A high-power charging pile charging cable insulation liquid cooling system and method

Abstract

The present application relates to the technical field of charging cable cooling, in particular to a high-power charging pile charging cable insulation liquid cooling system and method, comprising a cooling mechanism, the cooling mechanism is installed in the inside of the charging pile body, the cooling mechanism comprises a liquid cooling box assembly and a solid cooling anti-bending assembly, the cable body on one side in the charging box is immersed by the liquid cooling box assembly, and the solid cooling anti-bending assembly covers the surface of the cable body.The present application forms a circulating cooling system through the communication of the liquid cooling box assembly and the solid cooling anti-bending assembly, can continuously take away the heat generated by the high-power cable body when electrified, effectively guarantees the stable operation of the cable under high-power transmission, in addition, the connecting piece and the outer support structure cooperate to form a bending angle constraint system for the cable body, reduce the deformation, fracture or insulation layer damage of the cable body internal conductor strand caused by excessive bending, guarantee the safety of the charging process and the reliability of the liquid cooling.

Description

Technical Field

[0001] This invention relates to the field of charging cable cooling technology, and more specifically, to a liquid cooling system and method for the insulation of charging cables in high-power charging piles. Background Technology

[0002] With the rapid development of the new energy vehicle industry, the market demand for charging efficiency is becoming increasingly urgent. High-power charging piles, as charging facilities with high power output capabilities, can output power of tens or even hundreds of kilowatts, which can significantly shorten the charging time of electric vehicles and other equipment, and have become one of the key technologies for industry development.

[0003] Cross-linked polyethylene insulated power cables have become the preferred material for high-power charging piles due to their excellent performance. In terms of electrical performance, they have high insulation resistance and breakdown field strength, which can stably transmit the high voltage output of the charging pile and greatly reduce the risk of leakage. However, during high-power charging, a large amount of heat will be generated due to the large current and high power transmitted by the cable. If the heat cannot be dissipated in time, the cable temperature will continue to rise, accelerating the aging of the insulation layer. Therefore, effective cooling of the charging cable is a necessary measure to ensure the safe and efficient operation of the charging system.

[0004] In the prior art, such as the liquid-cooled high-toughness lightweight charging pile cable disclosed in Chinese Patent Publication No. CN222826134U, the cable is cooled by adding a liquid cooling pipe in the main insulated core to avoid the conductor temperature rising too quickly and thus reducing the transmission efficiency, thereby reducing the charging time and energy loss. However, the liquid cooling pipe in the main insulated core mainly cools the part of the conductor in contact with the liquid cooling pipe. For the conductor area far away from the liquid cooling pipe, the heat dissipation effect is relatively poor, and uneven heat dissipation is likely to occur.

[0005] In addition, high-power charging pile charging cables usually carry high current and high power power transmission tasks. They often use multi-strand stranded conductors. Nowadays, it is not easy to control the bending of charging pile cables. When using the charging pile, users are very likely to cause excessive bending of the cable due to improper operation. This will cause the strands of the stranded conductor to deform due to uneven stress, which will not only greatly reduce the power transmission efficiency, but also cause local overheating and accelerate the aging of the cable insulation layer.

[0006] Therefore, there is an urgent need for a liquid cooling system and method for the insulation of charging cables in high-power charging piles to solve the above problems. Summary of the Invention

[0007] This invention provides a liquid cooling system and method for the insulation of charging cables in high-power charging piles. It utilizes a micro-pump to pump insulating coolant to a solid cooling and anti-bending assembly, allowing the coolant to circulate within a flow chamber, exchanging heat with the cable. This removes heat generated by the cable and circulates it back. Simultaneously, a U-shaped rod and an inclined connecting plate work together to prevent excessive bending of the cable, thereby solving the problems mentioned in the background art.

[0008] Existing high-power charging pile charging cables suffer from uneven heat dissipation of liquid cooling pipes, difficulty in controlling bending, resulting in easy deformation of stranded conductors, reduced power transmission efficiency, local overheating, and accelerated aging of insulation layers.

[0009] To achieve the above objectives, one objective of this invention is to provide a high-power charging pile charging cable insulation liquid cooling system, including a cooling mechanism installed inside the charging pile body. The charging pile body includes a charging box, from which a cable body extends. The other end of the cable body is connected to a charging gun. An inner cavity is formed inside the side of the charging box, and the opening of the inner cavity is covered by a cover plate. The cooling mechanism includes a liquid cooling box assembly and a solid cooling anti-bending assembly. The liquid cooling box assembly immerses the cable body located on one side inside the charging box, achieving liquid cooling of the energized end of the cable body. The solid cooling anti-bending assembly covers the surface of the cable body, limiting the bending angle of the cable body. Furthermore, the solid cooling anti-bending assembly is connected to the liquid cooling box assembly. Coolant in the liquid cooling box assembly flows in from one end of the solid cooling anti-bending assembly, flows along the internal channel of the solid cooling anti-bending assembly, and then flows out from the other end. The coolant circulates continuously to cool the cable body.

[0010] In the above technical solution, when it is necessary to ensure the stable operation of the cable, the cooling mechanism is installed in the charging pile body. The liquid cooling box assembly is immersed in the energized end of the cable body for liquid cooling. The solid cooling anti-bending assembly is covered on the surface of the cable body to limit the bending angle. The solid cooling anti-bending assembly is connected to the liquid cooling box assembly, and the coolant circulates to continuously cool the cable body.

[0011] Based on this, both the first flow cavity and the second flow cavity are provided with connecting members. The connecting members are composed of multiple inclined connecting plates. One side of each of the multiple inclined connecting plates is connected to the inner wall of the outer tube, and the other end of each of the multiple inclined connecting plates is connected to the surface of the cable body. In the same cavity, the multiple inclined connecting plates form a bending cavity.

[0012] As a further improvement to this technical solution, the outer wall of the outer tube is provided with an external support structure, which includes multiple U-shaped rods that are wrapped around the surface of the outer tube.

[0013] By setting a connector composed of inclined connecting plates inside the first and second flow chambers, a bending cavity is formed, which extends the flow path of the coolant in the cavity, increases the contact time and area with the cable body, and enhances the cooling effect. At the same time, the outer wall of the outer tube is provided with an external support structure composed of multiple U-shaped rods, which reduces the direct contact between the outer tube and the ground, protects the structural integrity of the outer tube, and the U-shaped rods and inclined connecting plates work together to limit the bending angle of the cable body, prevent the cable from bending excessively, and ensure the safety and reliability of the cable in complex usage scenarios.

[0014] The second objective of this invention is to provide a method for operating a liquid cooling system for the insulation of charging cables in high-power charging piles, including any one of the above-described methods, comprising the following steps:

[0015] S1. When the charging pile body is turned on, the micro pump starts synchronously, driving the coolant to flow into the first flow chamber through the inlet chamber.

[0016] S2. The inclined connecting plate divides the first flow cavity and the second flow cavity into multiple bending cavities. When the coolant passes through the first flow cavity, it liquid cools one side of the cable body. At the same time, the inclined connecting plate, combined with the U-shaped rod, generates reverse resistance to constrain the bending angle of the cable body.

[0017] S3. At the same time, the coolant flows from the first flow chamber into the second flow chamber through the connecting hole and continues to flow along the tortuous path formed by the connector to complete the cooling of the other side surface of the cable body.

[0018] S4. Finally, the coolant flows back to the coolant tank through the outlet chamber, circulating repeatedly to form a closed-loop liquid cooling system.

[0019] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0020] In this high-power charging pile charging cable insulation liquid cooling system and method, a circulating cooling system is formed by connecting the liquid cooling tank assembly and the solid cooling anti-bending assembly. Driven by a micro pump, the coolant is injected into the first flow chamber through the inlet chamber. Relying on the bending chamber formed by the inclined connecting plate, the coolant achieves a tortuous flow path, which prolongs the contact time between the coolant and the cable body. Subsequently, the coolant enters the second flow chamber through the connecting hole to cool the other side of the cable body. After that, the coolant flows back to the coolant tank through the outlet chamber, forming a circulation. This circulating cooling method can continuously remove the heat generated when the high-power cable body is energized, reduce the aging of the cable insulation layer and the degradation of conductor performance caused by excessive temperature, effectively ensure the stable operation of the cable under high power transmission, and extend the service life of the cable body.

[0021] Furthermore, the connectors and the external support structure work together to form a bending angle constraint system for the cable body. Multiple oblique connecting plates are connected at one end to the inner wall of the outer tube and at the other end to the cable body, forming a bending cavity with a specific angle. When the cable is bent by external force, the oblique connecting plates generate a reverse support force. At the same time, the U-shaped rod provides radial support from the outside. Together, they limit the bending angle of the cable, reducing the deformation, breakage, or insulation layer damage of the internal conductor strands of the cable body caused by excessive bending. This effectively reduces the risks of leakage, short circuit, and impact on the liquid cooling flow path, ensuring the safety of the charging process and the reliability of liquid cooling. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0023] Figure 2 This is a schematic diagram of the installation structure of the cooling mechanism of the present invention;

[0024] Figure 3 This is a schematic diagram of the connection structure between the cooling and bending protection component and the cable body of the present invention;

[0025] Figure 4 This is a schematic diagram of the internal structure of the first flow cavity of the present invention;

[0026] Figure 5 This is a schematic diagram of the coolant flow structure in the first flow cavity of the present invention;

[0027] Figure 6 This is a schematic diagram of the coolant flow structure in the second flow cavity of the present invention;

[0028] Figure 7 This is a diagram showing the coolant flow structure of the present invention;

[0029] Figure 8 This is a schematic diagram of the coolant tank installation according to the present invention;

[0030] Figure 9 This is a schematic diagram of the cross-sectional structure of the coolant tank of the present invention;

[0031] Figure 10 For the present invention Figure 9 A schematic diagram of the structure at point A.

[0032] The meanings of the labels in the diagram are as follows:

[0033] 1. Charging pile body; 11. Charging box; 12. Charging gun; 13. Cable body; 14. Inner cavity; 15. Cover plate;

[0034] 2. Cooling mechanism; 21. Liquid cooling box assembly; 22. Solid cooling anti-bending assembly; 23. External support structure; 24. Connecting parts;

[0035] 211. Coolant tank; 212. Connecting pipe; 213. Inlet chamber; 214. Outlet chamber; 215. Miniature pump;

[0036] 221. Outer tube; 222. Cooling chamber; 223. Baffle; 2231. Connecting hole; 224. First flow chamber; 225. Second flow chamber;

[0037] 231. U-shaped rod; 241. Angled connecting plate; 242. Bending cavity;

[0038] 3. Side rounded corners;

[0039] 4. Sealing ring. Detailed Implementation

[0040] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0041] Example 1: Please refer to Figure 1 and Figure 2 As shown, the purpose of this embodiment is to provide a high-power charging pile charging cable insulation liquid cooling system, including a cooling mechanism 2, which is installed inside the charging pile body 1. The charging pile body 1 includes a charging box 11, and a cable body 13 extends from the inside of the charging box 11. The other end of the cable body 13 is connected to a charging gun 12. An inner cavity 14 is opened inside the side end of the charging box 11, and a cover plate 15 is covered at the opening of the inner cavity 14.

[0042] The cooling mechanism 2 includes a liquid cooling box assembly 21 and a solid cooling anti-bending assembly 22. The liquid cooling box assembly 21 immerses the cable body 13 located inside the charging box 11, thereby achieving liquid cooling of the energized end of the cable body 13. The solid cooling anti-bending assembly 22 covers the surface of the cable body 13, which can limit the bending angle of the cable body 13. Furthermore, the solid cooling anti-bending assembly 22 is connected to the liquid cooling box assembly 21. The coolant in the liquid cooling box assembly 21 flows in from one end of the solid cooling anti-bending assembly 22, flows along the internal channel of the solid cooling anti-bending assembly 22, and then flows out from the other end. The coolant circulates to continuously cool the cable body 13.

[0043] The liquid cooling box assembly 21 includes a coolant tank 211 installed inside the inner cavity 14. The interior of the coolant tank 211 is a hollow structure for storing coolant. A connecting pipe 212 is fixedly installed on one side of the coolant tank 211. The connecting pipe 212 has an inlet chamber 213 and an outlet chamber 214. A micro pump 215 is installed inside the inlet chamber 213.

[0044] See Figure 8 and combined Figure 9 and Figure 10 As shown, the coolant tank 211 is securely installed in the pre-opened inner cavity 14 inside the side of the charging box 11. The opening of the inner cavity 14 is equipped with a cover plate 15 for easy inspection and maintenance. The coolant tank 211 has a hollow structure for storing coolant. A section of the cable body 13 located inside the charging box 11 is immersed in the coolant, achieving efficient liquid cooling of the energized end of the cable through direct contact.

[0045] Meanwhile, a connecting pipe 212 is fixed on one side of the coolant tank 211, which is internally divided into an independent inlet chamber 213 and an outlet chamber 214. The inlet chamber 213 is responsible for transporting coolant from the coolant tank 211 to the solid cooling and anti-bending assembly 22 to cool the part of the cable body 13 that extends out of the charging box 11. The outlet chamber 214 is used to return the coolant, after heat exchange and temperature rise, to the coolant tank 211, thereby realizing the recycling of coolant. The micro pump 215 installed inside the inlet chamber 213 starts when the charging pile body 1 is running. By stabilizing the output pressure, it drives the coolant to circulate along the predetermined path of "coolant tank 211 → inlet chamber 213 → solid cooling and anti-bending assembly 22 → outlet chamber 214 → coolant tank 211", continuously removing the heat generated by the cable body 13 during operation and ensuring that the cable body 13 operates stably within a safe temperature range.

[0046] The aforementioned micro pump 215 operates on the principle well-known to those skilled in the art. Based on centrifugal force, it is well-suited for confined installation spaces due to its compact design. The impeller rotates at high speed, using centrifugal force to throw the coolant from the impeller center to the edge, delivering it into the inlet chamber 213. The low-pressure zone formed at the impeller center continuously replenishes the coolant in the coolant tank 211. Its compact structure, small axial dimension, and flexible installation allow it to fit within the confined space of the inlet chamber 213 of the connecting pipe 212, providing stable power for coolant circulation.

[0047] The cooling and anti-bending assembly 22 includes an outer tube 221 sleeved on the surface of the cable body 13. Two partitions 223 are symmetrically arranged inside the outer tube 221. The other ends of the two partitions 223 are fixedly installed on the outer wall of the cable body 13. A cooling chamber 222 is formed inside the outer tube 221. The two partitions 223 divide the cooling chamber 222 into a first flow chamber 224 and a second flow chamber 225. The first flow chamber 224 and the second flow chamber 225 are connected through a connecting hole 2231. The connecting hole 2231 is opened on the side of the partition 223 near the charging gun 12. The end of the first flow chamber 224 away from the connecting hole 2231 is connected to the inlet chamber 213. The end of the second flow chamber 225 away from the connecting hole 2231 is connected to the outlet chamber 214.

[0048] Both the first flow cavity 224 and the second flow cavity 225 are provided with a connector 24. The connector 24 is composed of multiple inclined connecting plates 241. One side of each of the multiple inclined connecting plates 241 is connected to the inner wall of the outer tube 221, and the other end of each of the multiple inclined connecting plates 241 is connected to the surface of the cable body 13. In the same cavity, the multiple inclined connecting plates 241 form a bending cavity 242.

[0049] The cooling and anti-bending assembly 22, as a key component ensuring the stable operation of the cable body 13, is designed to combine cooling and protection functions. Figure 3 and Figure 4 As shown, the outer tube 221 is tightly fitted onto the surface of the cable body 13 extending from the charging box 11, forming an outer protective structure. Inside, a cooling chamber 222 is formed. Two partitions 223 are symmetrically arranged within the cooling chamber 222. One end of each partition 223 is fixed to the inner wall of the outer tube 221, and the other end is attached to the outer wall of the cable body 13. The two partitions 223 divide the cooling chamber 222 into a first flow chamber 224 and a second flow chamber 225, which are independent yet interconnected. Figure 7 As shown, a connecting hole 2231 is opened on the partition 223 near the charging gun 12, which becomes a channel for the coolant to transfer between the two flow chambers. The end of the first flow chamber 224 away from the connecting hole 2231 is connected to the inlet chamber 213 of the liquid cooling box assembly 21, and the end of the second flow chamber 225 away from the connecting hole 2231 is connected to the outlet chamber 214.

[0050] See Figure 5 and Figure 6Inside the first flow cavity 224 and the second flow cavity 225, there are multiple inclined connecting plates 241. One side of each inclined connecting plate 241 is fixedly connected to the inner wall of the outer tube 221, and the other side is connected to the surface of the cable body 13. Multiple inclined connecting plates 241 in the same flow cavity are arranged at specific angles and spacings to form a bending cavity 242. This structural design extends the flow path of the coolant in the cavity. When the coolant from the inlet cavity 213 enters the first flow cavity 224, it needs to flow in a meandering manner in the bending cavity 242, which increases the contact time and contact area with the cable body 13 and enhances the cooling effect.

[0051] In actual use of the charging pile, the user's operation of plugging and unplugging the charging gun 12 and dragging the cable can easily cause the outer tube 221 of the solid cooling anti-bending component 22 to come into contact with the ground. Especially when high-power charging requires the cable to be placed for a long time, or when the charging pile is deployed on uneven ground with a lot of sand and gravel, the outer tube 221 is in direct contact with the ground, which will not only accelerate its surface wear, but may also affect the sealing of the internal cooling structure due to uneven force. Therefore, the outer wall of the outer tube 221 is provided with an external support structure 23, which includes multiple U-shaped rods 231, which are wrapped around the surface of the outer tube 221.

[0052] Each of the U-shaped rods 231 has a side fillet 3 on the side away from the outer tube 221.

[0053] The improvement lies in: combination Figure 4 As shown, the outer support structure 23 of the outer wall of the outer tube 221 is composed of multiple U-shaped rods 231. These U-shaped rods 231 are laid around the surface of the outer tube 221 to form a support system for the outside of the cooling and anti-bending assembly 22. The side of the U-shaped rod 231 away from the outer tube 221 has a side rounded corner 3. During the use of the cable body 13, when the cable is placed on the ground or other contact surface, the U-shaped rod 231 acts as a buffer support structure between the outer tube 221 and the contact surface. With its own U-shaped shape, it suspends the outer tube 221, reducing the direct contact area between the outer tube 221 and the ground. At the same time, the side rounded corner 3 avoids wear or scratching of the end of the U-shaped rod 231 with the ground due to sharp edges, reducing the risk of damage to the surface of the outer tube 221 caused by friction and compression, thereby effectively protecting the structural integrity of the outer tube 221.

[0054] In addition, multiple U-shaped rods 231 and inclined connecting plates 241 form a dual anti-bending protection mechanism through different modes of action. When the cable body 13 is subjected to a large external force and bends (such as a 90-degree bend), the inclined connecting plate 241 will generate reverse resistance by means of its inclined support angle. This resistance comes from the structural strength of the inclined connecting plate 241 itself and the connection force with the cable body 13, and can directly act on the cable body 13 to limit the bending angle of the cable from the inside.

[0055] The outer U-shaped rods 231 are wrapped around the surface of the outer tube 221. When the cable body 13 is bent, the adjacent U-shaped rods 231 collide, which restricts the degree of bending. The two structures work together. The inclined connecting plate 241 provides direct angle restriction and support from the inside, while the U-shaped rods 231 provide auxiliary constraint from the outside. The internal and external workings work together to restrict the cable body 13 from excessive bending. The inclined connecting plate 241 is made of hard rubber, which can not only ensure that the normal bending of the cable body 13 is not affected, but also effectively limit its excessive bending, such as avoiding bending at too large an angle like 90 degrees, and providing reasonable room for movement and necessary protective constraints for the cable body 13.

[0056] Considering that the weight of the cable body 13 affects the charging connection stability of the charging gun 12, the structure of the first flow cavity 224 and the second flow cavity 225 was optimized when designing the solid cooling and anti-bending assembly 22. While ensuring sufficient coolant flow to effectively remove heat from the cable, the thickness of these two flow cavities was made relatively thin to reduce the amount of coolant filling and lower the overall weight of the assembly. Simultaneously, the inclined connecting plate 241 used to construct the bending cavity 242 is made of a lightweight and elastic material such as rubber. This material is not only lightweight but also ensures structural strength while buffering external forces through elastic deformation, further reducing the impact of the assembly weight on the cable. Through the above design, without affecting the liquid cooling effect, the sag and sway of the cable caused by the excessive weight of the solid cooling and anti-bending assembly 22 are effectively reduced, ensuring a stable connection between the charging gun 12 and the vehicle charging interface, and improving the safety and reliability of the charging process.

[0057] Since the flow directions of the coolant in the first flow chamber 224 and the second flow chamber 225 are different, the coolant first enters the first flow chamber 224 through the inlet chamber 213, then flows into the second flow chamber 225 through the connecting hole 2231 on the partition 223, and finally flows back to the coolant tank 211 through the outlet chamber 214. Therefore, the inclined connecting plate 241 in the first flow chamber 224 and the inclined connecting plate 241 in the second flow chamber 225 are installed in opposite directions.

[0058] Combination Figure 5 and Figure 6The inclined connecting plate 241 in the first flow cavity 224 and the inclined connecting plate 241 in the second flow cavity 225 are installed in opposite directions. This design makes the opening direction of the bending cavity 242 formed by the inclined connecting plate 241 match the flow direction of the coolant in each cavity. When the coolant flows in the first flow cavity 224, the inclined connecting plate 241 arranged in a specific direction can guide the coolant to pass smoothly through the bending cavity 242. After the coolant flows into the second flow cavity 225, the inclined connecting plate 241 installed in the opposite direction can adapt to the new flow direction and continue to guide the coolant. In this way, the resistance caused by the frequent change of direction of the coolant when it flows in the cavity can be effectively reduced, ensuring that the coolant circulates efficiently in the solid cooling and anti-bending assembly 22 and improving the cooling effect on the cable body 13.

[0059] Since the liquid cooling box assembly 21 inside the charging box 11 contains coolant, if there is a gap between the cable body 13 and the side opening of the charging box 11 during the coolant circulation process, the coolant may leak. Therefore, a sealing ring 4 is installed on the side surface of the charging box 11, and the sealing ring 4 is sleeved on the surface of the cable body 13 where it extends out of the charging box 11.

[0060] like Figure 8 As shown, a sealing ring 4 (elastic material) is installed on the side surface of the charging box 11 and fitted onto the surface of the cable body 13 where it extends out of the charging box 11. The sealing ring 4 forms a sealing structure by tightly fitting the cable body 13 and the inner wall of the side opening of the charging box 11, which effectively prevents coolant from leaking from the gaps and isolates external dust, moisture and other impurities from entering the interior of the charging box 11, thus ensuring the sealing of the cooling system and the safety of cable operation.

[0061] The coolant used is an insulating liquid. In the insulating liquid cooling system of high-power charging pile charging cables, the use of an insulating liquid is based on the core requirement of electrical safety. Since the cable body 13 is energized during charging, if the coolant is conductive, leakage or contact with damaged areas of the cable insulation could lead to serious safety accidents such as short circuits and leakage. Using an insulating liquid as the coolant avoids electrical faults caused by coolant conductivity, ensuring that even in the event of accidental coolant leakage or minor defects in the system seal, the cable's normal energization and the safe operation of the charging pile will not be affected. Common insulating liquids include mineral oil, which has good chemical stability and insulating properties, is low in cost, and is readily available; silicone oil, which has excellent high and low temperature performance, oxidation resistance, and electrical insulation properties, and is suitable for a wide temperature range; fluorinated liquids, which have extremely high chemical stability, insulation, and low surface tension, and are often used in scenarios with high heat dissipation requirements and complex environments; and transformer oil, a commonly used insulating medium in power equipment, which performs excellently in electrical insulation and heat dissipation and can also be used as a coolant.

[0062] Working principle:

[0063] First, during the use of the cable body 13, the micro pump 215 in the liquid cooling tank assembly 21 is activated, pumping the insulating coolant in the coolant tank 211 through the inlet chamber 213 to the solid cooling and anti-bending assembly 22. The section of the cable body 13 located in the charging box 11 is directly cooled by the coolant immersed in the coolant tank 211. Then, the coolant enters the first flow chamber 224 and flows in a tortuous manner in the bending chamber 242 formed by the inclined connecting plate 241, increasing the contact area and time with the cable body 13. Next, the coolant flows into the second flow chamber 225 through the connecting hole 2231 on the partition 223, and flows again along the bending chamber 242 formed by the inclined connecting plate 241, completing the cooling of the other side of the cable body 13. After that, the coolant that has completed the heat exchange flows back to the coolant tank 211 through the outlet chamber 214, forming a closed loop, continuously carrying away the heat generated by the cable body 13 when it is energized.

[0064] During the cooling process, the U-shaped rod 231 on the outer wall of the outer tube 221 works in conjunction with the inclined connecting plate 241 inside. If the cable body 13 is bent by external force, the inclined connecting plate 241 generates a reverse support force from the inside, and the U-shaped rod 231 restricts the bending angle from the outside, together preventing the cable from bending excessively and providing reasonable room for movement and necessary protective constraints for the cable body 13.

[0065] Example 2: This example, based on the content provided in Example 1, aims to provide a method for using a liquid cooling system for the insulation of a high-power charging pile charging cable. The specific steps are as follows:

[0066] Step 1: When the charging pile body 1 is turned on, the micro pump 215 starts synchronously, driving the coolant to flow into the first flow chamber 224 through the inlet chamber 213.

[0067] Step 2: The inclined connecting plate 241 divides the first flow cavity 224 and the second flow cavity 225 into multiple bending cavities 242. When the coolant passes through the first flow cavity 224, it liquid cools one side of the cable body 13. At the same time, the inclined connecting plate 241, together with the U-shaped rod 231, generates reverse resistance to constrain the bending angle of the cable body 13.

[0068] Step 3: At the same time, the coolant flows from the first flow chamber 224 into the second flow chamber 225 through the connecting hole 2231, and continues to flow along the tortuous path formed by the connector 24 to complete the cooling of the other side surface of the cable body 13.

[0069] Step 4: Finally, the coolant flows back to the coolant tank 211 through the outlet chamber 214, circulating repeatedly to form a closed-loop liquid cooling system.

[0070] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely preferred examples and are not intended to limit the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of the present invention is defined by the appended claims and their equivalents.

Claims

1. A liquid cooling system for the insulation of a high-power charging pile charging cable, comprising a cooling mechanism (2) installed inside a charging pile body (1), the charging pile body (1) comprising a charging box (11), a cable body (13) extending from the inside of the charging box (11), the other end of the cable body (13) being connected to a charging gun (12), characterized in that: The charging box (11) has an inner cavity (14) inside its side end, and the opening of the inner cavity (14) is covered by a cover plate (15). The cooling mechanism (2) includes a liquid cooling box assembly (21) and a solid cooling anti-bending assembly (22). The liquid cooling box assembly (21) immerses the cable body (13) located inside the charging box (11) on one side, thereby achieving liquid cooling of the energized end of the cable body (13). The solid cooling anti-bending component (22) covers the surface of the cable body (13) and can limit the bending angle of the cable body (13). Furthermore, the solid cooling anti-bending component (22) is connected to the liquid cooling box component (21). The coolant in the liquid cooling box component (21) flows in from one end of the solid cooling anti-bending component (22), flows along the internal channel of the solid cooling anti-bending component (22), and then flows out from the other end. The coolant circulates to continuously cool the cable body (13). The solid cooling and anti-bending assembly (22) includes an outer tube (221) sleeved on the surface of the cable body (13). Two partitions (223) are symmetrically arranged inside the outer tube (221). The other ends of the two partitions (223) are fixedly installed on the outer wall of the cable body (13). A cooling chamber (222) is formed inside the outer tube (221). The two partitions (223) divide the cooling chamber (222) into a first flow chamber (224) and a second flow chamber (225). The first flow chamber (224) and the second flow chamber (225) are connected through a connecting hole (2231). The connecting hole (2231) is opened on the side of the partition (223) near the charging gun (12). The end of the first flow chamber (224) away from the connecting hole (2231) is connected to the inlet chamber (213). The end of the second flow chamber (225) away from the connecting hole (2231) is connected to the outlet chamber (214). Both the first flow cavity (224) and the second flow cavity (225) are provided with connectors (24). The connectors (24) are composed of multiple inclined connecting plates (241). One side of each of the multiple inclined connecting plates (241) is connected to the inner wall of the outer tube (221), and the other end of each of the multiple inclined connecting plates (241) is connected to the surface of the cable body (13). In the same cavity, the multiple inclined connecting plates (241) form a bending cavity (242).

2. The liquid cooling system for the insulation of charging cables in high-power charging piles according to claim 1, characterized in that: The liquid cooling box assembly (21) includes a coolant tank (211) installed inside the inner cavity (14). The interior of the coolant tank (211) is a hollow structure for storing coolant. A connecting pipe (212) is fixedly installed on one side of the coolant tank (211). The connecting pipe (212) has an inlet chamber (213) and an outlet chamber (214) inside. A micro pump (215) is installed inside the inlet chamber (213).

3. The liquid cooling system for the insulation of charging cables in high-power charging piles according to claim 1, characterized in that: The outer wall of the outer tube (221) is provided with an outer support structure (23), which includes a plurality of U-shaped rods (231) that are laid around the surface of the outer tube (221).

4. The liquid cooling system for the insulation of charging cables in high-power charging piles according to claim 3, characterized in that: Each of the U-shaped rods (231) has a side fillet (3) on the side away from the outer tube (221).

5. The liquid cooling system for the insulation of charging cables in high-power charging piles according to claim 1, characterized in that: The inclined connecting plate (241) in the first flow cavity (224) is installed in the opposite direction to the inclined connecting plate (241) in the second flow cavity (225).

6. The liquid cooling system for the insulation of charging cables in high-power charging piles according to claim 1, characterized in that: A sealing ring (4) is installed on the side surface of the charging box (11), and the sealing ring (4) is sleeved on the surface of the cable body (13) extending out of the charging box (11).

7. The liquid cooling system for the insulation of charging cables in high-power charging piles according to claim 1, characterized in that: The coolant is an insulating liquid.

8. A method of using a liquid cooling system for the insulation of a high-power charging cable of a charging pile as described in claim 3, characterized in that, The methods and steps include the following: S1. When the charging pile body (1) is turned on, the micro pump (215) starts synchronously, driving the coolant to flow into the first flow chamber (224) through the inlet chamber (213). S2. The inclined connecting plate (241) divides the first flow cavity (224) and the second flow cavity (225) into multiple bending cavities (242). When the coolant passes through the first flow cavity (224), it liquid cools one side of the cable body (13). At the same time, the inclined connecting plate (241) combined with the U-shaped rod (231) generates reverse resistance, which constrains the bending angle of the cable body (13). S3. At the same time, the coolant flows from the first flow chamber (224) into the second flow chamber (225) through the connecting hole (2231) and continues to flow along the tortuous path formed by the connector (24) to complete the cooling of the other side surface of the cable body (13); S4. Finally, the coolant flows back to the coolant tank (211) through the outlet cavity (214) and circulates back and forth to form a closed-loop liquid cooling system.

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