New energy automobile charging wear-resistant cable and preparation method thereof

Abstract

The application discloses a new energy automobile charging wear-resistant cable and a preparation method thereof, and solves the problems of poor wear resistance, difficulty in detecting internal damage and lack of early warning of the existing cable. The cable comprises a cable main body, a three-layer tightly attached outer sheath, a double-helix same-direction winding carbon fiber bundle belt and a circumferentially uniformly distributed filling block. When the cable is rubbed and extruded, the filling block induces the outer sheath to form a wrinkle to realize appearance early warning, meanwhile, the wrinkle causes the carbon fiber bundle belt electric signal parameter to change, so that damage can be automatically judged, and signal interruption can prompt serious damage. The preparation adopts processes such as extrusion and synchronous tension winding, the product improves performance and safety through double monitoring, is suitable for existing systems and is suitable for industrial production.

Description

Technical Field

[0001] This invention relates to the field of cable technology, and in particular to wear-resistant cables for charging new energy vehicles and their preparation methods. Background Technology

[0002] As a key component connecting charging piles and electric vehicles to achieve power transmission and conversion, the performance of charging cables for new energy vehicles directly affects the safety and efficiency of charging. Amidst the booming development of the new energy vehicle industry, the demand for charging cables continues to rise, and the market size is constantly expanding.

[0003] In terms of type, charging cables mainly include AC charging pile cables and DC charging pile cables. AC charging pile cables are generally used in scenarios with a rated voltage of 450 / 750V, commonly found in AC charging modes with relatively low power and slow charging speeds, such as home charging piles and some public AC charging piles. DC charging pile cables, on the other hand, are suitable for high-voltage, high-current scenarios with a rated voltage of DC 1kV, enabling fast charging and are widely used in public fast charging stations. In addition, there is a liquid-cooled charging pile cable, which emerged with the development of fast charging technology. By setting a dedicated liquid circulation channel between the cable and the charging gun, the coolant circulates under the drive of a power pump, effectively absorbing and conducting the heat generated during charging, maintaining the cable at a low temperature, preventing battery overheating, and greatly improving charging speed and safety.

[0004] Charging cables have extremely stringent performance requirements. Electrically, they must possess high voltage withstand capability and low loss characteristics. The insulation material must be able to withstand the rated voltage; for example, automotive cables typically require an insulation withstand voltage of ≥3000VAC, and the conductor uses high-purity oxygen-free copper to reduce resistance loss and ensure efficient power transmission. Simultaneously, to avoid signal interference, cables often employ a multi-layer shielding structure with a shielding efficiency of ≥85dB. In terms of physical and environmental performance, due to the complex and variable charging environment, cables must possess excellent high-temperature resistance and weather resistance. For example, the operating temperature range of automotive cables is typically -40℃ to 125℃, and in some areas near the engine compartment, it can even reach 150℃. Therefore, silicone rubber, cross-linked polyethylene, or fluororubber are often used as insulation materials. Cables used outdoors, such as those in public charging stations, also need good resistance to ultraviolet aging. Flexibility and bending resistance are also crucial; vehicle cables must withstand frequent vibrations of the vehicle body, with a bending radius ≤10D, and the insulation layer must not break after multiple bends. In terms of safety performance, some special scenarios also need to meet the requirements of low smoke and halogen-free to prevent the release of toxic gases during combustion.

[0005] In terms of product structure, the conductors mostly use multi-strand, fine-angle bundled bare copper wires to improve flexibility and ensure good conductivity and mechanical strength. The insulation layer uses specially formulated halogen-free TPV and other materials to enhance the cable's resistance to high and low temperatures, bending, abrasion, and oil, and this material is environmentally friendly. The control core wires are twisted into a cable, and the sheath is extruded with a black TPV composite material, further improving the cable's adaptability to complex environments.

[0006] With the continuous innovation of new energy vehicle technology, such as increased battery energy density and faster charging speeds, higher requirements are being placed on the performance of charging cables. Meanwhile, lightweighting and flexibility are also important trends, with thin-walled insulation structures and aluminum alloy conductors being used to meet the lightweighting needs of automobiles. Furthermore, intelligent monitoring functions will gradually become more widespread, with built-in temperature sensors and other equipment monitoring the cable's operating status in real time and providing early warnings of overload or aging risks.

[0007] With the popularization of new energy vehicles, charging cables, as a core component connecting charging equipment and vehicles, are used in complex and diverse environments: in outdoor charging scenarios, cables often rub against the ground, charging pile housing, vehicle chassis, etc.; during storage or dragging, they are easily subjected to external forces such as compression and bending. Existing charging cables mostly adopt a "single sheath + reinforcing rib" design for their protective structure, which has the following shortcomings:

[0008] Limited wear resistance. Traditional cable outer sheaths are mostly made of homogeneous rubber or plastic, which are prone to wear and cracking after long-term friction. However, in the early stages of wear, only minor scratches appear on the surface, which are difficult to detect in time through appearance. Problems are not discovered until the sheath is damaged and the internal conductor is exposed, which poses safety hazards such as leakage and short circuit.

[0009] Damage detection is lacking. When a cable is compressed, the internal conductor or insulation layer may have deformed or broken, but the outer sheath may not show obvious abnormalities. Traditional methods cannot detect hidden internal damage; problems can only be identified when the cable experiences charging interruption or a sudden drop in charging efficiency, thus delaying maintenance.

[0010] Furthermore, there is a lack of early warning functionality. Existing technology has not established a linkage mechanism of "wear / squeeze - early warning - detection," making it impossible to issue early warning signals in the early stages of damage. This leads to a shortened cable lifespan, increased replacement costs for users, and reduced safety and reliability during the charging process. Summary of the Invention

[0011] Based on this, the purpose of the present invention is to provide a wear-resistant cable for charging new energy vehicles and its preparation method, which has the advantages of wear resistance and detectable wear.

[0012] In one aspect, the present invention provides a wear-resistant cable for charging new energy vehicles, comprising a cable body, an outer sheath, a carbon fiber strap, and a filler block;

[0013] The outer sheath wraps around the cable body, and the carbon fiber strap and the filler block are respectively disposed inside the outer sheath;

[0014] The outer sheath includes an inner sheath layer, a middle sheath layer, and an outer sheath layer. The inner sheath layer wraps around the cable body, and the carbon fiber strapping is spirally wound around the inner sheath layer. The middle sheath layer wraps around the inner sheath layer and the carbon fiber strapping. A plurality of filler blocks are sequentially disposed outside the middle sheath layer. The outer sheath layer wraps around the middle sheath layer and the filler blocks.

[0015] The inner layer, the middle layer, and the outer layer of the sheath are tightly fitted together.

[0016] The filling block includes a pad and a crossbar. Multiple crossbars are arranged in parallel on the pad and the crossbars protrude from the surface of the pad. One surface of the pad is in close contact with the middle layer of the sheath, and the crossbars are in contact with the inner wall of the outer layer of the sheath.

[0017] Furthermore, the pad is circular or elliptical in shape;

[0018] Of the multiple transverse spacers, the one located in the middle of the pad is the longest, and the lengths of the transverse spacers decrease sequentially from the middle to both ends.

[0019] The length direction of the transverse spacer is perpendicular to the length direction of the cable body; so that when the outer sheath forms folds, the length direction of the folds is perpendicular to the length direction of the cable body.

[0020] Furthermore, the transverse partition is cylindrical and made of metal.

[0021] Furthermore, both ends of the carbon fiber strap extend to the outer side of the end of the outer sheath, forming a detection connection end for electrical signals;

[0022] Two carbon fiber straps are respectively wound around the inner layer of the sheath, and the two carbon fiber straps are spaced apart.

[0023] The two carbon fiber straps have one detection connection end overlapped, and the other detection connection end is respectively provided with a signal transmitting unit and a signal receiving unit.

[0024] Furthermore, the width of the carbon fiber strap is 5-50mm, and the ratio of the spacing between any two adjacent carbon fiber straps to the width of the carbon fiber strap is 4-10:1.

[0025] Another aspect of the present invention provides a method for preparing a wear-resistant cable for charging new energy vehicles, comprising the steps of:

[0026] S10. Prepare the main body of the cable bundled into a bundle;

[0027] S20. An inner sheath is extruded onto the outside of the cable body;

[0028] S30. Spiral-wrap the carbon fiber strapping around the outer wall of the inner layer of the sheath;

[0029] S40. A sheath intermediate layer is obtained by extrusion molding, which wraps around the inner sheath layer and the carbon fiber strapping.

[0030] S50. Attach the filler block to the outer wall of the intermediate layer of the sheath and squeeze the filler block to make the intermediate layer of the sheath at the filler block indented.

[0031] S60. An outer sheath layer is obtained by extrusion molding, which wraps around the middle sheath layer and the filler block.

[0032] S70. The outer sheath is aligned using a trumpet-shaped mold;

[0033] S80, cooling and forming, to obtain the wear-resistant cable for charging new energy vehicles as described in any of the above schemes.

[0034] Furthermore, during the extrusion process, the temperature of the inner layer of the sheath is higher than that of the middle layer of the sheath, and the temperature of the middle layer of the sheath is higher than that of the outer layer of the sheath.

[0035] Furthermore, in step S50, the two sides of the filler block are gripped by a suction cup, and a predetermined pushing force is applied to the two sides and the middle of the filler block. After the filler block is attached to the surface of the middle layer of the sheath, the middle filler layer is pressed down, so that a depression is formed at the corresponding position of the middle filler layer, and the filler block is embedded in the depression.

[0036] Furthermore, hot melt adhesive is applied to the inner wall of the filler block, and this hot melt adhesive-coated inner wall is used to attach to the surface of the intermediate layer of the sheath.

[0037] Furthermore, after step S80, the outer sheath at the corresponding position of the filling block is molded using a ring clamp, so that the outer sheath is flat and has smooth lines.

[0038] Furthermore, multiple hemispherical wear-resistant protrusions are installed on the surface of the outer sheath at the corresponding position of the filler block.

[0039] Compared with the prior art, the present invention has at least the following beneficial effects:

[0040] 1) Dual wear resistance warning to detect potential problems in advance. The synergistic design of the filler block and the three-layer outer sheath allows observable wrinkles and protrusions to form at the filler block when the cable rubs, achieving "visual warning". At the same time, the change in the electrical signal of the carbon fiber bundle can quantify the degree of wear, avoiding the problem of "invisible wear" in traditional cables and detecting the risk of sheath damage in advance.

[0041] 2) Full-scenario damage detection, covering both latent and overt problems. Whether it is internal structural damage caused by compression (latent) or sheath damage caused by friction (overt), it can be detected by changes in the electrical signal parameters of the carbon fiber straps. It can even locate the damage location by the signal difference between the two straps, solving the pain point of difficult detection of internal damage in traditional cables.

[0042] 3) Stable structure and significantly improved wear resistance. The increased thickness at the pleated areas enhances the cable's wear resistance. The three-layer outer sheath features a gradient hardness design, combined with the reinforcing effect of the metal crossbars in the filler blocks. This improves the cable's wear life compared to traditional cables, increases its compressive strength, and makes it suitable for complex environments such as outdoor use and garages.

[0043] 4) Strong compatibility, adaptable to existing charging systems. The conductive core of the cable complies with existing new energy vehicle charging standards. Functional upgrades are achieved only by optimizing the outer sheath and detection structure, without requiring modifications to the charging pile or vehicle's charging interface. This strong compatibility facilitates mass deployment and application.

[0044] 5) The manufacturing process is controllable and suitable for industrial production. The manufacturing process adopts mature processes such as extrusion, winding, and positioning attachment. Through synchronous tension control, gradient temperature extrusion, and contouring indenters, product consistency is ensured, resulting in a high yield rate and meeting the needs of large-scale industrial production.

[0045] To better understand and implement this invention, the following detailed description is provided in conjunction with the accompanying drawings. Attached Figure Description

[0046] Figure 1 This is a cross-sectional view of an exemplary wear-resistant cable for charging new energy vehicles according to the present invention.

[0047] Figure 2 This is a schematic diagram illustrating the positional relationship of multiple filling blocks as an example of the present invention;

[0048] Figure 3 This is a three-dimensional structural diagram of an exemplary filling block of the present invention;

[0049] Figure 4 This is a flowchart illustrating an exemplary method for preparing a wear-resistant cable for charging new energy vehicles according to the present invention.

[0050] Figure 5 This is a schematic diagram of the structure after step S20 of the present invention is completed, as an example.

[0051] Figure 6 This is a schematic diagram of the structure after step S30 of the present invention is completed, as an example.

[0052] Figure 7 This is a schematic diagram of the structure after step S40 of the present invention is completed, as an example.

[0053] Figure 8 This is a schematic diagram of the structure after step S50 of the present invention is completed, as an example.

[0054] Figure 9 This is a schematic diagram of the structure after step S60 of the present invention is completed, as an example.

[0055] Figure 10 This is a schematic diagram of the connection state of two carbon fiber ribbons after being wound and formed, which is an example of the present invention. Detailed Implementation

[0056] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings and are used only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. In the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0057] To address the problems of insufficient wear resistance, difficulty in detecting internal damage, and lack of early warning mechanisms in existing charging cables for new energy vehicles, this invention provides a wear-resistant cable for charging new energy vehicles. Through a design that combines a three-layer outer sheath structure, carbon fiber bundles for electrical signal detection, and a filler block with wrinkles for wear resistance and early warning, the following objectives are achieved:

[0058] 1) Improve the wear resistance and compression resistance of the cable outer sheath, and extend its service life;

[0059] 2) When the cable is squeezed or rubbed, the filler block induces the outer sheath to form identifiable wrinkles, achieving an initial warning at the appearance level, and improving the overall wear resistance of the cable at the wrinkles.

[0060] 3) By utilizing the conductive properties of carbon fiber ribbons, wrinkles / damage can be converted into changes in electrical signals, enabling precise detection of internal damage and even locating the fracture site.

[0061] 4) Establish a dual monitoring system of "appearance warning + electrical signal detection" to improve the safety and timeliness of maintenance during the charging process.

[0062] Please see Figures 1-10 The present invention provides an exemplary wear-resistant cable for charging new energy vehicles, comprising a cable body 10, an outer sheath 20, a carbon fiber strapping 40, and a filler block 30.

[0063] The outer sheath 20 wraps around the cable body 10, and the carbon fiber strap 40 and the filler block 30 are respectively disposed inside the outer sheath 20;

[0064] The outer sheath 20 includes an inner sheath layer 21, a middle sheath layer 22, and an outer sheath layer 23. The inner sheath layer 21 wraps around the cable body 10, and the carbon fiber strapping 40 is spirally wound around the inner sheath layer 21. The middle sheath layer 22 wraps around the inner sheath layer 21 and the carbon fiber strapping 40. A plurality of filler blocks 30 are sequentially arranged around the middle sheath layer 22. The outer sheath layer 23 wraps around the middle sheath layer 22 and the filler blocks 30.

[0065] The inner layer 21, the middle layer 22, and the outer layer 23 of the sheath are tightly fitted together.

[0066] The filling block 30 includes a pad block 31 and a crossbar 32. A plurality of crossbars 32 are arranged in parallel on the pad block 31, and the crossbars 32 protrude from the surface of the pad block 31. One surface of the pad block 31 is in close contact with the middle layer 22 of the sheath, and the crossbars 32 are in contact with the inner wall of the outer layer 23 of the sheath.

[0067] In some preferred embodiments, the pad 31 is circular or elliptical;

[0068] Among the multiple transverse spacers 32, the transverse spacer 32 located in the middle of the pad block 31 is the longest, and the length of the transverse spacers 32 decreases sequentially from the middle to both ends;

[0069] The length direction of the transverse spacer 32 is perpendicular to the length direction of the cable body 10, so that when the outer sheath 20 forms folds, the length direction of the folds is perpendicular to the length direction of the cable body 10.

[0070] In some preferred embodiments, the transverse spacer 32 is cylindrical and is made of metal.

[0071] In some preferred embodiments, the pad is made of plastic, or the pad is made of metal. Plastic is preferred for the pad.

[0072] First, prepare the spacer block and the crossbar separately. Then, process the crossbar to a specified length and degree of curvature, preferably by molding. Finally, assemble a set of crossbars onto the spacer block to obtain the desired result. Figure 3The structure shown is such that the cross-sections of the pad and the crossbar are curved, with the radius of the curve being smaller than the radius of the intermediate layer of the sheath and larger than the radius of the inner layer of the sheath, thus allowing the filler block to be accurately embedded within the intermediate layer of the sheath.

[0073] The crossbars should preferably be made of alloy material, such as stainless steel.

[0074] In some preferred embodiments, both ends of the transverse spacer are ground to round the ends of the transverse spacer.

[0075] In some preferred embodiments, the surface of the outer sheath, at the corresponding area of ​​the filler block, is provided with multiple hemispherical wear-resistant protrusions. These protrusions enhance the wear-resistant effect and effectively prevent further wear from the wrinkles that form on the outer sheath.

[0076] like Figure 10 As shown, in some preferred embodiments, both ends of the carbon fiber strap 40 extend to the outer side of the end of the outer sheath 20 to form a detection connection end for electrical signals.

[0077] Two carbon fiber straps 40 are respectively wound around the inner layer 21 of the sheath, and the two carbon fiber straps 40 are spaced apart.

[0078] The two carbon fiber straps 40 have one detection connection end overlapped, and the other detection connection end is respectively provided with a signal transmitting unit and a signal receiving unit.

[0079] In some preferred embodiments, the width of the carbon fiber strap 40 is 5-50 mm, and the ratio of the spacing between any two adjacent carbon fiber straps 40 to the width of the carbon fiber strap 40 is 4-10:1.

[0080] The spacing between two adjacent carbon fiber straps 40 refers to the distance between the midpoints of two adjacent carbon fiber straps 40 along the length of the cable body after being wrapped around the inner layer of the sheath; the width of the carbon fiber strap 40 is the actual width in its natural flat state.

[0081] The requirement and setting for the spacing between two adjacent carbon fiber straps 40 is to ensure that the spacing between the two adjacent carbon fiber straps 40 is large, so as to ensure that the contact area between the inner layer of the sheath and the middle layer of the sheath is large, thereby ensuring that the connection between the inner layer of the sheath and the middle layer of the sheath is tight enough.

[0082] The requirement for a 40mm width in the carbon fiber ribbon is to ensure good electrical conductivity.

[0083] In some preferred embodiments, the pad 31 and the transverse partition 32 are integrally formed, and the thickness of the pad 31 gradually decreases from the middle to the edge.

[0084] In some preferred embodiments, the cable body 10 includes copper conductors 11, insulating sleeves 12, and a filling layer 13; the copper conductors 11 are wrapped with insulating sleeves 12, and multiple insulating sleeves 12 are spirally wound into a bundle. The filling layer 13 fills the gaps between the insulating sleeves 12 and the external voids, thereby making the entire cable body 10 form a cylindrical structure. In the embodiment illustrated in the accompanying drawings, the cable body 10 has three copper conductors 11.

[0085] In some preferred embodiments, the pad 31 and the transverse spacer 32 are integrally formed; in some embodiments, the thickness of the pad 31 gradually decreases from the center to the edge. In other embodiments, the thickness of the pad 31 is uniform.

[0086] In some preferred embodiments, the outer surface of the outer sheath 23 is provided with annular wear-resistant textures distributed circumferentially thereon.

[0087] Please see Figures 1-9 The present invention provides an exemplary method for preparing a wear-resistant cable for charging new energy vehicles, comprising the following steps:

[0088] S10. Prepare the cable body 10 bundled into a bundle shape;

[0089] S20. An extruded inner sheath 21 is formed outside the cable body 10;

[0090] S30. The carbon fiber strapping 40 is spirally wound around the outer wall of the inner layer 21 of the sheath.

[0091] S40. A sheath intermediate layer 22 is obtained by extrusion molding. The sheath intermediate layer 22 wraps around the sheath inner layer 21 and the carbon fiber strap 40.

[0092] S50. Attach the filler block 30 to the outer wall of the intermediate layer 22 of the sheath and squeeze the filler block 30 so that the intermediate layer 22 of the sheath is concave at the filler block 30.

[0093] S60. The outer sheath layer 23 is obtained by extrusion molding, and the outer sheath layer 23 wraps around the middle sheath layer 22 and the filler block 30.

[0094] S70. The outer sheath 20 is aligned using a trumpet-shaped mold;

[0095] S80, cooling and forming, to obtain the wear-resistant cable for charging new energy vehicles as described in any of the above schemes.

[0096] In some preferred embodiments, cooling is performed by water cooling in step S80.

[0097] In some preferred embodiments, in step S30, two carbon fiber straps 40 are simultaneously wound around the outer wall of the inner layer 21 of the sheath, with the winding direction being the same and the straps being staggered.

[0098] During assembly, the cable is stripped, and the two carbon fiber straps 40 at both ends are extended. The excess parts are cut off. The two carbon fiber straps 40 are overlapped or wrapped at one end of the cable, and the transmitter and receiver are installed on the two carbon fiber straps 40 at the other end of the cable, so that the two carbon fiber straps 40 on the entire cable form a closed loop.

[0099] In some preferred embodiments, during the extrusion process, the temperature of the inner sheath layer 21 obtained in step S20 is higher than the temperature of the middle sheath layer 22 obtained in step S40, and the temperature of the middle sheath layer 22 obtained in step S40 is higher than the temperature of the outer sheath layer 23 obtained in step S60.

[0100] The inner sheath layer 21, the middle sheath layer 22, and the outer sheath layer 23 are each produced by three extrusion heads. They can be produced by three extruders separately, or by one extruder in three separate routes and extruded through three extrusion heads.

[0101] The discharge temperature of the three extruders is controlled by air cooling.

[0102] In some preferred embodiments, in step S50, the two sides of the filling block 30 are gripped by a suction cup, and a predetermined pushing force is applied to the two sides and the middle of the filling block 30. After the filling block 30 is attached to the surface of the intermediate layer 22 of the sheath, the intermediate filling layer 13 is pressed down, so that a depression is formed at the corresponding position of the intermediate filling layer 13, and the filling block 30 is embedded in the depression.

[0103] In some preferred embodiments, such as Figure 2 and Figure 8 As shown, the filler blocks are installed in pairs, with adjacent pairs of filler blocks staggered. As shown in the figure, one pair of filler blocks is installed vertically, and another pair is installed horizontally, alternating in assembly. This achieves uniform force distribution in multiple directions, and the outer sheath can form folds in multiple directions, which is beneficial for multi-angle detection and multi-angle wear resistance.

[0104] During assembly, the robotic arm's gripper is set in a C-shape, with suction cups on both sides of the gripper's web. The suction cups adsorb the two sides of the filler block, then grasp and attach it to the surface of the middle layer of the sheath. Then, pressure is applied to press the filler block into the middle layer of the sheath. When the pressure reaches the set value, such as 8-55N, the thrust lasts for 2-5 seconds.

[0105] When assembling multiple filler blocks, two robotic arms form a group, installing pairs of filler blocks from two directions respectively; two filler blocks are installed horizontally, and two filler blocks are installed vertically, thus forming a... Figure 2 The assembly state is shown.

[0106] like Figure 8 and Figure 9 As shown, it needs further explanation that after step S40 is completed, that is, after the sheath intermediate layer is formed, steps S50 and S60 have two possible sequences. Firstly, according to... Figure 8 The installation of two sets of filler blocks is completed in the manner shown, and then step S60 is performed; or, the installation of one pair of filler blocks is completed first, and then step S60 is performed to complete the installation of the other pair of filler blocks.

[0107] In other words, there are two sequences for installing two pairs of adjacent filler blocks. Either the filler blocks are assembled simultaneously before the outer sheath is covered, or one pair of filler blocks is assembled, the outer sheath is covered, and then the other pair of filler blocks is assembled in the opposite direction before the outer sheath is covered.

[0108] In some preferred embodiments, hot melt adhesive is applied to the inner wall of the filler block 30, which is used to attach to the surface of the sheath intermediate layer 22.

[0109] In some preferred embodiments, after step S80, the outer sheath 20 at the corresponding position of the filling block 30 is molded by a ring clamp, so that the outer sheath 20 is flat and has smooth lines.

[0110] In some preferred embodiments, a plurality of hemispherical wear-resistant protrusions are installed on the surface of the outer sheath 20 at the corresponding position of the filler block 30.

[0111] In some preferred embodiments, after cooling and forming, the electrical signal transmission of the carbon fiber ribbon 40 is detected by an impedance tester to ensure that its impedance value is within a preset range.

[0112] A brief description of the working principle of the wear-resistant cable for charging new energy vehicles of the present invention:

[0113] This invention achieves wear resistance and damage detection through a linkage mechanism of "external force application - induction of wrinkles by filler block - signal change of carbon fiber ribbon".

[0114] Friction Scenario: When the cable outer sheath rubs against an external object, wear first occurs at the location corresponding to the filler block. Because the outer sheath thickness at the filler block is slightly greater than in other areas, localized bulges will form in the early stages of wear. As wear intensifies and stress concentrates, the transverse strips of the filler block will induce wrinkles to form on the outer sheath along the circumference of the cable. The length of the wrinkles is perpendicular to the cable body, and the wear resistance can be judged by visual inspection. Moreover, after the outer sheath forms wrinkles, the carbon fiber strapping will also form wrinkles simultaneously, causing changes in electrical signal transmission parameters, including impedance, attenuation, and delay time. By detecting these changes in parameters through the signal receiving unit, the degree of compression damage can be determined.

[0115] Compression scenario: When a cable is compressed, external force is applied to the outer sheath. The pads and crossbars of the filler block transmit the external force to the middle layer of the sheath, causing a depression to form at the corresponding position in the middle layer of the sheath. The depression further causes deformation of the inner layer of the sheath, resulting in local wrinkles in the spirally wound carbon fiber bundle. Due to the wrinkles, the conductive path of the carbon fiber bundle bends, the contact gap increases, and it may even break, causing changes in electrical signal transmission parameters, including impedance, attenuation, and delay time. By detecting these changes in parameters through the signal receiving unit, the degree of compression damage can be determined.

[0116] Slight compression: local slight wrinkles in the carbon fiber strapping, impedance increases by 10%~30%, signal attenuation increases by 15%~25%, which is judged as "minor damage";

[0117] Moderate compression: The carbon fiber ribbon has obvious wrinkles, some fibers are broken, the impedance increases by 30%~80%, and the signal delay time increases by more than 30%, which is judged as "moderate damage".

[0118] Severe compression: The carbon fiber bundle is completely broken, and the electrical signal transmission is interrupted. It is judged as "severe damage", which indirectly indicates that the conductor inside the cable may be deformed or broken.

[0119] The cable of this invention significantly improves wear resistance and compression resistance through a dual monitoring system of "appearance warning + electrical signal detection", extends service life, can accurately locate damage, is compatible with existing charging systems, has a controllable manufacturing process, is suitable for industrial production, and effectively improves the safety and timeliness of maintenance during the charging process.

[0120] The embodiments described above are merely examples of several implementations of the present invention, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements all fall within the scope of protection of the present invention.

Claims

1. A wear-resistant cable for charging new energy vehicles, characterized in that: Includes the cable body, outer sheath, carbon fiber strapping, and filler blocks; The outer sheath wraps around the cable body, and the carbon fiber strap and the filler block are respectively disposed inside the outer sheath; The outer sheath includes an inner sheath layer, a middle sheath layer, and an outer sheath layer. The inner sheath layer wraps around the cable body, and the carbon fiber strapping is spirally wound around the inner sheath layer. The middle sheath layer wraps around the inner sheath layer and the carbon fiber strapping. A plurality of filler blocks are sequentially disposed outside the middle sheath layer. The outer sheath layer wraps around the middle sheath layer and the filler blocks. The inner layer, the middle layer, and the outer layer of the sheath are tightly fitted together. The filling block includes a pad and a crossbar. Multiple crossbars are arranged in parallel on the pad and the crossbars protrude from the surface of the pad. One surface of the pad is in close contact with the middle layer of the sheath, and the crossbars are in contact with the inner wall of the outer layer of the sheath. The two ends of the carbon fiber strap extend to the outer side of the end of the outer sheath to form a detection connection end for electrical signals. Two carbon fiber straps are respectively wound around the inner layer of the sheath, and the two carbon fiber straps are spaced apart. The two carbon fiber straps have one detection connection end overlapped, and the other detection connection end is respectively provided with a signal transmitting unit and a signal receiving unit.

2. The wear-resistant cable for charging new energy vehicles according to claim 1, characterized in that: The pad is round or oval; Of the multiple transverse spacers, the one located in the middle of the pad is the longest, and the lengths of the transverse spacers decrease sequentially from the middle to both ends. The length direction of the transverse spacer is perpendicular to the length direction of the cable body; so that when the outer sheath forms folds, the length direction of the folds is perpendicular to the length direction of the cable body.

3. The wear-resistant cable for charging new energy vehicles according to claim 2, characterized in that: The transverse partition is cylindrical and made of metal.

4. The wear-resistant cable for charging new energy vehicles according to claim 2, characterized in that: The width of the carbon fiber strap is 5-50mm, and the ratio of the spacing between any two adjacent carbon fiber straps to the width of the carbon fiber strap is 4-10:

1.

5. A method for preparing a wear-resistant cable for charging new energy vehicles, characterized in that, Including the following steps: S10. Prepare the main body of the cable bundled into a bundle; S20. An inner sheath is extruded onto the outside of the cable body; S30. Spiral-wrap the carbon fiber strapping around the outer wall of the inner layer of the sheath; S40. A sheath intermediate layer is obtained by extrusion molding, which wraps around the inner sheath layer and the carbon fiber strapping. S50. Attach the filler block to the outer wall of the intermediate layer of the sheath and squeeze the filler block to make the intermediate layer of the sheath at the filler block indented. S60. An outer sheath layer is obtained by extrusion molding, which wraps around the middle sheath layer and the filler block. S70. The outer sheath is aligned using a trumpet-shaped mold; S80, cooling and forming, and obtaining the wear-resistant cable for charging new energy vehicles as described in any one of claims 1-4.

6. The method for preparing the wear-resistant cable for charging new energy vehicles according to claim 5, characterized in that, During extrusion processing, the temperature of the inner layer of the sheath is higher than that of the middle layer of the sheath, and the temperature of the middle layer of the sheath is higher than that of the outer layer of the sheath.

7. The method for preparing the wear-resistant cable for charging new energy vehicles according to claim 5, characterized in that, In step S50, the two sides of the filler block are gripped by the suction cup, and a predetermined pushing force is applied to the two sides and the middle of the filler block. After the filler block is attached to the surface of the middle layer of the sheath, the middle layer of the sheath is pressed down, so that a depression is formed at the corresponding position of the middle layer of the sheath, and the filler block is embedded in the depression.

8. The method for preparing the wear-resistant cable for charging new energy vehicles according to claim 5, characterized in that, Hot melt adhesive is applied to the inner wall of the filler block, and this hot melt adhesive-coated inner wall is used to attach to the surface of the intermediate layer of the sheath. After step S80, the outer sheath at the corresponding position of the filling block is molded by a ring clamp, so that the outer sheath is flat and has smooth lines.

9. The method for preparing the wear-resistant cable for charging new energy vehicles according to claim 5, characterized in that, Multiple hemispherical wear-resistant protrusions are installed on the surface of the outer sheath at the corresponding position of the filler block.

Images