Anti-deformation charging pile cable for new energy automobile

Abstract

The invention relates to an anti-deformation charging pile cable for a new energy automobile. The anti-deformation charging pile cable comprises a cable main body, an inner insulating layer and a wear-resistant outer insulating layer which are sequentially arranged from inside to outside, electrorheological fluid is filled between the inner insulating layer and the wear-resistant outer insulating layer; the cable main body comprises conductive inner core bodies which are arranged in a square array, a current response type elastic band is connected between two groups of conductive inner core bodies which are adjacent in the horizontal direction and the vertical direction, and the rest space is filled with a high-elasticity rubber inner core; the pressure sensor is used for monitoring which side of the charging pile cable touches the ground in the charging use state, then the square structure is converted into the trapezoidal structure with the narrow top and the wide bottom, the bottom face of the charging pile cable of the trapezoidal structure is wide, stress is dispersed, and vertical compression resistance is remarkably improved.

Description

Technical Field

[0001] This invention relates to a deformation-resistant charging pile cable for new energy vehicles, belonging to the field of cable technology. Background Technology

[0002] With the continuous expansion of the new energy electric vehicle market, a large number of charging piles have emerged. The appearance of charging piles has greatly facilitated the charging of new energy vehicles. With the continuous improvement of fast charging technology, the requirements for charging pile cables are also getting higher and higher. Traditional cables cannot withstand the requirements of fast charging, so many special cables designed for charging piles have appeared on the market. To improve resistance to vehicle crushing, existing cables have thickened armor, which makes them increasingly thick. The excessively thick and rigid structure makes them impossible to rewind. Therefore, a charging cable that can harden during operation and soften when not in use for easy rewinding is needed. For example, the patent publication number CN118507136B discloses "a special cable for charging piles". By setting an electrorheological fluid on the outer layer of the cable body, the heat exchange conductive fluid in the electrorheological fluid is pressureless and the magnetic fluid is in a fluid state when it is stored. The electrorheological fluid is in a flexible state, which facilitates winding and plugging and unplugging charging operations. When charging, the heat exchange conductive fluid generates pressure under the action of the circulation pump, and the magnetic fluid solidifies under the action of the magnetic field generated by the current of the heat exchange conductive fluid. This can significantly improve the pressure resistance of the cable and effectively avoid damage to the cable during charging. However, the contact area between the circular charging pile cable and the ground is small, and the charging pile cable is prone to being crushed by vehicles during use. Summary of the Invention

[0003] The purpose of this invention is to provide a deformation-resistant charging pile cable for new energy vehicles to solve the problems mentioned in the background art.

[0004] The technical solution of the present invention is as follows: A deformation-resistant charging pile cable for new energy vehicles includes a cable body, an inner insulation layer, and a wear-resistant outer insulation layer arranged sequentially from the inside to the outside. An electrorheological fluid is filled between the inner insulation layer and the wear-resistant outer insulation layer. The cable body is wrapped with an inner insulation layer on the outside. The cable body includes conductive inner cores arranged in a square array. A current-responsive elastic band connects two adjacent sets of conductive inner cores. The remaining space is filled with a highly elastic rubber inner core. The current-responsive elastic band comprises a base layer, an electrorheological fluid layer, and a composite electroactive layer connected in sequence.

[0005] Preferably, a first conductive layer is provided on the inner side of the wear-resistant outer insulating layer, and a second conductive layer is provided on the outer side of the inner insulating layer. The first conductive layer and the second conductive layer are connected by multiple insulating connection layers.

[0006] Preferably, the thickness ratio of the substrate layer, the electrorheological fluid layer, and the composite electroactive layer is 2:3:6.

[0007] Preferably, multiple pressure sensors are evenly distributed circumferentially on the outer side wall of the charging pile cable.

[0008] Preferably, the outer wall of the charging pile cable is provided with a non-sensitive temperature detection module.

[0009] Preferably, the high-elasticity rubber core includes a rigid cross and high-elasticity rubber strips disposed in the four corner groove areas of the rigid cross.

[0010] Preferably, under normal conditions, the side length of the highly elastic rubber strip is greater than half the side length of the rigid cross, and a heat-conducting microchannel is formed between two adjacent sets of highly elastic rubber strips and the rigid cross.

[0011] Preferably, the opposite ends of the rigid cross are respectively provided with a protrusion and a concave portion that are adapted to be inserted and mated.

[0012] Preferably, when the charging pile cable charges a new energy vehicle, each current-responsive elastic band stretches or shortens, so that the charging pile cable forms a trapezoidal structure that is narrow at the top and wide at the bottom; finally, all the current-responsive elastic bands turn into a solid state and the electrorheological fluid turns into a solid state.

[0013] The present invention has the following beneficial effects: When stored, the electrorheological fluid is in a fluid, flexible state, facilitating winding and plugging / unplugging for charging operations. During charging, the electrorheological fluid solidifies, significantly improving the compressive strength of the charging cable and effectively preventing damage to the cable during charging.

[0014] By monitoring the location of the charging pile cable in contact with the ground during charging, a pressure sensor is used as a reference to provide a benchmark for the deformation of multiple current-responsive elastic bands. The structure is transformed from a circular structure to a trapezoidal structure that is narrow at the top and wide at the bottom. The trapezoidal structure of the charging pile cable has a wide bottom surface that disperses stress and significantly improves vertical compressive strength. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the three-dimensional cross-sectional structure of the present invention in the non-charging state; Figure 2 This is a schematic diagram of the lateral cross-sectional structure of the present invention in the non-charging state; Figure 3This is a schematic diagram of the lateral cross-sectional structure of the present invention in the charging state; Figure 4 This is a schematic diagram of the current-responsive elastic band structure of the present invention; Figure 5 This is a schematic diagram of the high-elasticity rubber core structure of the present invention; Figure 6 This is a schematic diagram of a second type of connection and engagement between the first conductive layer and the second conductive layer of the present invention; Figure 7 This is a schematic diagram of the present invention after determining the pressure sensor as the base point; Figure 8 This is a schematic diagram of the three-dimensional cross-sectional structure of Embodiment 2 of the present invention in the non-charging state; Figure 9 This is a schematic diagram of the lateral cross-sectional structure of Embodiment 2 of the present invention in the non-charging state.

[0016] The reference numerals in the figure are as follows: 1. Wear-resistant outer insulation layer; 2. Inner insulation layer; 3. Electrorheological fluid; 31. Isolation connection layer; 4. Conductive inner core; 5. Current-responsive elastic band; 51. Base layer; 52. Electrorheological fluid layer; 53. Composite electroactive layer; 6. High-elasticity rubber inner core; 61. Rigid cross; 62. High-elasticity rubber strip; 63. Thermally conductive microchannel. Detailed Implementation

[0017] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments.

[0018] Deformation-resistant charging pile cables for new energy vehicles, such as charging pile cables Figure 1-2 As shown, it has a circular structure when not charging; The charging pile cable includes: a cable body, an inner insulation layer 2 and a wear-resistant outer insulation layer 1 arranged sequentially from the inside to the outside; the inner insulation layer 2 and the wear-resistant outer insulation layer 1 have a certain elastic deformation capacity. The space between the second conductive layer on the outer side of the inner insulation layer 2 and the first conductive layer on the inner side of the wear-resistant outer insulation layer 1 is filled with electrorheological fluid 3, with a filling rate between 50% and 80%. The first conductive layer is connected to the positive terminal of the charging pile cable end, and the second conductive layer is connected to the negative terminal of the charging pile cable end. An insulating isolation connection layer 31 is uniformly disposed between the first conductive layer and the second conductive layer, which restricts the flow of electrorheological fluid 3 in each area to only within that area. Or, such as Figure 6 As shown, a first insulating protrusion and a second insulating protrusion are respectively provided on the side of the first conductive layer and the second conductive layer that are close to each other to replace the isolation connection layer 31, and the first insulating protrusion and the second insulating protrusion are arranged alternately.

[0019] Multiple pressure sensors are evenly installed circumferentially on the sidewall of the charging pile cable. These pressure sensors are resistive thin-film pressure sensors. When the charging pile cable is used to charge new energy vehicles, its extended portion contacts the ground. By judging the pressure values ​​of each pressure sensor, the system can automatically determine which sensor is closest to the ground. The relative positions of each conductive inner core 4 and each pressure sensor are pre-defined in a plane. Using the pressure sensor closest to the ground as the base point, and the radial direction from this base point to the center of the charging pile cable as the Y-axis and the tangential direction as the X-axis, the positional relationship of each array of conductive inner cores 4 relative to this base point can be determined. This allows for the calculation of the expansion and contraction of each current-responsive elastic band 5. Figure 7 As shown, even though the current-responsive elastic band 5, which is in a roughly horizontal state at this time, has an angle α with the X-axis, it can automatically straighten itself after deforming into a trapezoidal shape.

[0020] The outer side of the cable body is wrapped with an inner insulation layer 2. The cable body includes conductive inner cores 4 arranged in an array under normal conditions. Two adjacent sets of conductive inner cores 4 in the horizontal direction are connected by a current-responsive elastic band 5. Two adjacent sets of conductive inner cores 4 in the vertical direction are also connected by a current-responsive elastic band 5. The remaining space is filled with a highly elastic rubber inner core 6. For example, a set of highly elastic rubber inner cores 6 is filled between the space formed by four adjacent current-responsive elastic bands 5, the inner insulation layer 2, and the current-responsive elastic bands 5.

[0021] like Figure 4 As shown, the current-responsive elastic band 5 includes a base layer 51, an electrorheological fluid layer 52, and a composite electroactive layer 53 connected in sequence. The base layer 51 uses a flexible electrode carrier to maintain structural integrity; the electrorheological fluid layer 52 includes a flexible material mesh carrier filled with electrorheological fluid; the composite electroactive layer 53 can be a stretchable dielectric elastomer such as an electrostrictive grafted elastomer; the thickness ratio of the base layer 51, the electrorheological fluid layer 52 and the composite electroactive layer 53 is 2:3:6; the thickness of the composite electroactive layer 53 accounts for about 60%, ensuring that the capacitance characteristics dominate the total capacitive reactance of the system, and ensuring that the driving energy consumption is concentrated in the deformation work (rather than the ohmic loss of the electrorheological cavity); when the thickness of the electrorheological fluid layer 52 is 1 / 2 the thickness of the composite electroactive layer 53, the shear stress distribution is the most uniform.

[0022] High elastic rubber core 6 under normal conditions Figure 5As shown, it includes a rigid cross 61 and four sets of highly elastic rubber strips 62 distributed in its four regions. The cross-section of the highly elastic rubber strips 62 is square. Under normal conditions, the length and width of the highly elastic rubber strips 62 are greater than 1 / 2 the horizontal / vertical ends of the rigid cross 61, so that heat-conducting microchannels 63 are formed between adjacent two highly elastic rubber strips 62 and the horizontal / vertical ends of the rigid cross 61. Multiple heat dissipation channels can be formed inside the charging pile cable through the heat-conducting microchannels 63. The opposite ends of the rigid cross 61 are respectively designed with compatible plug-in protrusions and concave parts; as Figure 2 As shown, a set of highly elastic rubber cores 6 are provided between four adjacent current-responsive elastic strips 5; a set of highly elastic rubber cores 6 or highly elastic rubber strips 62 can be provided between the inner insulation layer 2 and the adjacent current-responsive elastic strips 5. Since the rigid cross 61 has a rigid structure, in order to avoid affecting the bending of the charging pile cable, the rigid cross 61 includes multiple sets of cross bodies arranged along the length of the charging pile cable, with a certain gap between adjacent cross bodies.

[0023] The current-responsive elastic band 5 has a channel through which the end of the rigid cross 61 passes. The conductive inner core 4 is not directly fixed to the inner wall of the inner insulating layer 2, or the inner wall of the inner insulating layer 2 of the outermost group of conductive inner cores 4 in the square array is fixed to other movable contacts.

[0024] Working principle: When the charging pile cable is not in use, such as Figure 1-2 As shown, at this time, the electrorheological fluid 3 between the inner insulation layer 2 and the wear-resistant outer insulation layer 1 is in a liquid state and will not hinder bending deformation; at this time, the electrorheological fluid layer 52 in the current-responsive elastic band 5 is in a liquid state and will not hinder bending deformation.

[0025] When a charging pile cable is charging a new energy vehicle, the side of the circular charging pile cable touches the ground. The data processing center can determine which side of the charging pile cable is touching the ground based on the pressure sensor on the side that is touching the ground, providing a directional basis for subsequent control.

[0026] After determining the reference, using the pressure sensor as the reference, each current-responsive elastic band 5 controls the corresponding composite electroactive layer 53 to shorten or lengthen by a set distance according to the preset extension amount, so that the charging pile cable forms a trapezoidal structure that is narrow at the top and wide at the bottom.

[0027] Afterwards, all the electrorheological fluid layers 52 in the current-responsive elastic strips 5 are cured. The cured current-responsive elastic strips 5 have a grid structure to support the inner cavity of the inner insulation layer 2 and improve the overall compressive strength. The rigid cross 61, which was originally vertically integrated, can be used to support the charging pile cable with a trapezoidal structure, further improving its compressive strength.

[0028] like Figure 3 The deformed charging pile cable is a symmetrical trapezoidal structure. Compared with the square structure, the deformed trapezoidal structure of the charging pile cable not only reduces the overall height but also increases the base area, effectively improving the structural compressive strength. Furthermore, the geometric design of the double-sided inclined surface provides a smooth transition surface for the vehicle tires, significantly reducing the impact risk when the wheels cross obstacles.

[0029] Example 2: Contains all the contents of Example 1, except that: Charging pile cables such as Figures 8-9 As shown, it has a square structure when not charging; pressure sensors are installed on all four side walls of the charging pile cable. Assuming that the length of the conductive inner core 4 in the same horizontal direction is L, when the charging pile cable is in a square state, first control the composite electroactive layer 53 in all vertical current-response elastic bands 5 to shorten by the same distance, so that the protrusions and concave parts of the upper and lower adjacent rigid crosses 61 are inserted and matched, so that the upper and lower adjacent rigid crosses 61 are connected into one.

[0030] Subsequently, the composite electroactive layer 53 in the current-responsive elastic band 5, which controls the horizontal state, shortens or lengthens by a set distance, causing the horizontal length L to increase sequentially from top to bottom, resulting in a trapezoidal structure that is narrower at the top and wider at the bottom for the charging pile cable. The shortening or lengthening distance of each composite electroactive layer 53 is adaptively adjusted according to later requirements.

[0031] The above description is merely an embodiment of the present invention and does not limit the scope of the patent of the present invention. Any equivalent structural or procedural transformations made based on the content of the present invention specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the scope of patent protection of the present invention.

Claims

1. A deformation-resistant charging pile cable for new energy vehicles, characterized in that, It includes a cable body, an inner insulation layer (2), and a wear-resistant outer insulation layer (1) arranged sequentially from the inside out; Electrorheological fluid (3) is filled between the inner insulation layer (2) and the wear-resistant outer insulation layer (1). The cable body is wrapped with an inner insulation layer (2) on the outside. The cable body includes conductive inner cores (4) arranged in a square array. A current-responsive elastic band (5) is connected between two adjacent sets of conductive inner cores (4). The remaining space is filled with a highly elastic rubber inner core (6). The current-responsive elastic band (5) includes a base layer (51), an electrorheological fluid layer (52), and a composite electroactive layer (53) connected in sequence.

2. The deformation-resistant charging pile cable for new energy vehicles as described in claim 1, characterized in that: The wear-resistant outer insulation layer (1) has a first conductive layer on its inner side and the inner insulation layer (2) has a second conductive layer on its outer side. The first conductive layer and the second conductive layer are connected by multiple isolation connection layers (31).

3. The deformation-resistant charging pile cable for new energy vehicles as described in claim 1, characterized in that: The thickness ratio of the substrate layer (51), the electrorheological fluid layer (52), and the composite electroactive layer (53) is 2:3:

6.

4. The deformation-resistant charging pile cable for new energy vehicles as described in claim 1, characterized in that: Multiple pressure sensors are evenly distributed circumferentially on the outer wall of the charging pile cable.

5. The deformation-resistant charging pile cable for new energy vehicles as described in claim 1, characterized in that: The outer wall of the charging pile cable is equipped with a non-sensitive temperature detection module.

6. The deformation-resistant charging pile cable for new energy vehicles as described in claim 1, characterized in that: The high-elasticity rubber core (6) includes a rigid cross (61) and high-elasticity rubber strips (62) disposed in the four corner groove areas of the rigid cross (61).

7. The deformation-resistant charging pile cable for new energy vehicles as described in claim 6, characterized in that: Under normal conditions, the side length of the high elastic rubber strip (62) is greater than half the side length of the rigid cross (61), and a heat-conducting microchannel (63) is formed between two adjacent sets of high elastic rubber strips (62) and rigid cross (61).

8. The deformation-resistant charging pile cable for new energy vehicles as described in claim 6, characterized in that: The rigid cross (61) has a protrusion and a concave part that are adapted to be inserted and mated at opposite ends.

9. The deformation-resistant charging pile cable for new energy vehicles as described in claim 8, characterized in that: When the charging pile cable charges the new energy vehicle, each current-responsive elastic band (5) stretches or shortens, so that the charging pile cable forms a trapezoidal structure that is narrow at the top and wide at the bottom; finally, all the current-responsive elastic bands (5) turn into a solid state and the electrorheological fluid (3) turns into a solid state.

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