A liquid-cooled charging pile

Abstract

The present invention provides a liquid-cooled charging pile, which relates to the technical field of charging piles, including a box body, a phase change heat exchanger and a first circulating pump, wherein a charging module is arranged in the box body, and the box body is filled with insulating coolant; the liquid inlet of the phase change heat exchanger is connected to the box body; one end of the first circulating pump is connected to the liquid outlet of the phase change heat exchanger, and the other end is connected to the box body; the present invention arranges the charging module in the box body and fills the box body with insulating coolant. Under the circulation action of the first circulating pump, the heat generated by the charging module can be continuously drawn out and stored in the phase change material of the phase change heat exchanger, thereby avoiding the problem that the charging module works for a long time in a high-temperature environment, resulting in reduced work efficiency or even fire, thereby ensuring the safety of the charging process and the high and stable charging efficiency, and is particularly suitable for occasions with high charging power such as fast charging piles.

Description

Technical Field

[0001] The present invention relates to the technical field of charging piles, and in particular to a liquid-cooled charging pile. Background Art

[0002] With technological advancements, the electric vehicle market has experienced explosive growth, and the demand for charging stations has also increased year-on-year. Supercharging stations offer higher charging power and faster charging speeds, resulting in greater market demand than standard charging stations.

[0003] Charging stations operate by converting AC power from the grid into DC power with adjustable voltage and current, which is then used to charge the battery pack within the electric vehicle. High voltage and current generate significant heat in the power components and charging cables within the station, causing the station's temperature to rise dramatically. This phenomenon is particularly pronounced in supercharging stations. Currently, charging a household new energy electric vehicle to 80% requires at least 30 minutes, primarily due to heating of the conductors and terminals during prolonged high-current charging. Excessive localized temperatures can lead to device degradation or even failure, potentially causing safety hazards such as ignition of flammable materials. This forces the charging station to implement current limiting when temperatures rise. This significantly limits charging efficiency and increases charging time. Summary of the Invention

[0004] The purpose of the present invention is to provide a liquid-cooled charging pile to solve the problems existing in the prior art. It can avoid the problem that the charging module works for a long time in a high-temperature environment, resulting in reduced work efficiency or even fire, and ensure the safety of the charging process and the high and stable charging efficiency.

[0005] To achieve the above object, the present invention provides the following solutions:

[0006] A liquid-cooled charging pile includes a box, a phase-change heat exchanger and a first circulating pump. A charging module is provided in the box, and the box is filled with insulating coolant. The liquid inlet of the phase-change heat exchanger is connected to the box. One end of the first circulating pump is connected to the liquid outlet of the phase-change heat exchanger, and the other end is connected to the box.

[0007] As one embodiment, it also includes a charging cable that is communicatively connected to the charging module, and the end of the charging cable is provided with a charging gun for connecting to the battery pack of an electric vehicle. A power core wire and a coolant return pipeline are provided in the charging cable, and the power core wire is communicatively connected to the charging module. The radial cross-section of the power core wire is a ring structure, and a coolant inlet pipeline is provided on the inner side of the ring structure. The inlet end of the coolant inlet pipeline is connected to the box body, and the outlet end of the coolant inlet pipeline is connected to the inlet end of the coolant return pipeline. The outlet end of the coolant return pipeline is connected to the box body through a second circulation pump.

[0008] As an embodiment, an air-cooled radiator is further provided between the liquid outlet end of the coolant return pipeline and the second circulation pump.

[0009] As an embodiment, the inner wall of the coolant inlet pipeline has a flow-disturbing structure for disturbing the flow of the coolant.

[0010] As an embodiment, the charging cable includes a sheath, in which the power core wire, the coolant return pipeline, the ground wire and the auxiliary power core wire are arranged. The ground wire and the auxiliary power core wire are both communicatively connected to the charging module.

[0011] As one embodiment, the sheath is further provided with a first control core wire and a second control core wire, both of which are communicatively connected to the charging module. A temperature sensor for monitoring the temperature of the charging cable is provided at the end of the first control core wire; the second control core wire is connected to the charging gun for controlling the on and off of the charging process.

[0012] As one embodiment, the power core wire is located in the middle of the sheath, the first control core wire and the second control core wire are located on one side of the power core wire, and the auxiliary power core wire and the ground wire are located on the other side of the power core wire.

[0013] As an embodiment, a pile body is further included, in which the box body, the air-cooled radiator, the first circulating pump, the second circulating pump and the phase change heat exchanger are arranged.

[0014] As an embodiment, the pile body is further provided with a leakage circuit breaker, a contactor, a DC output component, a surge protector, a display screen controller, a card reader and a charging indicator light.

[0015] As one embodiment, the coolant is perfluoropolyether.

[0016] Compared with the prior art, the present invention has the following technical effects:

[0017] The present invention arranges the charging module in a box and fills the box with insulating coolant. Under the circulation action of the first circulation pump, the heat generated by the charging module can be continuously drawn out and stored in the phase change material of the phase change heat exchanger, thereby avoiding the problem that the charging module works for a long time in a high-temperature environment, resulting in reduced work efficiency or even fire. The safety of the charging process and the high and stable charging efficiency are ensured, and it is particularly suitable for occasions with high charging power such as fast charging charging piles.

[0018] Other technical solutions in the present invention have the following technical effects compared with the prior art:

[0019] 1. The present invention provides a coolant inlet pipeline inside the power core cable, which increases the contact area between the coolant and the power core cable, improves heat transfer efficiency, and can quickly dissipate heat generated by the charging cable. This prevents the charging cable from overheating, which can lead to increased resistance and reduced charging efficiency, or even ignite combustible materials around the power core cable and cause fire.

[0020] 2. The inner wall of the coolant inlet pipe in the present invention has a flow-disturbing structure that disturbs the coolant flow. This structure causes the coolant in the coolant inlet pipe to experience turbulent flow and mixing, thereby enhancing the convective heat transfer effect between the coolant in the coolant inlet pipe and further improving the heat exchange efficiency between the coolant and the power core. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0022] Figure 1 A schematic diagram of the cooling principle of a liquid-cooled charging pile in one embodiment of the present invention;

[0023] Figure 2 This is a schematic diagram of the radial structure of a charging cable in one embodiment of the present invention;

[0024] Figure 3 This is a schematic diagram of the inner wall of the cooling liquid inlet pipeline in one embodiment of the present invention;

[0025] Figure 4 for Figure 3 Schematic diagram of the axial perspective;

[0026] Figure 5 This is a schematic structural diagram of a liquid-cooled charging pile in one embodiment of the present invention.

[0027] Description of reference numerals:

[0028] 1. Housing; 2. Phase-change heat exchanger; 3. First circulation pump; 4. Charging module; 5. Charging gun; 6. Power core wire; 7. Coolant return line; 8. Coolant inlet line; 9. Second circulation pump; 10. Air-cooled radiator; 11. Turbine structure; 12. Sheath; 13. Ground wire; 14. Auxiliary power core wire; 15. First control core wire; 16. Second control core wire; 17. Pile; 18. Leakage circuit breaker; 19. Contactor; 20. DC output component; 21. Surge protector; 22. Display controller; 23. Card reader; 24. Charging indicator light; 25. Temperature sensor; 26. PTC thermistor. DETAILED DESCRIPTION

[0029] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0030] The purpose of the present invention is to provide a liquid-cooled charging pile to solve the problems existing in the prior art. It can avoid the problem that the charging module works for a long time in a high-temperature environment, resulting in reduced work efficiency or even fire, and ensure the safety of the charging process and the high and stable charging efficiency.

[0031] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the present invention is further described in detail below with reference to the accompanying drawings and specific embodiments.

[0032] like Figures 1 to 5 As shown, this embodiment provides a liquid-cooled charging pile, including a box body 1, a phase change heat exchanger 2 and a first circulation pump 3. A charging module 4 is provided in the box body 1, and the box body 1 is filled with an insulating coolant, such as deionized water or perfluoropolyether; the liquid inlet of the phase change heat exchanger 2 is connected to the box body 1; one end of the first circulation pump 3 is connected to the liquid outlet of the phase change heat exchanger 2, and the other end is connected to the box body 1. The first circulation pump 3 is used to provide power for the circulation of the coolant. The phase change heat exchanger 2 includes a circulation pipeline and a phase change material. The phase change material can exchange heat with the circulating medium in the circulation pipeline and store heat. The phase change heat exchanger 2 is a commonly used device in this field, and the specific structure thereof will not be described in detail in this embodiment.

[0033] During use, charging module 4 controls the flow of current and the normal operation of other electrical components within the charging pile. Over extended periods of use, charging module 4 generates significant heat, which the coolant dissipates. The coolant then exchanges heat with the phase-change material in phase-change heat exchanger 2, where it absorbs the heat and undergoes a phase change, lowering the coolant's temperature. The coolant, driven by first circulating pump 3, continuously dissipates the heat generated by charging module 4, cooling it. When the charging pile is initially activated in cold weather, the temperature of charging module 4 is relatively low. The phase-change material releases this heat, allowing charging module 4 to quickly reach a suitable operating temperature and improve charging efficiency.

[0034] Therefore, this embodiment sets the charging module 4 in the box body 1 and fills the box body 1 with insulating coolant. Under the circulation action of the first circulation pump 3, the heat generated by the charging module 4 can be continuously drawn out and stored in the phase change material of the phase change heat exchanger 2, thereby avoiding the problem that the charging module 4 works for a long time in a high temperature environment, resulting in reduced work efficiency or even fire, ensuring the safety of the charging process and the high efficiency and stability of the charging efficiency, and is particularly suitable for occasions with high charging power such as fast charging charging piles.

[0035] like Figure 2 As shown, this embodiment also includes a charging cable that is communicatively connected to the charging module 4. The end of the charging cable is provided with a charging gun 5 for connecting to the battery pack of the electric vehicle. A power core wire 6 and a coolant return line 7 are provided in the charging cable. The power core wire 6 is communicatively connected to the charging module 4. The radial cross-section of the power core wire 6 is a ring structure. A coolant inlet line 8 is provided on the inner side of the ring structure. The inlet end of the coolant inlet line 8 is connected to the box 1, and the outlet end of the coolant inlet line 8 is connected to the inlet end of the coolant return line 7. The outlet end of the coolant return line 7 is connected to the box 1 through a second circulation pump 9. The power core wire 6 is the core part that undertakes power transmission. Its main function is to directly connect the charging pile and the battery pack of the electric vehicle, and is responsible for efficiently transmitting alternating current (AC) or direct current (DC) power to the battery pack. In the fast charging scenario, the power core wire 6 needs to carry a current of up to hundreds of amperes (such as DC fast charging can reach more than 200A). A coolant inlet pipe 8 is provided inside the power core wire 6, so that the contact area between the coolant and the power core wire 6 is larger, the heat transfer efficiency is higher, and the heat generated by the charging cable can be quickly taken out, thereby avoiding the problem of increased resistance caused by excessive temperature of the charging cable, which reduces the charging efficiency, and even causes combustible materials around the power core wire 6 to ignite and catch fire.

[0036] In this embodiment, an air-cooled radiator 10 is further provided between the outlet end of the coolant return line 7 and the second circulation pump 9. The air-cooled radiator 10 includes a fan and a coil. The coolant flows through the coil. After the coolant passes through the power core 6, the temperature rises. When the coolant flows through the air-cooled radiator 10, the fan blows out the hot air around the coil, and the outside cold air refills the coil, achieving air cooling of the coil and the coolant inside it, thereby further reducing the coolant temperature and preventing the coolant from being at a high temperature after a long period of heat exchange, which would cause the cooling capacity of the coolant to decrease.

[0037] like Figure 3 、 Figure 4 As shown, in this embodiment, the inner wall of the coolant inlet pipe 8 has a flow-disturbing structure 11 that disturbs the coolant flow. The flow-disturbing structure 11 causes the coolant in the coolant inlet pipe 8 to experience turbulence, turbulence, and mixing, thereby improving the heat exchange effect between the coolant within the coolant inlet pipe 8 and further improving the heat exchange efficiency between the coolant and the power core 6. Specifically, the flow-disturbing structure 11 can be a protrusion or a groove structure.

[0038] Of course, a turbulent structure 11 may also be provided inside the coolant return pipe 7 to improve the uniformity of the temperature inside the coolant.

[0039] In this embodiment, the charging cable includes a sheath 12, in which a power core wire 6, a coolant return line 7, a ground wire 13, and an auxiliary power core wire 14 are arranged. The ground wire 13 and the auxiliary power core wire 14 are both connected to the charging module 4. The sheath 12 is also provided with a filling material. The filling material is combined with multiple cables to form a composite cable with a cross-section that is approximately circular, so as to maintain the cylindrical structure of the sheath 12. Specifically, the filling material is made of flame-retardant high-strength PP rope (polypropylene rope) with a tensile strength of 50N·mm -2 The sheath 12 is made of thermoplastic polyurethane elastomer, which has the characteristics of high wear resistance and good tear resistance, and a tensile strength of 43MPa.

[0040] In this embodiment, the sheath 12 also houses a first control core wire 15 and a second control core wire 16, both of which are connected to the charging module 4. A temperature sensor 25 is located at the end of the first control core wire 15 to monitor the temperature of the charging cable. This temperature sensor 25 communicates with the charging module 4 via the first control core wire 15, providing real-time feedback on the charging cable's operating temperature. When the charging cable's temperature reaches a certain range, the charging module 4 increases the circulation speeds of the first and second circulation pumps 3 and 9 to improve heat exchange. The second control core wire 16 is connected to the charging gun 5 to control the on / off state of the charging process.

[0041] In this embodiment, the power core wire 6 is located in the middle of the sheath 12, the first control core wire 15 and the second control core wire 16 are located on one side of the power core wire 6, and the auxiliary power core wire 14 and the ground wire 13 are located on the other side of the power core wire 6. The coolant return line 7 can be located on the side where the first control core wire 15 and the second control core wire 16 are located.

[0042] This embodiment also includes a pile body 17, which houses the housing 1, air-cooled radiator 10, first circulating pump 3, second circulating pump 9, and phase-change heat exchanger 2. The charging cable can be stored within the pile body 17, with its end connected to the charging gun 5. The charging gun 5 is typically mounted on the pile body 17.

[0043] like Figure 5 As shown, in this embodiment, the pile body 17 is also provided with a PTC (Positive Temperature Coefficient) thermistor 26, a leakage circuit breaker 18, a contactor 19, a DC output component 20, a surge protector 21, a display controller 22, a card reader 23, and a charging indicator light 24. The PTC thermistor 26 is used for overheating protection; the leakage circuit breaker 18 and the contactor 19 are used to ensure power safety; the DC output component 20 is used to convert AC power into DC power; the surge protector 21 ensures safe and stable operation of the system by quickly discharging or limiting abnormally high voltage / current; the display controller 22 includes a display screen and a control panel. The display screen is exposed to the pile body 17. The control panel is in communication with the charging module 4 and is used to display the current working status of the charging pile on the display screen. The charging indicator light 24 is used to indicate the current charging status. For example, the red light of the charging indicator light 24 indicates that charging is in progress, and the green light indicates that charging is complete. The card reader 23 can be used to read the user's card information, such as a stored-value card. The above components are all commonly used equipment in this field, which are used to maintain the normal operation of the charging pile. The detailed structure of each component is not described in detail in this embodiment.

[0044] Adaptive changes based on actual needs are all within the scope of protection of the present invention.

[0045] The present invention uses specific examples to illustrate the principles and implementation methods of the present invention. The above examples are only intended to help understand the method and core concept of the present invention. At the same time, those skilled in the art will find that the specific implementation methods and application scopes may vary based on the concept of the present invention. In summary, the contents of this specification should not be construed as limiting the present invention.

Claims

1. A liquid-cooled charging pile, characterized in that: include: A box body, wherein a charging module is arranged in the box body and the box body is filled with insulating coolant; a phase-change heat exchanger, wherein a liquid inlet of the phase-change heat exchanger is in communication with the housing; and a first circulation pump, one end of which is connected to the liquid outlet of the phase change heat exchanger, and the other end of which is connected to the tank; It also includes a charging cable that is communicatively connected to the charging module, wherein the end of the charging cable is provided with a charging gun for connecting to the battery pack of the electric vehicle, and a power core wire and a coolant return line are provided in the charging cable, wherein the power core wire is communicatively connected to the charging module, and the radial cross-section of the power core wire is an annular structure, and a coolant inlet line is provided on the inner side of the annular structure, wherein the inlet end of the coolant inlet line is communicated with the box body, the outlet end of the coolant inlet line is communicated with the inlet end of the coolant return line, and the outlet end of the coolant return line is communicated with the box body via a second circulation pump; An air-cooled radiator is further provided between the liquid outlet end of the coolant return pipeline and the second circulating pump; The inner wall of the coolant inlet pipeline has a flow disturbing structure for disturbing the coolant.

2. The liquid-cooled charging pile according to claim 1, characterized in that: The charging cable includes a sheath, in which the power core wire, the coolant return pipeline, the ground wire and the auxiliary power core wire are arranged. The ground wire and the auxiliary power core wire are both communicatively connected to the charging module.

3. The liquid-cooled charging pile according to claim 2, characterized in that: The sheath is also provided with a first control core wire and a second control core wire, both of which are communicatively connected to the charging module. The end of the first control core wire is provided with a temperature sensor for monitoring the temperature of the charging cable; the second control core wire is connected to the charging gun for controlling the on and off of the charging process.

4. The liquid-cooled charging pile according to claim 3, characterized in that: The power core wire is located in the middle of the sheath, the first control core wire and the second control core wire are located on one side of the power core wire, and the auxiliary power core wire and the ground wire are located on the other side of the power core wire.

5. The liquid-cooled charging pile according to claim 1, characterized in that: It also includes a pile body, in which the box body, the air-cooled radiator, the first circulating pump, the second circulating pump and the phase change heat exchanger are arranged.

6. The liquid-cooled charging pile according to claim 5, characterized in that: The pile body is also provided with a leakage circuit breaker, a contactor, a DC output component, a surge protector, a display screen controller, a card reader and a charging indicator light.

7. The liquid-cooled charging pile according to claim 1, characterized in that: The coolant is perfluoropolyether.

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