, and the contact between the cores is good, while reducing the cable cross-section to ensure the proper mechanical strength and electrical performance.

[0040] 3. Cooling pipe installation

[0041] Cooling pipe selection: Nylon pipes are selected as cooling pipes, including liquid inlet pipe 2 and liquid discharge pipe 6. Nylon pipes have good chemical stability, corrosion resistance and certain flexibility, can adapt to the complex environment inside the cable, and are not easily damaged when the coolant circulates for a long time.

[0042] Spiral wrapping: Wrap the inlet pipe 2 and the drain pipe 6 side by side on the cable body 9 in a spiral. The wrapping process requires the use of special wrapping equipment to accurately control the wrapping pitch and tension. The wrapping pitch is 10-15 times the outer diameter of the cable body. The smaller pitch ensures that the two nylon tubes fit tightly on the surface of the cable body 9, and the spacing of the spiral wrapping is uniform. The spiral wrapping method greatly increases the path of the coolant circulation reflux and the contact area with each wire core, which can more efficiently remove the heat generated by the cable operation. After the inlet pipe 2 and the drain pipe 9 are wrapped, wrap a layer of PP tape on the outside to fix them, so that the cooling pipe will not be scattered and shifted during the subsequent outer sheath extrusion process.

[0043] 4. Extrusion of outer sheath

[0044] After the cooling pipe is wrapped, an outer sheath 1 is extruded on the outside of the cooling pipe. The outer sheath 1 is made of a material with good mechanical properties, weather resistance and wear resistance, and is evenly coated on the outer surface of the cooling pipe through an extrusion process. The extrusion process requires strict control of temperature, extrusion speed and mold parameters to ensure that the outer sheath 1 has a uniform thickness, a smooth surface, and no defects such as cracks and bubbles, providing all-round protection for the cable and protecting the internal structure from external mechanical damage, chemical corrosion and environmental factors.

[0045] The small-section, unfilled liquid-cooled cable obtained by adopting the technical solution of the present invention eliminates unnecessary filling materials and complex structural designs, which not only simplifies the manufacturing process and reduces production difficulty and cost, but also makes the cable more lightweight and flexible during installation, transportation and use, which is conducive to the wide application and promotion of the product.

[0046] The above is only an embodiment of the present invention, and the common knowledge such as the known specific technical solutions and / or characteristics in the solution is not described in detail here. It should be pointed out that for those skilled in the art, without departing from the technical solution of the present invention, several modifications and improvements can be made, which should also be regarded as the protection scope of the present invention, and these will not affect the effect of the implementation of the present invention and the practicality of the patent. The scope of protection required by this application shall be based on the content of its claims, and the specific implementation methods and other records in the specification can be used to interpret the content of the claims.

Claims

1. Small cross-section non-filled liquid-cooled cable, characterized by: It comprises two main power line cores, the conductors of which are respectively bundled with a control line group and a signal line group, the two main power line cores and a ground wire are twisted together by compression to form a cable body, the ground wire is pressed tightly at the center of the cable body by the two main power line cores, a cooling pipe is spirally wrapped around the outside of the cable body, and an outer sheath is extruded around the outer side of the cooling pipe.

2. The small-section non-filled liquid-cooled cable according to claim 1, characterized in that: The cooling pipe comprises a liquid inlet pipe and a liquid discharge pipe, and the liquid inlet pipe and the liquid discharge pipe are spirally wrapped side by side on the cable body.

3. The small-section non-filled liquid-cooled cable according to claim 2, characterized in that: The control wire group comprises a control wire group insulation layer and a plurality of twisted control wire cores.

4. The small-section non-filled liquid-cooled cable according to claim 3, characterized in that: The signal line group includes a signal line group insulation layer and a plurality of twisted signal line cores.

5. The small-section non-filled liquid-cooled cable according to claim 4, characterized in that: The liquid inlet pipe and the liquid discharge pipe are nylon tubes.

6. The small-section non-filled liquid-cooled cable according to claim 5, characterized in that: The cross-sectional areas of the two main power line cores are the same.

7. The small-section non-filled liquid-cooled cable according to claim 6, characterized in that: The ground wire includes a ground wire conductor and a ground wire insulation layer.

8. The small-section non-filled liquid-cooled cable according to claim 7, characterized in that: The conductor of the main power line core is a soft Category 6 conductor.

9. The small-section non-filled liquid-cooled cable according to claim 8, characterized in that: A main power insulation layer is extruded outside the conductor of the main power line core, and the main power insulation layers of the two main power line cores respectively wrap the conductor and the control line group and the signal line group.

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