A liquid-cooled charging harness

Abstract

The present invention relates to the technical field of charging structures, and in particular to a liquid-cooled charging harness. This liquid-cooled charging harness includes a cable with a built-in liquid cooling tube, one end of the cable is connected to the charging seat connector, and the other end is connected to the liquid-cooled connector. The liquid-cooled connector includes a metal shell, a terminal liquid cooling module assembly, a sealing ring and a back cover. The terminal liquid cooling module assembly includes a water tank body with a water tank structure. The upper end of the water tank body is provided with a metal upper cover, the upper end of the metal upper cover is covered with the metal upper cover, and the lower end of the water tank body is covered with a plastic shell lower cover. This liquid-cooled charging harness is configured with liquid cooling modules at both ends, which can effectively dissipate heat. The overall design uses a modular solution. Through liquid cooling modular assembly, it can be applied to different connectors and charging seats, shortening the development cycle. The liquid cooling system has safe and reliable operation. The thermal grease and ceramic cover plate effectively increase the thermal conductivity efficiency and reduce the impact on the ceramic cover plate.

Description

Technical Field

[0001] The present invention relates to a wiring harness, in particular to a liquid-cooled charging wiring harness. Background Art

[0002] Major automakers are preparing to launch their own 800V platforms. With this significant increase in current, if no cooling measures are implemented, the most direct impact is that the cables will become thicker, resulting in a poorer charging experience. Research into heat dissipation within cables has revealed that, based on the current-based standard for selecting wire size, thicker charging cables are necessary, but this will increase vehicle weight and cost.

[0003] However, if the charging current is increased without increasing the cross-sectional area of ​​the conductor, the cable will generate excessive heat and damage the insulation layer. To increase the current and the charging power, additional heat dissipation measures must be added while maintaining the current cable structure. If the cable specifications remain unchanged, then some complex measures need to be taken, such as adding a cooling system. Whether using an external cooling cycle for the cable or a cooling cycle inside the cable, not only can the temperature drop rapidly, but the weight and cost of the cable will also be reduced. The water pipe connected to the cable is easily dragged, causing the interface to leak. A fixed structure must be added to the cable to ensure the stability of the interface. At the same time, the heat dissipation of the terminal in the metal connector needs to be solved. Conventional ceramic sheets are fragile, and a transition layer needs to be added to match the terminal. Summary of the Invention

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

[0005] In order to overcome the defects existing in the background technology, the technical solution adopted by the present invention to solve its technical problems is: this liquid-cooled charging harness includes a cable with a built-in liquid cooling pipe, one end of the cable is connected to the charging seat connector, and the other end is connected to the liquid cooling connector. The charging seat connector is also connected to a water inlet pipe. The liquid cooling connector includes a metal shell, a terminal liquid cooling module assembly, a sealing ring and a back cover. The terminal liquid cooling module assembly includes a water tank body with a water tank structure. The upper end of the water tank body is provided with a metal upper cover, 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. , thermal grease 1, ceramic cover plate, and thermal grease 2 are welded on the upper plane of the metal cover in sequence from bottom to top. The other end of the cable is provided with a welding terminal, and a fixing ring is provided at the connection. The lower plane of the welding terminal is attached to the thermal grease 2, and the bolt connection hole provided at the front end of the welding terminal protrudes from the upper front of the terminal liquid cooling module assembly. The water tank body includes a water tank, and a water outlet and a cable connection port are provided on one side of the water tank. The top of the water tank is connected to the metal cover by bolts to form a closed water storage structure. The water outlet is connected to the water outlet pipe, and the cable connection port is connected to the other end of the cable.

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

[0007] According to another embodiment of the present invention, a protective plate is further provided on the cable.

[0008] According to another embodiment of the present invention, the charging base connector is further connected to the charging base socket, and the charging base connector includes a shell assembly and a liquid cooling module with a closed water tank. The liquid cooling module is placed in the shell assembly, and the liquid cooling module includes a cable connection port and a water inlet on one side, 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, an inclined channel is further provided at the upper end of the metal shell, and the metal shell is connected to a bolt connection hole provided at the front end of the welding terminal by a fixing bolt placed in the inclined channel.

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

[0011] According to another embodiment of the present invention, the lower cover of the plastic shell is further connected to the metal upper cover by bolts, so that the water tank body is located between the lower cover of the plastic shell and the metal upper cover, and a placement groove for a limiting fixing ring is provided on the lower cover of the plastic shell.

[0012] According to another embodiment of the present invention, the lower cover of the plastic shell and the upper cover of the plastic shell are further connected by snap fasteners.

[0013] The present invention provides the following benefits: This liquid-cooled charging harness features liquid cooling modules at both ends for effective heat dissipation. The overall modular design allows for modular assembly of liquid cooling components, adapting to various connectors and charging stations, shortening development cycles. The liquid cooling system offers safe and reliable operation, while the thermal grease and ceramic cover effectively increase thermal conductivity and reduce impact on the ceramic cover. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The present invention will be further described below with reference to the accompanying drawings and examples.

[0015] Figure 1 It is a structural schematic diagram of the present invention;

[0016] Figure 2 It is a structural diagram of the liquid cooling connector;

[0017] Figure 3 It is a structural diagram of the exploded view of the liquid cooling connector;

[0018] Figure 4This is a structural diagram of the connection between the water tank body and the cable on the liquid cooling connector;

[0019] Figure 5 This is a schematic diagram of the structure of the water tank body on the liquid cooling connector;

[0020] Figure 6 It is a structural diagram of the charging base connector;

[0021] Among them: 1. Charging seat socket, 2. Charging seat connector, 3. Through-hole rubber sleeve, 4. Cable, 5. Water inlet pipe, 6. Guard plate, 7. Water outlet pipe, 8. Liquid cooling connector, 9. Water tank body, 10. Metal upper cover, 11. Plastic shell upper cover, 12. Plastic shell lower cover, 13. Metal shell, 14. Terminal liquid cooling module assembly, 15. Sealing ring, 16. Back cover, 17. Fixing bolt, 18. Welding terminal, 19. Inclined channel, 20. Thermal grease 2, 21. Ceramic cover, 22. Thermal grease 1, 23. Bolt connection hole, 24. Placement groove, 25. Water tank, 26. Water outlet, 27. Cable connection port, 28. Liquid cooling module, 29. Shell assembly, 30. Fixing ring. DETAILED DESCRIPTION

[0022] To make the objectives, technical solutions, and advantages of the embodiments of the present invention more clear, 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 only part of the embodiments of the present invention, not all of them. All other embodiments derived by persons of ordinary skill in the art without creative effort based on the embodiments of the present invention are within the scope of protection of the present invention.

[0023] like Figure 1-6As shown, the figure includes a cable 4 with a built-in liquid cooling pipe, 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, and the liquid cooling connector 8 includes a metal shell 13, a terminal liquid cooling module assembly 14, a sealing ring 15 and a back cover 16. The terminal liquid cooling module assembly 14 includes a water tank body 9 with a water tank structure, and 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, and 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, there are thermal grease 1 22, a ceramic cover plate 21, and thermal grease 2 20 in sequence 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 point. The lower plane of the welding terminal 18 is attached to the thermal grease 2 20, and the bolt connection hole 23 set at the front end of the welding terminal 18 protrudes from the upper front of 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 wires coming out at different angles, ensuring stable versatility. The heat transfer design between the water tank body 9 and the welding terminal 18 uses thermal grease 1, ceramic cover, thermal grease 2, and welding terminal 18. Due to the creepage distance, there is no direct contact between the metal and the welding terminal 18. This design greatly increases the electrical safety performance. The ceramic cover itself is in direct contact with the terminal and the metal water tank under severe vibration in the car, and there is a risk of breakage. The design of thermal grease not only increases the heat dissipation of liquid cooling itself, but also makes it a buffer layer for the ceramic cover, reducing collisions between metals.

[0024] The structure of the plastic upper cover 11 and the plastic lower cover 12 uses the plastic upper and lower covers to fix the water tank body 9 and the welding terminal 18, effectively positioning the position of the welding terminal 18 and the water tank body 9 as a protective structure. In addition, a combination of buckles and bolts is used. Considering the structure of the water tank on the water tank body 9, two small bolts are used to fix the direction of the water outlet, and a large bolt is used to fix the terminal exposure direction. The side is supplemented with buckles to achieve the purpose of preliminary fixing.

[0025] like Figure 1 As 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 more neat.

[0026] like Figure 1 As shown, a guard plate 6 is also provided on the cable 4. The cable 4 is in an L shape as a whole to ensure that the flow rate of the fluid in the liquid cooling tube is not affected. The guard plate 6 is fixed with multiple points of staggered position and a gentle design to ensure that the water flows steadily to the water inlet.

[0027] like 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 an enclosed water tank. The liquid cooling module 28 is placed in the housing assembly 29. The liquid cooling module 28 includes a cable connection port and a water inlet on one side. 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 to ensure consistent liquid cooling efficiency.

[0028] like Figure 2 As shown, the upper end of the metal housing 13 is provided with an inclined channel 19. The metal housing 13 is connected to the bolt connection holes 23 provided at the front ends of the welding terminals 18 via fixing bolts 17 placed within the inclined channel 19. A sealing ring 15 and a rear cover 16 are fitted over the cable 4 and secured to the rear end of the metal housing 13. The terminal liquid cooling module assembly 14 is inserted into the metal housing 13, with the welding terminals 18 at the front ends located at the ends of the inclined channel 19. Fixing bolts 17 securely connect the terminal liquid cooling module assembly 14 to the metal housing 13.

[0029] like Figure 3 As shown, the lower cover 12 of the plastic case is connected to the metal upper cover 10 by bolts, so that the water tank body 9 is located between the lower cover 12 of the plastic case and the metal upper cover 10. The lower cover 12 of the plastic case is provided with a placement groove 24 for the limit fixing ring 30. 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 faucet connection is not pulled by external forces after assembly.

[0030] like Figure 3 As shown, the lower cover 12 of the plastic shell is connected to the upper cover 11 of the plastic shell by means of buckles. The buckles and bolts are combined, and the side buckles are used to achieve the purpose of preliminary fixation.

[0031] like Figure 5 As shown, the water tank body 9 includes a water tank 25, with a water outlet 26 and a cable connection port 27 on one side. The top of the water tank 25 is bolted to a metal cover 10, forming a sealed 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. The water tank 25 is die-cast from metal to ensure wear resistance under long-term water flow. The water outlet 26 is also die-cast simultaneously, reducing the risk of seal failure. The water tank body 9 adopts a top and bottom cover design, secured with bolts on all four sides, reducing the risk of seal failure.

[0032] Working Principle: Water is supplied by the vehicle's water pump, which connects to the water inlet on the liquid cooling module 28 through the water inlet pipe 5. This water enters the cable 4, flows through the entire charging harness, and is then absorbed by the fluid, flowing into the water tank 25 on the terminal liquid cooling module assembly 14. It then flows out through the water outlet pipe 7 connected to the water outlet 26 and into the vehicle's water pump. This achieves a circulating heat dissipation effect. The heat transfer design between the water tank body 9 and the welding terminal 18, using metal, thermal grease 1, ceramic cover, thermal grease 2, and welding terminal 18, allows for better heat dissipation.

[0033] The liquid-cooled charging harness uses a crimping limit ring 20 during application, which has the ability to resist the risk of pulling the water pipe interface when the cable is in different directions. During the use of the liquid-cooled charging harness, there will be a temperature difference between the terminals on both sides, so it is necessary to adopt an inlet and outlet water path to ensure the temperature stability of the terminals on both sides. The degree of fit between the water tank and the terminal determines the cooling effect, so the upper and lower plastic buckles are used to fix it once, and then the upper and lower plastic parts of the water tank are fixed again with bolts to make them fit fully and exert the heat dissipation performance. The power terminal of the liquid-cooled connector uses a bolt connection method, and the contact resistance is significantly reduced compared to the quick-plug connector, which improves its current carrying capacity. To ensure the convenience of assembly, the water pipe is plug-and-play with the water tank, without the need for complex assembly methods, saving manpower and working hours.

[0034] Temperature rise test (rated):

[0035] Test conditions: According to the vehicle wiring harness layout, the liquid inlet is the connector end, the liquid outlet is the charging base end, and the charging base end uses a 150mm² copper wire charging gun.

[0036] Test current:

[0037] 1. 400A / 500A / 600A / 650A(35mm²);

[0038] 2. 600A / 700A / 800A / 900A(70mm²);

[0039] Ambient temperature: ≥30℃;

[0040] Liquid temperature: 65°C;

[0041] Test flow rate: 2.0L / min;

[0042] Monitoring location: welding, core wire, terminal, contact, wire sheath, and liquid inlet temperature;

[0043] The temperature rise K value is calculated as follows: stable temperature - sample temperature before current is applied;

[0044] Judgment rules:

[0045] Charging dock end temperature rise ≤50K;

[0046] The temperature rise of the connector end and cable is ≤55K.

[0047] The specific data results are as follows, as shown in Table 1 and Table 2.

[0048] Table 1:

[0049]

[0050] Table 2:

[0051]

[0052] From the test data in Tables 1 and 2, it can be seen that the current carrying capacity of 35mm² copper wire and 70mm² copper wire is significantly improved with the support of the liquid cooling system. The current carrying capacity of 35mm² copper wire is increased from 400A to 650A under the condition of conventional current carrying of 200A, and the current carrying capacity of 70mm² copper wire is increased from 600A to 900A under the condition of conventional current carrying of 300A. The temperature rise of the charging base end and the temperature rise of the connector end and the cable end do not exceed 55K. This liquid-cooled charging harness can greatly improve the vehicle charging speed.

[0053] Temperature rise test (MAP):

[0054] Test conditions: According to the vehicle wiring harness layout, the liquid inlet is the connector end, the liquid outlet is the charging base end, and the charging base end uses a 150mm² copper wire charging gun.

[0055] Test current:

[0056] 1150A&1.1min+1050A&1min+1000A&1.5min+950A&0.5min+800A&0.8min+760A&0.7min+680A&0.8min+620A&0.8min;

[0057] Ambient temperature: ≥30℃;

[0058] Liquid temperature: 65°C;

[0059] Test liquid cooling flow rate: 1.0L / min, 1.5L / min, 2.0L / min;

[0060] Monitoring location: welding, core wire, terminal, contact, wire sheath, and liquid inlet temperature;

[0061] The calculation method of temperature rise K value is: maximum temperature - sample temperature before current is loaded;

[0062] Decision rule: record the actual value;

[0063] Test sample: Liquid-cooled charging harness 70mm².

[0064] The specific data results are as follows, shown in Table 3.

[0065] Table 3:

[0066]

[0067] From the test data in Table 3, it can be seen that under different charging conditions, namely 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 rise is reflected when the liquid cooling flow rate is set 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 extreme test state. However, under different charging conditions, it can be seen that the more coolant flows, the more heat is taken away per unit time. The heat dissipation effect is better when the liquid cooling flow rate is 2.0L / min. The normal current carrying capacity of 70mm² copper wire is 300A. Under the condition of exceeding the rated current, and even under the extreme test condition of the flow rate of 900A, the short-term maximum temperature of each monitoring position is below 140℃, which is below the safe temperature resistance.

[0068] The above description is only a preferred specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any technician familiar with the technical field, within the technical scope disclosed by the present invention, who makes equivalent replacements or changes based on the technical solution and inventive concept of the present invention, should be covered by the scope of protection of the present invention.

Claims

1. A liquid-cooled charging harness comprising a cable (4) with a built-in liquid cooling tube, characterized in that: One end of the cable (4) is connected to the charging seat connector (2), and the other end is connected to the liquid cooling connector (8). The charging seat connector (2) is also connected to the water inlet pipe (5). The liquid cooling connector (8) includes a metal shell (13), a terminal liquid cooling module assembly (14), a sealing ring (15) and a back 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), thermal conductive silicone grease 1 (22), ceramic cover plate (21), and thermal conductive silicone grease 2 (20) are welded in sequence 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 point. The lower plane of the welding terminal (18) is attached to the thermal conductive silicone grease. The bolt connection hole (23) provided on the silicone grease (20) and the front end of the welding terminal (18) protrudes from the upper front of the terminal liquid cooling module assembly (14). The water tank body (9) includes a water tank (25). A water outlet (26) and a cable connection port (27) are provided on one side of the water tank (25). 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). The charging seat connector (2) is connected to the charging seat socket (1). The charging seat connector (2) includes a shell assembly (29) and a liquid cooling module (28) with a closed water tank. The liquid cooling module (28) is placed in the shell assembly (29). The liquid cooling module (28) includes a cable connection port and a water inlet on one side. 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).

2. The liquid-cooled charging harness according to claim 1, characterized in that: The cable (4) is sleeved with a through-hole rubber sleeve (3), 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 harness according to claim 1, characterized in that: An inclined channel (19) is provided at the upper end of the metal shell (13), and the metal shell (13) is connected to a bolt connection hole (23) provided at the front end of the welding terminal (18) via a fixing bolt (17) disposed in the inclined channel (19).

5. The liquid-cooled charging harness according to claim 1, characterized in that: 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).

6. The liquid-cooled charging harness according to claim 1, characterized in that: 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). The plastic shell lower cover (12) is provided with a placement groove (24) for the limiting fixing ring (30).

7. The liquid-cooled charging harness according to claim 1, characterized in that: The plastic shell lower cover (12) and the metal upper cover (10) are connected via snap fasteners.

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