Liquid cooling charging wire harness

Abstract

The invention relates to the technical field of charging structures, in particular to a liquid cooling charging wire harness. The liquid cooling charging wire harness comprises a cable with a built-in liquid cooling pipe, one end of the cable is connected with a charging base connector, the other end of the cable is connected with a liquid cooling connector, the liquid cooling connector comprises a metal shell, a terminal liquid cooling module assembly, a sealing ring and a rear cover, and the terminal liquid cooling module assembly comprises a water tank body with a water tank structure. A metal upper cover is arranged at the upper end of the water tank body, the upper end of the metal upper cover covers the metal upper cover, and the lower end of the water tank body covers the plastic shell lower cover. The liquid-cooled charging wire harness is provided with the liquid-cooled modules at the two ends, can effectively dissipate heat, is integrally designed by using a modular scheme, can be suitable for different connectors and charging seats through liquid-cooled modular assembly, and shortens the development period. The liquid cooling system has the performance of safe and reliable operation, and the heat conduction silicone grease and the ceramic cover plate effectively increase the heat conduction efficiency and reduce the impact on the ceramic cover plate.

Description

Technical Field

[0001] The present invention relates to a wire harness, and more particularly to a liquid-cooled charging wire harness. Background Art

[0002] Major automobile manufacturers have successively prepared to launch their own 800V platforms. After a significant increase in current, if no cooling measures are taken on the cable, the most direct impact is that the cable will become thicker and the charging experience will be even worse. It is found that when studying heat dissipation in the cable, according to the general rule of selecting wire size based on current magnitude, the charging cable needs to be thickened, but this will lead to an increase in the weight of the whole vehicle and the cost.

[0003] However, without increasing the cross-sectional area of the wire, increasing the charging current will cause excessive heat generation in the cable and damage the insulation layer. If the current is to be increased and the charging power is to be increased, additional cooling measures must be added while maintaining the current cable structure. If the cable specifications are to be kept unchanged, then some complex measures need to be taken, such as adding a cooling system. Whether using external cooling circulation for the cable or internal cooling circulation in the cable, not only can the temperature drop rapidly, but also the weight and cost of the cable will decrease. It is easy for the water pipe connected inside the cable to be dragged, causing leakage at the interface, and a fixing structure must be added to the cable to ensure the stability of the interface. At the same time, heat dissipation of the terminal in the metal connector needs to be solved. Conventional ceramic chips are fragile, and a transition layer needs to be added for cooperation with the terminal. Summary of the Invention

[0004] The present invention aims to solve the above-mentioned defects and provides a liquid-cooled charging wire harness.

[0005] To overcome the defects in the background art, the technical solution adopted by the present invention to solve its technical problems is: This liquid-cooled charging wire harness includes a cable with an internal liquid-cooling pipe. One end of the cable is connected to a charging socket connector, and the other end is connected to a liquid-cooling connector. A water inlet pipe is also connected to the charging socket connector. The liquid-cooling connector includes a metal shell, a terminal liquid-cooling module assembly, a sealing ring, and a rear cover. The terminal liquid-cooling module assembly includes a water tank body with a water tank structure. A metal upper cover is provided at the upper end of the water tank body. The upper end of the metal upper cover is covered with a plastic shell upper cover, and the lower end of the water tank body is covered with a plastic shell lower cover. On the upper plane of the metal upper cover, thermal grease one, a ceramic cover plate, and thermal grease two are welded in sequence from bottom to top. The other end of the cable is provided with a welded terminal, and a fixing ring is provided at the connection part. The lower plane of the welded terminal is attached to the thermal grease two, and the bolt connection hole provided at the front end of the welded terminal protrudes in front of the upper part of the terminal liquid-cooling module assembly. The water tank body includes a water tank. An outlet and a cable connection port are provided on one side of the water tank. The upper part of the water tank is connected to the metal upper cover by bolts to form a sealed water storage structure. An outlet pipe is connected to the outlet, and the other end of the cable is connected to the cable connection port.

[0006] According to another embodiment of the present invention, it further includes a through-hole rubber sleeve sleeved on the cable, and the water inlet pipe is fixed on the through-hole rubber sleeve.

[0007] According to another embodiment of the present invention, it further includes a guard plate provided on the cable.

[0008] According to another embodiment of the present invention, it further includes that the charging base connector is connected to the charging base socket. The charging base connector includes a housing assembly and a liquid cooling module with a closed water tank. The liquid cooling module is placed inside the housing assembly. One side of the liquid cooling module is provided with a cable connection port and a water inlet. The cable connection port is connected to one end of the cable, and the water inlet is connected to the water inlet pipe.

[0009] According to another embodiment of the present invention, it further includes that the upper end of the metal housing is provided with an inclined channel, and the metal housing is connected to the bolt connection hole provided at the front end of the welding terminal through a fixing bolt placed in the inclined channel.

[0010] According to another embodiment of the present invention, it further includes that the sealing ring and the rear cover are sleeved on the cable and fixed to the rear end of the metal housing.

[0011] According to another embodiment of the present invention, it further includes that the plastic shell lower cover is connected to the metal upper cover through bolts, so that the water tank main body is located between the plastic shell lower cover and the metal upper cover. The plastic shell lower cover is provided with a placement groove for the limit fixing ring.

[0012] According to another embodiment of the present invention, it further includes that the plastic shell lower cover and the plastic shell upper cover are connected by buckles.

[0013] The beneficial effects of the present invention are as follows: This liquid-cooled charging harness is configured with liquid-cooling modules at both ends, which can effectively dissipate heat. The overall use of a modular design scheme. Through liquid-cooled modular assembly, it can be applied to different connectors and charging bases, shortening the development cycle. The liquid-cooling system has safe and reliable operating performance. The thermal conductive silicone grease and the ceramic cover plate effectively increase the heat conduction efficiency and reduce the impact on the ceramic cover plate. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The present invention will be further described below in conjunction with the drawings and embodiments.

[0015] Figure 1 is a schematic structural diagram of the present invention; Figure 2 is a schematic structural diagram of the liquid-cooled connector; Figure 3 is a schematic structural diagram of the exploded view of the liquid-cooled connector; Figure 4 is a schematic structural diagram of the connection between the water tank main body and the cable on the liquid-cooled connector; Figure 5 It is a schematic structural diagram of the upper water tank body of the liquid-cooled connector; Figure 6 It is a schematic structural diagram of the charging socket connector; Among them: 1. Charging socket, 2. Charging socket connector, 3. Through-hole rubber sleeve, 4. Cable, 5. Water inlet pipe, 6. Guard plate, 7. Water outlet pipe, 8. Liquid-cooled connector, 9. Water tank body, 10. Metal upper cover, 11. Plastic upper cover, 12. Plastic lower cover, 13. Metal outer shell, 14. Terminal liquid-cooled module assembly, 15. Sealing ring, 16. Rear cover, 17. Fixed bolt, 18. Welding terminal, 19. Tilt channel, 20. Thermal grease II, 21. Ceramic cover plate, 22. Thermal grease I, 23. Bolt connection hole, 24. Placing groove, 25. Water tank, 26. Water outlet, 27. Cable connection port, 28. Liquid-cooled module, 29. Outer shell assembly, 30. Fixed ring. Specific implementation manners

[0016] To make the objectives, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the embodiments of the present invention. Obviously, the described embodiments are some, rather than all, of the embodiments of the present invention. For the embodiments in the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0017] As Figure 1-6As shown in the figure, the figure includes a cable 4 with a built-in liquid cooling pipe. One end of the cable 4 is connected to a charging base connector 2, and the other end is connected to a liquid cooling connector 8. A water inlet pipe 5 is also connected to the charging base connector 2. The liquid cooling connector 8 includes a metal shell 13, a terminal liquid cooling module assembly 14, a sealing ring 15, and a rear cover 16. The terminal liquid cooling module assembly 14 includes a water tank main body 9 with a water tank structure. A metal upper cover 10 is provided at the upper end of the water tank main body 9. A plastic shell upper cover 11 is closed on the upper end of the metal upper cover 10. A plastic shell lower cover 12 is closed on the lower end of the water tank main body 9. On the upper plane of the metal upper cover 10, there are sequentially a thermal grease one 22, a ceramic cover plate 21, and a thermal grease two 20 from bottom to top. The other end of the cable 4 is provided with a welding terminal 18, and a fixing ring 30 is provided at the connection part. The lower plane of the welding terminal 18 is attached to the thermal grease two 20, and the bolt connection hole 23 provided at the front end of the welding terminal 18 protrudes forward above the terminal liquid cooling module assembly 14. The terminal liquid cooling module assembly 14 is designed with a modular water tank terminal assembly method. The terminal welding area is inside the water tank, and the bent part is outside the water tank. At this time, the overall structure of the water tank can adapt to connectors with different angle outlets, ensuring stable versatility. The heat transfer design between the water tank main body 9 and the welding terminal 18 uses thermal grease one, a ceramic cover plate, thermal grease two, and the welding terminal 18. Due to the creepage distance, the metal and the welding terminal 18 cannot be directly in contact. This design greatly increases the electrical safety performance. The ceramic cover plate itself has a risk of cracking when directly contacting the terminal and the metal water tank under severe vibration in the vehicle. The design of the thermal grease not only increases the liquid cooling heat dissipation performance itself but also becomes a buffer layer for the ceramic cover plate, reducing the collision between metals.

[0018] The structures of the plastic shell upper cover 11 and the plastic shell lower cover 12 use the form of upper and lower plastic covers to fix the water tank main body 9 and the welding terminal 18, effectively positioning the positions of the welding terminal 18 and the water tank main body 9, and serving as a protection structure. In addition, a combination of buckles and bolts is used. Considering the structure of the water tank on the water tank main body 9, two small bolts are used to fix the water outlet direction, and one large bolt is used to fix the direction of the exposed terminal. Buckles are supplemented on the side to achieve the purpose of preliminary fixation. As Figure 1 shown, a through-hole rubber sleeve 3 is sleeved on the cable 4, and the water inlet pipe 5 is fixed on the through-hole rubber sleeve 3. The through-hole rubber sleeve 3 can make the cable structure neater.

[0019] As Figure 1 shown, a guard plate 6 is also provided on the cable 4. The overall shape of the cable 4 is L-shaped to ensure that it does not affect the fluid flow rate in the liquid cooling pipe. The guard plate 6 is fixed with multiple points staggered and has a smooth design to ensure the stability when the water flows into the water inlet.

[0020] As Figure 6As shown, the charging base connector 2 is connected to the charging base socket 1. The charging base connector 2 includes a housing assembly 29 and a liquid cooling module 28 with a closed water tank. The liquid cooling module 28 is placed inside the housing assembly 29. One side of the liquid cooling module 28 is provided with a cable connection port and a water inlet. The cable connection port is connected to one end of the cable 4, and the water inlet is connected to the water inlet pipe 5. The charging base connector 2 also uses a liquid cooling modular water tank design, ensuring the consistency of liquid cooling efficiency.

[0021] As Figure 2 shown, an inclined channel 19 is provided at the upper end of the metal housing 13. The metal housing 13 is connected to the bolt connection hole 23 provided at the front end of the welding terminal 18 through a fixing bolt 17 placed in the inclined channel 19. The sealing ring 15 and the rear cover 16 are sleeved on the cable 4 and fixed to the rear end of the metal housing 13. The terminal liquid cooling module assembly 14 is inserted into the metal housing 13, and the welding terminal 18 at its front end is located at the end of the inclined channel 19. The terminal liquid cooling module assembly 14 and the metal housing 13 are fixedly connected through the fixing bolt 17.

[0022] As Figure 3 shown, the plastic shell lower cover 12 is connected to the metal upper cover 10 through bolts, so that the water tank main body 9 is located between the plastic shell lower cover 12 and the metal upper cover 10. A placement groove 24 for limiting and fixing the fixing ring 30 is provided on the plastic shell lower cover 12. The cable 4 is crimped with a crimping ring and then installed in the corresponding placement groove 24 of the plastic cover, so that the water nozzle connection is not pulled by external force after assembly.

[0023] As Figure 3 shown, the plastic shell lower cover 12 and the plastic shell upper cover 11 are connected by snaps. A combination of snaps and bolts is used, and snaps are supplemented on the side to achieve the purpose of preliminary fixation.

[0024] As Figure 5 shown, the water tank main body 9 includes a water tank 25. One side of the water tank 25 is provided with a water outlet 26 and a cable connection port 27. The upper part of the water tank 25 is connected to the metal upper cover 10 through bolts to form a sealed water storage structure. The water outlet pipe 7 is connected to the water outlet 26, and the other end of the cable 4 is connected to the cable connection port 27. The water tank 25 is formed by die-casting metal, ensuring wear resistance under long-term water flow and can simultaneously die-cast the water outlet 26, reducing the risk of seal failure. The water tank main body 9 adopts an upper and lower cover design and is fixed with bolts on four sides, reducing the risk of seal failure.

[0025] Working principle: Water is supplied by the in-vehicle water pump and connected to the water inlet on the liquid cooling module 28 through the water inlet pipe 5, allowing the in-vehicle water to enter the cable 4. It passes through the entire charging harness, and heat is carried away by the fluid. Then it flows into the water tank 25 on the terminal liquid cooling module assembly 14 and flows out through the outlet pipe 7 connected to the water outlet 26, and then flows into the in-vehicle water pump. Thus, the purpose of circulating heat dissipation is achieved. Due to the heat transfer design between the water tank body 9 and the welded terminal 18, using metal, thermal grease one, ceramic cover plate, thermal grease two, and welded terminal 18, heat dissipation can be better carried out.

[0026] During the application of the liquid-cooled charging harness, a crimping limit ring 20 is used to resist the risk of pulling on the water pipe interface under different cable orientations. In the use of the liquid-cooled charging harness, there will be a temperature difference between the two sides of the terminals. Therefore, a one-in-one-out water flow direction needs to be adopted to ensure the stability of the temperatures of the two sides of the terminals. The degree of fit between the water tank and the terminals determines the cooling effect. Therefore, a plastic buckle is used to fasten up and down for the first fixation, and then a bolt connection method is used to fix the upper and lower plastic parts of the water tank again to make them fit closely and give full play to the heat dissipation performance. The power terminals of the liquid-cooled connector use a bolt connection method, and the contact resistance is significantly reduced compared with the quick-connect connector, improving its current-carrying capacity. To ensure assembly convenience, the water pipe is plug-and-play for the water tank, without complex assembly methods, saving labor and working hours.

[0027] Temperature rise test (rated): Test conditions: According to the layout state of the vehicle wiring harness, the liquid inlet is at the connector end, the liquid outlet is at the charging seat end, and a 150mm² copper wire charging gun is used at the charging seat end.

[0028] Test current: 1. 400A / 500A / 600A / 650A (35mm²); 2. 600A / 700A / 800A / 900A (70mm²); Ambient temperature: ≥30°C; Liquid temperature: 65°C; Test flow rate: 2.0L / min; Monitoring positions: Welding, core wire, terminal, contact, wire sheath, liquid inlet temperature; The calculation method of the temperature rise K value is: Stable temperature - Temperature before sample current loading; Judgment rules: Temperature rise at the charging seat end ≤ 50K; Temperature rise at the connector end and the cable ≤ 55K.

[0029] The specific data results are as shown in Table 1 and Table 2 below.

[0030] Table 1:

[0031] Table 2:

[0032] It can be seen from the test data in Tables 1 and 2 that with the addition of the liquid cooling system, the current-carrying capacity of 35 mm² copper wire and 70 mm² copper wire has been significantly improved. For the 35 mm² copper wire, the current-carrying capacity has been increased from 400 A to 650 A from the conventional 200 A, and for the 70 mm² copper wire, the current-carrying capacity has been increased from 600 A to 900 A from the conventional 300 A. The temperature rise at the charging socket end and the temperature rise at the connector end and the cable do not exceed 55 K. This liquid-cooled charging harness can significantly improve the vehicle charging speed.

[0033] Temperature rise test (MAP): Test conditions: According to the layout state of the vehicle wiring harness, the liquid inlet is the connector end, the liquid outlet is the charging socket end, and a 150 mm² copper wire charging gun is used at the charging socket end.

[0034] Test current: 1150 A & 1.1 min + 1050 A & 1 min + 1000 A & 1.5 min + 950 A & 0.5 min + 800 A & 0.8 min + 760 A & 0.7 min + 680 A & 0.8 min + 620 A & 0.8 min; Ambient temperature: ≥ 30 °C; Liquid temperature: 65 °C; Test liquid cooling flow rate: 1.0 L / min, 1.5 L / min, 2.0 L / min; Monitoring positions: Welding, core wire, terminal, contact, wire sheath, liquid inlet temperature; The calculation method of the temperature rise K value is: the highest temperature - the temperature of the sample before current loading; Judgment rule: Record the actual value; Test sample: 70 mm² liquid-cooled charging harness.

[0035] The specific data results are as follows, shown in Table 3.

[0036] Table 3:

[0037] It can be seen from the test data in Table 3 that under different charging conditions, namely the condition of 1150A&1.1min+1050A&1min+1000A&1.5min+950A&0.5min+800A&0.8min+760A&0.7min+680A&0.8min+620A&0.8min, the temperature rises reflected by setting the liquid cooling flow rate at 1.0L / min, 1.5L / min, and 2.0L / min respectively. The liquid cooling charging harness used is 70mm², and its test flow rate of 900A is the limit test state. However, under different charging conditions, it can be seen that the more coolant flows through, the more heat is carried away per unit time, and the heat dissipation effect is better when the liquid cooling flow rate is 2.0L / min. The conventional current-carrying capacity of 70mm² copper wire is 300A. Under the condition of exceeding the rated current, even exceeding the limit test state with a flow rate of 900A, the short-time maximum temperature at each monitoring position is also below 140°C, which is below the safe temperature tolerance.

[0038] As described above, it is only the preferred specific implementation manner of the present invention, but the protection scope of the present invention is not limited thereto. Any person skilled in the art within the technical scope disclosed by the present invention, according to the technical solution and inventive concept of the present invention, makes equivalent substitutions or changes, and should be covered by the protection scope of the present invention.

Claims

1. A liquid-cooled charging harness, comprising a cable (4) with an internal liquid-cooling tube, characterized in that: One end of the cable (4) is connected to the charging base connector (2), and the other end is connected to the liquid cooling connector (8). The charging base connector (2) is also connected to the water inlet pipe (5). The liquid cooling connector (8) includes a metal housing (13), a terminal liquid cooling module assembly (14), a sealing ring (15), and a rear cover (16). The terminal liquid cooling module assembly (14) includes a water tank body (9) with a metal structure. The upper end of the water tank body (9) is provided with a metal upper cover (10). The upper end of the metal upper cover (10) is covered with a plastic shell upper cover (11). The lower end of the water tank body (9) is covered with a plastic shell lower cover (12). On the upper plane of the metal upper cover (10), a thermal grease one (22), a ceramic cover plate (21), and a thermal grease two (20) are welded in sequence from bottom to top. The other end of the cable (4) is provided with a welding terminal (18). A fixing ring (30) is provided at the connection part. The lower plane of the welding terminal (18) is attached to the thermal grease two (20), and the bolt connection hole (23) provided at the front end of the welding terminal (18) protrudes forward above the terminal liquid cooling module assembly (14). The water tank body (9) includes a water tank (25). One side of the water tank (25) is provided with a water outlet (26) and a cable connection port (27). The upper part of the water tank (25) is connected to the metal upper cover (10) by bolts to form a closed water storage structure. The water outlet (26) is connected to the water outlet pipe (7), and the cable connection port (27) is connected to the other end of the cable (4).

2. The liquid-cooled charging harness according to claim 1, wherein: A through-hole rubber sleeve (3) is sleeved on the cable (4), and the water inlet pipe (5) is fixed on the through-hole rubber sleeve (3).

3. The liquid-cooled charging harness according to claim 1, characterized in that: A protective plate (6) is also provided on the cable (4).

4. The liquid-cooled charging wire harness according to claim 1, wherein: The charging base connector (2) is connected to the charging base socket (1). The charging base connector (2) includes a housing assembly (29) and a liquid cooling module (28) with a closed water tank. The liquid cooling module (28) is placed in the housing assembly (29). One side of the liquid cooling module (28) is provided with a cable connection port and a water inlet. The cable connection port is connected to one end of the cable (4), and the water inlet is connected to the water inlet pipe (5).

5. The liquid-cooled charging wire harness according to claim 1, wherein: An inclined channel (19) is provided at the upper end of the metal housing (13). The metal housing (13) is connected to the bolt connection hole (23) provided at the front end of the welding terminal (18) through a fixing bolt (17) placed in the inclined channel (19).

6. The liquid-cooled charging harness according to claim 1, wherein: The sealing ring (15) and the rear cover (16) are sleeved on the cable (4) and fixed to the rear end of the metal housing (13).

7. The liquid-cooled charging wire harness according to claim 1, wherein: The plastic shell lower cover (12) is connected to the metal upper cover (10) by bolts, so that the water tank body (9) is located between the plastic shell lower cover (12) and the metal upper cover (10). A placement groove (24) for limiting the fixing ring (30) is provided on the plastic shell lower cover (12).

8. The liquid-cooled charging harness according to claim 1, wherein: The plastic shell lower cover (12) and the metal upper cover (10) are connected by a buckle.

Images