Direct current charging cable

Abstract

The invention belongs to the technical field of charging cables, and discloses a direct current charging cable. The direct-current charging cable comprises an insulating sheath, a flexible main wire core group and a flexible signal wire, an accommodating space is formed in the insulating sheath; the flexible main wire core group comprises a plurality of main wire cores, the plurality of main wire cores are distributed along the inner circumference of the insulating sheath, and the peripheries of the plurality of main wire cores are coated with first insulating layers; the flexible signal wire is formed by wrapping a signal conductor and a signal line with a second insulating layer, and the signal conductor is formed by twisting a plurality of bare copper wires, a plurality of bulletproof wires and a plurality of copper foil wires; the flexible main wire core group and the flexible signal wires are arranged in the accommodating space, and fillers are arranged between the inner peripheries of the plurality of main wire cores, the flexible signal wires and the insulating sheath. The direct-current charging cable is good in flexibility, resistant to bending, capable of bearing large pulling force and not prone to breakage in the dragging process.

Description

Technical Field

[0001] The present invention relates to the technical field of charging cables, and in particular to a DC charging cable. Background Art

[0002] The electric vehicle industry is developing rapidly, and electric vehicles are driving further growth in the charging market. Electric vehicle charging requires a DC charging cable. Existing charging cables are not only heavy and inconvenient to drag, but also have poor flexibility and are vulnerable to bending due to their unique structure. Furthermore, the frequency of use and the demographics of users vary depending on the location of the charging station. Furthermore, improper use often results in cable core breakage, severely impacting the user experience.

[0003] Therefore, there is an urgent need for a DC charging cable to solve the above problems. Summary of the Invention

[0004] The object of the present invention is to provide a DC charging cable that has good flexibility, is resistant to bending, can withstand large tensile forces, and is not easily broken during dragging.

[0005] To achieve this object, the present invention adopts the following technical solutions:

[0006] A DC charging cable, comprising:

[0007] An insulating sheath having an accommodating space provided therein;

[0008] A flexible main line core group includes a plurality of main line cores, wherein the plurality of main line cores are distributed along the inner periphery of the insulating sheath, and the outer peripheries of the plurality of main line cores are all covered with a first insulating layer;

[0009] A flexible signal conductor, comprising a signal conductor and a signal line wrapped with a second insulating layer, wherein the signal conductor is formed by twisting a plurality of bare copper wires, a plurality of bulletproof wires, and a plurality of copper foil wires;

[0010] The flexible main line core group and the flexible signal wires are both arranged in the accommodating space, and fillers are arranged between the plurality of main line cores, the flexible signal wires and the inner periphery of the insulating sheath.

[0011] Preferably, the diameter of each bare copper wire in the signal conductor is not higher than 0.21 mm, the resistivity of each bare copper wire is not higher than 0.0171 Ω·mm2 / m, and the elongation of each bare copper wire is not lower than 15%.

[0012] Preferably, the bulletproof wire is made of aramid fiber material, each of the bulletproof wires can withstand a tensile force of not less than 40N, and the flexible signal wire can withstand a tensile force in the range of 0-345N.

[0013] Preferably, there are four main cores, and the cross-sectional area of ​​each main core is not more than 35mm 2 .

[0014] Preferably, the DC charging cable has a cable pitch-to-diameter ratio of 14.8-15.2.

[0015] Preferably, the first insulating layer is made of a cross-linked polyolefin material, the tensile strength of the first insulating layer is not less than 10.3 MPa, and the volume resistivity of the first insulating layer is not less than 1.0×10 15 Ω·mm, and the elongation at break of the first insulating layer is not less than 200%.

[0016] Preferably, the second insulating layer is made of fluoroplastic, the tensile strength of the second insulating layer is not less than 17.0 MPa, and the elongation at break of the second insulating layer is not less than 200%.

[0017] Preferably, the insulating sheath is made of polyether polyurethane material, the hardness of the insulating sheath is between 82A and 88A, the tensile strength of the insulating sheath is not less than 20 MPa, and the elongation at break of the insulating sheath is not less than 300%.

[0018] Preferably, the outer periphery of the signal line is woven with tinned copper wires, and a shielding layer is provided between the tinned copper wires and the outer periphery of the signal line.

[0019] Preferably, a wrapping tape is provided between the insulating sheath and the filler.

[0020] Beneficial effects of the present invention:

[0021] The present invention discloses a DC charging cable. The DC charging cable includes an insulating sheath, a flexible main core group, and a flexible signal conductor; the insulating sheath is provided with a storage space inside; the flexible main core group includes multiple main cores, and the multiple main cores are distributed along the inner circumference of the insulating sheath, and the outer circumference of the multiple main cores is covered with a first insulation layer; the flexible signal conductor is composed of a signal conductor and a signal line wrapped with a second insulation layer, and the signal conductor is twisted together by multiple bare copper wires, multiple bulletproof wires, and multiple copper foil wires; the flexible main core group and the flexible signal conductor are both arranged in the storage space, and fillers are provided between the multiple main cores, the flexible signal conductors, and the inner circumference of the insulating sheath. The DC charging cable is not only flexible and resistant to bending, but also can withstand large tensile forces and is not easily broken during dragging.

[0022] Multiple main line cores can ensure good charging efficiency, and the outer periphery of the multiple main line cores is covered with a first insulating layer, which can ensure the insulation state between the multiple main line cores; and the signal conductor is composed of multiple bare copper wires, multiple bulletproof wires and multiple copper foil wires. The bare copper wire can not only reduce the resistivity, but also has good ductility. At the same time, the bulletproof wire and copper foil wire replace the nylon wire in the existing technology, which not only improves the tensile strength of the signal line, but also improves the bending resistance of the cable while ensuring flexibility, and effectively avoids the breakage of the cable signal conductor during dragging. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 It is a cross-sectional schematic diagram of the DC charging cable provided by the present invention.

[0024] In the picture:

[0025] 10. Insulation sheath;

[0026] 20. Flexible main line core group; 21. Main line core; 22. First insulation layer;

[0027] 30. Flexible signal wire; 31. Signal conductor; 32. Signal line; 33. Second insulation layer;

[0028] 40. Filling;

[0029] 50. Bag strap;

[0030] 60. Auxiliary power line; 61. Power conductor; 62. Third insulation layer;

[0031] 70. Ground conductor; 71. Ground wire; 72. Fourth insulation layer. DETAILED DESCRIPTION

[0032] The present invention will be further described in detail below with reference to the accompanying drawings and examples. It will be understood that the specific embodiments described herein are intended only to illustrate the present invention and are not intended to limit the present invention. It should also be noted that, for ease of description, the accompanying drawings only illustrate portions relevant to the present invention, not all structures.

[0033] In the description of the present invention, unless otherwise expressly specified or limited, the terms "connected," "connected," and "fixed" should be understood in a broad sense. For example, they may refer to fixed connections, detachable connections, or integration; mechanical connections or electrical connections; direct connections or indirect connections through an intermediate medium; and internal communication between two components or interaction between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention in specific circumstances.

[0034] In the present invention, unless otherwise expressly specified or limited, a first feature being "above" or "below" a second feature may include the first and second features being in direct contact, or may include the first and second features being in contact not directly but through another feature between them. Furthermore, a first feature being "above," "above," and "above" a second feature may include the first feature being directly above or obliquely above the second feature, or may simply mean that the first feature is higher in level than the second feature. A first feature being "below," "below," and "below" a second feature may include the first feature being directly below or obliquely below the second feature, or may simply mean that the first feature is lower in level than the second feature.

[0035] In the description of this embodiment, terms such as "upper," "lower," "left," and "right" are used to refer to positions or locations based on those shown in the accompanying drawings. These terms are intended solely to facilitate description and simplify operation, and are not intended to indicate or imply that the devices or components referred to must have, be constructed, or operate in a specific orientation. Therefore, they should not be construed as limitations on the present invention. Furthermore, the terms "first" and "second" are used solely for descriptive purposes and have no special meaning.

[0036] This embodiment provides a DC charging cable, such as Figure 1 As shown, the cable specifically includes an insulating sheath 10, a flexible main core group 20 and a flexible signal conductor 30; an accommodating space is provided inside the insulating sheath 10; the flexible main core group 20 includes a plurality of main cores 21, and the plurality of main cores 21 are distributed along the inner circumference of the insulating sheath 10, and the outer circumference of the plurality of main cores 21 are all covered with a first insulating layer 22; the flexible signal conductor 30 is composed of a signal conductor 31 and a signal line 32 wrapped by a second insulating layer 33, and the signal conductor 31 is formed by twisting a plurality of bare copper wires, a plurality of bulletproof wires and a plurality of copper foil wires; the flexible main core group 20 and the flexible signal conductor 30 are both arranged in the accommodating space, and fillers 40 are provided between the plurality of main cores 21, the flexible signal conductor 30 and the inner circumference of the insulating sheath 10.

[0037] The multiple main cores 21 in this embodiment can ensure good charging efficiency, and the outer periphery of the multiple main cores 21 is covered with a first insulating layer 22, which can ensure the insulation state between the multiple main cores 21; and the signal conductor 31 is formed by twisting multiple bare copper wires, multiple bulletproof wires and multiple copper foil wires. The bare copper wire can not only reduce the resistivity, but also has good ductility. At the same time, the bulletproof wire and copper foil wire replace the nylon wire in the prior art, which not only improves the tensile strength of the signal conductor 31, but also improves the bending resistance of the cable while ensuring flexibility, and effectively avoids the breakage of the signal conductor 31 of the cable during dragging.

[0038] Furthermore, in this embodiment, the bare copper wires within the signal conductor 31 are Category V bare copper conductors as specified in GB / T3956. Each bare copper wire within the signal conductor 31 has a diameter no greater than 0.21 mm, a resistivity no greater than 0.0171 Ω·mm² / m, and an elongation no less than 15%. The bare copper wire diameter of no greater than 0.21 mm effectively reduces the diameter of the signal conductor 31, thereby indirectly reducing the diameter of the cable. Furthermore, the resistivity no greater than 0.0171 Ω·mm² / m effectively reduces energy loss, and the unique elongation improves the ductility of the signal conductor 31, preventing breakage during stretching and preventing charging.

[0039] In addition, the bulletproof wire is made of aramid fiber material. Each bulletproof wire can withstand a tensile force of no less than 40N, and the flexible signal conductor 30 can withstand a tensile force range of 0-345N. Most of the existing technologies use nylon wire, which is not only not resistant to high temperatures, but also can withstand a tensile force of no more than 190N, making it extremely easy to be damaged during use. The bulletproof wire in this embodiment can not only withstand high temperatures of 250°C, but the maximum tensile force that the product can withstand is also increased to 345N. This not only ensures that charging can be performed in a high-temperature environment, but also improves the cable's anti-torsion and anti-stretching capabilities, thereby improving the user experience.

[0040] like Figure 1 As shown, there are four main cores 21, and the cross-sectional area of ​​each main core 21 is not higher than 35mm 2 This structure not only ensures the charging speed, but also effectively reduces the outer diameter of the cable, thereby indirectly improving the flexibility of the cable. At the same time, it also fully reduces the overall weight of the cable, making it easier to drag and drop, thereby improving the user experience.

[0041] In addition, during the cabling process, the larger the cabling pitch (the length of the wire core wrapped around the center), the greater the deformation of the cable when bent, which in turn leads to worse flexibility of the cable. Therefore, to solve this problem, the cabling pitch ratio of the DC charging cable is in the range of 14.8-15.2. The cabling pitch ratio (cabling pitch / cable diameter) within this range can fully guarantee the flexibility of the cable, and also improve the torsion and bending resistance of the cable. In this embodiment, the cabling pitch ratio is 15. In other embodiments, different cabling pitch ratios can be selected according to actual needs and production conditions, as long as the flexibility and bending resistance of the cable can be guaranteed.

[0042] In addition, in this embodiment, the first insulating layer 22 is made of a cross-linked polyolefin material (XLPO material), and the tensile strength of the first insulating layer 22 is not less than 10.3 MPa, and the volume resistivity of the first insulating layer 22 is not less than 1.0×10 15Ω·mm, and the elongation at break of the first insulating layer 22 is not less than 200%. This configuration not only ensures insulation effectiveness but also improves the tensile strength of the flexible main core assembly 20 by modifying the properties of the first insulating layer 22. Furthermore, due to its high volume resistivity, it effectively reduces radial attenuation of electrical energy along the main core 21, thereby improving electrical energy transmission capacity and reducing energy loss. It also fundamentally reduces heat generation within the main core 21. Furthermore, XLPO material offers advantages such as chemical stability and ease of processing.

[0043] Considering that the signal line 32 needs to shield external signals to avoid interference when transmitting electrical signals. Therefore, in this embodiment, the periphery of the signal line 32 is woven with tinned copper wire, and a shielding layer is provided between the tinned copper wire and the periphery of the signal line 32. The tinned copper wire can initially isolate the external signal, while the shielding layer can provide a second layer of protection. At the same time, it can also prevent the signal line 32 from diffusing the signal radially outward, thereby ensuring the transmission strength of the signal. In addition, in this embodiment, the shielding layer is aluminum foil, which is not only low in price, but also easy to process into other shapes, thereby improving the convenience of production.

[0044] Furthermore, the second insulating layer 33 is made of fluoroplastic, with a tensile strength of no less than 17.0 MPa and an elongation at break of no less than 200%. This configuration not only ensures effective insulation but also modifies the properties of the second insulating layer 33 to improve the tensile strength of the flexible signal conductor 30 and enhance signal transmission capabilities. Fluoroplastic also offers advantages such as chemical stability and excellent insulation properties.

[0045] It should be noted that if Figure 1 As shown, to ensure proper charging of the DC charging cable, the insulating sheath 10 houses an auxiliary power line 60 and a ground conductor 70. The auxiliary power line 60 comprises a power conductor 61 surrounded by a third insulating layer 62, while the ground conductor 70 comprises a ground conductor 71 surrounded by a fourth insulating layer 72. In this embodiment, both the third insulating layer 62 and the fourth insulating layer 72 are made of fluoroplastic, ensuring that both the auxiliary power line 60 and the ground conductor 70 have good flexibility and tensile strength, enhancing the user experience.

[0046] Furthermore, in this embodiment, the insulating sheath 10 is made of a polyether-based polyurethane material, with a hardness between 82A and 88A, a tensile strength of no less than 20 MPa, and an elongation at break of no less than 300%. This material ensures the safety of the cable. Its hardness, between 82A and 88A, is medium to hard, providing both elasticity and a certain degree of rigidity, ensuring flexibility while significantly improving the cable's resistance to stretching and fracture.

[0047] In addition, in order to further improve the safety of cable use, Figure 1 As shown, a wrapping tape 50 is provided between the insulating sheath 10 and the filler 40. The wrapping tape 50 can not only wrap the filler, but also further improve the tensile strength of the cable. At the same time, it can also play a good moisture-proof and waterproof effect, thereby improving the safety of the cable.

[0048] In summary, the DC charging cable in this embodiment is not only flexible and resistant to bending, but also can withstand large tensile forces and is not prone to breaking during dragging, thereby improving the user experience.

[0049] Obviously, the above embodiments of the present invention are merely examples for the purpose of clearly illustrating the present invention and are not intended to limit the embodiments of the present invention. A person skilled in the art would be able to make various obvious changes, readjustments, and substitutions without departing from the scope of protection of the present invention. It is not necessary and impossible to enumerate all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention shall be included within the scope of protection of the claims of the present invention.

Claims

1. A DC charging cable, characterized in that: include: An insulating sheath (10) having an accommodation space therein; A flexible main core group (20) includes a plurality of main cores (21), wherein the plurality of main cores (21) are distributed along the inner periphery of the insulating sheath (10), and the outer peripheries of the plurality of main cores (21) are all covered with a first insulating layer (22); A flexible signal conductor (30) is composed of a signal conductor (31) and a signal line (32) wrapped with a second insulating layer (33), wherein the signal conductor (31) is formed by twisting a plurality of bare copper wires, a plurality of bulletproof wires, and a plurality of copper foil wires; The flexible main line core group (20) and the flexible signal wire (30) are both arranged in the accommodation space, and fillers (40) are provided between each of the plurality of main line cores (21), the flexible signal wire (30) and the inner periphery of the insulating sheath (10).

2. The DC charging cable according to claim 1, characterized in that: The diameter of each bare copper wire in the signal conductor (31) is not higher than 0.21 mm, the resistivity of each bare copper wire is not higher than 0.0171Ω·mm2 / m, and the elongation of each bare copper wire is not lower than 15%.

3. The DC charging cable according to claim 2, characterized in that: The bulletproof wire is made of aramid fiber material, and each of the bulletproof wires can withstand a tension of not less than 40N, and the flexible signal wire (30) can withstand a tension in the range of 0-345N.

4. The DC charging cable according to any one of claims 1 to 3, characterized in that: There are four main cores (21), and the cross-sectional area of ​​each main core (21) is not greater than 35 mm. 2 .

5. The DC charging cable according to claim 1, characterized in that: The cable pitch-to-diameter ratio of the DC charging cable is 14.8-15.

2.

6. The DC charging cable according to any one of claims 1 to 3, characterized in that: The first insulating layer (22) is made of a cross-linked polyolefin material, the tensile strength of the first insulating layer (22) is not less than 10.3 MPa, and the volume resistivity of the first insulating layer (22) is not less than 1.0×10 15 Ω·mm, and the breaking elongation of the first insulating layer (22) is not less than 200%.

7. The DC charging cable according to any one of claims 1 to 3, characterized in that: The second insulating layer (33) is made of fluoroplastics, the tensile strength of the second insulating layer (33) is not less than 17.0 MPa, and the elongation at break of the second insulating layer (33) is not less than 200%.

8. The DC charging cable according to any one of claims 1 to 3, characterized in that: The insulating sheath (10) is made of polyether polyurethane material, the hardness of the insulating sheath (10) is between 82A and 88A, the tensile strength of the insulating sheath (10) is not less than 20 MPa, and the elongation at break of the insulating sheath (10) is not less than 300%.

9. The DC charging cable according to any one of claims 1 to 3, characterized in that: Tinned copper wires are woven around the periphery of the signal wire (32), and a shielding layer is provided on the periphery of the tinned copper wires and the periphery of the signal wire (32).

10. The DC charging cable according to any one of claims 1 to 3, characterized in that: A wrapping tape (50) is provided between the insulating sheath (10) and the filler (40).

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