New energy automobile liquid-cooled battery power cable and preparation method thereof

Abstract

The invention discloses a new energy automobile liquid-cooled battery power cable and a preparation method thereof. The new energy automobile liquid-cooled battery power cable comprises a cable core, a composite phase change material layer, an aluminum foil shielding layer, a braided shielding layer and a sheath which are sequentially arranged from inside to outside. The cable core comprises a plurality of insulating wire cores, and each insulating wire core comprises a built-in cooling pipe located in the middle, a built-in protective belt layer wrapping the built-in cooling pipe, a plurality of conductors arranged outside the built-in protective belt layer and an insulating layer located on the outermost layer; elliptical pits are uniformly distributed on the pipe wall of the built-in cooling pipe; the outer side of the sheath is provided with a heat dissipation cooling coating. The cable is high in heat dissipation efficiency and stable in heat dissipation effect, the temperature of the cable can be effectively reduced, and the risks of fire breakout, battery electric leakage and the like caused by cable overheating are avoided.

Description

Technical Field

[0001] The present invention belongs to the technical field of cables, and in particular relates to a new energy vehicle liquid-cooled battery power cable and a preparation method thereof. Background Art

[0002] With the improvement of the new energy vehicle industry chain and supply chain system, and the improvement of the competitiveness of new energy vehicle products, the supply level of new energy vehicles will be further improved, and the acceptance of demand will also be further improved. The rapid rise of the new energy vehicle industry has not only accelerated the electrification process of the domestic automobile industry, but also led the transformation and upgrading of the global automobile industry through technology output and market expansion.

[0003] Compared with traditional fuel vehicles, new energy vehicles have advantages such as energy saving, environmental protection, strong power and low cost, but their development is limited by low charging efficiency. To solve this problem, liquid-cooled high-power cables came into being. By adding liquid cooling tubes to the cable structure, the heat generated during the charging process can be effectively absorbed, thereby improving charging efficiency and extending the service life of the cable.

[0004] Existing liquid-cooled cables have many shortcomings, such as: the contact area between the coolant and the conductor is limited, resulting in the heat not being completely absorbed and dissipated, and the heat dissipation efficiency is low. Summary of the invention

[0005] In order to solve the above technical problems, the purpose of the present invention is to provide a new energy vehicle liquid-cooled battery power cable and a preparation method thereof. The cable has high heat dissipation efficiency and stable heat dissipation effect, can effectively reduce the cable temperature, and avoid the risks of fire caused by cable overheating and battery leakage.

[0006] In order to achieve the above technical objectives and the above technical effects, the present invention is implemented through the following technical solutions:

[0007] On the one hand, the present invention provides a new energy vehicle liquid-cooled battery power cable, comprising a cable core, a composite phase change material layer, an aluminum foil shielding layer, a braided shielding layer and a sheath arranged in sequence from the inside to the outside; the cable core comprises a plurality of insulating cores, each insulating core comprises a built-in cooling tube located in the middle, a built-in protective tape layer wrapped outside the built-in cooling tube, a plurality of conductors arranged outside the built-in protective tape layer and an insulating layer located at the outermost layer; elliptical pits are evenly distributed on the tube wall of the built-in cooling tube; a heat dissipation and cooling coating is provided on the outer side of the sheath.

[0008] Furthermore, the cable core is also provided with an external cooling tube located between the multiple insulating cores, and the outer side of the external cooling tube is coated with an external protective tape layer.

[0009] Furthermore, needle-shaped fins made of thermal deformation material are evenly distributed on the tube wall of the built-in cooling tube.

[0010] Furthermore, the conductor is wrapped around the periphery of the built-in protective tape layer in an oblique wrapping or braiding manner.

[0011] Furthermore, the internal cooling tube and the external cooling tube are both nylon tubes.

[0012] Furthermore, the sheath is a TPV sheath.

[0013] Furthermore, a Teflon tape wrapping layer is provided between the braided shielding layer and the sheath.

[0014] Furthermore, the inner protective tape layer and the outer protective tape layer are both formed by wrapping with Teflon tape.

[0015] Another aspect of the present invention provides a method for preparing a liquid-cooled battery power cable for a new energy vehicle, comprising the following steps:

[0016] 1) A built-in protective tape layer is coated on the built-in cooling tube, and then a conductor is coated outside the built-in protective tape layer, and an insulating layer is wrapped on the outermost layer to make an insulated wire core;

[0017] 2) Using multiple insulated wire cores as cable cores, wrapping a composite phase change material layer outside the cable core, wrapping an aluminum foil shielding layer outside the composite phase change material layer, and then wrapping a braided shielding layer outside the aluminum foil shielding layer;

[0018] 3) forming a sheath on the outermost layer by melt extrusion process;

[0019] 4) Apply heat dissipation and cooling paint on the sheath, and form a heat dissipation and cooling coating after curing.

[0020] Furthermore, the preparation process of the composite phase change material layer is: immersing the biomass fiber woven tape in the phase change material solution, and obtaining the composite phase change material tape after sufficient absorption; and wrapping the composite phase change material tape around the cable core.

[0021] The beneficial effects of the present invention are:

[0022] The insulated wire core of the present invention is provided with a built-in cooling tube, and the conductor is coated on the built-in cooling tube, so that the conductor is fully in contact with the cooling tube, and the coolant passed into the cooling tube can absorb heat more fully, thereby improving the heat dissipation efficiency and heat dissipation effect;

[0023] The cable core of the present invention is also provided with an external cooling tube located between the insulating cores, which can further improve the heat dissipation effect; at the same time, the external cooling tube can also be used as a filler in the cable core, which can not only play a heat dissipation role, but also improve the roundness of the cable and the strength of the cable core;

[0024] The outer layer of the internal cooling pipe and the external cooling pipe are wrapped with Teflon tape, which can play a protective role and avoid damage to the cooling pipe during the processing;

[0025] The wall of the built-in cooling tube in the present invention is provided with elliptical pits, which can significantly increase the heat transfer area in the tube, enhance turbulence, and effectively destroy the boundary layer of the inner wall of the tube, thereby enhancing the heat exchange effect between the coolant and the tube wall.

[0026] In addition, needle-shaped fins made of thermal deformation material can be arranged on the tube wall of the built-in cooling tube of the present invention. When the temperature of a certain area of ​​the cable is high, the needle-shaped fins produce greater thermal deformation, the flow area of ​​the area with higher temperature becomes larger, the flow resistance decreases, and the flow rate of the coolant increases, thereby cooling the area with higher temperature more specifically.

[0027] The composite phase change material layer in the present invention can absorb heat through phase change when the cable temperature is high, thereby reducing the temperature of the surrounding environment. In conjunction with the built-in cooling pipe and the external cooling pipe, the cable can be cooled more quickly. In addition, the composite phase change material layer can also keep the cable temperature stable by releasing heat when the ambient temperature is low. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 It is a schematic structural diagram of the liquid-cooled battery power cable for new energy vehicles of the present invention.

[0029] Figure 2 It is a schematic diagram of the cross-sectional structure of the built-in cooling tube in the liquid-cooled battery power cable of the new energy vehicle of the present invention.

[0030] In the figure, 1: insulated wire core, 11: built-in cooling tube, 111: pits, 112: needle-shaped fins, 12: built-in protective tape layer, 13: conductor, 14: insulating layer; 2: external cooling tube, 21: external protective tape layer; 3: composite phase change material layer; 4: aluminum foil shielding layer; 5: braided shielding layer; 6: Teflon tape wrapping layer; 7: sheath. DETAILED DESCRIPTION

[0031] The technical solutions in the present invention will be described clearly and completely below in conjunction with specific embodiments. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0032] like Figure 1 and Figure 2As shown, the present invention provides a new energy vehicle liquid-cooled battery power cable, comprising a cable core, a composite phase change material layer 3, an aluminum foil shielding layer 4, a braided shielding layer 5 and a sheath arranged in sequence from the inside to the outside; the cable core comprises a plurality of insulating cores 1, each insulating core 1 comprises a built-in cooling tube 11 located in the middle, a built-in protective tape layer 12 wrapped outside the built-in cooling tube 11, a plurality of conductors 13 arranged outside the built-in protective tape layer 12, and an insulating layer 14 located at the outermost layer; the conductor 13 is coated on the periphery of the built-in protective tape layer 12 in an oblique or braided manner; elliptical pits 111 are evenly distributed on the tube wall of the built-in cooling tube 11; and a heat dissipation and cooling coating is provided on the outer side of the sheath 7.

[0033] The inner wall of the built-in cooling tube 11 in the present invention is provided with an elliptical pit 111, which can significantly increase the heat transfer area in the tube, enhance turbulence, and effectively destroy the boundary layer of the inner wall of the tube, thereby enhancing the heat exchange effect between the coolant and the tube wall.

[0034] The wall of the built-in cooling tube 11 is also evenly distributed with needle-shaped fins 112 made of thermal deformation material. When the temperature of a certain area of ​​the cable is relatively high, the needle-shaped fins 112 undergo greater thermal deformation, the flow area of ​​the area with higher temperature becomes larger, the flow resistance decreases, and the flow rate of the coolant increases in this area, thereby cooling the area with higher temperature more specifically. The design of the needle-shaped fins provides a cooling adjustment function, which can achieve more targeted heat dissipation.

[0035] In order to further improve the heat dissipation effect, the cable core is also provided with an external cooling tube 2 located between the multiple insulating wire cores 1, and the outer side of the external cooling tube 2 is coated with an external protective tape layer 21. In addition, the external cooling tube 2 can also be used as a filler in the cable core, which can not only play a heat dissipation role, but also improve the roundness of the cable and the strength of the cable core;

[0036] Cooling liquid is introduced into both the internal cooling pipe 11 and the external cooling pipe 2 .

[0037] In addition, the inner tube wall of the external cooling tube 2 can also be processed to form elliptical pits or provided with needle-shaped fins.

[0038] The internal cooling tube 11 and the external cooling tube 2 are preferably nylon tubes, which have the characteristics of high strength, strong wear resistance, and good chemical corrosion resistance. They can resist the erosion of chemical substances such as acid, alkali, and salt, and are suitable for various harsh environments.

[0039] The internal protection tape layer 12 and the external protection tape layer 21 are both formed by wrapping with Teflon tape, which can play a protective role and prevent the cooling pipe from being damaged during the processing.

[0040] The composite phase change material layer 3 is formed by wrapping a composite phase change material tape, and the composite phase change material tape is made by impregnating a biomass fiber woven tape with a phase change material. The composite phase change material layer in the present invention can absorb heat through phase change when the cable temperature is high, thereby reducing the temperature of the surrounding environment, and cooperate with the built-in cooling pipe and the external cooling pipe to achieve faster cooling of the cable; in addition, the composite phase change material layer can also keep the cable temperature stable by releasing heat when the ambient temperature is low.

[0041] The aluminum foil shielding layer 4 is wrapped on the composite phase change material layer 3 by wrapping an aluminum foil tape. The braided shielding layer 5 is braided by tinned copper wire. The aluminum foil shielding layer 4 and the braided shielding layer 5 cooperate to achieve a better shielding effect, effectively absorb and disperse external electromagnetic interference, and provide the cable with higher mechanical strength and flexibility.

[0042] In order to further improve the strength of the cable, a Teflon tape wrapping layer 6 is provided between the braided shielding layer 5 and the sheath 7 .

[0043] The sheath 7 is a TPV sheath, which can withstand high temperatures above 150° C. and has a lower cost. A heat dissipation and cooling coating is provided on the outer side of the sheath, which is formed by coating a heat dissipation and cooling coating on the sheath and curing it.

[0044] The preparation method of the new energy vehicle liquid-cooled battery power cable comprises the following steps:

[0045] 1) A built-in protective tape layer is coated on the built-in cooling tube, and then a conductor is coated outside the built-in protective tape layer, and an insulating layer is wrapped on the outermost layer to make an insulated wire core;

[0046] 2) Using multiple insulated wire cores as cable cores, wrapping a composite phase change material layer outside the cable core, wrapping an aluminum foil shielding layer outside the composite phase change material layer, and wrapping a braided shielding layer outside the aluminum foil shielding layer; in this step, an external cooling tube located between the multiple insulated wire cores can also be filled in the cable core;

[0047] 3) forming a sheath through a melt extrusion process on the outermost layer of the structure formed in step 2;

[0048] 4) Apply heat dissipation and cooling paint on the sheath, and form a heat dissipation and cooling coating after curing.

[0049] The preparation process of the composite phase change material layer is as follows: immersing the biomass fiber braided tape in the phase change material solution, and obtaining the composite phase change material tape after sufficient absorption; and wrapping the composite phase change material tape around the cable core.

[0050] Among them, the heat dissipation and cooling coating may preferably include the following components in parts by mass: 30-40 parts of epoxy resin, 2-3 parts of active diluent, 1-2 parts of dispersant, 3-5 parts of curing agent, 2-3.5 parts of nitrogen-boron compound, 2-3 parts of titanium compound, and 0.01-0.03 parts of graphene oxide powder.

[0051] Example

[0052] like Figure 1 and Figure 2 As shown, the new energy vehicle liquid-cooled battery power cable of this embodiment 1 includes a cable core, a composite phase change material layer 3, an aluminum foil shielding layer 4, a braided shielding layer 5, a Teflon tape wrapping layer 6 and a sheath 7 arranged in sequence from the inside to the outside; in this embodiment, the cable core includes four insulating cores 1, each insulating core 1 includes a built-in cooling tube 11 located in the middle, a built-in protective tape layer 12 wrapped outside the built-in cooling tube 11, a plurality of conductors 13 arranged outside the built-in protective tape layer 11, and an insulating layer 14 located at the outermost layer; the conductor 13 is wrapped around the periphery of the built-in protective tape layer 12 in an oblique or braided manner; elliptical pits 111 are evenly distributed on the wall of the built-in cooling tube 11; the cable core is also provided with an external cooling tube 2 located between the plurality of insulating cores 1, and the outer side of the external cooling tube 2 is coated with an external protective tape layer 21; coolant is passed through both the built-in cooling tube 11 and the external cooling tube 2; a heat dissipation and cooling coating is provided on the outer side of the sheath 7.

[0053] Needle-shaped fins 112 made of thermal deformation material are evenly distributed on the tube wall of the built-in cooling tube 11 .

[0054] The internal cooling tube 11 and the external cooling tube 2 are nylon tubes.

[0055] The internal protection tape layer 12 and the external protection tape layer 21 are both Teflon tape wrapped layers.

[0056] The composite phase change material layer 3 is formed by wrapping a composite phase change material tape, and the composite phase change material tape is formed by impregnating a biomass fiber woven tape with a phase change material.

[0057] The aluminum foil shielding layer 4 is wrapped on the composite phase change material layer by wrapping an aluminum foil tape. The braided shielding layer 5 is braided by tinned copper wire.

[0058] The sheath 7 is a TPV sheath, which can withstand high temperatures above 150° C. and has a lower cost.

[0059] The outer side of the sheath 7 is provided with a heat dissipation and cooling coating, which is formed by coating the heat dissipation and cooling coating on the sheath and curing. In this embodiment, the heat dissipation and cooling coating includes the following components by mass: epoxy resin: 35 parts, active diluent 2 parts, dispersant 1 part, curing agent 3 parts, nitrogen boron compound 2 parts, titanium dioxide 2 parts, graphene oxide powder 0.01 parts.

[0060] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above and that the present invention can be implemented in other specific forms without departing from the spirit or essential features of the present invention. Therefore, the embodiments should be considered exemplary and non-restrictive in all respects, and the scope of the present invention is defined by the appended claims rather than the above description, and it is intended that all changes falling within the meaning and scope of the equivalent elements of the claims be included in the present invention.

[0061] In addition, it should be understood that although the present specification is described according to implementation modes, not every implementation mode contains only one independent technical solution. This description of the specification is only for the sake of clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in each embodiment may also be appropriately combined to form other implementation modes that can be understood by those skilled in the art.

Claims

1. A new energy vehicle liquid-cooled battery power cable, characterized in that: It includes a cable core, a composite phase change material layer, an aluminum foil shielding layer, a braided shielding layer and a sheath which are arranged in sequence from the inside to the outside; the cable core includes multiple insulating cores, each insulating core includes a built-in cooling tube located in the middle, a built-in protective tape layer wrapped outside the built-in cooling tube, multiple conductors arranged outside the built-in protective tape layer and an insulating layer located at the outermost layer; elliptical pits are evenly distributed on the tube wall of the built-in cooling tube; and a heat dissipation and cooling coating is provided on the outer side of the sheath.

2. A new energy vehicle liquid-cooled battery power cable according to claim 1, characterized in that: The cable core is also provided with an external cooling tube located between the multiple insulating wire cores, and the outer side of the external cooling tube is covered with an external protective tape layer.

3. A new energy vehicle liquid-cooled battery power cable according to claim 1, characterized in that: Needle-shaped fins made of thermal deformation material are evenly distributed on the tube wall of the built-in cooling tube.

4. A new energy vehicle liquid-cooled battery power cable according to claim 1, characterized in that: The conductor is wrapped around the periphery of the built-in protective tape layer in an oblique wrapping or braiding manner.

5. A new energy vehicle liquid-cooled battery power cable according to claim 1, characterized in that: The internal cooling tube and the external cooling tube are both nylon tubes.

6. A new energy vehicle liquid-cooled battery power cable according to claim 1, characterized in that: The sheath is a TPV sheath.

7. A new energy vehicle liquid-cooled battery power cable according to claim 1, characterized in that: A Teflon tape wrapping layer is also provided between the braided shielding layer and the sheath.

8. A new energy vehicle liquid-cooled battery power cable according to claim 1, characterized in that: The inner protective tape layer and the outer protective tape layer are both formed by wrapping with Teflon tape.

9. A method for preparing a new energy vehicle liquid-cooled battery power cable according to any one of claims 1 to 8, characterized in that: The steps include: 1) A built-in protective tape layer is coated on the built-in cooling tube, and then a conductor is coated outside the built-in protective tape layer, and an insulating layer is wrapped on the outermost layer to make an insulated wire core; 2) Using multiple insulated wire cores as cable cores, wrapping a composite phase change material layer outside the cable core, wrapping an aluminum foil shielding layer outside the composite phase change material layer, and then wrapping a braided shielding layer outside the aluminum foil shielding layer; 3) forming a sheath on the outermost layer by melt extrusion process; 4) Apply heat dissipation and cooling paint on the sheath, and form a heat dissipation and cooling coating after curing.

10. The method for preparing a new energy vehicle liquid-cooled battery power cable according to claim 9, characterized in that: The preparation process of the composite phase change material layer is as follows: immersing the biomass fiber braided tape in the phase change material solution, and obtaining the composite phase change material tape after fully absorbing it; and wrapping the composite phase change material tape around the cable core.

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