Liquid-cooling over-charging cable and production process

Abstract

The invention relates to the field of new energy charging cables, and discloses a liquid-cooling over-charging cable and a production process thereof, and the cable comprises an inner cooling pipe, two main wire cores are arranged in the inner cooling pipe side by side, an outer cooling pipe is spirally wrapped outside the inner cooling pipe, and an outer sheath is extruded outside the outer cooling pipe. A ground wire, a control wire set and a signal wire set are arranged between the outer cooling pipe and the outer sheath, the outer cooling pipe and the inner cooling pipe are communicated at the cable charging gun end, and the liquid cooling medium flows in the inner cooling pipe and the outer cooling pipe in a one-way mode. According to the invention, the problem of insufficient heat dissipation of the charging cable of the existing overcharge charging pile can be improved.

Description

Technical Field

[0001] The present invention relates to the field of new energy charging cables, and in particular to a liquid-cooled super-charging cable and a production process. Background Art

[0002] Against the backdrop of global advocacy of green travel and sustainable development, the electric vehicle market is booming at an unprecedented rate. The continuous increase in the number of electric vehicles has made charging piles, as key charging infrastructure, increasingly important. As the "energy link" connecting the charging pile and the electric vehicle, the performance of the charging pile cable is directly related to the efficiency, safety and user experience of the charging process. Therefore, the safety and durability of the charging pile cable have become the focus of attention within and outside the industry.

[0003] At present, in order to meet the needs of fast charging of electric vehicles, charging pile cables generally use high-grade insulation materials. These materials can not only effectively support the stable transmission of large currents and ensure the efficient charging process, but also have excellent waterproof performance, can resist moisture erosion under various severe weather conditions, and ensure the safe operation of cables in humid environments; have good heat resistance, can maintain stable physical and chemical properties under high temperature environments, and avoid insulation performance degradation or material aging due to overheating; at the same time, they also have excellent oil resistance, which can adapt to complex use scenarios with more oil pollution such as gas stations and parking lots, and extend the service life of cables.

[0004] Looking to the future, with the continuous advancement of science and technology and the increasing diversification of user needs, charging pile cables are moving towards a lighter and more intelligent direction. In terms of lightweighting, the industry is actively exploring and adopting new materials, such as high-strength, low-density composite materials, to effectively reduce the weight of the cable. This can not only reduce the labor intensity during the installation process and improve the convenience of installation, but also greatly improve the portability of some charging piles that need to be frequently moved or used portable (such as portable charging piles equipped with the vehicle), providing users with a more convenient charging experience. In terms of intelligence, by integrating sensors, smart chips and other components in the cable, real-time monitoring and intelligent control of key parameters such as current, voltage, and temperature during the charging process can be achieved, thereby further improving charging efficiency and safety.

[0005] Although the current charging pile cable technology has made certain progress, it still faces many challenges. In the high-current charging scenario, the common high-current charging cables on the market have serious heating problems. The large amount of heat generated leads to insufficient current carrying capacity of the wire cores of the same specifications, which makes the charging speed slow and cannot meet the user's urgent demand for fast charging. At the same time, the heating of the main wire core will also have a negative impact on the transmission rate and loss of the signal line, interfere with the stable transmission of the signal, and reduce the overall performance of the charging system. Although ordinary liquid-cooled charging cables have improved the heat dissipation problem to a certain extent, there is still insufficient heat dissipation, and it is impossible to completely solve the problem of heat accumulation caused by high-current charging. Therefore, the development of a liquid-cooled super-charging charging cable and production process that can effectively solve the heat dissipation problem and achieve efficient and fast charging has important practical significance and market demand. Summary of the invention

[0006] The present invention is intended to provide a liquid-cooled supercharging cable to improve the problem of insufficient heat dissipation of existing supercharging pile charging cables.

[0007] To achieve the above-mentioned purpose, the present invention adopts the following technical scheme: a liquid-cooled supercharging cable, comprising an inner cooling tube, two main wire cores are arranged side by side in the inner cooling tube, an outer cooling tube is spirally wrapped around the outside of the inner cooling tube, an outer sheath is extruded on the outside of the outer cooling tube, a ground wire, a control wire group and a signal wire group are arranged between the outer cooling tube and the outer sheath, the outer cooling tube and the inner cooling tube are connected at the cable charging gun end, and the liquid cooling medium flows unidirectionally in the inner cooling tube and the outer cooling tube.

[0008] Preferably, as an improvement, the inner cooling tube is closed at both the cable charging pile end and the charging gun end, the main line core passes through the closed end of the inner cooling tube, the inner cooling tube at the cable charging pile end is opened laterally and connected to a water inlet pipe, and the outer cooling tube passes into the inner cooling tube at the cable charging gun end.

[0009] Preferably, as an improvement, the inner cooling tubes at the charging pile end and the charging gun end of the cable are hot-melt sealed on the main line core.

[0010] Preferably, as an improvement, the cross-section of the inner cooling pipe is oblate, and the ground wire and the control wire group are respectively located on both sides of the inner cooling pipe.

[0011] Preferably, as an improvement, an auxiliary wire core is provided on both sides of the ground wire and the control wire group.

[0012] Preferably, as an improvement, the conductor of the main core is a Category 5 conductor, and the insulation of the main core, ground wire, and control wire group all adopts low-smoke halogen-free flame-retardant polyolefin insulation, and flame-retardant rope is filled between the outer sheath and the outer cooling tube, ground wire, control wire group and auxiliary core.

[0013] Preferably, as an improvement, the inner cooling tube is an EPDM rubber tube, the outer cooling tube is a nylon hose, and the outer sheath is an elastomeric sheath.

[0014] The present invention also provides a liquid-cooled supercharger cable production process, which is used to produce the above liquid-cooled supercharger cable, comprising:

[0015] A. Prepare the main core, control line group, ground wire, and auxiliary core. The main core uses Category 5 conductors with low-smoke, halogen-free, flame-retardant polyolefin insulation. The ground wire uses a yellow-green ground wire. The control line group uses multiple control cores twisted together and then extruded with a low-smoke, halogen-free, flame-retardant polyolefin insulation sheath. The auxiliary core uses two-core wires.

[0016] B. Preparation of cooling pipe: nylon hose is used as the outer cooling pipe; two main line cores are fed into the extruder side by side, and ethylene propylene rubber is used as the raw material to extrude and form the inner cooling pipe on the outer side of the two main line cores;

[0017] C. Tightly spirally wind the outer cooling tube around the inner cooling tube to form the main cable body, and then cable the ground wire, auxiliary wire core, control wire group and flame-retardant rope together with the main cable body. After cabling, wrap the glass fiber tape around the outside to form the cable core;

[0018] D. Using the elastomer sheath material as raw material, an outer sheath is extruded outside the cable core on an extruder to form a cable;

[0019] E. Cut off a section of the inner cooling tube at both ends of the cable to expose the main core, and heat-melt the inner cooling tube end and the main core insulation together to seal the inner cooling tube end;

[0020] F. Open the side wall of the inner cooling tube at the head end of the cable, apply adhesive to the end of the outer cooling tube and insert and bond it into the opening of the side wall of the inner cooling tube; open the side wall of the inner cooling tube at the tail end of the cable, apply adhesive in the opening and insert and bond a hose as a water inlet pipe.

[0021] Preferably, as an improvement, in step B, an extrusion die with an oblate extrusion port is used, and the extruded inner cooling tube has an oblate cross-section.

[0022] Preferably, as an improvement, in step C, a glass fiber tape is wrapped around the main cable body to fix the external cooling tube.

[0023] The principles of the present invention include:

[0024] Unique cooling structure design: The liquid-cooled supercharger cable of the present invention innovatively adopts a double-layer cooling structure of an inner cooling tube and an outer cooling tube. In the inner cooling tube part, two main cores are placed side by side. The inner cooling tube is formed by ethylene propylene rubber being extruded and wrapped on the outside of the main core through an extruder. Its cross-section is oblate. This design allows the coolant to flow in the gap between the main core and the inner cooling tube, greatly increasing the contact area between the coolant and the main core, greatly enhancing the heat dissipation capacity, and greatly improving the current carrying capacity of cables of the same specifications. Ethylene propylene rubber has good flexibility and chemical corrosion resistance, which ensures the durability and sealing of the cooling tube, and provides reliable guarantee for the stable flow of the coolant. The outer cooling tube adopts a nylon hose, which is tightly spirally wrapped around the outside of the inner cooling tube, further increasing the running distance of the coolant and extending the heat dissipation path, thereby significantly improving the heat dissipation efficiency.

[0025] Efficient heat dissipation principle: The coolant flows unidirectionally in the inner cooling tube and the outer cooling tube, forming an efficient heat dissipation circulation system. When a large current passes through the main core, the heat generated is quickly transferred to the coolant in close contact with it. In the inner cooling tube, the coolant directly absorbs the heat dissipated by the main core. Due to the large gap between the inner cooling tube and the main core, the contact area between the coolant and the main core is greatly increased, and the heat can be quickly transferred from the main core to the coolant. The spiral winding design of the outer cooling tube further increases the flow path of the coolant, allowing the coolant to fully absorb the heat and bring it out of the cable, thereby achieving efficient heat dissipation and effectively solving the problem of insufficient heat dissipation of traditional charging cables.

[0026] Safe and reliable connection and sealing design: During the production and use of the cable, each joint and seal is carefully designed. At both ends of the cable, a section of the inner cooling tube end is cut off to expose the main wire core, and then the inner cooling tube end is tightly combined with the main wire core insulation through a hot melt process to ensure that the inner cooling tube end is closed to prevent coolant leakage. At the head end of the cable, the side wall of the inner cooling tube is opened, and the end of the outer cooling tube is coated with adhesive and inserted and bonded into the opening of the side wall of the inner cooling tube to achieve the connection between the inner cooling tube and the outer cooling tube; at the tail end of the cable, the side wall of the inner cooling tube is opened and a hose is inserted and bonded as a water inlet pipe to ensure that the coolant can smoothly enter the inner cooling tube. This design not only ensures the safe and free flow of coolant, but also ensures the safety of electricity use and avoids safety hazards caused by coolant leakage.

[0027] Optimized design of signal transmission: The ground wire, control wire group and auxiliary wire core are distributed between the outer cooling tube and the outer sheath, and the outer cooling tube isolates the main wire core from the control signal wire core. The heat generated by the main wire core during the transmission of large current is greatly reduced due to the isolation of the outer cooling tube, which ensures the stable transmission of the control signal and improves the overall performance of the charging system.

[0028] Advantages of the present invention include:

[0029] 1. Super strong heat dissipation capacity and high current carrying capacity: The unique internal cooling tube and main core layout greatly increase the contact area between the coolant and the main core, greatly enhancing the heat dissipation capacity. In high-current charging scenarios, the heat generated by the main core can be quickly taken away, effectively solving the problem of insufficient current carrying capacity of cores of the same specification due to heat. Compared with traditional charging cables, the current carrying capacity of the cable of the present invention is greatly improved under the same specifications, which can meet the needs of fast charging of electric vehicles, significantly shorten the charging time, and improve the user experience.

[0030] 2. Extend the cooling path of the coolant: The design of the outer cooling tube spirally wrapped around the inner cooling tube not only increases the running distance of the coolant, but also further enhances the heat dissipation effect. By extending the flow path of the coolant, the coolant can fully absorb the heat generated by the cable, ensuring that the cable always remains within a safe operating temperature range during long-term, high-load charging, improving the stability and reliability of the cable and extending the service life of the cable.

[0031] 3. Stable signal transmission: The external cooling tube effectively isolates the main line core and the control signal line core, reducing the interference of the main line core heating on the control signal line core signal transmission. This enables the control signal to be transmitted stably and accurately, ensuring the precise regulation of charging parameters by the control system during the charging process, improving the overall performance and safety of the charging system, and avoiding charging anomalies or failures caused by signal interference.

[0032] 4. Reliable safety performance: In the cable connection and sealing design, hot melt sealing and adhesive bonding technologies are used to ensure that the coolant will not leak, while ensuring the connection between the internal and external cooling pipes, so that the coolant can flow safely and freely. The design of the water inlet and outlet parts effectively avoids electrical safety hazards while ensuring the cooling effect, providing users with reliable safety protection and ensuring the safe and stable charging process.

[0033] 5. Good production process and operability: The production process of the present invention has good operability and high efficiency. From the preparation of the wire core, the processing of the cooling tube, to the assembly of various components and the extrusion of the outer sheath, each link has been carefully designed and optimized. For example, in the preparation process of the cooling tube, the use of a specific extrusion die and process can quickly and accurately produce inner cooling tubes and outer cooling tubes that meet the requirements; in the assembly process of components, the layout of each component is reasonable, which is easy to operate and install, improves production efficiency and reduces production costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Figure 1 It is a schematic diagram of the cross-sectional structure of Example 1 of the present invention.

[0035] Figure 2 This is a schematic diagram of the structure of the cable charging pile end in Example 1 of the present invention.

[0036] Figure 3 This is a schematic diagram of the structure of the cable charging gun end in Example 1 of the present invention. DETAILED DESCRIPTION

[0037] The following is further described in detail through specific implementation methods:

[0038] The reference numerals in the drawings of the specification include: main line core 1, inner cooling tube 2, outer cooling tube 3, ground wire 4, control line group 5, auxiliary line core 6, outer sheath 7, water inlet pipe 8.

[0039] Embodiment 1, basically as attached Figure 1 As shown: A liquid-cooled supercharge charging cable includes an inner cooling tube 2 made of ethylene propylene rubber. The cross section of the inner cooling tube 2 is oblate. Two main cores 1 are arranged side by side in the inner cooling tube 2. The conductor of the main core 1 is a Class V conductor, and the insulation of the main core 1 is low-smoke halogen-free flame-retardant polyolefin insulation. The outer cooling tube 2 is spirally wrapped with an outer cooling tube 3, which is a nylon hose. The outer side of the outer cooling tube 3 is extruded with an outer sheath 7, and the outer sheath 7 is formed by an elastomer sheath material. A ground wire 4, a control wire group 5 and a signal wire group are arranged between the outer cooling tube 3 and the outer sheath 7. The ground wire 4 and the control wire group 5 are respectively located on both sides of the inner cooling tube 2, and an auxiliary wire core 6 is arranged on both sides of the ground wire 4 and the control wire group 5. The insulation of the ground wire 4 and the control wire group 5 is low-smoke halogen-free flame-retardant polyolefin insulation, and a flame-retardant rope is filled between the outer sheath 7 and the outer cooling tube 3, the ground wire 4, the control wire group 5 and the auxiliary wire core 6. The outer cooling tube 3 is connected to the inner cooling tube 2 at the cable charging gun end, and the liquid cooling medium flows unidirectionally in the inner cooling tube 2 and the outer cooling tube 3 .

[0040] Combination Figure 2 , Figure 3 As shown, the inner cooling tubes 2 at the cable charging pile end and the charging gun end are hot-melt sealed on the main wire core 1, the main wire core 1 passes through the closed end of the inner cooling tube 2, the inner cooling tube 2 at the cable charging pile end is opened laterally and bonded with a water inlet pipe 8, the side end of the inner cooling tube 2 at the cable charging gun end is opened and the end of the outer cooling tube 3 is inserted into the inner cooling tube 2 and bonded and fixed.

[0041] Embodiment 2, a liquid-cooled supercharger cable production process, used to produce a liquid-cooled supercharger cable as in Embodiment 1, comprising:

[0042] A. Prepare the main core 1, control wire group 5, ground wire 4, and auxiliary core 6. The main core 1 is made of Category 5 conductor with low-smoke halogen-free flame-retardant polyolefin insulation, the ground wire 4 is made of yellow-green ground wire 4, the control wire group 5 is made of multiple control cores twisted together and then extruded into a low-smoke halogen-free flame-retardant polyolefin insulation sheath, and the auxiliary core 6 is made of two-core wires;

[0043] B. Preparation of cooling pipes: using nylon hose as the outer cooling pipe 3; feeding two main line cores 1 into the extruder side by side, using an extrusion die with an oblate extrusion port, using EPDM as the raw material, and extruding the outer sides of the two main line cores 1 to form an inner cooling pipe 2 with an oblate cross section;

[0044] C. Tightly spirally wind the outer cooling tube 3 around the inner cooling tube 2 to form the main cable body, wrap the glass fiber tape around the main cable body to fix the outer cooling tube 3, and then cable the ground wire 4, auxiliary wire core 6, control wire group 5 and flame retardant rope together with the main cable body, and after cabling, wrap the glass fiber tape around the outside to form the cable core;

[0045] D. Using an elastomer sheath material as raw material, an outer sheath 7 is extruded outside the cable core to form a cable on an extruder;

[0046] E. Cut off a section of the inner cooling tube 2 at both ends of the cable to expose the main core 1, and heat-melt the inner cooling tube 2 and the main core 1 together to seal the inner cooling tube 2.

[0047] F. At the head end of the cable, open the side wall of the inner cooling tube 2, apply adhesive to the end of the outer cooling tube 3 and insert and bond it into the opening of the side wall of the inner cooling tube 2; at the tail end of the cable, open the side wall of the inner cooling tube 2 and apply adhesive in the opening and insert and bond a hose as the water inlet pipe 8.

[0048] During specific use, the cooling medium enters the inner cooling tube 2 from the water inlet, flows unidirectionally in the inner cooling tube 2 toward the charging gun, and the cooling medium fully contacts the surface of the main core 1 to liquid-cool the internal main core 1. Then the cooling medium enters the outer cooling tube 3 at the charging gun end of the cable, and flows in a spiral path toward the charging pile in the outer cooling tube 3, further increasing the running distance of the coolant. The outer cooling tube 3 isolates the main core 1 from the control line group 5, reducing the influence of the heating of the main core 1 on the signal transmission of the control line group 5. The common high-current charging cables on the market generate a lot of heat, resulting in insufficient current carrying capacity of the cores of the same specifications and slow charging. The heating of the main core 1 will also affect the transmission rate and loss of the signal line. The problem of insufficient heat dissipation still exists in ordinary liquid-cooled charging cables, which can be effectively improved.

[0049] 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. A liquid-cooled supercharger cable, characterized in that: It includes an inner cooling tube, two main line cores are arranged side by side in the inner cooling tube, an outer cooling tube is spirally wrapped outside the inner cooling tube, an outer sheath is extruded outside the outer cooling tube, a ground wire, a control wire group and a signal wire group are arranged between the outer cooling tube and the outer sheath, the outer cooling tube is connected with the inner cooling tube at the cable charging gun end, and the liquid cooling medium flows unidirectionally in the inner cooling tube and the outer cooling tube.

2. A liquid-cooled supercharger cable according to claim 1, characterized in that: The inner cooling tube is closed at both the cable charging pile end and the charging gun end. The main line core passes through the closed end of the inner cooling tube. The inner cooling tube at the cable charging pile end is open laterally and connected to a water inlet pipe. The outer cooling tube passes into the inner cooling tube at the cable charging gun end.

3. A liquid-cooled supercharger cable according to claim 2, characterized in that: The inner cooling tubes at the charging pile end and the charging gun end of the cable are hot-melt sealed on the main wire core.

4. A liquid-cooled supercharger cable according to claim 3, characterized in that: The cross section of the inner cooling pipe is oblate, and the ground wire and the control wire group are respectively located on both sides of the inner cooling pipe.

5. A liquid-cooled supercharger cable according to claim 4, characterized in that: An auxiliary wire core is provided on each side of the ground wire and the control wire group.

6. A liquid-cooled supercharger cable according to claim 5, characterized in that: The conductor of the main line core is a Category 5 conductor. The insulation of the main line core, ground wire, and control wire group all adopts low-smoke halogen-free flame-retardant polyolefin insulation. Flame-retardant rope is filled between the outer sheath and the external cooling tube, ground wire, control wire group and auxiliary wire core.

7. A liquid-cooled supercharger cable according to claim 6, characterized in that: The inner cooling pipe is an EPDM rubber pipe, the outer cooling pipe is a nylon hose, and the outer sheath is an elastomer sheath.

8. A liquid-cooled supercharger cable production process, used to produce a liquid-cooled supercharger cable as claimed in any one of claims 1 to 7, characterized in that: include A. Prepare the main core, control line group, ground wire, and auxiliary core. The main core uses Category 5 conductors with low-smoke, halogen-free, flame-retardant polyolefin insulation. The ground wire uses a yellow-green ground wire. The control line group uses multiple control cores twisted together and then extruded with a low-smoke, halogen-free, flame-retardant polyolefin insulation sheath. The auxiliary core uses two-core wires. B. Preparation of cooling pipe: use nylon hose as the outer cooling pipe; send two main line cores into the extruder side by side, use EPDM as the raw material, and extrude the inner cooling pipe on the outer side of the two main line cores; C. Tightly spirally wind the outer cooling tube around the inner cooling tube to form the main cable body, and then cable the ground wire, auxiliary wire core, control wire group and flame-retardant rope together with the main cable body. After cabling, wrap the glass fiber tape around the outside to form the cable core; D. Using the elastomer sheath material as raw material, an outer sheath is extruded outside the cable core on an extruder to form a cable; E. Cut off a section of the inner cooling tube at both ends of the cable to expose the main core, and heat-melt the inner cooling tube end and the main core insulation together to seal the inner cooling tube end; F. Open the side wall of the inner cooling pipe at the cable head end, apply adhesive to the end of the outer cooling pipe, and then insert and bond it into the opening of the side wall of the inner cooling pipe; An opening is made on the side wall of the inner cooling pipe at the rear end of the cable, and adhesive is applied in the opening, after which a hose is inserted and bonded as a water inlet pipe.

9. A liquid-cooled supercharger cable production process according to claim 8, characterized in that: In step B, an extrusion die with an oblate extrusion port is used to extrude an inner cooling tube with an oblate cross-section.

10. A liquid-cooled supercharger cable production process according to claim 9, characterized in that: In step C, a glass fiber tape is wrapped around the main cable body to fix the external cooling tube.

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